JP2004240513A - Production facility status analysis device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To facilitate designation of a control signal to be used for analysis in a device collecting the control signal from a sequence controller controlling a manufacturing facility and analyzing it. <P>SOLUTION: In an address list 2, an address of each control signal, which is inputted/outputted to/from a PLC 100 serving as a kind of sequence controller, and information representing its signal contents are registered. As to a type to be analyzed among the types of units constituting the manufacturing facility, a condition to be satisfied by the signal contents of the one or more control signal used for type analysis is inputted from an input device 1. In this way, for each unit type of the analysis object, a unit library 3 showing a condition of the control signal to be collected for analysis can be formed. In a data collection processing part 7, the control signal satisfying the condition shown in the unit library 3 is collected from the PLC 100. A display analysis processing part 9 carries out analysis processing on each unit according to the collection data of the control signal related to the unit. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an apparatus that creates data for analyzing the operation state of a production facility based on data collected from a sequence controller that performs sequence control on the production facility.
[0002]
[Prior art]
In a production facility, various devices constituting the facility are controlled by a sequence controller, thereby realizing a production process in accordance with a predetermined procedure. The sequence controller is provided for each individual device or for each group of a plurality of devices, and the sequence controller exchanges control signals via a network, thereby realizing the process flow of the entire production facility. . In recent years, a sequence controller capable of supporting various devices by mounting a microcomputer and changing a program, that is, a PLC (programmable logic controller) has been widely used.
[0003]
Conventionally, the detection of abnormalities in production equipment has been performed manually by visual inspection or the like, but due to the complexity of production equipment in recent years, such manual inspection work has become extremely difficult. Therefore, as in Patent Document 1, a management device that temporarily saves data of various control signals used by a PLC for sequence control and analyzes the operating state of the device from the saved data is used. The management device disclosed in Patent Document 1 extracts a data specified in an operation status detection condition file from a data group of a control signal temporarily stored, creates a transition record file, and creates a transition record file included in the transition record file. The operating status is determined by analyzing the data.
[0004]
[Patent Document 1]
JP-A-07-129206
[0005]
[Problems to be solved by the invention]
In the device of Patent Document 1, the data of the signal specified in the operation status detection condition file is extracted from the data of all the signals temporarily stored and used for analysis. It does not show how the user designates a control signal to be extracted, and how to select a signal to be extracted in accordance with the designation. When the number of control signals handled by the sequence controller becomes enormous, there is a problem that the specification of the control signals to be extracted and the specification of the analysis processing to be applied to the extracted control signals are complicated. No. 1 does not show a solution to such a problem.
[0006]
The present invention has been made in view of such a problem, and has as its object to provide a technique for facilitating designation of a control signal collected from a sequence controller and used for analysis processing.
[0007]
[Means for Solving the Problems]
The present invention relates to a production equipment state analysis apparatus which collects and accumulates control signals used by a sequence controller for controlling production equipment for control, and generates output data for analyzing the operation state of the production equipment based on the accumulated information. A signal list including information indicating the signal content of the control signal for each control signal used by the sequence controller, and condition input means for inputting a condition to be satisfied by the signal content of the control signal used for analysis, A collection target signal extraction unit that extracts, from the signal list, a control signal having a signal content that satisfies the condition input by the condition input unit, and outputs the control signals extracted by the collection target signal extraction unit from the sequence controller. A signal collecting means for collecting and accumulating the data sequentially; and Analyzing means for producing an analysis result data available for analysis equipment Health, there is provided production equipment status analysis device comprising a.
[0008]
In a preferred aspect of the present invention, the signal list includes corresponding unit information indicating which control signal is a signal related to any of the units constituting the production facility, and the analysis unit includes: The information of each control signal collected and accumulated by the signal collecting unit is grouped for each control signal related to the same unit based on the corresponding unit information, and for each unit, the information of the control signal related to the unit is obtained from the information of the control signal related to the unit. Create analysis result data on operation status.
[0009]
In a further preferred aspect, the production equipment operation state analysis device includes, for each type of units constituting the production equipment, means for storing analysis processing contents corresponding to the type, and each unit constituting the production equipment includes: Means for storing type determination information for determining which of the types the device belongs to, wherein the analysis unit performs control related to the unit according to the analysis processing corresponding to the type to which the unit belongs. Analysis result data relating to the operating state of the unit is created from the signal information.
[0010]
In another preferred aspect of the present invention, the condition input means, the condition to be satisfied by the signal content of each control signal used for analysis, for each type to be analyzed among the types of units constituting the production equipment, A user interface is provided for inputting as a set of conditions to be satisfied by the signal content of each control signal related to the type.
[0011]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention (hereinafter, referred to as embodiments) will be described with reference to the drawings.
[0012]
FIG. 1 is a diagram for explaining control signals handled by a PLC (programmable logic controller) that performs sequence control of production equipment.
[0013]
As shown in this figure, when viewing the PLC 100 from the viewpoint of control signals, the input unit 102 that receives signals from input devices such as a sensor 112 (for example, an optical sensor) and a switch 114 (for example, a limit switch), a solenoid valve 122, An output unit 104 that sends a signal to an output device such as a motor 124 can be roughly classified into a logical operation unit 106 that performs a logical operation for sequence control. Here, the input device and the output device are devices that are provided in a production facility to be controlled by the PLC 100 and exchange signals with the PLC 100. The input device detects, for example, the state of an element constituting the production facility, and inputs a signal indicating the detection result or the like to the PLC 100. The output device performs a function of changing a state of an element constituting the production facility according to a signal supplied from the PLC 100. Hereinafter, a signal input from the input device to the PLC 100 and a signal output from the PLC 100 to the output device are collectively referred to as a control signal in the sense of a signal used for sequence control.
[0014]
These input / output devices can be regarded as communication partner elements when the production equipment is viewed from the viewpoint of exchange of control signals with the PLC 100. On the other hand, from the viewpoint of the operation performed by the production facility for production, the production facility can be divided into operation units. This operation unit is called a “unit”. For example, actuators such as motors that drive cylinders and processing tables that realize linear motion for press working, etc., lamps and other display devices that display abnormalities in certain elements in production equipment, and operations that are operated by workers A board or the like can be regarded as one operation unit in a process realized by each production facility, that is, a “unit”.
[0015]
One unit is associated with an input device such as a sensor for monitoring the operation state and the like of the unit and an output device such as an actuator for driving the unit. Of course, some units can only be associated with input devices and some units can only be associated with output devices, while other units can be associated with multiple input devices and multiple output devices. For example, FIG. 2 shows a cylinder 200 that realizes a linear operation in a production line or the like as an example of a unit. In controlling the operation of the cylinder 200, it is necessary to detect that the piston 205 has reached the forward or backward end of its stroke. Therefore, a forward end limit switch 214 and a backward end limit switch 212 are provided for the cylinder 200. These switches 212 are input devices for the PLC 100. In the example of FIG. 2, the operation direction of the cylinder 200 (piston 205) is switched between forward and backward by switching the electromagnetic solenoid valve 220 to switch the flow of air to the conduit 225. Since the electromagnetic solenoid valve 220 is switched by a forward instruction signal and a backward instruction signal from the PLC 100, the electromagnetic solenoid valve 220 is an output device. The operating state of the cylinder 200 can be represented by signals from the forward end limit switch 214 and the backward end limit switch 212, and forward and backward instruction signals to the electromagnetic solenoid valve 220.
[0016]
As can be understood from the above description, the devices and units for input and output are classified from different viewpoints of the elements included in the production equipment, and the physically same device is an input or output device. At the same time, it may be a “unit”. For example, a lamp that indicates an abnormal state is an output device that itself receives a control signal from the PLC 100, and is also a “unit” that realizes an operation unit of “displaying an abnormal state”.
[0017]
Returning to FIG. 1 again, the logical operation unit 106 executes a logical operation according to a predetermined sequence control program based on an input signal (or a result of another logical operation on the signal, etc.), and outputs a control signal to the output device. Find data used for another logical operation (this data may be supplied to another PLC via a network). The latter is herein referred to as internal dummy data. However, the internal dummy data is logically equivalent to control signals exchanged with input and output devices, and is often meaningful in analyzing the operating state of production equipment. Data is also treated as a kind of control signal. That is, in the present embodiment, both the signal exchanged by the PLC 100 with the input / output device and the internal dummy data used in the logical operation inside the PLC 100 are handled as control signals to be collected for analysis.
[0018]
Generally, in the PLC, input devices such as the sensor 112 and output devices such as the solenoid valve 122 are identified by I / O addresses indicated as X000, X001, Y000, and Y001 in the figure. The control signal exchanged in the above is also identified by the I / O address. In some cases, one physical device supplies a plurality of detection signals to the PLC 100 or receives a plurality of drive control signals from the PLC 100. In this case, each of the signals at the input and output of the PLC 100 is generally separated by a separate I / O. Assigned to O address. In addition, a memory address where the data is stored is also determined for the internal dummy data used in the logical operation unit 106. Therefore, each of the control signals can be uniquely identified by the corresponding address.
[0019]
The present embodiment provides an analysis device that collects and analyzes control signals from the PLC 100 as described above. Some existing PLCs include an output terminal for outputting the various control signals to the outside for monitoring or the like. As an example, the analyzer of the present embodiment can be realized as a device connected to such an output terminal. It is also possible to incorporate this analyzer into a PLC.
[0020]
In the analysis device of the present embodiment, a control signal collected from the PLC 100 and used for analysis can be specified from two data, an address list and a unit library. FIG. 3 shows an example of the data contents of the address list, and FIG. 6 shows an example of the data contents of the unit library. Hereinafter, these data will be described in order.
[0021]
As shown in FIG. 3, three data items of “address”, “signal content code”, and “comment” are registered in the address list for each control signal handled by the PLC 100. The address is an address (I / O or memory address) for identifying the control signal. The signal content code is a code indicating the content of the control signal. The comment is an explanation that shows the contents of the control signal so that the person concerned can understand. Conventionally, an address list including addresses and comments of these three items has been created and stored for creating a sequence control program, installing a sequence controller for production equipment, inspecting and analyzing production equipment, and the like. However, it can be said that the address list of the present embodiment is obtained by adding a signal content code to such a conventional address list.
[0022]
The signal content code illustrated in FIG. 3 is configured by a combination of three codes, such as a classification code, a serial number, and a function code, such as “R1P”.
[0023]
The classification code is a code indicating a classification type when the control signal is classified from a viewpoint different from the function, for example, from a viewpoint of a source or a mode. FIG. 4 shows an example of the classification code. For example, the classification code R indicates an input signal from the input device to the PLC, W indicates an output signal from the PLC to the output device, and D indicates internal dummy data used inside the PLC. The classification codes T, C, and L indicate signals from a timer, a counter, and a latch used in a control operation performed by the PLC. Also, for example, even if an output signal from a PLC to an output device is a signal to an output device connected to another PLC (or a similar control device) via a network, the signal is directly output from the device I / O. In some cases, the data is not input / output, but is first written to a certain memory address as internal dummy data and then communicated by a network communication protocol. Even in other cases, there is a signal once via internal dummy data instead of directly communicating with an output device or an input device via a device I / O. Since it is sometimes better to distinguish such a signal from a normal input / output signal, a classification such as "RD" or "WD" is used for a signal once passing through an internal dummy state. A code can be assigned (omitted in FIG. 4).
[0024]
The function code is a code indicating a type when the control signal is classified in terms of a function performed by the signal (in other words, a purpose of using the signal). FIG. 5 is a diagram showing an example of function codes, showing the meaning of each code and a specific example of a signal. For example, the symbol M indicates a control signal for safety, and specific examples include a signal related to a safety device-related relay such as a relay used for operation preparation. Further, for example, a symbol P indicates a control signal used for confirming the operation and the position of the device. As a specific example, when a device to be monitored reaches a position that must be checked for control, such as a relay using a limit switch for confirming a forward end of a cylinder, or an operation that must be checked. Signals related to relays and timers by the position / operation check device that functions when the function is activated. Note that the description in the description section of FIG. 5 ends with “relay” or the like, but this is for the sake of easy understanding by persons concerned in view of the fact that sequence control is traditionally represented by a combination of relays and the like. It is expressed in.
[0025]
In addition, since the operation of the unit according to the flow of the sequence control is various depending on the type of the unit, the control signals relating to the instruction of the operation and the like have no function code in the example of FIG.
[0026]
The content of the control signal can be expressed by such a combination of the classification code and the function code. However, there are cases where the PLC uses a plurality of control signals having the same signal contents (for example, signals for different units), and in such a case, it is sometimes convenient to be able to distinguish control signals having the same contents. For this reason, in this embodiment, a serial number is given to a control signal having the same combination of the classification code and the function code. In the example of FIG. 3, one signal content code is represented by combining a classification code, a serial number, and a function code in this order.
[0027]
To explain a specific example of the signal content code, for example, “R1P” indicates a signal input from a sensor or the like that detects an operation state, a position, or the like (for example, a forward end) of a control target (unit) to be checked, “R2W” indicates a signal indicating a “work present” state from a sensor or the like that detects the presence or absence of a work. The signal content code “W10” indicates an output signal related to a relay that operates according to a sequence control procedure since there is no function code.
[0028]
The “comment” in the address list generally includes the name of the control target (unit) corresponding to the signal, the detection state of the control target (in the case of a signal from a sensor or the like), and an operation instruction for the control target (to the actuator or the like) In the case of the signal of (1). In the example of FIG. 3, it can be seen that the four control signals of the addresses L773, L752, L772, and L753 are signals related to the same unit named “close contact socket”. Further, in this example, from the comment of the signal L773, for example, it can be read that the signal indicates that the close contact socket, which is a kind of cylinder, has come to the "falling end".
[0029]
As described above, in the present embodiment, the signal content of the control signal is expressed by the “comment” and the “signal content code” of the address list.
[0030]
The data structure of the address list described above is only an example. For example, in the above example, the identification information indicating the unit to which the control signal is related is not included in the signal content code because the information of the existing “comment” can be used. It is also possible.
[0031]
The address list has been described above. Next, the unit library will be described with reference to FIG.
[0032]
While the address list is an extension of the existing one, the unit library is newly introduced in the system of the present embodiment.
[0033]
The unit library is data indicating conditions to be satisfied by a control signal collected and analyzed from the PLC 100. That is, in the analysis device of the present embodiment, the control signal handled by the PLC 100 (that is, the control signal that is input to the PLC, output from the PLC, or generated by the PLC, is listed in the address list from another viewpoint). Signals that satisfy the conditions described in the unit library are collected and used for analysis. The reason that such a condition collection is called a “unit” library is that conditions are collectively described for each type of control target unit.
[0034]
For example, in the example of FIG. 6, conditions that should be satisfied by each control signal related to control of a unit belonging to the unit type are described for each unit type such as “cylinder” and “ramp”. For example, in the “cylinder”, the detection of two operation instruction signals in the opposite directions, ie, forward and backward, and the detection of two operation checkpoints (in this case, the operation end) corresponding to the respective operation instructions of the forward end and the backward end. Associated with the indicated signal. Therefore, in the example of FIG. 6, for example, in the “condition” column of “cylinder”, two signals “operation instruction 1” and “operation instruction 2” for the operation instruction to the cylinder are related to operations in opposite directions. Both the condition that the signal is a signal and the condition that both signals are signals that are output from the PLC directly (via I / O) or indirectly (once through an internal dummy) to the cylinder (the actuator that drives the cylinder) Is required to be satisfied. The latter condition is represented by a condition that the signal content code of the control signal is a pattern of “W *” or “WD *” (* indicates an arbitrary character string). Further, in the present embodiment, since the direction of operation of the unit is described in the comment (see FIG. 3) of the address list, the former condition is that the description of the operation direction in the comment is between two signals related to the same unit. The description indicates that the direction is opposite (for example, ascending and descending, or forward and backward). Although this description is shown in FIG. 6 in a natural language expression for convenience, any description may be used as long as it can be interpreted by the analysis device. For example, for a word indicating the direction described in a comment, if a dictionary in which words indicating the opposite direction are registered is created in advance, such a pair of signals in the opposite direction can be automatically extracted from the description of the comment. it can. Note that signals related to the same unit can be determined by the unit name in the comment of the address list. Similarly, the condition column of the cylinder indicates a condition that the signals “operating end 1” and “operating end 2” indicating the operating end are signals indicating the “end” corresponding to each of the above-described operation instructions. I have. This condition is that the signal content code is a pattern of “* P”, and the description of the comment is the name of the above-mentioned operation instruction with the word “end” added.
[0035]
Similarly, in the unit library, any of the words “abnormal”, “forecast”, and “work present” is included in the comment of the address list as a condition that the control signal related to the unit type “lamp” should satisfy. Is shown. This corresponds to a lamp indicating each state of “abnormal”, “forecast”, or “work present” (corresponding to a lamp indicating the state of each element in the production equipment. There is a lamp indicating a state other than these three types) In this case, in this case, the conditions for the lamps in FIG. 6 include only three types of analysis targets, “abnormal”, “forecast”, and “work present”, from the lamps corresponding to more than three types of states. In addition, since the lamp color is determined for each state corresponding to each lamp, the color is indicated in the unit library. When displaying the analysis result of, there is a use such as using as a color indicating the result.
[0036]
Since the conditions shown in the unit library are for each unit "type", it can be generally said that in an actual production facility, a plurality of corresponding units exist for one unit type. For example, the example in FIG. 3 includes two lamp units, “close contact abnormality” and “vibration abnormality”, and two cylinder units, “close contact socket” and “vibration unit”.
[0037]
This unit library can be created as appropriate according to the purpose of the analysis. In other words, a unit library may be created by inputting a unit type that needs to be investigated for that purpose and a condition that a control signal related to the unit type should satisfy.
[0038]
The analyzer according to the present embodiment selects a control signal that satisfies the condition indicated in the unit library from the control signals indicated in the address list, and sorts the extracted control signals into units. Then, the analyzer collects and accumulates the momentary values of the selected control signals from the PLC 100, and analyzes each unit based on the accumulated data of the control signals related to the unit.
[0039]
The configuration and processing contents of the production equipment operation state analysis device will be described with reference to FIG.
[0040]
In the configuration of FIG. 7, the input device 1 is a functional module for inputting the contents of the address list 2 and the unit library 3 described above. The input device 1 may be a device that allows a user to input each item by a graphical user interface. The input to the unit library 3 is performed by, for example, inputting the type of the unit to be analyzed by the user and the condition that the signal content of the control signal used for the analysis of the unit type should satisfy. As described with reference to FIG. 6, the condition may be in the form of a condition to be satisfied by each control signal, may be in the form of a condition to be satisfied among a plurality of control signals, or may be a combination thereof. In the present embodiment, this condition can be specified as a condition for the signal content code or comment in the address list 2. The condition for the signal content code can be described in the form of, for example, a regular expression. The condition for the comment can be input by specifying a word to be included in the comment of the control signal used for analysis, or by specifying a relationship (for example, an opposite word) that the words should satisfy among a plurality of control signals. It is also possible to specify these plural conditions in combination in the form of an AND condition, an OR condition, or the like.
[0041]
Here, since the conventional address list is generally created at the time of designing the sequence control system, if the address list 2 of the present embodiment is also created at the time of design (the signal list is not The content code may be added), and at the time of analysis, the created address list 2 may be simply read into the analyzer.
[0042]
On the other hand, the unit library 3 may be appropriately created by inputting the condition of the control signal used for the analysis of the unit type for each unit type to be analyzed according to the purpose of the analysis. It is of course possible to input the unit library 3 created before to the analyzer at the time of the subsequent analysis and reuse it.
[0043]
The comment extraction processing unit 4 extracts, from among the control signals shown in the address list 2, those whose signal content code and comment satisfy the conditions shown in the unit library 3, and collects these data into the collection setting data 5 and the analysis setting Register in data 6.
[0044]
The collection setting data 5 is data that defines the data structure of a file (called a collected data file) that stores control signals collected from the PLC 100. FIG. 8 shows an example of the collection setting data. This is an example of collection setting data created from the address list illustrated in FIG. 3 and the unit library illustrated in FIG. Of the signals in the address list in FIG. 3, the condition of the unit library in FIG. 6 is satisfied by the lamps of “contact failure” and “vibration failure” and the cylinders of “contact socket” and “vibration unit”. , Respectively. Accordingly, as shown in FIG. 8, the collection setting data indicates in which “storage position” of the collection data file the values of the control signals M002 and M003 and below in the address list satisfying the conditions are stored. Data. As shown in FIG. 10, the collected data file may be in the form of a two-dimensional table in which the values of the respective control signals are recorded at each sampling time. You just need to specify the number. As described above, the collection setting data is created as data obtained by adding the item of “storage position” to the address list.
[0045]
The analysis setting data 6 is data indicating how to combine the values of the respective control signals collected from the PLC 100 to perform the analysis. In the present embodiment, since the operating state of the production equipment is analyzed in units of unit, the analysis setting data 6 also indicates the relationship between each control signal and the unit. FIG. 9 shows an example of the analysis setting data created from the address list shown in FIG. 3 and the unit library shown in FIG. In this example, “operation instruction 1”, “operation instruction 2”, “operation end 1”, and “operation end 2” are applied to “close contact socket” and “vibration unit” corresponding to the unit type “cylinder”. The addresses and comments of the four control signals are registered. This is because, in the address list (FIG. 3), control signals satisfying the condition described in the condition column of “cylinder” are extracted, and they are assigned the same unit name (this is described at the head of “comment”). What you have should be put together. In this case, if the control signal of “contact socket lowering” is “operation instruction 1”, a control signal of “contact socket lowering end” having “end” in the corresponding operation direction is selected as “operation end 1”. For example, each control signal is registered in such a manner that the correspondence between a plurality of control signals can be identified according to the conditions of the unit library. In the analysis setting data of FIG. 9, the addresses and comments of the corresponding control signals are registered for each of the two units corresponding to the unit type “lamp”. As for “lamp”, “color” of the signal is registered in the condition column of the unit library. In this example, since the control signal corresponds to the keyword “abnormal”, “red” (see FIG. 6) corresponding to the control signal is registered.
[0046]
Returning to the description of FIG. 7 again, when the collection setting data 5 and the analysis setting data 6 are created as described above, the data collection processing unit 7 chronologically converts each control signal from the PLC 100 according to the collection setting data 5. The collected control signal values are collected and stored in the “storage location” of the collected data file indicated in the collection setting data 5. The collection of the control signal is performed by sampling the value of each address indicated in the collection setting data 5 in time series. As a result, a collected data file 8 having data contents as shown in FIG. 10 is created.
[0047]
In the collected data file illustrated in FIG. 10, a column of each control signal (indicated by an address in the figure) to be collected is set in the order according to the setting of the collection setting data, and the value of each control signal at each sampling time is set. Are registered in chronological order. In the collected data file 8, for example, the value of each control signal collected during a predetermined inspection period is registered. Since the control signal handled by the PLC 100 is generally a binary value of ON / OFF, in the example of FIG. 10, the collected data file 8 records whether the control signal is 0 or 1 at each time.
[0048]
When the collected data file 8 is completed in this way, the display analysis processing unit 9 analyzes the values of the control signals stored in the file 8 while referring to the analysis setting data 6 and the collection setting data 5. Create display analysis data to be provided to the user.
[0049]
In the analysis processing by the display analysis processing unit 9, for each unit indicated in the analysis setting data 6, analysis is performed on the unit from collected data of each control signal corresponding to the unit. The content of the analysis can be set in advance for each unit type.
[0050]
FIG. 11 exemplifies an analysis flow for a unit called “close contact socket” corresponding to the unit type “cylinder”. Here, it is assumed that an analysis is performed in which a time chart showing a time-series change in the operating state is created for the cylinder.
[0051]
In the flow of FIG. 11, first, the addresses of four control signals related to the contact socket, which is the first cylinder unit, are specified from the analysis setting data 6 (A), and the signal data of each of these addresses is stored in the collected data file 8. The column in which the data is stored is specified from the collection setting data 5 (B), and the data of each specified column is extracted as time-series data of the value of each control signal of the contact cylinder (C). For the purpose of explanation, D shows the time-series data of each control signal in association with the type of each signal (indicated by the description of “comment”). As can be seen, the time is plotted on the horizontal axis, the two operating ends (rising end and falling end) are the upper and lower limits of the vertical axis, respectively, and the operation instruction 1 (down) is turned on (value “1”). To the point at which the operation end 1 (falling end) corresponding to the instruction is turned on by an arrow, and similarly, from the point at which the operation instruction 2 (up) is turned on, the operation end 2 (upward) corresponding to the instruction. A time chart showing a time-series change in the position of the close contact socket is obtained by connecting the point at which the end is turned on with an arrow (E).
[0052]
Similarly, a time chart of the position change can be created for the vibration unit.
[0053]
For the adhesion abnormality and the vibration abnormality, the time is plotted on the horizontal axis, and the period in which the control signal indicating the abnormality is ON is the color “red” shown in the analysis setting data 6, and the other periods are An analysis process can be performed to create a band graph having a background color.
[0054]
As described above, the two unit types of the cylinder and the lamp have been exemplified. However, if the analysis process corresponding to the other unit type is defined, the analysis result corresponding to the unit type is obtained in the same manner as described above. You can ask. For example, when it is desired to see a change in the number of production units, the value of the production number counter at each sampling time is collected from the PLC by registering the production number counter in the unit library 3 and the time of the accumulated production number is calculated based on the value. A graph showing a change or the like can be created.
[0055]
FIG. 12 is a list display example of the analysis result of the operating state of each unit of the production facility obtained in this way. In this example, the state change of each unit is shown in a time chart.
[0056]
As described above, according to the present embodiment, the control signal collected from the sequence controller (PLC) and used for analysis satisfies the signal content of the control signal (indicated by the signal content code and comment in the address list). If a condition to be specified is specified, the analyzer automatically extracts a control signal having a signal content satisfying the condition. Therefore, in the present embodiment, it is not necessary for the operator to individually select control signals used for analysis one by one, so that the burden on the operator can be reduced.
[0057]
Further, in this embodiment, for each unit type to be analyzed, a unit library in which a set of conditions to be satisfied by a control signal related to the type is used is used. You can see which unit is involved. Thereby, the operation state of each unit can be analyzed from the collected data of the control signals related to each unit.
[0058]
The above embodiment is merely an example, and various changes can be made within the scope of the present invention. For example, in the above embodiment, two data, the collection setting data 5 and the analysis setting data 6, are created from the address list 2 and the unit library 3, but the collection setting data 5 and the analysis setting data 6 are combined into one data. It can also be created.
[0059]
In the above embodiment, the control signals satisfying the conditions shown in the unit library 3 are collected in time series from the PLC, and the analysis is performed based on the collected control signals. All control signals that may be performed (in extreme cases, all control signals handled by the PLC) are collected from the PLC and accumulated, and the conditions indicated in the unit library 3 are selected from among the accumulated control signals. A configuration is also possible in which what is satisfied is extracted and used for analysis.
[0060]
In addition, the analyzer of the present embodiment is always connected to the PLC, and the storage capacity for the collected data file in the analyzer is used like a ring buffer, and the collected data from the current time to a predetermined period before is always used. Can be stored. According to this configuration, when an abnormality occurs in the production equipment, the operation state of each unit for a predetermined period until the abnormality occurs can be analyzed by the analysis device. In this case, if a control signal indicating an abnormal state to be noticed is registered in the analyzer in advance, the turning on of the control signal is used as a trigger to store the collected data file held by the analyzer at that time. A configuration is also possible in which an analysis process is automatically executed and an analysis result as shown in FIG. 12 is output.
[Brief description of the drawings]
FIG. 1 is a diagram for explaining control signals handled by a PLC that controls a production facility in sequence.
FIG. 2 is a diagram for explaining input / output devices corresponding to a unit called a cylinder.
FIG. 3 is a diagram illustrating an example of data content of an address list.
FIG. 4 is a diagram illustrating an example of a classification code.
FIG. 5 is a diagram showing an example of a function code.
FIG. 6 is a diagram showing an example of data contents of a unit library.
FIG. 7 is a functional block diagram illustrating a schematic configuration of a production facility operation state analysis device of the embodiment.
FIG. 8 is a diagram illustrating an example of the data content of collection setting data.
FIG. 9 is a diagram showing an example of the data content of analysis setting data.
FIG. 10 is a diagram illustrating an example of data contents of a collected data file.
FIG. 11 is a diagram for explaining a flow of analysis of a “close contact socket” corresponding to a unit type “cylinder”;
FIG. 12 is a diagram showing an example of a time chart of an operation state of a production facility generated as an analysis result.
[Explanation of symbols]
1 input device, 2 address list, 3 unit library, 4 comment extraction unit, 5 collection setting data, 6 analysis setting data, 7 data collection processing unit, 8 collection data file, 9 display analysis processing unit.

Claims (4)

A production equipment state analysis device that collects and accumulates control signals used for control by a sequence controller that controls the production equipment, and generates output data for use in analyzing the operation state of the production equipment based on the accumulated information,
For each control signal used by the sequence controller, a signal list including information indicating the signal content of the control signal,
Condition input means for inputting a condition to be satisfied by the signal content of the control signal used for analysis,
Collection target signal extraction means for extracting from the signal list a control signal having a signal content satisfying the condition input by the condition input means,
Signal collection means for collecting and accumulating each control signal extracted by the collection target signal extraction means in time series from the sequence controller,
Analysis means for creating analysis result data that can be used for analyzing the operation state of the production facility based on each control signal collected and accumulated by the signal collection means,
A production equipment condition analysis device comprising: The signal list includes corresponding unit information indicating which control signal is a signal related to which of the units constituting the production facility,
The analysis unit summarizes information of each control signal collected and accumulated by the signal collection unit for each control signal related to the same unit based on the corresponding unit information, and for each unit, a control signal related to the unit. 2. The production equipment state analysis apparatus according to claim 1, wherein analysis result data relating to the operation state of the unit is created from the information of the unit. Means for storing, for each type of unit constituting the production facility, an analysis process corresponding to the type;
Means for storing type determination information for determining which of the types each unit constituting the production equipment belongs to,
Wherein the analysis means creates analysis result data relating to the operating state of the unit from information of a control signal related to the unit according to the analysis processing content corresponding to the type to which the unit belongs. The production equipment condition analysis device according to claim 2. The condition input means includes a condition to be satisfied by the signal content of each control signal used in the analysis, for each type to be analyzed among the types of the units constituting the production equipment, a signal of each control signal related to the type. 2. The production equipment state analyzing apparatus according to claim 1, further comprising a user interface for inputting a set of conditions to be satisfied.

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