JP2009064185A - Monitor for automatic machine and operation device for automatic machine - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an operation device for an automatic machine, allowing reduction of a time spent for narrowing down a part wherein abnormality occurs in time of an abnormality stop of the automatic machine performing repetition operation. <P>SOLUTION: This monitor for the automatic machine has: a monitor data acquisition part 80 acquiring present situations in a plurality of production processes and small processes constituting the production processes as monitor data; a process decision part 83 deciding the production process presently performed based on the monitor data; an image storage part 85 previously storing a process image of the automatic machine in each of the plurality of production processes; an image calling part 84 calling the process image from the image storage part 85; a situation detection part 81 detecting the abnormality based on the monitor data, and outputting it as situation information; a situation storage part 82 storing the situation information together with information about a detection time; and a display 56 displaying the process image called in the image calling part 84, and displaying the information stored in the situation storage part 82 in order of the detection time. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to, for example, a monitoring device for an automatic machine such as a packing device that cuts a fiber as a raw material and packs it in a certain amount, and an operation device for the automatic machine.

For example, a plant that performs automatic operation is provided with a monitoring device, and this monitoring device detects and displays an abnormal operation item in the manufacturing process, thereby notifying an operator of the occurrence of an abnormality during operation (for example, , See Patent Document 1).
In factory automation (hereinafter referred to as “FA”), an apparatus capable of monitoring a system via a programmable controller (hereinafter referred to as “PLC”) has been proposed.
JP-A-11-143528 JP 2003-295914 A

  By the way, in the above prior art, a plurality of processes are usually performed in parallel according to a PLC ladder program. For this reason, when there is some abnormality and the apparatus is stopped, it is necessary to visually estimate the state of the apparatus to determine which process is stopped, and specify it on the ladder program. However, in an automatic machine that performs repeated operations, if the device is in a stopped state, it is unclear whether the stopped process is a process in the forward path or a process in the backward path.・ In the function chart, it is unknown whether the current process is stopped because the conditions in the subsequent process are not met, or whether the current process is stopped because the conditions in the current process are not met. There is a problem that it takes time to narrow down the stopped processes and it takes time to return to normal.

  SUMMARY OF THE INVENTION Accordingly, the present invention provides an automatic machine operating device capable of shortening the time for narrowing down the location where an abnormality has occurred when the automatic machine that is repeatedly operating is abnormally stopped.

  In order to solve the above-mentioned problem, the invention described in claim 1 is a monitoring device for an automatic machine that continuously repeats all processes from raw material charging to product delivery. A monitor data acquisition unit (for example, the monitor data acquisition unit 80 in the embodiment) that acquires the current state of the production process and the small processes constituting the production process as monitor data, and the monitor data acquired by the monitor data acquisition unit A process determination unit (for example, a process determination unit 83 in the embodiment) that determines a production process that is currently performed based on the above, and a process image of the automatic machine that is colored only on a component that performs the production process, An image storage unit (for example, the image storage unit 85 in the embodiment) stored in advance for each of the plurality of production processes and the process determination unit. An image calling unit (for example, the image calling unit 84 in the embodiment) that calls the process image corresponding to the produced production process from the image storage unit, and at least an abnormality in the small process of the production process based on the monitor data A situation detection unit (for example, the situation detection unit 81 in the embodiment) that detects and outputs situation information, and a situation storage unit (for example, the situation information detected by the situation detection unit together with detection time information) , A status storage unit 82) in the embodiment, and a display unit that displays the process image called by the image calling unit and displays the information stored in the status storage unit in the order of the detection time (for example, implementation) And a display 56).

  The invention described in claim 2 is characterized in that the situation detection unit detects occurrence of abnormality, cancellation of abnormality, and mode switching operation as a current situation of the automatic machine based on the monitor data.

  The invention described in claim 3 is characterized in that the situation detecting unit detects the occurrence of the abnormality based on a standard operating time preset for each of a plurality of components in the production process.

  The invention described in claim 4 includes a control device (for example, the control device 21 in the embodiment) for operating the automatic machine, and a communication device (for example, the monitor communication unit 30 in the embodiment, 32) and the monitor device according to claim 1 or 2, wherein the monitor device transmits a command signal sent from the control device to the automatic machine, and a component of the automatic machine. And a storage unit (for example, an implementation unit) that writes various signals sent from the detection devices (for example, the degenerate position limit switch 50 and the extension position limit switch 51 in the embodiment) to the control device via the communication device. Storage unit 40) in the embodiment, and monitor data stored in the storage unit via the communication network is stored in the storage unit from the storage unit. A server to be read periodically (for example, the data server 34 in the embodiment) is connected, and an input terminal (for example, the a and b clients 35 and 36 in the embodiment) having the display unit is connected. It is characterized by that.

According to the first aspect of the invention, the process determination unit determines the production process based on the monitor data acquired by the monitor data acquisition unit, and the process image corresponding to the production process is called from the image storage unit and displayed. By displaying in the section, there is an effect that the production process currently being performed can be easily grasped.
Furthermore, when an automatic machine stops due to some abnormality, it is possible to instantly grasp in which production process the automatic machine is stopped. In addition, when an abnormality occurs in this way and the automatic machine stops, the situation detection unit detects an abnormality in a small process unit of the production process and stores it in the situation storage unit, which is stored in this situation storage unit. By displaying information on the display unit together with process images, it is possible to quickly identify when an abnormality has occurred and at which sub-process of the production process is stopped. -It is possible to shorten the time for narrowing down the abnormal part by the amount that can omit the work of narrowing down the failure part by referring to the chart or ladder program.

  According to the second aspect of the present invention, in addition to the effect of the first aspect, by detecting the occurrence of abnormality, the cancellation of abnormality, and the mode switching operation, an abnormality that has occurred along with the mode state of the automatic machine is currently There is an effect that it is possible to grasp what kind of state it is.

  According to the invention described in claim 3, since it is possible to detect the occurrence of an abnormality for each small process based on a preset standard operating time, before the components operating in the small process completely move There is an effect that the abnormality of the component can be detected and the automatic machine can be prevented from abnormally stopping.

  According to the invention described in claim 4, the monitor data stored in the storage unit of the monitor device can be periodically sent to the server and the input terminal, and the monitor data is input to the server without imposing a load on the control device. Since it can be taken into the terminal, there is an effect that it is possible to identify the location where an abnormality has occurred in all the processes at an early stage.

  Next, embodiments of the present invention will be described with reference to the drawings. 1 and 2 show a packing device 1, which cuts strip-shaped acrylic fibers continuously carried as raw materials into a predetermined length, weighs the cut fibers, and sets a certain amount. Then, wrap it in a sheet, hang it on a band, and ship it for packing.

  The packing device 1 is provided with a cutter 2 for cutting a strip-shaped acrylic fiber, which is a raw material in a raw material box carried into a factory, to a predetermined length, and the cutter 2 is used for measuring the weight of the cut fiber. A hopper 3 is connected. The weighing by the weighing hopper 3 is performed eight times in units of 50 kg, and every 50 kg is dropped from the weighing hopper 3 to the lower shovel loader 4 and dropped onto the closed bottom plate 6 of the precompression box 5 from the shovel loader 4. In this state, preliminary compression is performed by the preliminary compression cylinder 7 positioned above. This is repeated 8 times, and when the fiber reaches 400 kg, the bottom plate 6 of the precompression box 5 opens, and the precompressed 400 kg of fiber is dropped into the A packing car 8 or the B packing car 9 positioned below. Here, a pair of the cutter 2, the weighing hopper 3, the shovel loader 4, and the precompression box 5 are arranged on the left and right.

  The A packing car 8 and the B packing car 9 arranged under each pre-compression box 5 are arranged in a pre-compression position with a main compression position, which will be described later, sandwiched between them. Perform compression. The A packing car 8 and the B packing car 9 are provided so as to be movable along a rail 10 provided between the main compression position located at the center of both and the preliminary compression position. When the final preliminary compression of 400 kg of fibers using the preliminary compression cylinder 7 is completed in any of the packing cars 8 and 9, the preliminary compression cylinder 7 is retracted upward, and the packing car moves to the main compression position. A table 11 is disposed at the main compression position, fibers are placed on the table 11, and main compression is performed by a main compression cylinder 12 disposed above the table 11.

In the packing apparatus 1, while the A and B packing carts 8 and 9 are standing by at the preliminary compression position and performing the preliminary compression, the upper sheet 19 is loaded and waited above the main compression position. Then, a lower sheet feeding device 14 for loading and waiting the lower sheet 20 on the table 11 below the main compression position is disposed.
Further, a banding device 15 is provided on the front side of the table 11 to band the fiber bundle in the main compression state in the front-rear direction. An upper sheet folding device 16 is provided below the compression cylinder 12, and a lower sheet folding device 17 is provided below the table 11. In addition, the packing device 1 is provided with a carry-out device 18 that tilts the fiber bundle that has been banded and packed on the rear side of the table 11 and is carried away to the back side.

  The cutter 2, the weighing hopper 3, the excavator loader 4, the precompression box 5, the A and B carts 8 and 9, the precompression cylinder 7, the main compression cylinder 12, the upper and lower sheet supply devices 13 and 14, and the banding The device 15, the upper and lower sheet folding devices 16, 17, and the carry-out device 18 constitute the packaging device 1, and the existing control device 21 that controls the packaging device 1 by this packaging device 1 and the operation of the packaging device 1 are monitored. A monitor device 22 is provided.

  As shown by a broken line in FIG. 3, the existing control device 21 that controls the operation of the packing device 1 is a main compression control panel 23 related to the process using the main compression cylinder 12, the banding device 15, the carry-out device 18, and the like. It has. The main compression control panel 23 is mainly composed of a well-known PLC. The PLC is a controller for FA including a processing unit (CPU), a storage unit, an input circuit, and an output circuit. The PLC fetches input signals from various sensors, limit switches, etc., which are input devices, into the input circuit, and outputs ON / OFF output signals from the output circuit under the conditions set in advance by the ladder program. 15, it is sent to output devices such as electromagnetic valves, motors, indicator lamps, etc., which are components such as the carry-out device 18, and these are driven and controlled.

  The control device 21 includes a precompression A control panel 24 that handles precompression work using the A packing car 8 and a precompression B control board 25 that handles precompression work using the B packing car 9. The configurations of the preliminary compression A control panel 24 and the preliminary compression B control panel 25 are similar to the compression control panel 23 in that the main component is a PLC that is a controller for FA. The PLC is a processing unit (CPU). And a storage unit, an input circuit, and an output circuit, the cutter 2, the weighing hopper 3, A or B packing cars 8, 9 corresponding to each of the preliminary compression A control panel 24 and the preliminary compression B control panel 25, and the preliminary compression cylinder 7 is driven and controlled, which is a solenoid valve, a motor, an indicator lamp, and the like.

  The main compression control panel 23, the preliminary compression A control panel 24, and the preliminary compression B control panel 25 are each provided with a communication unit 26. Each communication unit 26 is connected to each other, and each communication unit 26 is connected to a corresponding operation panel 27, 28, 29. The operation panels 27, 28, and 29 are provided with three types of buttons “automatic”, “manual”, and “safety device activation” for inputting the operation mode. When each button is pressed, the corresponding button is lit. Here, “automatic” means the automatic operation mode, “manual” indicates the manual operation mode in which the process is moved every step when pressed, and “safety device operation” is pressed when the safety fence is opened. This button is mainly pressed during inspection.

The compression control panel 23 is provided with a monitor communication unit 30, and this monitor communication unit 30 is connected to a monitor communication unit 32 provided in a monitor PLC 31 that forms the main body of the monitor device 22. Here, the monitor communication unit 30 of the compression control panel 23 is connected to an empty slot for connecting an external device.
Command signals sent from the output circuits of the main compression control panel 23, the preliminary compression A control panel 24 and the preliminary compression B control panel 25 constituting the control device 21 to the packaging device 1, and the components and detection of the packaging device 1 Various signals taken from the devices into the input circuit of the main compression control panel 23, the preliminary compression A control panel 24, and the preliminary compression B control panel 25, which are the control device 21, are the main compression control panel 23, the preliminary compression A control panel 24, and The data is written in the storage unit of each PLC of the preliminary compression B control panel 25. The state of the internal relay is also written as data in the storage unit. Since the monitor communication unit 30 is connected to the main compression control panel 23, the data written in each storage unit is read from each storage unit and is transmitted from each communication unit 26 to the monitor communication unit 30 of the main compression control panel 23. From here, it is sent to the monitor communication unit 32 of the monitoring PLC 31.

The command signal sequentially sent to the monitor communication unit 32 of the monitoring PLC 31 is, for example, “1” and “0” data relating to ON / OFF of the limit switch, which is directly written in the storage unit as data. In addition, there is data that requires calculation, but the data of the calculation result is also written in the storage unit. Thus, the processing unit of the monitor PLC 31 and the storage data length of the storage unit 40 are stored in each control panel of the control device 21, that is, in relation to storing calculation results and handling large data such as analog data. The compression unit is set longer than the processing unit of the processing unit of the main compression control panel 23, the preliminary compression A control panel 24, and the preliminary compression B control panel 25 and the data length of the storage unit. Here, the monitor PLC 31 is connected with an extra air temperature sensor, an oil temperature sensor, an analog sensor AS of a cooling water temperature sensor system, a digital sensor DS, etc., which are specially added sensors for monitoring. ing.
Accordingly, the main compression control panel 23, the preliminary compression A control panel 24, and the preliminary compression B control panel 25 perform only the control of the packing device 1. Since the monitoring process can be left to the monitoring PLC 31, it is advantageous in that no load is applied to the drive control of the packaging device 1.

  The monitor PLC 31 is provided with a network communication unit 33. This network communication unit 33 uses an existing network card and is connected to an external data server 34 and a and b clients 35 and 36 which are input / output terminals.

FIG. 4 is a block diagram of the monitor PLC 31. As shown in the figure, the monitor PLC 31 includes a processing unit (CPU) 37 that performs comparison, determination, arithmetic processing, and the like. An input circuit 38 and an output circuit 39 are connected to the processing unit 37, and the various sensors AS and DS shown in FIG. 3 are connected to the input circuit 38. The output circuit 39 is connected to the external device G added when the monitor PLC 31 is added. A network communication unit 33 and a monitor communication unit 32 are connected to the processing unit 37.
A storage unit 40 is connected to the processing unit 37, and input / output signals from the input circuit 38 and the output circuit 39 are written to the storage unit 40 as data via the processing unit 37 and read by the processing unit 37. The result of arithmetic processing of the output data is written as arithmetic result data, and these are held. Note that a timer 41 is connected to the processing unit 37.

  Of the data written in the storage unit 40, digital data is read out by the processing unit 37 every minute, for example, transmitted from the network communication unit 33 to the data servers 34, a, b clients 35, 36, and analog data. For example, the data is read out by the processing unit 37 every second and transmitted from the network communication unit 33 to the data server 34, a, b clients 35, 36.

FIG. 5 shows a hydraulic circuit for operating the compression cylinder 12. A procedure from when an operation command is transmitted to the main compression cylinder 12 to when the main compression cylinder 12 is operated is detected by various sensors and data of detection results of the sensors is monitored will be briefly described. In this example, a new compression oil tank temperature sensor 54 for detecting the temperature of the oil in the oil tank 42 when a monitoring PLC 31 is added to the existing control device 21 is newly provided. In the figure, for convenience of illustration, the main compression cylinder 12 is depicted in a horizontal state.
A suction side of a pump 44 driven by a motor 43 is connected to an oil tank 42 that stores hydraulic oil, and an IN port 46 of an electromagnetic valve 45 is connected to the discharge side of the pump 44. A return pipe 47 to the oil tank 42 is connected to the return port of the electromagnetic valve 45. The electromagnetic valve 45 switches the hydraulic oil supply flow path between the expansion side pressure chamber and the contraction side pressure chamber of the compression cylinder 12. The electromagnetic valve 45 has two supply ports connected to the main compression cylinder 12. When the electromagnetic valve 45 is switched to the a side (normal position), hydraulic oil is supplied from the expansion side supply port 48 to extend the main compression cylinder 12. Then, when switched to the b side, hydraulic oil is supplied from the contraction side supply port 49 to operate the main compression cylinder 12 to the contraction side.

The main compression cylinder 12 is provided with a contraction position limit switch 50 and an expansion position limit switch 51 for detecting the position of the rod tip of the main compression cylinder 12 in order to confirm the start position and the end position of the expansion operation. The solenoid valve 45 is provided with a detection switch 52 that outputs a signal ON when switched to the a side and is turned OFF when switched to the b side.
The motor 43 and the electromagnetic valve 45 are operated by relays 53 and 55 provided on the compression control panel 23, respectively. Signals from the degeneracy position limit switch 50 and the expansion / contraction position limit switch 51 are written as data in the storage unit of the main compression control panel 23, and the monitor communication unit 30 of the monitoring PLC 31 is changed from the monitor communication unit 30 of the main compression control panel 23. Then, the data is written in the storage unit 40 of the monitor PLC 31.
Further, the oil tank 42 is provided with a main compression oil tank temperature sensor 54 for detecting the oil temperature. Since the main compression oil tank temperature sensor 54 is not provided in the existing equipment, it is added together with the monitoring PLC 31. The detection signal from the compressed oil tank temperature sensor 54 is written as data in the storage unit 40 of the monitoring PLC 31.

  Here, the command signal of the internal relay, the detection switch 52, the degenerative position limit switch, which are necessary for monitoring the driving of the motor 43 and the switching operation of the electromagnetic valve 45 performed by the relays 53 and 55 of the compression control panel 23. 50 and the signal from the extension position limit switch 51 are written from the compression control panel 23 to the storage unit 40 of the monitoring PLC 31, and from these data written to the storage unit 40 of the monitoring PLC 31, the monitoring PLC 31 The processing unit 37 calculates the expansion speed and the contraction speed of the main compression cylinder 12, and the calculation result data is also written in the storage unit of the monitoring PLC 31. Specifically, the extension speed of the compression cylinder 12 is obtained by dividing the distance between the retracted position and the extended position by the time from passing through the retracted position limit switch 50 to passing through the extended position limit switch 51. The reduction speed is obtained by dividing the distance between the extension position and the reduction position by the time from passing through the extension position limit switch 51 until passing through the reduction position limit switch 50.

  Further, the time from when the command signal is issued until the operation is started and the time until the operation is completed are calculated by the processing unit 37 of the monitoring PLC 31 and then written as data in the storage unit 40. These data are written in the storage unit 40 in association with the data of the time at which the command is issued. These data are time on the horizontal axis and the time to start the operation after the command is issued, or until the operation is completed. The history is written in the data server 34 as the time taken, and is displayed as history data on an application program of a client 35 and b client 36 described later (see the temperature example in FIG. 14). Similarly, history data is stored in the data server 34 for the operation of the components other than the main compression cylinder 12. By displaying these as a history using a graph, abnormalities can be confirmed at a glance as compared with normal times.

  In the example of FIG. 5, after the command signal is issued, the solenoid valve 45 returns to the a side, the motor 43 is driven and hydraulic pressure is generated, the rod of the main compression cylinder 12 starts to expand, and the rod tip is in the retracted position. The time until it passes through the limit switch 50 is the time until the expansion operation of the main compression cylinder 12 starts, and the time until it passes through the expansion position limit switch 51 is the time until the main compression cylinder 12 ends the expansion operation. Also, after the command signal is issued, the solenoid valve 45 is switched to the b side and the motor 43 is driven to generate hydraulic pressure, the rod of the compression cylinder 12 starts to retract, and the tip of the rod moves the extension position limit switch 51. The time until the compression operation of the main compression cylinder 12 is started is the time until the compression operation of the main compression cylinder 12 starts, and the time until the compression operation of the main compression cylinder 12 is completed is the time until the compression position limit switch 50 is passed. These times are stored in the storage unit 40 of the monitoring PLC 31 and written as history data in the data server 34.

  As shown in FIG. 3, the data server 34 stores the data sent from the monitoring PLC 31 as a file in association with the time data. For example, when one month is collected, a new next file is created. Data transmission to the data server 34 may be performed from the data server 34 side as a transmission request, or may be transmitted from the monitoring PLC 31. In addition, data can be read from the data server 34 by the a and b clients 35 and 36. Further, a success rate described later and data related thereto are written as CSV files in the data server 34 for each component and every 8 hours.

  The a client 35 is an ordinary personal computer, and information sent from the network communication unit 33 of the monitoring PLC 31 and information in the data server 34 are displayed on the display 56 which is a display unit of the a client 35. It is displayed via an application program on the client 35 side. Since the b client 36 has the same configuration as the a client 35, the description thereof is omitted.

FIG. 6 is a sequential function chart showing the steps from weighing to unloading by the weighing hopper 3 according to the process. Originally, this sequential function chart should be described after the explanation of the main screen, which will be described later, as the contents displayed on the display 56 of the a and b clients 35 and 36. However, for convenience of explaining the flow of the process, a, The explanation will be given prior to the explanation of the main graphic screen of the clients 35 and 36 (see FIG. 7).
This sequential function chart is displayed as an SFC monitoring screen when “SFC monitoring” (shown in FIG. 7) is selected on the display 56 of the a and b clients 35 and 36 based on information from the monitoring PLC 31 and the data server 34. Is displayed. SFC is a sequential function chart.

  In the weighing process A of step S1a, weighing is performed every 50 kg by the weighing hopper on the preliminary compression A side, and a total of 400 kg of fibers are packed into the A packing car from the preliminary compression box in the packing car packing process of step S2a. The A packing car packed with a predetermined amount of fibers starts to move to the main compression position in step S3a (A packing car movement (main pressure)), and reaches the main compression position in step S5 (A packing car moving process). At the main compression position, as shown in step S6, the main compression cylinder is lowered from above the A-packed car to perform main compression with the table (main compression lowering step). Thereafter, in step S4a, the main compression cylinder is raised halfway, and the A-packaged car moves to the precompression position with the door open (A-packed car movement (preliminary compression)), and proceeds to step S2a.

  Next, in step S7, the fiber bundle is wrapped with the upper sheet and the lower sheet that are set in advance with the main compression cylinder lowered (packing process), and the band is hung on the fiber bundle wrapped in step S8 by the banding device. And tighten (banding process).

  When the banding process ends, the main compression cylinder rises in step S9, and the unloading apparatus unloads the fiber bundle as a product in step S10 (unloading process). Next, in step S11, the process shifts to a loading operation in a warehouse (warehouse process).

When the product on the table is unloaded in the unloading process of step S10, the process proceeds to the sheet feeding process of step S12, and the upper sheet and the lower sheet are supplied to predetermined positions by the upper sheet supply device and the lower sheet supply device, and step In S13, it prepares for the movement of the B packing car on the B pre-compression side to the main compression position (packing car moving process in step S5) (standby process). The processes from Step S1b to Step S4b on the side of the B packaging car are the same as the processes from Step S1a to Step S4a on the side of the A packaging car described above, and thus description thereof is omitted.
Here, this sequential function chart is displayed on the display 56 of the a client 35 and the b client 36, and is in the process being executed (indicated by cross-hatching) and the process having been executed immediately before (indicated by hatching). Are displayed with different colors.

By the way, in the storage unit 40 of the monitoring PLC 31, work names performed by the components of the packaging device 1 are written in association with the small process number, the small process start time, and the small process end time. In addition, since the small process corresponds to a component that performs a plurality of operations, the apparatus name is also associated with the small process and stored. Each process shown in FIG. 6 is composed of a group of operations by a plurality of apparatuses in which a plurality of small processes of such an apparatus are combined.
The start of each process is the start timing of the small process that is first performed in the process, that is, the start time of the movement of a specific component of an apparatus, and the end of each process is the small process that is performed at the end of the process. This is the end timing of the process, that is, the end time of the movement of a specific component of an apparatus.

  Therefore, if the block indicating the process including the current small process read from the storage unit 40 of the monitoring PLC 31 in FIG. 6 is being executed, the color of the block indicating the process is, for example, the a and b clients 35. 36, the data of the storage unit 40 of the monitoring PLC 31 and the data server 34 are read and changed to red, and the color of the step just completed is, for example, the application of the a, b clients 35, 36. The program reads the data in the storage unit 40 of the monitoring PLC 31 and the data server 34, and changes the data to, for example, green indicating completion different from that being executed. Here, the color is changed during the process execution is the start time of the small process that comes at the beginning of the process, and the color during the process execution is changed to the color of the process completion at the end of the process. End time. In this example, the weighing process A, the weighing process B, the sheet feeding process, and the unloading process are being executed, and the packed car packing process is completed. The operation time required last time is displayed beside each block.

FIG. 7 shows a main graphic screen. An initial screen (not shown) is displayed on the display 56 of the a and b clients 35 and 36 based on the information from the monitor PLC 31 and the information from the data server 34. Displayed when “Monitor” is selected from the arranged menu.
The displays 56 of the a and b clients 35 and 36 are provided with an overall perspective view of the packing device 1 displayed in monochrome on the uppermost part, and an alarm display field on a part of the lower part. In the overall perspective view, all the components operating in the process are colored for each process shown in FIG. 6, and it is possible to confirm at a glance which process is currently in progress. Therefore, when the apparatus is stopped due to a failure, the screen is also stopped in a state where the component is colored, so that it can be easily confirmed that the colored part is a failed part.

  Here, the image data indicating the overall view is provided for the required number of steps, and this is stored in the data server 34 as image data in which the portions of the steps are colored in association with each step. The image data may be stored in the a and b clients 35 and 36. In addition, you may use the image color-coded for every small process. In response to the current process sent from the monitoring PLC 31 to the a and b clients 35 and 36, the application programs of the a and b clients 35 and 36 are sent from the data server 34 (or the a and b clients 35 and 36). The corresponding image is read and displayed on the display 56 of the a and b clients 35 and 36.

  In the alarm display column, alarm information and operation information of the operation panels 27 to 29 are displayed in the order of event occurrence from the bottom so that the latest situation is at the top. Here, the alarm information is displayed in order of time when an abnormality occurs in the packaging device 1 and when the abnormality that occurs when the existing PLC outputs the next operation signal is canceled. The display items in the alarm display column are “NO” indicating the event number, “occurrence time” indicating the time when the alarm etc. occurred, “situation” indicating whether the operation has occurred or has been canceled, and alarm. “Category” indicating the cause of the occurrence of the error, and specifically “Message” indicating the contents of the small process.

Here, in the “category”, when threshold values are provided for the operation time, speed, temperature, current value, etc. of the component parts, the threshold value range (LO) is not reached. When the threshold range is exceeded (threshold value (HI)), when the threshold range is exceeded within a certain range (answer operation), when a certain range is exceeded, or when it is not operating (Answerback), and (Status) when operation is switched by pressing the operation panel automatically or manually.
“Situation” includes an occurrence of an alarm or release of the alarm by the output of the next operation signal from the existing PLC (release), and a change of the operation mode on the operation panels 27 to 29 (switch). There is. The answer operation and answer back are collectively referred to as an answer error.

By the way, the storage unit 40 of the monitoring PLC 31 stores threshold values related to the operation time, speed, temperature, and current value of the component parts together with actual data in association with the small process. As a result of the comparison between the actual data and the threshold value, if it is within the threshold range, it is stored as “success”, and the number of successes from the reset is added and stored. In the case of LO), threshold (HI), answer operation, and answer back, this result is stored for notification by the alarm described above. Here, the reset means a case where the number reset button is pressed in FIG.
Further, the operation status of the operation panels 27 to 29 is stored every time “automatic”, “manual”, and “safety device activation” are pressed. Therefore, when an alarm is generated in a small process or when an operation is performed on the operation panel, this situation is displayed on the main graphic screen of the a and b clients 35 and 36 as shown in FIG. A history is displayed as the operation status (alarm event) 27-29. These alarm events are stored in the data server 34 as a CSV file for each component or every 8 hours.

In the main graphic screen shown in FIG. 7, the menu displayed on the left side includes “Threshold setting / monitor”, “Status”, “SFC monitoring”, “Alarm status”, “Display group”, “Trend”, and currently active. The “monitor” is placed.
Here, regarding the alarm currently occurring, when “alarm status” is selected from the menu of the display 56 of the a and b clients 35 and 36, the current alarm status is displayed on a screen (not shown), and the corresponding small alarm is displayed. You can check the process name, date, time, and alarm category. When “SFC monitoring” in this menu is selected, the above-described sequential function chart of FIG. 6 is displayed.

  FIG. 8 shows an operation status monitor screen. This operation status monitor screen is displayed when “threshold setting / monitor” is selected in the menu of the display 56 of the a and b clients 35 and 36 based on the information from the monitoring PLC 31 and the information from the data server 34. In this operation status monitor screen, the input / output signal state, the time from the operation signal to the operation completion answer, and the number of operations are monitored, and when the result is compared with the threshold value, the color is displayed when it is out of the threshold range. In addition, by managing the number of operations of the equipment used, it is possible to make a replacement plan before the equipment design limit.

  The display items of the threshold setting screen are “NO” indicating an event number, “device name” used across a plurality of small processes, “name” of the small process, and actual “operation time” of the small process. “Number of operations 1” to “Number of operations 5” for each component or sensor, “In operation” that is ON when in operation, “Answer back” that is an alarm, “Threshold (HI)”, “Threshold (LO)” “Number of times” that is ON within the threshold of the number of times, “Answer back” and “Threshold” that are set. “In operation”, alarm relation, and “number of times” are displayed as ON and OFF, and the number of times is displayed otherwise. In this example, the operation time of 49 seconds exceeded the threshold value of 7 seconds in the process of lowering the front and rear sheet folding candles (warehouse side) in the small process of event number 126, the threshold value (HI) was turned on, and the color of the cell in this part changed and alarm (Hatched part). These data are fetched from the monitor PLC 31.

  Here, when each sub-process column of the menu is clicked, a threshold setting screen shown in FIG. 9 is popped up on the screen of FIG. This threshold setting screen is displayed on the display 56 of the a and b clients 35 and 36 based on the information from the monitoring PLC 31 and the information from the data server 34. Here, an example of a screen for setting a time threshold value in the front and rear sheet folding candle lowering (head side) process in the packaging process is shown. The setting data in the storage unit 40 of the monitoring PLC 31 can be rewritten directly on this threshold setting screen. As a display item, the threshold value is given a certain width, and here, a range with a width of 5 seconds each from the threshold value 12 seconds to the plus side and the minus side is set, and the range is within this range. Is normal, and when it falls below 7 seconds that does not reach this range, it becomes a threshold (LO), and when it exceeds 17 seconds, it becomes a threshold (HI) and becomes an alarm target. Further, if the time exceeds 100 seconds, an answerback occurs, and if it is shorter than that, an answer abnormality occurs. Therefore, the values of “threshold”, “threshold (LO)”, “threshold (HI)”, and “answerback” can be set by the a and b clients 35 and 36. Also, there is a setting item of “operation frequency alarm”, and when this operation frequency (here, 1000000) is set and reached, an alarm can be issued. Thereby, regular maintenance can be notified.

  Here, on this threshold value setting screen, the upper limit of the number of operations of devices including the sensor used in this small process can be set as a threshold value. Here, the “number of operations” of the PLC, relay, solenoid valve, cylinder and sensor of the control panel for compression can be set. The “number of operations” corresponds to the number of operations 1 to 5 in FIG. 8, and the number of operations can be reset by pressing the number reset button. This is because the number of operations of each device is different for each device, and is preferably set for each device. Therefore, compared to the case where all devices are replaced by regular inspection regardless of the type of devices, there is no waste of replacing devices that do not need replacement, and the maintenance cost can be reduced. . Here, data used in this setting screen is taken from the storage unit 40 of the monitor PLC 31.

  FIG. 10 shows a status monitoring screen. This status monitoring screen is displayed when “status monitoring” is selected from the menu of the display 56 of the a and b clients 35 and 36 based on the information from the monitoring PLC 31 and the information from the data server 34. Specifically, images corresponding to the main compression control panel, the precompression A control panel, and the precompression B control panel are displayed, and the lighting states of these operation panels 27 to 29 are monitored. This eliminates the need for confirmation of the actual operation panels 27-29. The rectangular portions corresponding to the “automatic”, “manual”, and “safety device activation” buttons on the operation panels 27 to 29 are displayed separately so that the currently lit portion can be recognized. Such selective display is also performed by the application programs of the a and b clients 35 and 36 based on the display data associated with the current status from the monitor PLC 31 and the data server 34.

  FIG. 11 shows a state in which a pop-up screen for threshold setting is displayed on the SFC monitoring screen of FIG. 6 described above. This pop-up screen is displayed superimposed on the display 56 of the a and b clients 35 and 36 based on the information from the monitor PLC 31 and the information from the data server 34. This pop-up screen is a screen that is opened by clicking each block for each process in FIG. 6 and shows as an item whether the block is a process that is currently being executed, a process that has been completed immediately after, or an unexecuted process. Information of “operation status”, that is, three types of “being executed”, “not executed”, and “completed” are displayed. In addition, “execution count” and “success count” since the previous count reset in the process are displayed together with “success rate”. In addition, items of “operation time” and “setting value / threshold” are provided, “operation time” displays the time actually taken, and “setting value / threshold” displays the value set here. The

The items related to the operation status are displayed as “execution status” and “completed” as the operation status when these are selected based on the information related to the current process stored in the monitor PLC 31 and the completion process completed immediately before. If any other option is selected, “not executed” is displayed.
The “execution count” is read out from the storage unit 40 of the monitoring PLC 31 and displayed after the count reset button is pressed, and the “success count” and “success rate” are also stored in the storage unit 40 of the monitoring PLC 31. Is read and displayed. The “operation time” is also read from the storage unit 40 of the monitor PLC 31, and the value set here is written in the storage unit 40 of the monitor PLC 31 and displayed here. Here, the “success count” refers to the number of times that an alarm has not occurred since the number of times was reset, that is, the number of times (threshold (LO), threshold (HI), answer operation, no answer back). “Rate” means the percentage of the number of successes with respect to the number of executions.In the example of FIG. 11, the banding process is neither executed nor completed (see the description of FIG. 6). The “execution count” is 5, the “success count” is 5, the “success rate” is 100% (5 ÷ 5 × 100%), the “operation time” is 84 seconds, and the set value / threshold is 100. This data is written in the storage unit of the data server 34 as a CSV file at the time of resetting the number of times, and the timing of writing, that is, resetting is a changeover time of 3 shifts every 8 hours, for example, It is set at 7 o'clock, 15 o'clock, and 23 o'clock, which makes it possible to grasp the success rate in units of substitution when driving one day in three shifts.

  FIG. 12 shows an alarm analysis screen. This alarm analysis screen is displayed when “alarm analysis” is selected from the menu of the display 56 of the a and b clients 35 and 36 based on the data stored as a log in the data server 34 and the data in the storage unit 40 of the monitoring PLC 31. Is displayed. Data with a large number of alarms in each small process at the present time are arranged in order. It is also possible to display in ascending order. Looking at the success rate for each process shown in FIG. 11, an error as a process may not occur because an alarm with a short operation time and an alarm with a long operation time are issued in a small process. In such a case, there is an advantage that the substance can be examined by alarm analysis in a small process.

The display items on the alarm analysis screen are “NO” indicating an event number, “device name” used over a plurality of small processes, “name” of small processes, “monitor” indicating the number of executions, and alarm “ "Answerback", "answer operation", threshold (HI), "threshold anomaly" including threshold (LO), "success rate" at the current small process, success at small process when numbered in order of good It is the “rank” of the rate, and the number and value are displayed.
This data is stored in real time in the storage unit 40 of the monitoring PLC 31 and written to the data server 34 at the same time. The a and b clients 35 and 36 read the data from the storage unit 40 of the monitoring PLC 31 or the data server 34. This data is also written into the storage unit of the data server 34 as a CSV file at the time of the number of times reset in FIG. The timing of writing, that is, resetting, is a change time of 3 shifts every 8 hours, for example, 7 o'clock, 15 o'clock, and 23 o'clock. Thereby, when driving one day by three shifts, the success rate for each small process can be grasped by the shift unit.

  FIG. 13 is a setting screen for various sensors displayed in analog, in particular, sensors added with the installation of the monitoring PLC 31. This setting screen is also displayed when “display group” is selected from the menu of the display 56 of the a and b clients 35 and 36 based on the data stored in the monitoring PLC 31 and the data server 34. In the display group, temperature, current value, voltage, pressure and the like are set. In this example, since temperature is selected as the display group, sensors related to the temperature sensor are to be displayed. Specifically, an outside air temperature sensor, a main compression oil tank temperature sensor, a preliminary compression A oil tank temperature sensor, and a preliminary compression B oil tank temperature sensor are displayed. Below the position corresponding to each sensor, the current temperature taken from the monitoring PLC 31 every minute is displayed, and this temperature is displayed as a bar graph. The values of threshold value LL, threshold value H, and threshold value HH are displayed beside the bar graph, and these values are set by the a and b clients 35 and 36 and written to the storage unit 40 of the monitoring PLC 31. An alarm target is generated when the range set by the threshold value LL and the threshold value H deviates.

  FIG. 14 is a screen showing a trend. This trend means history, and in this example, a trend related to temperature corresponding to FIG. 13 is selected and displayed. This trend screen is displayed when “Trend” is selected from the menu of the display 56 of the a and b clients 35 and 36 based on the data stored as a log in the data server 34 and the data in the storage unit 40 of the monitor PLC 31. The Specifically, a graph with time on the horizontal axis and temperature on the vertical axis is displayed by the application programs of the a and b clients 35 and 36. By displaying it as a history with a graph, it is possible to confirm the abnormality at a glance as compared with the normal state. The trend information is read by the data server 34 and the a and b clients 35 and 36 from the storage unit of the monitoring PLC 31. In addition to the temperature, this trend uses sensor detection results corresponding to various display groups such as time, speed, and current that can be selected in FIG. In FIG. 14, trends of an outside air temperature sensor, a main compression oil tank temperature sensor, a preliminary compression A oil tank temperature sensor, and a preliminary compression B oil tank temperature sensor are displayed.

  Here, FIG. 15 is a block diagram for displaying the main graphic screen described in FIG. 7 on the display 56. Each production process x, y, z when all processes are assigned to a plurality of production processes can be divided into a plurality of sub-processes. The processing unit 37 of the monitoring PLC 31 described above measures the operation time in each small process by accumulating the operation time of each component performed in each small process. The measurement includes the transition time of each small process.

  The processing unit 37 of the monitoring PLC 31 writes the measurement result of the operation time of each small process in the storage unit 40 of the monitoring PLC 31 in association with the information of the small process as actual operation time data. The operating time of each component in the small process is also written in the storage unit 40 of the monitoring PLC 31.

  On the other hand, a standard operating time is set for each production process x, y, z, and this standard operating time is an operating time in a normal state where no alarm is output at the beginning of the operation of the packaging device 1 or immediately after periodic maintenance. Is set as a reference. This standard operating time data is written in association with small process information in a predetermined storage area secured in the storage unit 40 of the monitoring PLC 31.

  The monitor data acquisition unit 80 acquires, as monitor data, necessary information, that is, switching information for operation modes such as automatic / manual operation using the operation panels 27 to 29 and alarm release information in addition to the above-described actual operation time. The monitor data acquired by the monitor data acquisition unit 80 is temporarily stored in the storage unit 40 or the like, and then output to the situation detection unit 81 and the process determination unit 83, respectively. Here, the alarm is released by the PLC program when the next operation signal in a small process is issued.

The status detection unit 81 determines the alarm status of the small process, the alarm release status, and the operation status of the operation panels 27 to 29 based on the monitor data acquired by the monitor data acquisition unit 80.
The situation storage unit 82 stores the result determined by the situation detection unit 81 in association with identification information such as the names of the small processes x, y, and z and the names of the operation panels 27 to 29.

  More specifically, the situation detection unit 81 determines whether or not the actual operation time of each of the small processes x, y, and z is within the range of the standard operation time, and the actual operation time is the standard operation time. When it is determined that it is not within the range, information on the answer abnormality or the threshold abnormality is written in the status storage unit 82 in association with the name of the small process and the determination time as the alarm information of the small process x, y, z.

  Further, when it is determined by the status detection unit 81 that the operation mode switching operation has been performed on the operation panels 27 to 29, the name of the operation mode determined to have been switched and the determination time are associated with the operation information. Is written in the status storage unit 82. Further, when the situation detection unit 81 determines that the alarm for the location (small process) where the alarm is generated has been released, the alarm release information, the name of the sub-process from which the alarm has been released, and its determination time, Are written in the status storage unit 82 in association with each other. When the status storage unit 82 is in the data server 34, the information written in the status storage unit 82 is transmitted to the a and b clients 35 and 36 in accordance with requests from the a and b clients 35 and 36. .

  Here, a certain range is set for the standard operation time. Specifically, as shown in FIG. 11, when the operation time in the process is 84 seconds, a delay of 16 seconds is expected. The standard operating time is set to 100 seconds as a threshold, and this setting can be set and changed from the a and b clients 35 and 36 including the operating time. When changed, the data of the standard operating time secured in the storage unit 40 of the monitoring PLC 31 is updated.

  The process determination unit 83 determines the production process currently being performed based on the monitor data acquired by the monitor data acquisition unit 80. The production process is determined by the same method as in the case of changing the color of the block being executed on the SFC screen shown in FIG. In other words, among the small processes constituting the production process, the production process to which the small process between the start time and the end time belongs is determined as the currently executing production process.

  Based on the currently executed production process determined by the process determining unit 83, the image calling unit 84 performs the production from the image data of the overall perspective view, which is a plurality of process drawings stored in advance in the image storage unit 85. The image data of the whole perspective view in which all of the components operating in the process are colored is called, and the image data is temporarily stored in a predetermined storage area of the data server 34 or the a, b clients 35 and 36. And when the current production process shifts to the next production process, the image data of the overall perspective view corresponding to the current production process temporarily stored is the overall perspective view corresponding to the next production process. Overwrite with the image data.

  Here, since the image data of the whole perspective view corresponding to all the production processes carried out by the packing device 1 is stored in the image storage unit 85 for each production process, the production can be performed by designating the production process. The image data of the whole perspective view associated with the process can be called up. Generally, since the image data has a large file size, it is advantageous to provide the a and b clients 35 and 36 and the data server 34 rather than providing the image storage unit 85 in the monitor PLC 31 because the time for transferring the image data can be shortened. It is.

  The display 56 displays an overall perspective view on the screen based on the image data called by the image calling unit 84. On the other hand, the display 56 displays alarm information and switching operation information stored in the situation storage unit 82 in the order of event occurrence, in other words, in the alarm display column arranged on the lower side of the overall perspective view, in other words, the determination time is present. Display items close to the time in order from the top or bottom.

  That is, on the screen of the display 56, an overall perspective view in which the components operating in the current production process are colored based on the monitor data of the small processes x, y, and z acquired by the monitor data acquisition unit 80. In addition, an alarm display field in which an alarm status of a small process up to the present, an operation mode switching status, and an alarm release status are displayed is displayed at the same time.

  Here, the monitor data acquisition unit 80 is provided in the monitor PLC 31, and the process determination unit 83, the situation detection unit 81, the situation storage unit 82, and the image storage unit 85 are provided in the data server 34. Further, the image calling unit 84 and the display 56 are provided in the a and b clients 35 and 36. As described above, the image storage unit 85 may be provided in the a and b clients 35 and 36.

  Therefore, according to the above embodiment, the process determination unit 83 determines the production process based on the monitor data acquired by the monitor data acquisition unit 80, and the entire perspective view that is a process image corresponding to the production process is stored in the image. By calling from the unit 85 and displaying on the display 56, it is possible to easily grasp the production process currently being performed.

  Further, when the packaging device 1 is stopped due to some abnormality, the packaging device 1 is checked in which production process by checking the overall perspective view in which the components operating in the current production process are colored on the display 56. You can instantly know if it stopped. Further, when any abnormality occurs in this way and the packaging device 1 is stopped, the situation detection unit 81 detects an abnormality in a small process unit of the production process and stores it in the situation storage unit 82, and this situation storage unit 82. By displaying the alarm information stored in the display unit together with the overall perspective view, it is possible to quickly identify at what time the abnormality has occurred and which production process is stopped, Compared to the conventional method, the time for narrowing down the abnormal part can be shortened by the amount that the work of narrowing down the faulty part by referring to the sequential function chart and the ladder program can be omitted.

  Further, by detecting the occurrence of an alarm, the release of the alarm, and the switching of the operation mode, it is possible to grasp the status of the operation mode of the packaging device 1 and what state is currently in the small process where the abnormality has occurred. You can figure out what you are doing.

  And since it is possible to detect the occurrence of abnormality for each small process based on the preset standard operating time, the abnormality of the component is detected before the component operating in the small process stops moving completely. It is possible to prevent the packing apparatus 1 from abnormally stopping.

  Furthermore, the monitor data stored in the storage unit 40 can be periodically sent to the data server 34, the a client 35, and the b client 36, and the monitor data can be sent to the data server 34, a, b Since the data can be taken into the clients 35 and 36, it is possible to identify the location where an abnormality has occurred in all processes at an early stage.

  The present invention is not limited to the above embodiment. For example, the case where the monitor data acquisition unit 80, the process determination unit 83, and the situation detection unit 81 are provided in the monitor PLC 31 has been described. The monitor data provided in the application programs of the a and b clients 35 and 36 are processed on the application program to display an overall perspective view and an alarm display column on the screen of the display 56. You may make it display.

Moreover, although an example of the perspective view which looked at the packaging apparatus from diagonally right front was shown as a whole perspective view, it is more suitable to use the whole perspective view of the angle which is easy to see the component in operation for every production process.
Moreover, although embodiment mentioned above demonstrated the packing apparatus as an example as an automatic machine, it is not restricted to this.

It is a front view of the packing apparatus of embodiment of this invention. It is a top view of FIG. It is a block diagram which shows the whole driving | operation apparatus of the automatic machine of FIG. It is a block diagram of PLC for monitoring. It is a schematic diagram which shows the operation circuit of this compression cylinder. It is a sequential function chart figure which shows the progress of each process. It is a figure which shows the main graphic screen. It is a figure which shows an operation condition monitor screen. It is a figure which shows the pop-up screen for threshold value setting. It is a figure which shows a status monitoring screen It is a figure which shows the pop-up screen for threshold value setting. It is a figure which shows an alarm analysis screen. It is a figure which shows the setting screen of sensors. It is a figure which shows a trend screen. It is a block diagram which produces | generates a main graphic screen.

Explanation of symbols

21 Control device (control device)
34 Data server (server)
35 a Client (input terminal)
36b client (input terminal)
40 storage unit 50 degenerate position limit switch (detection equipment)
51 Extension position limit switch (detection equipment)
56 Display (display unit)
80 Monitor Data Acquisition Unit 81 Situation Detection Unit 82 Situation Storage Unit 83 Process Determination Unit 84 Image Calling Unit 85 Image Storage Unit

Claims (4)

In an automatic machine monitoring device that continuously repeats the entire process from raw material preparation to product delivery,
A monitor data acquisition unit for acquiring, as monitor data, a plurality of production processes assigned in all the processes and a current situation in a small process constituting the production process;
A process determination unit for determining a production process currently being performed based on the monitor data acquired by the monitor data acquisition unit;
An image storage unit that stores in advance the process image of the automatic machine that is colored only on the component that performs the production process, for each of the plurality of production processes;
An image calling unit that calls the process image corresponding to the production process determined by the process determining unit from the image storage unit;
A situation detection unit that detects at least an abnormality in a small process of the production process based on the monitor data and outputs the situation information;
A status storage unit that stores the status information detected by the status detection unit together with at least detection time information;
An automatic machine monitor device, comprising: a display unit that displays the process image called by the image calling unit and displays information stored in the status storage unit in the order of the detection times.   The situation detecting unit detects an occurrence of an abnormality for each small process, a cancellation of the abnormality for each small process, and a mode switching operation based on the monitor data as a current situation of the automatic machine. The monitoring device for an automatic machine according to claim 1.   3. The automatic machine according to claim 1, wherein the situation detection unit detects the occurrence of the abnormality based on a standard operation time set in advance for each of a plurality of small processes in the production process. Monitor device. A control device for operating the automatic machine, and the monitor device according to any one of claims 1 to 3 connected to the control device via a communication device, the monitor device from the control device A command signal sent to the automatic machine and various signals sent from the components and detection devices of the automatic machine to the control device are written as monitor data via the communication device, and a measuring unit based on the monitor data Including a storage unit for writing as measurement data measured in
The storage unit is connected to a server that periodically reads monitor data and measurement data stored in the storage unit from the storage unit via a communication network, and an input terminal including the display unit is connected to the storage unit. A driving device for an automatic machine, characterized in that

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