JP2009122980A - Automated machine monitoring unit - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an automated machine monitoring unit, reducing maintenance costs by managing an exchange period for each device related to drive of components. <P>SOLUTION: When a packaging unit, consecutively repeating the entire processes from preparation of materials to the shipping of products, is driven through a control unit, the automated machine monitoring unit monitors a status of the packaging unit by reading data transmitted from the control unit through a monitor communication section. The monitoring unit includes a counting section 85 for counting the number of operating times of each device 1-5, namely a PLC 80, a relay 81, an electromagnetic valve 82, a cylinder 83 and a sensor 84, related to the drive of the components in the packaging unit; and a reset section 87 for resetting the number of operating times of each device counted by the counting section 85. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a monitoring device for an automatic machine such as a packing device that cuts a fiber as a raw material and packs the fiber every predetermined amount.

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 the operator of the occurrence of an abnormality during operation ( Patent Document 1).
In factory automation (hereinafter referred to as “FA”), there are devices that control the operation of various devices via a programmable controller (hereinafter referred to as “PLC”), so that no load is applied to the control system on the PLC side. An apparatus capable of monitoring the system has been proposed (see Patent Document 2).
JP-A-11-143528 JP 2003-295914 A

By the way, in the above-described prior art, when the equipment related to the component parts of each process in the system is regularly replaced for maintenance or the like, generally, all the components are replaced in units. Yes.
However, the lifespan of equipment usually varies from part to part. If a piece of equipment reaches the end of its life, replacing parts that have not yet reached the end of their life will cause a high frequency of parts replacement. Therefore, there is a problem that the maintenance cost increases.

  SUMMARY OF THE INVENTION An object of the present invention is to provide an automatic machine monitoring device capable of reducing maintenance costs by managing replacement time for each device related to driving of components.

In order to achieve the above object, the invention described in claim 1 is directed to a control device (for example, an automatic machine (for example, the packaging device 1 in the embodiment) that continuously repeats all the steps from the charging of raw materials to the production of products. When driving via the control device 21) in the embodiment, data transmitted from the control device via the communication device (for example, the monitor communication units 30 and 32 in the embodiment) is read to monitor the state of the automatic machine. It is a monitoring device for an automatic machine, and each device (for example, the devices 1 to 5 in the embodiment, that is, the PLC 80, the relay 81, the electromagnetic valve 82, the cylinder 83, and the sensor 84) related to the driving of the components of the automatic machine. Counting unit for counting the number of operations (for example, counting unit 85 in the embodiment), and resetting the number of operations for each device counted by the counting unit That the reset unit (e.g., the reset unit 87 in the embodiment), characterized in that it comprises a.
By configuring in this way, based on the number of operations counted by the counting unit for each device, the devices can be replaced when the appropriate number of operations has passed, and the number of operations is reset by the reset unit at the time of replacement Thus, it is possible to count the number of operations of the replaced new device.

According to the first aspect of the present invention, based on the number of operations counted by the counting unit for each device, the devices can be replaced when an appropriate number of operations is performed, and the device is operated by the reset unit at the time of replacement. Because the number of operations can be counted by resetting the number of times, the number of operations of a new device that has been replaced can be counted. effective.
Therefore, compared to the case where all devices are replaced by regular inspection regardless of the type of devices, there is no need to replace devices that do not need to be replaced, and the maintenance cost can be reduced. In addition, it is possible to easily measure the deterioration life in the state of use by managing the number of operations of the equipment, and to make a repair plan with higher accuracy before the equipment design limit.

  Next, embodiments of the present invention will be described with reference to the drawings. 1 and 2 show a packing device 1 as an automatic machine. This packing device 1 continuously cuts strip-shaped acrylic fibers carried as raw materials into a predetermined length and measures the cut fibers. When it reaches a certain amount, 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 carried out eight times in units of 50 kg, and every 50 kg is dropped from the weighing hopper 3 to the lower shovel loader 4 chamber and dropped onto the closed bottom plate 6 of the precompression box 5 from the shovel loader 4 chamber. It is. 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 the operation command is transmitted to the main compression cylinder 12 until the main compression cylinder 12 starts operating, is detected by various sensors, and data of detection results of the sensors is 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 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 passes through 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 panel operation information 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 chronological order when a certain abnormality occurs in the packaging device 1 and when the abnormality is canceled. The operation panel operation information is displayed in order of time when the operation panels 27 to 29 are operated. The display items in the display column are “NO” indicating the event number, “occurrence time” indicating the time when the alarm etc. occurred, “situation” indicating whether the operation has been switched or has occurred, and the alarm is displayed. It is a “category” indicating the cause of occurrence, and specifically a “message” indicating the contents of a 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 a certain range is exceeded or when the system is not operating (answerback), when there is more than one input per output (Answer operation), when the safety device operation button on the operation panel is pressed (touch panel), automatically on the operation panel, and when the operation is switched by pressing the manual button (status).
The “situation” is operated by the operation panels 27 to 29 when an alarm is generated or when the safety device operation button of the operation panels 27 to 29 is pressed (occurrence), when the alarm is canceled (release). There is (switching) when the mode is switched. 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.
The operation panel operation status is also stored each time “automatic”, “manual”, or “safety device activation” is pressed. Therefore, when an alarm is generated in a small process or when an operation panel is operated, this situation is displayed on the main graphic screen of the a and b clients 35 and 36 as shown in FIG. The history is displayed as the status (alarm event). These alarm events are stored in the data server as CSV files 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 case where the value is out of the threshold value range is displayed. In addition, by managing the number of operations of the equipment used, it is possible to easily measure the deterioration life in the usage state, and to make a replacement plan before the equipment design limit.

  Display items on the threshold setting screen are “NO” indicating an event number, “device name” used across a plurality of small processes, “name” of the small process, actual “operation time” of the small process, and each configuration. “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)” “The number of times” that is OFF within the threshold of the number of times, the set “answerback” and “threshold”. “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, when the time exceeds 100 seconds, an answer back error occurs, and when there is an input twice or more at the first output, an answer operation is performed. Therefore, the values of “threshold”, “threshold (LO)”, “threshold (HI)”, and “answerback error” 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.

  Further, the “number of operations” of the PLC, relay, solenoid valve, cylinder, and sensor of the compression control panel can be reset here. These devices are devices related to the driving of the arm member, which is a component for folding the sheet called candle, and the solenoid valve is switched via the PLC and relay of this compression control panel, and the cylinder expands and contracts. To drive the candle. The sensor detects this when the candle completes its operation. The basic configuration is similar to that of the present compression cylinder shown in FIG. The “number of operations” of these devices corresponds to the number of operations 1 to 5 in FIG. 8, and an area for accumulating the number of operations is secured in the storage unit 40 of the monitor PLC 31, and by pressing the number reset button, The number of operations stored in the storage unit 40 can be reset (= 0). This is because the number of operations to be replaced for each device differs depending on the lifetime of 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. 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 square portions corresponding to the “automatic”, “manual”, and “safety device activation” buttons 27 to 29 are displayed so as to distinguish the currently lit portion. 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.

  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 in an overlapping manner on the display 56 of the a and b clients 35 and 36 based on information from the monitor PLC 31 and information from the data server. 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 and the data in the storage unit 40 of the monitoring PLC 31. Is done. 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 is simultaneously written in the data server 34, and the a and b clients 35 and 36 read the data from the storage unit 40 of the monitoring PLC 31. 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 and the data in the storage unit 40 of the monitoring PLC 31. . Specifically, on the application programs of the a and b clients 35 and 36, the horizontal axis time and the vertical axis are displayed as a graph. 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 from the storage unit of the monitor PLC 31 by the data server and the a and b clients 35 and 36. 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 showing processing for resetting the number of operations of devices related to the components of the packaging device 1 as an automatic machine on the threshold setting screen popped up in FIG.
The devices 1 to 5 include a PLC 80 of the main compression control panel 23, a relay (relay of the main compression control panel 23) 81, a solenoid valve (cylinder driving relay) 82, a cylinder (cylinder driving cylinder) 83, a sensor ( This corresponds to 84 (detection of end of candle operation). When a signal is output from the PLC 80 of the compression control panel 23, the monitoring PLC 31 monitors it, and the number of times of operation of the PLC secured in the storage unit 40 is increased by "1" and updated, as shown in FIG. Allocate the item “NO”.

  Next, when the corresponding relay 81 of the compression control panel 23 is activated, the number of operations of the relay 81 of the storage unit 40 of the monitoring PLC 31 is updated by “1”. When the electromagnetic valve 82 is activated and switched by the command signal of the compression control panel 23, the detection switch detects that the electromagnetic valve 82 has been switched to the cylinder expansion side, and the memory of the monitoring PLC 31 is stored by the signal of the detection switch. The number of operations of the electromagnetic valve 82 of the unit 40 is updated by “1”. When the cylinder 83 expands to reach the stroke end, this is detected by the limit switch, and the number of operations of the cylinder 83 of the storage unit 40 of the monitoring PLC 31 is increased and updated by this detection signal. Finally, when the operation of the candle is completed by extending the cylinder 83, the sensor 84 detects this, and the number of operations of the sensor 84 of the storage unit 40 of the monitoring PLC 31 is increased by "1" by the detection signal of the sensor 84. And updated.

  Here, the updating of each device in the storage unit 40 of the monitoring PLC 31 is performed by the processing unit 37 of the monitoring PLC 31 which is the counting unit 85, and the result is displayed on the a and b clients 35 and 36 shown in FIG. It is also displayed in the text box of the pop-up screen of the display 56 as the unit 86.

  The number of operations updated by the processing unit 37 of the monitoring PLC 31 is performed by the processing unit 37 of the monitoring PLC 31 which is a reset unit 87. The resetting of the number of operations (= 0) is performed by the PLC, relay, electromagnetic of the pop-up screen. This is triggered by pressing a button corresponding to a valve, cylinder, or sensor.

  As described above, the “number of operations” of each device 1 to 5 is reset at the timing of component replacement or the like, but the accumulated number of operations of this small process itself is stored in advance in the storage unit 40 of the monitoring PLC 31. The number threshold (1000000 times in FIG. 9) is compared with the determination unit 88 (the processing unit 37 of the monitoring PLC 31), and if the result exceeds the operation number threshold, the display unit 86 of the a, b clients 35, 36. Is displayed by setting the “number of times” status of the alarm item on the operation status monitor screen of FIG. 8 to “ON”.

According to the above embodiment, as shown in FIG. 15, the counting unit 85 counts for each of the devices 1 to 5, that is, the PLC 80, the relay 81, the electromagnetic valve 82, the cylinder 83, and the sensor 84 of the compression control panel 23. Based on the number of operations, replacement can be performed when each device reaches an appropriate number of operations.
Therefore, equipment can be replaced according to the device life that is different for each PLC 80, relay 81, solenoid valve 82, cylinder 83, and sensor 84, and the number of operations is reset by the reset unit 78 at the time of replacement. It is possible to count the number of operations of new devices that have been made from scratch. Therefore, as compared with 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 to be replaced, and the maintenance cost can be reduced.
By managing the number of operations of the devices used in this way, the deterioration life in the usage state can be easily measured, and an exchange plan can be made before the device design limit.

  The accumulated number of operations of the small process itself is the operation number threshold (1000000 times in FIG. 9) stored in advance in the storage unit 40 of the monitoring PLC 31 and the determination unit 88 regardless of the reset of the number of operations of each device. Comparison is made by the processing unit 37 of the monitor PLC 31. If the determination result exceeds the operation count threshold, the status of “number of times” in the alarm item on the operation status monitor screen of FIG. 8 is displayed on the display 56 as the display unit 86 of the a and b clients 35 and 36. Is set to “ON” so that the cumulative number of small processes can be confirmed and used as a reference for the maintenance plan for the entire small process.

In addition, this invention is not restricted to the said embodiment, For example, it can apply to any components other than the sheet folding candle before and behind a packaging process as a component.
Moreover, although the packing apparatus was taken 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 for resetting the number of operations of devices mainly related to components.

Explanation of symbols

1 Packing device (automatic machine)
21 Control Device 22 Monitor Device 30, 32 Monitor Communication Unit 80 PLC (Device 1)
81 Relay (Device 2)
82 Solenoid valve (equipment 3)
83 cylinder (equipment 4)
84 Sensor (device 5)
85 Counting unit 86 Reset unit

Claims (1)

  When driving an automatic machine that repeats all processes from raw material charging to product delivery via a control device, the data transmitted from the control device via a communication device is read and the state of the automatic machine is monitored. A monitoring device for an automatic machine, which counts the number of operations for each device related to driving of the components of the automatic machine, and a reset for resetting the number of operations for each device counted by the counting unit And a monitoring device for an automatic machine.

Images