JP2010033391A - Production system and method for processing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production system allowing continuation of an operation state of production facilities without receiving restriction of software or hardware constituting a data processor, and allowing certain collection of processing data of a product produced by the production facilities, and to provide a method for processing the same. <P>SOLUTION: In the production system and the method for processing the same, a life-and-death confirmation part 36 of a line controller C1, C2 transmits a life-and-death confirmation command to a data processor D1, D2. Meanwhile, when receiving the life-and-death confirmation command, the life-and-death response part 46 of the data processor D1, D2 transmits a life-and-death response command to the line controller C1, C2 having transmitted the life-and-death confirmation command. The line controller C1, C2 selects the data processor D1, D2 in a normal operation state according to the life-and-death response command, and transmits the processing data thereto. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention provides a facility control device that controls production facilities for products, and a plurality of processing data for the products produced by the production facilities from the facility control device and performs predetermined data processing on the processing data The present invention relates to a production system including a data processing apparatus and a processing method thereof.

  In a production system that produces products, the production equipment is controlled by the equipment control device to produce the products, while information related to the production results of the products is collected as processing data by the data processing device, and predetermined data corresponding to the production equipment is collected. Product management is performed by processing. Examples of the processing data include product number, product size, weight, quality information such as the presence or absence of defects, product storage location information, and the like.

  By the way, once a production facility is stopped, it takes a long time before it can be restarted, and production during that time cannot be performed. It is normal to operate continuously. Therefore, when a data processing device that collects and processes processing data from a facility control device that controls a production facility becomes incapable of functioning due to, for example, a hardware or software failure, it collects processing data generated during that time. It becomes impossible to do.

  Therefore, as a countermeasure against such a failure, for example, the cluster function disclosed in Patent Document 1 is installed in a plurality of data processing devices, and these data processing devices are connected to the equipment control device to be normally used. When a failure occurs in a data processing apparatus, it is possible to switch to another data processing apparatus and continue the processing.

JP 2007-310710 A

  However, in Patent Document 1, the presence or absence of a failure is monitored between a plurality of nodes (corresponding to data processing devices) equipped with a cluster function, and when switching from a failed node to an alternative node, the software of the alternative node is installed. It is necessary to start up. In this case, it is not possible to collect processing data from the equipment control device while starting up the alternative node. On the other hand, since the equipment control device continuously operates the production equipment, a part of the processing data generated during that time is lost.

  In addition, when a failure occurs in a network interface that connects nodes, it becomes impossible to perform mutual monitoring of a failure of the node.

  Furthermore, in order to perform mutual monitoring of nodes, it is usually necessary for each node to be configured by the same hardware, OS, and software, and these restrictions significantly restrict the degree of freedom in system construction. There is a bug that will be done. That is, conventionally, monitoring of the alive state of each node has been performed using software integrated with the OS. Therefore, if the OS differs, mutual monitoring cannot be performed.

  The present invention has been made to solve the above-described problems, and is capable of continuing the operation state of the production facility without being restricted by hardware and software constituting the data processing apparatus. An object of the present invention is to provide a production system and a processing method thereof that can reliably collect processing data of products produced by a production facility.

The present invention includes an equipment control device that controls production facilities of products,
A plurality of data processing devices that obtain processing data of the product produced by the production facility from the facility control device, and perform predetermined data processing on the processing data;
With
The facility control device transmits a data processing device selection unit that selects the data processing device that is the transmission destination of the processing data, and a life / death confirmation command that confirms a life / death state for the selected data processing device, A life and death confirmation unit for confirming the life and death state of the data processing device,
Each of the data processing devices, when receiving the life / death confirmation command, a life / death response unit that transmits a life / death response command to the facility control device that is the transmission source of the life / death confirmation command, and a source of the life / death confirmation command A transmission source identification unit that identifies the facility control device, and a data processing unit that performs data processing corresponding to the identified facility control device with respect to the processing data transmitted from the facility control device It is characterized by that.

The present invention also provides an equipment control device that controls product production equipment, processing data of the product produced by the production equipment from the equipment control device, and performs predetermined data processing on the processing data. In a processing method of a production system comprising a plurality of data processing devices to perform,
Selecting the data processing device that is the transmission destination of the processing data;
Transmitting a life / death confirmation command for confirming a life / death state to the selected data processing device;
When receiving the life and death confirmation command, sending a life and death response command to the equipment control device that is the transmission source of the life and death confirmation command;
Transmitting the processing data to the data processing device that is the source of the life / death response command;
Identifying the equipment control device that is the source of the processing data;
Performing data processing corresponding to the identified equipment control device for the processing data;
It is characterized by having.

  In the production system and the processing method thereof according to the present invention, in the equipment control device that controls the production equipment, the alive state of the data processing device that processes the processing data is monitored. In order to select an appropriate data processing device, it is possible to monitor the life and death status of each data processing device without being restricted by hardware or software, and to keep the production equipment operating and to produce it with the production equipment. It is possible to reliably collect processing data of products to be processed.

  FIG. 1 is a configuration block diagram of a production system 10 according to the present embodiment. In this production system 10, management and control of production lines L1 and L2 (production equipment) shown in FIG. 2 are performed.

  Here, the production lines L1 and L2 are lines for continuously producing roll-shaped film. For example, the film raw material melted in a liquid state is extruded from the die 12, and passes between the cast drum 14 and the touch rolls 16 and 18. After the sheet is formed into a sheet, the sheet is heated and solidified in the heating unit 20, and then the sheet body is wound up by a predetermined length and cut by the cutter 22 to produce the roll film 24. The produced roll film 24 is loaded with wrapping paper to form a wrapping film 26, which is placed on a transport carriage 28 and transported to an automatic warehouse. Each production line L1, L2 is usually installed in a different building, and roll films 24 having different sizes and compositions are produced in each production line L1, L2.

  The production system 10 transmits production instruction information such as the type, size, production amount, heating temperature, heating time, and cooling time of the sheet body during the production lines L1 and L2 via the network 30. On the other hand, a production management computer 32 that receives production results and manages the production lines L1 and L2 is provided.

  The network 30 includes line control devices C1 and C2 (equipment control devices) that control the production lines L1 and L2, and an inspection control device S1 that performs inspection processing by controlling the sensors 34 of the production lines L1 and L2. , S2 (facility control device), product transport control devices M1 and M2 (facility control device) for controlling the transport cart 28 and transporting the produced packaging film 26 to a predetermined automatic warehouse, and line control devices C1 and C2. , While supplying production instruction information from the production management computer 32 to the inspection control devices S1, S2 and the product transport control devices M1, M2, the product number of the roll film 24 produced in each production line L1, L2, A data processing device D that collects and processes processing data related to production results such as completed quantity (length, width, weight), quality data (number of minute defects), product storage location information, etc. , It is connected and D2.

  The data processing device D1 processes the processing data transmitted from the line control device C1, the inspection control device S1, and the product conveyance control device M1, and the data processing device D2 includes the line control device C2, the inspection control device S2, and the product conveyance. The processing data transmitted from the control device M2 is processed. The data processing devices D1 and D2 can be configured by different hardware, OS, and software.

  Each of the data processing devices D1 and D2 has a capability of simultaneously processing the processing data supplied from the two production lines L1 and L2. Label printers P1 and P2 are connected to the data processing devices D1 and D2 for printing the processing data relating to the production results of the produced packaging film 26 on the labels. The printed label is affixed to the packaging film 26. Further, a recording device DB that records data processed by the data processing devices D1 and D2 is connected to the network 30.

  FIG. 3 is a configuration block diagram centering on line control devices C1 and C2 that control the production lines L1 and L2, and data processing devices D1 and D2 that collect and process the processing data from the line control devices C1 and C2. is there.

  The line control devices C1 and C2 transmit a life / death confirmation command for confirming the life / death state of the data processing devices D1 and D2 to the data processing devices D1 and D2, and the life / death confirmation unit 36 for confirming the life / death state of the data processing devices D1 and D2. A data processing device selection unit 38 that selects the data processing devices D1 and D2 that are transmission destinations of the life / death confirmation command and processing data, and a selection table storage unit 40 that stores the data processing devices D1 and D2 to be selected as a table, A line control unit 42 that controls the production lines L1 and L2 and a processing data storage unit 44 that stores the processing data of the production lines L1 and L2 are provided.

  The inspection control devices S1 and S2 and the product conveyance control devices M1 and M2 are the same as the line control devices C1 and C2, and the life and death confirmation unit 36 that confirms the life and death state of the data processing devices D1 and D2, the life and death confirmation command, and the processing Data processing device selection unit 38 that selects data processing devices D1 and D2 that are data transmission destinations, selection table storage unit 40 that stores data processing devices D1 and D2 to be selected as a table, and processing data that stores processing data A storage unit 44 is provided.

  When the data processing devices D1 and D2 receive the life and death confirmation command, the life and death response unit 46 that transmits a life and death response command to the line control devices C1 and C2 that are the transmission source of the life and death confirmation command, and the line control device C1 , C2, the inspection control devices S1 and S2, and the processing data storage unit 48 that stores the processing data transmitted from the product conveyance control devices M1 and M2, and the production line that is the transmission source of the processing data based on the transmitted processing data The line identification unit 50 (transmission source identification unit) that identifies L1 and L2, the line parameter storage unit 52 that stores line parameters for data processing for each production line L1 and L2, and the line identification unit 50 A data processing unit 54 that performs data processing on the processing data using line parameters.

  The processing data storage unit 48 includes production line folders F1 and F2 that store processing data for each of the production lines L1 and L2. In this case, the processing data stored in each of the production line folders F1 and F2 is given the identification names of the production lines L1 and L2 to the file names, and the production line folders F1 and F2 are selected according to the file names. The relationship between the file name of the processing data and the folder names of the production line folders F1 and F2 is stored as a table in the recording apparatus DB.

  The production system 10 of this embodiment is basically configured as described above. Next, the operation will be described with reference to the flowcharts shown in FIGS. 4 and 5. 4 is an operation flowchart of the data processing devices D1 and D2, and FIG. 5 is an operation flowchart of the line control devices C1 and C2.

  First, each data processing device D1, D2 receives production instruction information from the production management computer 32 via the network 30, and transmits the production instruction information to the corresponding line control devices C1, C2 (step S1). . In this case, when each data processing device D1, D2 is in a normal operation state, the data processing device D1 performs processing of the line control device C1, the inspection control device S1, and the product transport control device M1, as shown by the solid line in FIG. Data is processed, and the data processing device D2 processes the processing data of the line control device C2, the inspection control device S2, and the product conveyance control device M2.

  The line control devices C1 and C2 that have received the production instruction information from the data processing devices D1 and D2 control the production lines L1 and L2 according to the control program stored in the line control unit 42 (step S21). The line control unit 42 stores the processing data generated when the production lines L1 and L2 are controlled, for example, the processing data such as the product number and the production quantity, in the processing data storage unit 44 (step S22).

  Similarly, the inspection control devices S1 and S2 control the sensors 34 arranged on the production lines L1 and L2 according to the production instruction information received from the data processing devices D1 and D2, and complete the inspection results of the roll film 24. Quantity (length, width, weight), quality data (number of micro defects), etc. are acquired as processing data. Further, the product conveyance control devices M1 and M2 control the conveyance carriage 28 according to the production instruction information received from the data processing devices D1 and D2, and convey the packaging film 26 produced by the production lines L1 and L2 to a predetermined automatic warehouse. At the same time, the product number and product storage location information of the transported packaging film 26 are acquired.

  Next, the alive confirmation unit 36 of the line control devices C1 and C2 is a confirmation packet signal (ping command) common to the network devices for the data processing devices D1 and D2 selected by the data processing device selection unit 38. A life / death confirmation command is transmitted (step S23). The data processing device selection unit 38 selects the data processing devices D1 and D2 according to the connection relationship between the line control devices C1 and C2 and the data processing devices D1 and D2 stored in the selection table storage unit 40.

  When the life and death response unit 46 of the data processing devices D1 and D2 receives the life and death confirmation command from the line control devices C1 and C2 (step S2), the life and death response unit 46 sends a life and death to the line control devices C1 and C2 that are the source of the life and death confirmation command. A response command is transmitted (step S3).

  The life and death confirmation unit 36 of the line control devices C1 and C2 confirms the presence or absence of a life and death response command from the selected data processing devices D1 and D2 (step S24). In this case, when the life / death confirmation command cannot be received within a certain time after the transmission of the life / death confirmation command, the life / death confirmation unit 36 repeats, for example, the process of transmitting the life / death confirmation command three times and still cannot receive the life / death response command. At this time, it is determined that a problem has occurred in the operation of the selected data processing devices D1 and D2, and the connection relationship between the data processing devices D1 and D2 is changed (step S25).

  Therefore, the data processing device selection unit 38 selects the data processing devices D1 and D2 having the next connection relationship from the selection table storage unit 40. The life and death confirmation unit 36 confirms the life and death states of the data processing devices D1 and D2 by transmitting a life and death confirmation command to the new data processing devices D1 and D2.

  In this case, confirmation processing of the alive state of the data processing devices D1 and D2 is performed on the line control devices C1 and C2, and the data processing devices D1 and D2 receive the alive confirmation command transmitted from the line control devices C1 and C2. It only has a function capable of transmitting a life / death response command. Therefore, the data processing devices D1 and D2 may have different OSs or hardware configurations, and can cope with the addition or change of the data processing devices D1 and D2 very easily.

  When the line control devices C1 and C2 receive the life / death response command from the data processing devices D1 and D2, the line control devices C1 and C2 determine that the data processing devices D1 and D2 are operating normally, and the data processing devices D1 and D2 Then, the processing data stored in the processing data storage unit 44 is transmitted (step S26). In this case, since the processing data is transmitted by selecting the data processing devices D1 and D2 that are normally operating on the line control devices C1 and C2, a part of the processing data is caused due to the malfunction of the data processing devices D1 and D2. The problem of losing will not occur.

  The line control devices C1 and C2 convert the processing data into text files, and send the data to the data processing devices D1 and D2 with file names that identify the production lines L1 and L2 controlled by the line control devices C1 and C2. . Note that the transmission timing of the processing data from the line control devices C1 and C2 to the data processing devices D1 and D2 can be, for example, the time when one roll film 24 is produced.

  When the data processing devices D1 and D2 operating normally receive the processing data from the line control devices C1 and C2 (step S4), the production line folder of the processing data storage unit 48 specified by the file name is processed. F1 and F2 are stored (step S5).

  On the other hand, the line identification unit 50 of the data processing devices D1 and D2 checks the processing data stored in the processing data storage unit 48 at regular intervals (step S6). The line control devices C1 and C2 are identified from the data file name (step S7).

  Next, the data processing unit 54 reads the line parameters related to the line control devices C1 and C2 identified by the line identifying unit 50 from the line parameter storage unit 52 (step S8), and processes the processing data using the line parameters. (Step S9). As processing of processing data in the data processing devices D1 and D2, for example, processing for counting received quality data (micro defects), determining whether the product is within the standard, The process etc. which calculate the thickness of a product from length, width, weight) are mentioned.

  Production results, which are processed data processed by the data processing devices D1 and D2, are printed on the labels by the label printers P1 and P2, and then attached to the produced packaging film 26 (step S10). Further, the processing data processed by the data processing unit 54 is transmitted and recorded in the recording device DB via the network 30 as processing data for each of the line control devices C1 and C2 (step S11).

  Similarly, the inspection control devices S1 and S2 and the product transport control devices M1 and M2 confirm the alive state of the data processing devices D1 and D2 that are connected, and the data processing device D1 that is determined to be operating normally. , Each processing data is transmitted to D2. The data processing devices D1 and D2 that have received the processing data from the inspection control devices S1 and S2 and the product transport control devices M1 and M2 perform processing corresponding to the identified production lines L1 and L2 on the processing data. And recording in the recording device DB.

  In addition, this invention is not limited to embodiment mentioned above, Of course, it can change freely in the range which does not deviate from the main point of this invention.

  For example, if the time required to receive the life / death response command from the data processing devices D1 and D2 is long, the data processing device selection unit 38 determines that the load on the data processing devices D1 and D2 is large and the load is small. The processing data can also be transmitted by selecting the data processing devices D1 and D2.

It is a block diagram of the configuration of the production system of the present embodiment. It is explanatory drawing of the production line managed and controlled by the production system of this embodiment. 1 is a configuration block diagram centering on a line control device and a data processing device that constitute a production system of the present embodiment; FIG. It is a flowchart of the data processing apparatus which comprises the production system of this embodiment. It is a flowchart of the line control apparatus which comprises the production system of this embodiment. It is explanatory drawing of the connection relation of the data processing apparatus and line control apparatus in the production system of this embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Production system 24 ... Roll film 26 ... Packaging film 28 ... Conveyance cart 30 ... Network 32 ... Production management computer C1, C2 ... Line control device D1, D2 ... Data processing device L1, L2 ... Production line M1, M2 ... Product conveyance Control devices P1, P2 ... Label printers S1, S2 ... Inspection control device

Claims (9)

Equipment control equipment for controlling product production equipment;
A plurality of data processing devices that obtain processing data of the product produced by the production facility from the facility control device, and perform predetermined data processing on the processing data;
With
The facility control device transmits a data processing device selection unit that selects the data processing device that is the transmission destination of the processing data, and a life / death confirmation command that confirms a life / death state for the selected data processing device, A life and death confirmation unit for confirming the life and death state of the data processing device,
Each of the data processing devices, when receiving the life / death confirmation command, a life / death response unit that transmits a life / death response command to the facility control device that is the transmission source of the life / death confirmation command, and a source of the life / death confirmation command A transmission source identification unit that identifies the facility control device, and a data processing unit that performs data processing corresponding to the identified facility control device with respect to the processing data transmitted from the facility control device A production system characterized by that. The system of claim 1, wherein
The production system, wherein the equipment control device is a line control device for controlling a production line of the product. The system of claim 1, wherein
The production system according to claim 1, wherein the facility control device is an inspection control device that controls an inspection device that inspects the processing data in the production line of the product. The system of claim 1, wherein
The production system, wherein the equipment control device is a product conveyance control device that controls a product conveyance device that conveys the product. The system of claim 1, wherein
The production system according to claim 1, wherein the data processing device selection unit selects the data processing device with a low load. The system of claim 1, wherein
The transmission source identifying unit identifies the facility control device based on a file name of the processing data. Equipment control device for controlling product production equipment, and a plurality of data processing devices for obtaining processing data of the product produced by the production equipment from the equipment control device and performing predetermined data processing on the processing data In a processing method of a production system comprising
Selecting the data processing device that is the transmission destination of the processing data;
Transmitting a life / death confirmation command for confirming a life / death state to the selected data processing device;
When receiving the life and death confirmation command, sending a life and death response command to the equipment control device that is the transmission source of the life and death confirmation command;
Transmitting the processing data to the data processing device that is the source of the life / death response command;
Identifying the equipment control device that is the source of the processing data;
Performing data processing corresponding to the identified equipment control device for the processing data;
A method for processing a production system, comprising: The method of claim 7, wherein
A processing method for a production system, wherein the equipment control device is identified based on a file name of the processing data. The method of claim 7, wherein
A processing method for a production system, characterized in that the data processing device with a low load is selected.

Images