JP2011145816A - Control system and data analysis support system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To synchronously store data in a control system and to support analysis based on the stored data, by simple configurations. <P>SOLUTION: This control system 1 includes: a counter device connected via a control network to control data collection devices 41 to 43 for storing control data; and a level 2 computer 6 and a data accumulation device 12 connected via a network to the counter device. The counter device 13 is configured to generate control information by adding a counter to the control data stored in a common memory shared by scan transmission in a control network 51 installed in the control data collection devices 41 to 43 at a prescribed update cycle, and to transmit the counter to a second network 53 at the update cycle, and the level 2 computer 6 is configured to generate control relevant data, and to generate event information by adding the counter to the control relevant data, and the data accumulation device 12 is configured to store the control information and the event information. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention is widely used for control of industrial systems such as FA field including assembly work of steel and paper plant and automobile industry, PA field such as chemical plant, water supply and sewage system and other public systems. The present invention relates to a system and a data analysis support system that supports analysis of data of a control system.

  A general control system for controlling plant equipment includes a plurality of control devices connected via a network. By transferring control data between the control devices via this network, plant equipment is controlled. There is something to control.

  In this control system, control data is stored while controlling the plant equipment.For example, if any abnormal event occurs in the plant equipment, the stored control data is analyzed to determine the cause of the abnormal event that has occurred. It can be useful for investigation and planning of countermeasures.

  Patent Document 1 proposes a data recording apparatus that records information including a recording time and data as one block configuration.

JP-A-9-306146

  However, when the technique described in Patent Document 1 is applied to a general control system, each of the plurality of control devices has a clock inside, and based on the time measured by the clock, the recording time and data Is recorded as one block configuration, a time difference occurs between the control devices, and it is difficult to synchronize data between the control devices.

  It is also conceivable to arrange data collection devices that collect data from a plurality of control devices to synchronize the time. In such a case, since a plurality of control devices operate at a control cycle of several msec, a high device capability is required to collect data transferred by a plurality of control devices at a control cycle of several msec, There existed a subject that the manufacturing cost of an apparatus increased. Furthermore, if a configuration is provided with a plurality of data collection devices for the purpose of distributing the device load, a time difference occurs between these data collection devices, making it difficult to synchronize data between the data collection devices.

  Furthermore, a general control system often includes a host computer that supplies various control-related data such as manufacturing instruction data in addition to the control device. In such a case, in order to perform data analysis, it is necessary to store the control-related data and control data from a plurality of control devices in synchronization. However, it has been very difficult to correlate the control data of the control device generated every control cycle with the control related data of the host computer generated every event.

  The present invention has been made in view of the above problems, and has a simple configuration and stores data in a control system in a synchronized manner, and a control system and data analysis support for supporting analysis based on the stored data To provide a system.

  In order to achieve the above object, a first feature of the control system according to the present invention is that a plurality of control data storage devices for storing control data for controlling a control target and a counter device connected via a control network are provided. A control-related computer and a data storage device connected to the counter device via a network, and the counter device is shared by scan transmission within the control network provided in the plurality of control data storage devices. Control information generating means for generating control information by adding a counter to the control data stored in the common memory at a predetermined update cycle shorter than the control cycle of the control network; and the counter on the network at the update cycle Counter transmission means for transmitting, and the control-related computer controls the control object Control-related data generating means for generating continuous data, and when the control-related data is generated by the control-related data generating means, a counter transmitted by the counter transmitting means is added to the generated control-related data. Event information generating means for generating event information, and the data storage device stores the control information generated by the control information generating means and the event information generated by the event information generating means Means.

  A second feature of the control system according to the present invention is that the control-related data and the control data are extracted in association with a search request from the outside based on the control information and the event information stored in the storage means. A search device is further provided.

  A first feature of the data analysis support system according to the present invention is the control information and the event corresponding to the predetermined number of counts stored in the data storage device according to the first feature of the control system according to the present invention. A data holding device that stores information, and a data generation device that sequentially generates the control data and the control-related data according to the count based on the control information and event information stored in the data holding device. That is.

  According to the control system and the data analysis support system of the present invention, the data in the control system can be stored in synchronization with a simple configuration, and the analysis based on the stored data can be supported.

It is the figure which showed the connection relation of the control system which is the 1st Embodiment of this invention. It is the figure which showed typically the concept of the scan transmission of the common memory with which a level 1 computer, a level 0 computer, a control data collection apparatus, and a counter apparatus are provided. It is the flowchart which showed the process sequence of the control information storage process by the data collection device with which the control system which is the 1st Embodiment of this invention is provided. It is the flowchart which showed the process sequence of the event information storage process by the level 2 computer and data collection apparatus with which the control system which is the 1st Embodiment of this invention is provided. (A) is the figure which showed an example of the control information memorize | stored in the data storage apparatus with which the control system which is the 1st Embodiment of this invention is provided, (b) is the 1st Embodiment of this invention. It is the figure which showed an example of the event information memorize | stored in the data storage device with which the control system which is. It is the figure which showed the connection relation of the data analysis assistance system which is the 2nd Embodiment of this invention.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

<First Embodiment>
FIG. 1 is a diagram showing the connection relationship of the control system according to the first embodiment of the present invention.

  As shown in FIG. 1, the control system 1 according to the first embodiment of the present invention is connected to a level 1 computer 2, a level 0 computer 3, and control data collection devices 41 to 43 via a control network 51. ing. The control system 1 is connected to the control data collection devices 41 to 43 via the first network 52 and is connected to the search device 5 via the second network 53.

  The level 1 computer 2 is constituted by a control controller represented by a PLC (Programmable Logic Controller), for example.

  The level 0 computer 3 is composed of, for example, a drive control device, hydraulic equipment, or the like.

  The control data collection devices 41 to 43 collect control data.

  Based on control information and event information stored in the data storage device 12 described later, the search device 5 extracts control-related data and control data described later in association with a search request supplied from the outside.

  The control system 1 according to the first embodiment of the present invention includes a data collection device 11, a data storage device 12, a counter device 13, and a level 2 computer 6.

  When the counter update period is reached, the data collection device 11 extracts control information from the common memory, and stores the extracted control information in the data storage device 12 described later. Further, the data collection device 11 causes the data storage device 12 to store event information transmitted from the level 2 computer 6 described later.

  The counter device 13 includes a control information generation unit 13a and a counter transmission unit 13b in terms of its functions.

  The control information generation unit 13a counts the control data stored in the common memory shared between the control networks 51 provided in the control data collection devices 41 to 43 at a predetermined update cycle shorter than the control cycle of the control network 51. Is added to generate control information. Here, the control period and the update period are preset periods. For example, when the control period is 2 (msec), the update period is set as a period shorter than 2 (msec), preferably, A value of 1/2 or less of the control period is set. Here, a case where 1 (msec) is set as the update cycle will be described as an example. In addition, the counter is generated as a continuous number from “Counter 1” with an update cycle with a predetermined time as a reference time, such as “Counter 1”, “Counter 2”,. Is done.

  The counter transmission unit 13b transmits the counter on the second network 53 at the update cycle. For example, the counter transmission unit 13 b multicasts the counter onto the second network 53 every 1 (msec) which is the update cycle.

  The level 2 computer 6 is composed of a control computer, and includes a control related data generation unit 6a and an event information generation unit 6b in terms of its functions.

  The control related data generation unit 6a generates control related data related to the plant equipment that is the control target. Here, the control-related data is, for example, when the plant equipment of a hot rolling plant is a control target, production instruction data, production result data, alarm data, work data, role data, model calculation data, model learning data, Various data related to plant control equipment necessary for operating a hot rolling plant, such as constant data and parameter data.

  When the control-related data is generated by the control-related data generation unit 6a, the event information generation unit 6b adds a counter multicasted by the counter transmission unit 13b of the counter device 13 to the generated control-related data. Generate as information.

  The data storage device 12 includes a storage unit 12a in terms of its function.

  The storage unit 12 a stores the control information generated by the control information generation unit 13 a of the counter device 13 and the event information generated by the event information generation unit 6 b of the level 2 computer 6.

  Further, the level 1 computer 2, the level 0 computer 3, the control data collection devices 41 to 43, and the counter device 13 connected to the control network 51 have a common memory, and control data is transmitted between the respective devices. It functions as a network device by performing scan transmission (cyclic transmission).

  Therefore, in each common memory, a transmission data area and a reception data area assigned to each device are provided. Thereby, for example, data in the transmission data area of the level 1 computer 2 is transferred to a common memory in all devices connected to the control network 51 by one data transmission.

  The concept of such scan transmission will be described with reference to FIG.

  FIG. 2 is a diagram schematically showing the concept of scan transmission of the common memory included in the level 1 computer 2, the level 0 computer 3, the control data collection devices 41 to 43, and the counter device 13.

  As shown in FIG. 2, the data in the transmission data area of the level 1 computer 2 are all connected to the same transmission line by one data transmission every control cycle as shown in the C1 line. Are transferred to the common memory of each of the devices (level 0 computer 3, control data collection devices 41 to 43, and counter device 13). Similarly, as shown in the C2 line, the data in the transmission data area of the level 0 computer 3 is also common to the level 1 computer 2, the control data collection devices 41 to 43, and the counter device 13 for each control cycle. Transferred to memory.

  Further, as shown in line C0, the counter generated by the control information generation unit 13a of the counter device 13 is stored in the counter storage area of the common memory of the counter device 13, and the data in the counter storage area is updated every update cycle. The data is transferred to the common memory of all the devices (level 1 computer 2, level 0 computer 3, and control data collection devices 41 to 43) connected to the same transmission path in one data transmission.

  In this way, in each common memory, a transmission data area and a reception data area allocated to each device are provided, and control data is transferred to the common memory in all devices by scan transmission. The same control data can be shared between devices.

≪Control information storage process≫
Next, control information storage processing by the data collection device 11 provided in the control system 1 according to the first embodiment of the present invention will be described.

  FIG. 3 is a flowchart showing a processing procedure of control information storage processing by the data collection device 11 provided in the control system 1 according to the first embodiment of the present invention.

  As shown in FIG. 3, the data collection device 11 determines whether or not the counter update period has been reached (step S101). Specifically, the data collection device 11 determines whether or not the counter value included in the control information stored in the common memory has been updated.

  If it is determined in step S101 that the counter update period has been reached, the data collection device 11 extracts control information from the common memory (step S103).

  Next, the data collection device 11 stores the control information extracted in step S103 in the data storage device 12 (step S105).

  FIG. 5A is a diagram illustrating an example of control information stored in the data storage device 12 included in the control system 1 according to the first embodiment of the present invention.

  As shown in FIG. 5 (a), the control data from the level 1 computer 2 and the control data from the level 0 computer 3 are used as control data, and a counter is associated with the control data and used as control information. 12 is stored.

  Since this control information is stored every time the counter update period is reached, counters 1, 2,..., N are stored for each counter.

≪Event information storage process≫
Next, event information storage processing by the level 2 computer 6 and the data collection device 11 provided in the control system 1 according to the first embodiment of the present invention will be described.

  FIG. 4 is a flowchart showing a processing procedure of event information storage processing by the level 2 computer 6 and the data collection device 11 included in the control system 1 according to the first embodiment of the present invention.

  As shown in FIG. 4, the event information generation unit 6b of the level 2 computer 6 determines whether or not a counter has been received (step S201). Specifically, it is determined whether or not a counter multicasted on the second network 53 has been received by the counter transmission unit 13b of the counter device 13.

  If it is determined in step S201 that the counter has been received (in the case of YES), the event information generating unit 6b stores the received counter in the memory built in the level 2 computer 6 (step S203).

  Next, the event information generation unit 6b determines whether an event has occurred (step S205). Specifically, when control-related data related to plant equipment is generated by the control-related data generation unit 6a, the event information generation unit 6b determines that an event has occurred.

  When it is determined in step S205 that an event has occurred (in the case of YES), the event information generation unit 6b reads a counter stored in the memory built in the level 2 computer 6 (step S207).

  Then, the event information generation unit 6b associates the counter read in step S207 with the control related data generated by the control related data generation unit 6a, and generates event information (step S209).

  Next, the event information generation unit 6b transmits the event information generated in step S209 to the data collection device 11 (step S211).

  Then, the data collection device 11 stores the event information transmitted in step S211 in the data storage device 12 (step S213).

  FIG. 5B is a diagram illustrating an example of event information stored in the data storage device 12 included in the control system 1 according to the first embodiment of the present invention.

  As shown in FIG. 5B, a counter when an event occurs and the control related data generated by the control related data generation unit 6a at that time are associated with each other and stored as event information. As the control related data, for example, control instruction data, manufacturing performance data, and the like are stored.

  Thus, since the control information and the event information are stored in the data storage device 12 and the information is associated with each counter, for example, the search device 5 is supplied with a search request from the outside. Then, the control data and control related data corresponding to a certain counter value can be extracted as synchronized data in response to the search request.

  As described above, according to the control system 1 according to the first embodiment of the present invention, the counter device 13 is provided in the control data collection devices 41 to 43 at a predetermined update cycle shorter than the control cycle of the control network 51. The control data stored in the common memory shared by the scan transmission in the control network 51 is added with a counter to generate control information, and the counter is transmitted to the second network 53 at the update cycle. 2 The computer 6 generates control related data related to the plant control device that is the control target, adds the counter transmitted by the counter device 13 to the generated control related data, generates event information, and the data storage device 12 Are the control information generated by the control information generator 13a of the counter device 13 and the level 2 computer 6 The event information generated by the event information generation unit 6b is stored, so that if any abnormal event occurs in the plant, the user analyzes the stored control information and event information to generate the error It can be used for investigating the cause of events and planning countermeasures. The stored control information and event information can also be used when considering improvements to plant equipment for the purpose of improving product quality.

  In the first embodiment of the present invention, the control system 1 connected to the search device 5 via the second network 53 has been described as an example. However, the present invention is not limited to this, and the control system 1 includes the search device 5. It is good also as a structure provided with.

<Second Embodiment>
FIG. 6 is a diagram showing the connection relationship of the data analysis support system according to the second embodiment of the present invention.

  As shown in FIG. 6, the data analysis support system 10 according to the second embodiment of the present invention includes a search device 8, a data generation device 18, a data holding device 17, an optical disk device 15, and a level 2 computer 7. Are connected to each other via the second network 53.

  Based on control information and event information stored in a data holding device 17 (to be described later), the search device 8 extracts control-related data (to be described later) and control data in association with each other in response to a search request supplied from the outside.

  The optical disk device 15 is a device capable of reading and recording the optical disk 16, reads control information and event information from the optical disk 16, and stores the read control information and event information in the storage unit 17 a of the data holding device 17. Remember. Here, on the optical disc 16, control information and event information corresponding to a predetermined number of counts stored in the storage unit 12a of the data storage device 12 included in the control system 1 according to the first embodiment of the present invention are recorded. Yes. Here, the predetermined number is the number of counts that can be set by the user. For example, a count number corresponding to the time at which an abnormal event analysis is to be performed is designated based on an external input, such as 100 to 10000 counts. Is done.

  The data holding device 17 includes a storage unit 17a in terms of its function.

  The storage unit 17a stores control information and event information corresponding to a predetermined number of counts read from the optical disc 16 by the optical disc apparatus 15.

  Based on the control information and event information stored in the storage unit 17a of the data holding device 17, the data generator 18 generates control data and control-related data for the plant equipment that is the control target. Specifically, the data generator 18 sequentially extracts the control information and the control related information in accordance with the count order for each update cycle (here, 1 (msec)). The data generator 18 stores the extracted control information in a built-in common memory, and transmits the extracted event information to the level 2 computer.

  The level 2 computer 7 includes an event playback unit 7a in terms of its function.

  The event reproducing unit 7a displays the event on a display unit (not shown) based on the event information transmitted from the data generating device 18.

  As described above, the data analysis support system 10 according to the second embodiment of the present invention corresponds to a predetermined number of counts stored in the data storage device 12 included in the control system 1 according to the first embodiment of the present invention. Control information and event information to be stored, and control data and control related data of the plant equipment are generated based on the stored control information and event information, so that the movement of the plant equipment can be simulated .

  As a result, the user can easily investigate the cause of the abnormal event that has occurred, plan countermeasures, and improve plant equipment for the purpose of improving product quality.

  In the data analysis support system 10 according to the second embodiment of the present invention, control information and event information corresponding to a predetermined number of counts are stored in the storage unit 17a of the data holding device 17 using the optical disc 16. However, the present invention is not limited to this, and other storage media may be used, and control information and event information corresponding to a predetermined number of counts may be stored in the storage unit 17a of the data holding device 17 via the network. May be.

DESCRIPTION OF SYMBOLS 1 ... Control system 2 ... Level 1 computer 3 ... Level 0 computer 5 ... Search device 6, 7 ... Level 2 computer (control related computer)
6a ... Control related data generation unit 6b ... Event information generation unit 7a ... Event reproduction unit 10 ... Data analysis support system 11 ... Data collection device 12 ... Data storage device 12a ... Storage unit 13 ... Counter device 13a ... Control information generation unit 13b ... Counter transmission unit 15 ... optical disk device 16 ... optical disk 17 ... data holding device 17a ... storage unit 18 ... data generation device 41 to 43 ... control data collection device (control data storage device)
51 ... Control network 52 ... First network 53 ... Second network

Claims (3)

A counter device connected via a control network to a plurality of control data storage devices for storing control data for controlling a control object; a control-related computer and a data storage device connected to the counter device via a network; With
The counter device
A counter is added to the control data stored in a common memory shared by scan transmission in the control network provided in the plurality of control data storage devices at a predetermined update cycle shorter than the control cycle of the control network. Control information generating means for generating control information;
Counter transmission means for transmitting the counter on the network at the update period,
The control related computer is:
Control-related data generating means for generating control-related data related to the control object;
An event information generating means for generating event information by adding a counter transmitted by the counter transmitting means to the generated control related data when the control related data is generated by the control related data generating means; Have
The data storage device includes:
A control system comprising: storage means for storing control information generated by the control information generation means and event information generated by the event information generation means. The apparatus further comprises: a search device that extracts control-related data and control data in association with each other in response to an external search request based on the control information and event information stored in the storage means. The control system according to 1. A data holding device for storing the control information and the event information corresponding to the predetermined number of counts stored in the data storage device according to claim 1;
A data generator for sequentially generating the control data and the control-related data according to the count based on the control information and event information stored in the data holding device;
A data analysis support system characterized by comprising:

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