JP2020204798A - Data collection device - Google Patents

Abstract

To provide a data collection device capable of making factor analysis of singular points more efficient.SOLUTION: The data collection device 1 includes a process data storage unit 12, a sensor arrival time calculation unit 13, and a display unit 14. The sensor arrival time calculation unit 13 calculates a cumulative sampling cycle time at which an integrated distance before a singularity detection time, that is integrated values obtained by an average transport speed for each sampling cycle multiplied by the sampling cycle, is equal to or greater than a sensor-to-sensor distance that is the distance from a singular point detection sensor to a physical quantity sensor, and calculates a sensor arrival time when the singularity reaches the physical quantity sensor by subtracting the cumulative sampling cycle time from the singularity detection time. The display unit 14 displays a first marker indicating the singularity detection time and a second marker indicating the sensor arrival time on a time axis of a graph.SELECTED DRAWING: Figure 3

Description

The present invention relates to a data collecting device that collects data on a production line.

Industrial plants (paper manufacturing plants, steel plants, power plants, petroleum plants, chemical plants, etc.) that produce materials and resources necessary for industrial activities are known. The plant monitoring and control system of an industrial plant controls an input / output device (I / O) to which a large number of field devices (including actuators and sensors) constituting the plant are connected and a large number of field devices via a control network. It has a configuration in which programmable logic controllers (hereinafter referred to as PLCs) are connected to each other.

Input / output signals of PLC and input / output device are called process data. In a large-scale plant, there are thousands and tens of thousands of input / output points, and a wide variety of process data exists. These process data are collected in a data collection device and used for data analysis during testing, adjustment, operation, and failure.

A data collection device (for example, Patent Document 1) of a conventional plant monitoring and control system connects to a control network and collects process data input / output by a PLC.

International Publication No. 2014/002176

When a singular point such as a scratch, stain, wrinkle, or tear is found on the surface of a long material such as paper, film, or steel plate that is transported on the production line, the operator uses a data collection device to determine the cause of the singular point. To analyze. For the analysis, it is effective to confirm the change in the physical quantity of the singular point or the change in the physical quantity of the device acting on the singular point in the process of being transported on the production line. In particular, it is desirable that the singular point can be accurately tracked and the change in the physical quantity of the singular point in the transport process can be visually confirmed even when the transport speed of the long material changes in the production line.

However, the data collection device of Patent Document 1 has not examined the analysis of the collected data. Therefore, it is necessary to manually calculate the passing time when the singular point generated in the long material passes through the sensor, and it is difficult to accurately calculate the passing time corresponding to the change in the transport speed. Moreover, even if the collected process data is displayed in a graph format, it is necessary to manually scroll the graph to find the singular point, and it is not possible to efficiently find the data related to the singular point.

The present invention has been made to solve the above-mentioned problems. An object of the present invention is to automatically calculate the position of a singular point in consideration of the speed change of a long material to be conveyed, and visualize the time when the singular point passes through each sensor by a graph with a marker. This is to provide a data collecting device capable of streamlining factor analysis of singular points.

In order to achieve the above object, the data collecting device according to the present invention is configured as follows.

The data collecting device according to the present invention collects data of a production line for processing a long material to be transported.

In one preferred embodiment, the production line has a speed sensor, a singularity detection sensor, and a physical quantity sensor. The speed sensor measures the transport speed of a long material. The singularity detection sensor detects the singularity of a long material at its installation position. The physical quantity sensor is installed upstream of the singularity detection sensor and measures the physical quantity of the long material or the physical quantity of the device acting on the long material at the installation position.

The data collection device includes a process data storage unit, a sensor arrival time calculation unit, and a display unit.

The process data storage unit has the transfer speed of each time measured by the speed sensor for each sampling cycle, the singular point detection time when the singular point detection sensor detects the singular point, and each time measured by the physical quantity sensor for each sampling cycle. Memorize the physical quantity.

When the integrated distance obtained by multiplying the average transport speed for each sampling cycle before the singular point detection time by the sampling cycle is equal to or greater than the distance between the sensors from the singular point detection sensor to the physical quantity sensor. The cumulative sampling cycle time of is calculated, and the cumulative sampling cycle time is subtracted from the singular point detection time to calculate the sensor arrival time when the singular point reaches the physical quantity sensor.

The display unit displays the physical quantity of each time measured by the physical quantity sensor for each sampling cycle in a graph, and displays the first marker indicating the singular point detection time and the second marker indicating the sensor arrival time on the time axis of the graph. ..

Preferably, the physical quantity at each time measured by the physical quantity sensor is displayed for at least the period from before the singular point passes through the physical quantity sensor to when it passes through the singular point detection sensor.

In another preferred embodiment, the production line has a camera in addition to the above configuration. The camera is installed downstream of the singularity detection sensor and photographs the long material at the installation position.

In addition to the above configuration, the data collection device includes an image data storage unit and a camera arrival time calculation unit.

The image data storage unit stores image data at each time taken by the camera for each sampling cycle.

The camera arrival time calculation unit is used when the integrated distance obtained by multiplying the average transport speed for each sampling cycle before the singularity detection time by the sampling cycle is equal to or greater than the distance between the sensors from the singularity detection sensor to the camera. The cumulative sampling cycle time is calculated, and the cumulative sampling cycle time is subtracted from the singular point detection time to calculate the camera arrival time when the singular point reaches the camera.

In addition to the above-described configuration, the display unit displays image data of the long material taken at the camera arrival time together with the graph, and further displays a third marker indicating the camera arrival time on the time axis of the graph.

Preferably, the graph shows at least the period from before the singularity passes through the physical quantity sensor and the most upstream sensor of the camera to when it passes through the singularity detection sensor, at each time measured by the physical quantity sensor. Display the physical quantity.

According to the data collecting device according to the present invention, the position of the singular point can be automatically and accurately tracked even when the transport speed of the long material changes. Then, the data collection device displays a graph with a marker (time line) attached to the time when the singular point passes through each sensor (physical quantity sensor, camera, singular point detection sensor), thereby changing the physical quantity related to the singular point. Can be visualized. In addition, the process data can be confirmed by the graph with a marker attached to the shooting time of the image data together with the image data obtained by shooting the singular point. As described above, according to the data collecting device according to the present invention, the factor analysis of the singular point can be made more efficient.

It is a block diagram of the plant monitoring control system in Embodiment 1 of this invention. It is a conceptual diagram of the production line in Embodiment 1 of this invention. It is a block diagram of the data collection apparatus in Embodiment 1 of this invention. It is a figure for demonstrating the sensor arrival time calculation part in Embodiment 1 of this invention. It is a block diagram of the plant monitoring control system in Embodiment 2 of this invention. It is a conceptual diagram of the production line in Embodiment 2 of this invention. It is a block diagram of the data collection apparatus in Embodiment 2 of this invention. It is a conceptual diagram of the production line in Embodiment 3 of this invention. It is a block diagram of the data collection apparatus in Embodiment 3 of this invention. It is a conceptual diagram of the production line in Embodiment 4 of this invention. It is a block diagram of the data collection apparatus in Embodiment 4 of this invention. It is a block diagram which shows the hardware configuration example of the processing circuit which a data collection apparatus has.

A mode for carrying out the present invention will be described with reference to the accompanying drawings. In each figure, the same or corresponding parts are designated by the same reference numerals. The duplicate description of the relevant part will be simplified or omitted as appropriate.

Embodiment 1.
(System configuration)
FIG. 1 is a configuration diagram of a plant monitoring and control system according to the first embodiment.

The data collection device 1 includes an input / output device (I / O) 3 connected to a plurality of field devices 2 (including actuators and sensors) constituting a production line of an industrial plant via a control network 5, and a plurality of fields. It is connected to a programmable logic controller (PLC) 4 that controls the device 2.

The control network 5 has a plurality of nodes having a common memory, and synchronizes process data on the common memory by periodic broadcast transmission between the plurality of nodes. As a result, the data collection device 1 connected to the node A5a, the PLC4 connected to the node B5b, and the input / output device 3 connected to the node C5c virtually share the same memory space. A storage area (address) for each data is assigned to the common memory. The device connected to each node can send and receive process data by writing to the common memory and reading from the common memory.

The input / output signals of the PLC 4 and the input / output device 3 are referred to as process data (character data, numerical data). The process data includes various data regarding the equipment group constituting the industrial plant and the materials processed in the equipment group. For example, it includes actuator control values, sensor detection values, material specifications, and the like. Large-scale plants such as steel plants have thousands or tens of thousands of input / output points, and a wide variety of process data exists. These process data are collected in the data collection device 1 and are mainly used for data analysis.

FIG. 2 is a conceptual diagram of a manufacturing line of an industrial plant according to the first embodiment.

The production line 20 processes while transporting the long material 21. The long material 21 includes a sheet-like material such as paper, film, and steel plate. The production line 20 includes a plurality of field devices 2 (FIG. 1). The plurality of field devices 2 include a speed sensor 22, a singular point detection sensor 23, physical quantity sensors 24a, 24b, and various actuators (hydraulic device, motor, etc.) for driving equipment acting on the long member 21.

The speed sensor 22 measures the transport speed of the long member 21. The transport speed of the long member 21 may be measured based on the rotation speed of the motor that drives the roller that transports the long member 21.

The singularity detection sensor 23 detects the singularity of the long member 21 at the installation position.

The physical quantity sensors 24a and 24b are installed upstream of the singularity detection sensor 23, and measure the physical quantity of the long member 21 at the installation position or the physical quantity of the device acting on the long member 21. The distance from the singularity detection sensor 23 to the physical quantity sensor 24a is L1. The distance from the singularity detection sensor 23 to the physical quantity sensor 24b is L2. One or more physical quantity sensors are installed.

The production line 20 is, for example, a paper production line, a cold rolling line, a process line, or the like.

The paper production line is equipped with a rewinder, a coating unit, a dryer, and a winder in order from the upstream. In the paper production line, the long material 21 is a sheet-shaped paper. The singularity detection sensor 23 is a defect point detection sensor installed on the winder entry side. The defect point detection sensor detects tears, stains, wrinkles, etc. of paper. The physical quantity sensors 24a and 24b are temperature sensors that measure the spraying temperature of the dryer, for example. The physical quantity sensors 24a and 24b may be a tension meter, or may be a voltmeter or an ammeter connected to an actuator that drives a device acting on the long member 21.

The cold rolling line is provided with a payoff reel, a welding machine, a continuous rolling machine, and a tension reel in order from the upstream. In the cold rolling line, the long member 21 is a sheet-shaped thin plate. The singularity detection sensor 23 is a surface scratch inspection device installed on the tension reel entry side. The surface scratch inspection device detects scratches on the surface of a thin plate that has passed through a continuous rolling mill. The singularity detection sensor 23 may be a flatness meter, a shape meter, a plate thickness meter, a temperature sensor, or the like. The physical quantity sensors 24a and 24b are temperature sensors that measure the inlet temperature and the outlet temperature of the continuous rolling mill, for example. The physical quantity sensors 24a and 24b may be a tension meter, a meandering meter, a plate thickness meter, or a voltmeter or an ammeter connected to an actuator that drives a device acting on the long member 21.

The process line, for example, the annealing line, includes a payoff reel, a welding machine, an annealing furnace, a temper rolling mill, and a tension reel in order from the upstream. In the annealing line, the long member 21 is a cold-rolled thin plate. The singularity detection sensor 23 is a surface scratch inspection device installed on the tension reel entry side. The surface scratch inspection device detects scratches on the surface of the thin sheet that has passed through the temper rolling mill. The singularity detection sensor 23 may be a flatness meter, a shape meter, a plate thickness meter, a temperature sensor, or the like. The physical quantity sensors 24a and 24b are temperature sensors that measure the temperature of each part of the annealing furnace, for example. The physical quantity sensors 24a and 24b may be a tension meter, a meandering meter, a plate thickness meter, or a voltmeter or an ammeter connected to an actuator that drives a device acting on the long member 21.

(Data collection device)
Next, the detailed function of the data collecting device 1 for collecting the data of the production line 20 for processing the long material 21 to be conveyed will be described. FIG. 3 is a block diagram of the data collection device 1 according to the first embodiment.

The data collection device 1 includes a process data collection unit 11, a process data storage unit 12, a sensor arrival time calculation unit 13, and a display unit 14.

The process data collection unit 11 collects process data related to a large number of field devices 2 constituting the production line 20 and the long material 21 processed by the field devices 2. Specifically, the process data collection unit 11 collects various process data flowing through the control network 5 (FIG. 1) for each sampling cycle. The process data collection unit 11 assigns a data collection time to the process data and outputs the data to the process data storage unit 12.

In the example shown in FIG. 2, the process data collection unit 11 determines the transfer speed measured by the speed sensor 22, the singular point detection time when the singular point detection sensor 23 detects the singular point, and the physical quantity sensor 24a, for each sampling cycle. The physical quantities measured by each of the 24bs are collected. The method for detecting the singular point is not limited, but as an example, when the value based on the physical quantity measured by the singular point detection sensor 23 exceeds a predetermined threshold range, it can be determined that there is a singular point, and the time can be determined. Let it be the singularity detection time.

The process data storage unit 12 stores various process data at each time. In the example shown in FIG. 2, the process data storage unit 12 has a transport speed at each time measured by the speed sensor 22 for each sampling cycle, a singular point detection time when the singular point detection sensor 23 detects a singular point, and a physical quantity sensor. 24a and 24b store the physical quantity at each time measured for each sampling cycle. The data collecting device 1 stores in advance the distance L1 from the singularity detection sensor 23 to the physical quantity sensor 24a and the distance L2 from the singularity detection sensor 23 to the physical quantity sensor 24b.

The sensor arrival time calculation unit 13 calculates the sensor arrival time when the singular point detected by the singular point detection sensor 23 passes through the physical quantity sensors 24a and 24b before the detection.

The sensor arrival time calculation unit 13 first calculates a value obtained by multiplying the average transport speed for each sampling cycle before the singularity detection time by the sampling cycle. This value means the moving distance of the long member 21 in each sampling cycle.

This will be described with reference to FIG. The sampling period is 10 [ms]. The position X is the position where the singular point detection sensor 23 detects the singular point. The position A is the position of the singular point one sampling cycle before the position X. The position B is the position of the singular point two sampling cycles before the position X. The position C is the position of the singular point 3 sampling cycles before the position X. The position D is the position of the singular point 4 sampling cycles before the position X.

The transport speed of the long member 21 changes. The transport speed at position X is 0.20 [m / ms], the transport speed at position A is 0.21 [m / ms], the transport speed at position B is 0.22 [m / ms], and the transport at position C is The speed is 0.25 [m / ms] and the transport speed at position D is 0.30 [m / ms].

At this time, the average transport speed in the sampling cycle of the section XA is (0.20 + 0.21) / 2 = 0.205 [m / ms]. Therefore, the distance of the section XA (the value obtained by multiplying the average line speed of the section XA by the sampling period) is 2.05 [m / ms] × 10 [ms] = 2.05 [m]. By the same calculation, the distance of the section AB shown in FIG. 4 is 2.15 [m], the distance of the section BC is 2.35 [m], and the distance of the section CD is 2.75 [m]. Is.

Further, the sensor arrival time calculation unit 13 calculates the integrated distance from the position X by integrating these values (moving distance in each sampling cycle). In the example of FIG. 4, the integrated distance of the section X-B is 4.2 [m], the integrated distance of the section X-C is 6.55 [m], and the integrated distance of the section X-D is 9.3 [m]. Is.

Further, the sensor arrival time calculation unit 13 calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the inter-sensor distance L1 from the singular point detection sensor 23 to the physical quantity sensor 24a. For example, when the distance L1 between the sensors is 9.3 [m], it matches the integrated distance of the sections XD in FIG. The cumulative sampling period time used to calculate the integrated distance in the sections XD is 40 [ms]. Similarly, the sensor arrival time calculation unit 13 calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the inter-sensor distance L2 from the singular point detection sensor 23 to the physical quantity sensor 24b.

Further, the sensor arrival time calculation unit 13 calculates the sensor arrival time when the singular point reaches the physical quantity sensor 24a by subtracting the cumulative sampling cycle time from the singular point detection time. Similarly, the sensor arrival time calculation unit 13 calculates the sensor arrival time when the singular point reaches the physical quantity sensor 24b. In this way, the data collecting device 1 can accurately track the position of the singular point even when the transport speed of the long member 21 changes.

The display unit 14 causes the graph display area 30 of the monitor 117 to display a graph showing the relationship between the process data stored in the process data storage unit 12 and the data collection time. In the graph display area 30, the transport speed data 31 at each time measured by the speed sensor 22 for each sampling cycle, the physical quantity data 32 at each time measured by the physical quantity sensor 24a for each sampling cycle, and the physical quantity sensor 24b for each sampling cycle. The measured physical quantity data 33 at each time is displayed in a graph format. In the example shown in FIG. 3, the horizontal axis of the graph is time and the vertical axis is the process data value.

Further, the display unit 14 has a marker 41 indicating the singular point detection time on the time axis of the graph, a marker 42 indicating the sensor arrival time when the singular point reaches the physical quantity sensor 24a, and a sensor arrival where the singular point reaches the physical quantity sensor 24b. A marker 43 indicating the time is displayed. These markers are timelines.

Preferably, the graph shows the transport speed at each time measured by the speed sensor 22 and the physical quantity sensor 24a, for a period from at least before the singular point passes through the physical quantity sensor 24b to when it passes through the singular point detection sensor 23. The physical quantity at each time measured by 24b is displayed. Preferably, the graph displays the change in process data from the line entry side to the exit side of the tracked singularity. Displaying process data for such a wide period contributes to the investigation of the cause of the occurrence of singular points in the transport process.

As described above, according to the data collecting device 1 according to the first embodiment, the position of the singular point can be automatically and accurately tracked even when the transport speed of the long member 21 changes. Then, the data collecting device 1 displays a graph with markers 41 to 43 (time line) attached to the time when the singular point passes through various sensors (singular point detection sensor 23, physical quantity sensor 24a, 24b), and displays the singular point. It is possible to visualize changes in physical quantities related to. According to this, the factor analysis of the singular point can be made more efficient.

For example, in the above-mentioned paper production line, when the defect point detection sensor detects a paper tear (singular point), the data collection device 1 sets the time when the singular point passes through the defect point detection sensor and the singular point. A graph with a marker is displayed at the time when the temperature sensor that measures the blowing temperature of the dryer is passed. This graph represents changes in the dryer blowing temperature and changes in the transport speed for the period from before the singularity passes through the dryer to when it passes through the defect detection sensor.

By the way, the data collecting device 1 of the first embodiment described above does not include the monitor 117, the keyboard 118, and the mouse 119 shown in FIG. 12, which will be described later, but these may be included in the data collecting device 1. This point is the same in the following embodiments.

Embodiment 2.
Next, the second embodiment will be described with reference to FIGS. 5 to 7. In the data collection device according to the second embodiment, in addition to the configuration of the first embodiment, a process in which a camera is arranged on the production line and a marker is attached to the camera passing time together with the image data of the time when the singular point passes the camera. Displaying a graph of the data facilitates factor analysis of specific phenomena.

(System configuration)
FIG. 5 is a configuration diagram of the plant monitoring and control system according to the second embodiment. The plant monitoring and control system shown in FIG. 5 includes a plurality of cameras 6 and an information network 7 in addition to the configuration shown in FIG. The image data obtained by the plurality of cameras 6 taking a picture target is transmitted to the data collection device 1 via the information network 7.

FIG. 6 is a conceptual diagram of the production line according to the second embodiment. In the production line 20 shown in FIG. 6, in addition to the configuration shown in FIG. 2, the plurality of cameras 6 include cameras 25a and 25b. The camera 25a is installed upstream of the singularity detection sensor 23, and photographs the long member 21 at the installation position. The camera 25b is installed upstream of the camera 25a and photographs the long member 21 at the installation position. The distance from the singularity detection sensor 23 to the camera 25a is L3. The distance from the singularity detection sensor 23 to the camera 25b is L4. One or more cameras are installed.

(Data collection device)
FIG. 7 is a block diagram of the data collection device 1 according to the second embodiment. The data collecting device 1 shown in FIG. 7 newly includes an image data collecting unit 15, an image data storage unit 16, and a camera arrival time calculation unit 17, and includes a display unit 14a in place of the display unit 14, except that the display unit 14a is provided in FIG. It is the same as the configuration shown in. The data collecting device 1 stores in advance the distance L3 from the singularity detection sensor 23 to the camera 25a and the distance L4 from the singularity detection sensor 23 to the camera 25b.

The image data collection unit 15 collects image data captured by each of the plurality of cameras 6 for each sampling cycle. The image data collection unit 15 assigns a data collection time to the image data and outputs the data to the image data storage unit 16.

The image data storage unit 16 stores image data at each time taken by each of the plurality of cameras 6 in each sampling cycle.

The camera arrival time calculation unit 17 calculates the camera arrival time when the singular point detected by the singular point detection sensor 23 passes through the cameras 25a and 25b before the detection.

The camera arrival time calculation unit 17 first calculates a value obtained by multiplying the average transport speed for each sampling cycle before the singularity detection time by the sampling cycle. This value means the moving distance of the long member 21 in each sampling cycle. This calculation is the same as the sensor arrival time calculation unit 13 in the first embodiment.

Further, the camera arrival time calculation unit 17 calculates the integrated distance from the singular point detection sensor 23 by integrating these values (moving distance in each sampling cycle). This calculation is the same as the sensor arrival time calculation unit 13 in the first embodiment.

Further, the camera arrival time calculation unit 17 calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the sensor-to-sensor distance L3 from the singular point detection sensor 23 to the camera 25a. Similarly, the camera arrival time calculation unit 17 calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the sensor-to-sensor distance L4 from the singular point detection sensor 23 to the camera 25b. These calculations are the same as those of the sensor arrival time calculation unit 13 in the first embodiment.

Further, the camera arrival time calculation unit 17 calculates the camera arrival time when the singular point reaches the camera 25a by subtracting the cumulative sampling cycle time from the singular point detection time. Similarly, the camera arrival time calculation unit 17 calculates the camera arrival time when the singular point reaches the camera 25b.

The display unit 14a has the following functions in addition to the graph display function with markers equivalent to the display unit 14 in the first embodiment.

The display unit 14a displays the image data of the long member 21 taken at the time when the camera arrives in the image display area 50 of the monitor 117 together with the graph. In the example of FIG. 7, in the image display area 50, the image data taken when the singular point 51 passes through the camera 25a and the image data taken when the singular point 51 passes through the camera 25b are displayed. Further, the display unit 14a displays a marker 44 indicating the camera arrival time when the singular point reaches the camera 25a and a marker 45 indicating the camera arrival time when the singular point reaches the camera 25b on the time axis of the graph.

Preferably, the graph shows the period from before the singularity passes through the physical quantity sensor and the sensor installed most upstream of the camera (physical quantity sensor 24b in the example of FIG. 6) to the passage through the singularity detection sensor 23. The transport speed at each time measured by the speed sensor 22 and the physical quantity at each time measured by the physical quantity sensors 24a and 24b are displayed. Preferably, the graph displays the change in process data from the line entry side to the exit side of the tracked singularity.

As described above, according to the data collecting device 1 according to the second embodiment, in addition to the same effect as that of the first embodiment, the data passes through the camera together with the image data when the singular point passes through the cameras 25a and 25b. A graph of process data with markers 44 and 45 attached to the time is displayed. According to this, the factor analysis of the singular point can be made more efficient.

For example, in the above-mentioned paper production line, when a tear (singular point) of paper is detected by a defect point detection sensor, the image data in which the singular point is photographed and the process data in which a marker is attached to the photographing time are added. Graph is displayed. Therefore, it is possible to confirm the change in the dryer spraying temperature and the change in the transport speed corresponding to the shooting time of the image data.

(Modification example)
By the way, in the second embodiment described above, the cameras 25a and 25b may be installed at any place upstream of the singularity detection sensor 23.

Embodiment 3.
Next, the third embodiment will be described with reference to FIGS. 8 and 9. According to the first embodiment, the physical quantity of the singular point upstream of the singular point detection sensor 23 can be analyzed. By the way, there is a case where it is desired to analyze the physical quantity of the singular point downstream of the singular point detection sensor 23. For example, in a cold rolling line or a process line, it may be desired to observe the state of a welded portion downstream while tracking the welded portion.

(System configuration)
The configuration of the plant monitoring and control system in the third embodiment is the same as that in FIG.

FIG. 8 is a conceptual diagram of the production line according to the third embodiment. The production line 20 shown in FIG. 8 includes physical quantity sensors 26a and 26b in place of the physical quantity sensors 24a and 24b shown in FIG. The physical quantity sensors 26a and 26b are installed downstream of the singularity detection sensor 23, and measure the physical quantity of the long member 21 at the installation position or the physical quantity of the device acting on the long member 21. The distance from the singularity detection sensor 23 to the physical quantity sensor 26a is L5. The distance from the singularity detection sensor 23 to the physical quantity sensor 26b is L6. One or more physical quantity sensors are installed.

The production line 20 is, for example, a cold rolling line. The cold rolling line is provided with a payoff reel, a welding machine, a continuous rolling machine, and a tension reel in order from the upstream. In the cold rolling line, the long member 21 is a sheet-shaped thin plate. The singularity detection sensor 23 is a welding point detector (Weld Point Detector: WPD) installed on the exit side of the welding machine. The singularity detection sensor 23 may be a flatness meter, a shape meter, a plate thickness meter, a temperature sensor, or the like. The physical quantity sensors 26a and 26b are temperature sensors that measure the inlet temperature and the outlet temperature of the continuous rolling mill, for example. The physical quantity sensors 26a and 26b may be a tension meter, a meandering meter, a plate thickness meter, or a voltmeter or an ammeter connected to an actuator for driving a device acting on the long member 21.

(Data collection device)
FIG. 9 is a block diagram of the data collection device 1 according to the third embodiment. The data collecting device 1 shown in FIG. 9 has the same configuration as that shown in FIG. 3 except that the sensor arrival time calculation unit 13 is provided in place of the sensor arrival time calculation unit 13 and the display unit 14b is provided in place of the display unit 14. Is. The data collecting device 1 stores in advance the distance L5 from the singularity detection sensor 23 to the physical quantity sensor 26a and the distance L6 from the singularity detection sensor 23 to the physical quantity sensor 26b.

The sensor arrival time calculation unit 13b calculates the sensor arrival time when the singular point detected by the singular point detection sensor 23 passes through the physical quantity sensors 26a and 26b after the detection.

The sensor arrival time calculation unit 13b first calculates a value obtained by multiplying the average transport speed for each sampling cycle after the singularity detection time by the sampling cycle. This value means the moving distance of the long member 21 in each sampling cycle. This calculation is the same as the sensor arrival time calculation unit 13 in the first embodiment.

Further, the sensor arrival time calculation unit 13b calculates the integrated distance from the singular point detection sensor 23 by integrating these values (moving distance in each sampling cycle). This calculation is the same as the sensor arrival time calculation unit 13 in the first embodiment.

Further, the sensor arrival time calculation unit 13b calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the inter-sensor distance L5 from the singular point detection sensor 23 to the physical quantity sensor 26a. Similarly, the sensor arrival time calculation unit 13b calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the inter-sensor distance L6 from the singular point detection sensor 23 to the physical quantity sensor 26b. These calculations are the same as those of the sensor arrival time calculation unit 13 in the first embodiment.

Further, the sensor arrival time calculation unit 13b adds the cumulative sampling cycle time to the singular point detection time to calculate the sensor arrival time when the singular point reaches the physical quantity sensor 26a. Similarly, the sensor arrival time calculation unit 13b calculates the sensor arrival time when the singular point reaches the physical quantity sensor 26b.

The display unit 14b causes the graph display area 30 of the monitor 117 to display a graph showing the relationship between the process data stored in the process data storage unit 12 and the data collection time. In the graph display area 30, the transport speed data 31 for each time measured by the speed sensor 22 for each sampling cycle, the physical quantity data 34 for each time measured by the physical quantity sensor 26a for each sampling cycle, and the physical quantity sensor 26b for each sampling cycle. The measured physical quantity data 35 at each time is displayed in a graph format. In the example shown in FIG. 9, the horizontal axis of the graph is time, and the vertical axis is the process data value.

Further, the display unit 14b has a marker 41 indicating the singular point detection time on the time axis of the graph, a marker 46 indicating the sensor arrival time when the singular point reaches the physical quantity sensor 26a, and a sensor reaching the sensor where the singular point reaches the physical quantity sensor 26b. A marker 47 indicating the time is displayed. These markers are timelines.

Preferably, the graph shows the transport speed at each time measured by the speed sensor 22 and the physical quantity sensor 26a, at least for the period from before the singular point passes through the singular point detection sensor 23 to when it passes through the physical quantity sensor 26b. The physical quantity at each time measured by 26b is displayed. Preferably, the graph displays the change in process data from the line entry side to the exit side of the tracked singularity. Displaying such a wide period contributes to the investigation of the cause of the occurrence of singular points in the transport process.

As described above, according to the data collecting device 1 according to the third embodiment, the same effect as that of the first embodiment can be obtained. Therefore, the change of the singular point downstream of the singular point detection sensor 23 can be analyzed. For example, in a cold rolling line or a process line, it is possible to observe the state of the welded part downstream while tracking the welded part.

Embodiment 4.
Next, the fourth embodiment will be described with reference to FIGS. 10 and 11. In the data collection device according to the fourth embodiment, in addition to the configuration of the third embodiment, a process in which a camera is arranged on the production line and a marker is attached to the camera passage time together with the image data of the time when the singular point passes the camera. Displaying a graph of the data facilitates factor analysis of specific phenomena.

(System configuration)
The configuration of the plant monitoring and control system in the fourth embodiment is the same as that in FIG.

FIG. 10 is a conceptual diagram of the production line according to the fourth embodiment. In the production line 20 shown in FIG. 10, in addition to the configuration shown in FIG. 8, a plurality of cameras 6 (FIG. 5) include cameras 27a and 27b. The camera 27a is installed downstream of the singularity detection sensor 23, and photographs the long member 21 at the installation position. The camera 27b is installed downstream of the camera 27a and photographs the long member 21 at the installation position. The distance from the singularity detection sensor 23 to the camera 27a is L7. The distance from the singularity detection sensor 23 to the camera 27b is L8. One or more cameras are installed.

(Data collection device)
FIG. 11 is a block diagram of the data collection device 1 according to the fourth embodiment. The data collection device 1 shown in FIG. 11 newly includes an image data collection unit 15, an image data storage unit 16, and a camera arrival time calculation unit 17c, and includes a display unit 14c instead of the display unit 14b. It is the same as the configuration shown in. The data collecting device 1 stores in advance the distance L7 from the singularity detection sensor 23 to the camera 27a and the distance L8 from the singularity detection sensor 23 to the camera 27b.

The image data collection unit 15 collects image data captured by each of the plurality of cameras 6 for each sampling cycle. The image data collection unit 15 assigns a data collection time to the image data and outputs the data to the image data storage unit 16.

The image data storage unit 16 stores image data at each time taken by each of the plurality of cameras 6 in each sampling cycle.

The camera arrival time calculation unit 17c calculates the camera arrival time when the singular point detected by the singular point detection sensor 23 passes through the cameras 27a and 27b after the detection.

The camera arrival time calculation unit 17c first calculates a value obtained by multiplying the average transport speed for each sampling cycle after the singularity detection time by the sampling cycle. This value means the moving distance of the long member 21 in each sampling cycle. This calculation is the same as the sensor arrival time calculation unit 13 in the first embodiment.

Further, the camera arrival time calculation unit 17c calculates the integrated distance from the singular point detection sensor 23 by integrating these values (moving distance in each sampling cycle). This calculation is the same as that of the sensor arrival time calculation unit 13 in the first embodiment.

Further, the camera arrival time calculation unit 17c calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the sensor-to-sensor distance L7 from the singular point detection sensor 23 to the camera 27a. Similarly, the camera arrival time calculation unit 17c calculates the cumulative sampling cycle time when the integrated distance is equal to or greater than the sensor-to-sensor distance L8 from the singular point detection sensor 23 to the camera 27b. These calculations are the same as those of the sensor arrival time calculation unit 13 in the first embodiment.

Further, the camera arrival time calculation unit 17c adds the sampling cycle cumulative time to the singular point detection time to calculate the camera arrival time when the singular point reaches the camera 27a. Similarly, the camera arrival time calculation unit 17c calculates the camera arrival time when the singular point reaches the camera 27b.

The display unit 14c has the following functions in addition to the graph display function with markers equivalent to the display unit 14b in the third embodiment.

The display unit 14c displays the image data of the long member 21 taken at the time when the camera arrives in the image display area 50 of the monitor 117 together with the graph. In the example of FIG. 11, in the image display area 50, the image data taken when the singular point 51 passes through the camera 27a and the image data taken when the singular point 51 passes through the camera 27b are displayed. Further, the display unit 14c displays a marker 48 indicating the camera arrival time when the singular point reaches the camera 27a and a marker 49 indicating the camera arrival time when the singular point reaches the camera 27b on the time axis of the graph.

Preferably, the graph shows the period from at least before the singularity passes through the singularity detection sensor 23 to the passage through the physical quantity sensor and the sensor installed most downstream of the camera (physical quantity sensor 26b in the example of FIG. 10). The transport speed at each time measured by the speed sensor 22 and the physical quantity at each time measured by the physical quantity sensors 26a and 26b are displayed. Preferably, the graph displays the change in process data from the line entry side to the exit side of the tracked singularity.

As described above, according to the data collecting device 1 according to the fourth embodiment, in addition to the same effect as that of the third embodiment, the data passes through the camera together with the image data when the singular point passes through the cameras 27a and 27b. A graph of process data with markers 48 and 49 attached to the time is displayed. According to this, the factor analysis of the singular point can be made more efficient.

(Hardware configuration example)
The hardware configuration of the data collection device 1 in each of the above-described embodiments will be described with reference to FIG. FIG. 12 is a block diagram showing a hardware configuration example of the processing circuit included in the data collection device 1. Each part of the data collection device 1 shows a part of the functions of the data collection device 1, and each function is realized by a processing circuit. For example, the processing circuit includes a CPU 111, a memory 112, a storage 113 such as an HDD or a large-capacity memory, an external device I / F (interface) unit 114, a control network I / F unit 115a, and an information network I / F. The unit 115b is connected to the unit 115b via the internal bus 116.

The CPU 111 realizes the functions of each unit of FIG. 3 by executing various application programs stored in the program storage unit 113a of the storage 113.

The memory 112 is used as a calculation area unit for temporarily storing and expanding data when the CPU 111 executes various application programs.

The storage 113 has a program storage unit 113a and a data storage unit 113b. The program storage unit 113a stores an OS (operating system) and various application programs. In addition, the data storage unit 113b stores the collected process data and image data. The memory 112 and the storage 113 are also collectively referred to as a memory.

The external device I / F unit 114 is an interface for connecting an external device such as a monitor 117, a keyboard 118, and a mouse 119 to the data collecting device 1.

The control network I / F unit 115a is an interface for connecting the control network 5 and the data collection device 1. Further, the information network I / F unit 115b is an interface for connecting the information network 7 and the data collection device 1.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and can be variously modified and implemented without departing from the spirit of the present invention.

1 Data collection device 2 Field device 3 Input / output device 4 PLC
5 Control network 6 Camera 7 Information network 11 Process data collection unit 12 Process data storage unit 13, 13b Sensor arrival time calculation unit 14, 14a, 14b, 14c Display unit 15 Image data collection unit 16 Image data storage unit 17, 17c Camera arrival Time calculation unit 20 Production line 21 Long material 22 Speed sensor 23 Singular point detection sensor 24a, 24b Physical quantity sensor 25a, 25b Camera 26a, 26b Physical quantity sensor 27a, 27b Camera 30 Graph display area 31 Transport speed data 32-35 Physical quantity data 41 −49 Marker 50 Image display area 51 Singularity 111 CPU
112 Memory 113 Storage 113a Program storage 113b Data storage 114 External device I / F 115a Control network I / F 115b Information network I / F 116 Internal bus 117 Monitor 118 Keyboard 119 Mouse

Claims (8)

A data collection device that collects data from a manufacturing line that processes long materials to be transported.
The production line
A speed sensor that measures the transport speed of the long material, and
A singularity detection sensor that detects the singularity of the long material at the installation position,
It is installed upstream of the singularity detection sensor and has a physical quantity sensor that measures the physical quantity of the long material or the physical quantity of the device acting on the long material at the installation position.
The data collection device
The transport speed at each time measured by the speed sensor for each sampling cycle, the singular point detection time when the singular point detection sensor detects the singular point, and the physical quantity at each time measured by the physical quantity sensor for each sampling cycle. The process data storage unit that stores,
Sampling when the integrated distance obtained by multiplying the average transport speed for each sampling cycle before the singularity detection time by the sampling cycle is equal to or greater than the distance between the sensors from the singularity detection sensor to the physical quantity sensor. A sensor arrival time calculation unit that calculates the cumulative cycle time, subtracts the cumulative sampling cycle time from the singularity detection time, and calculates the sensor arrival time when the singularity reaches the physical quantity sensor.
The physical quantity of each time measured by the physical quantity sensor for each sampling cycle is displayed in a graph, and a first marker indicating the singular point detection time and a second marker indicating the sensor arrival time are displayed on the time axis of the graph. Display part and
A data collection device characterized by comprising. The graph displays the physical quantity at each time measured by the physical quantity sensor, at least for the period from before the singular point passes through the physical quantity sensor to when it passes through the singular point detection sensor.
The data collecting device according to claim 1. The production line
It is installed upstream of the singularity detection sensor and further has a camera that captures the long material at the installation position.
The data collection device
An image data storage unit that stores image data at each time taken by the camera in each sampling cycle.
Sampling cycle when the integrated distance obtained by multiplying the average transport speed for each sampling cycle before the singular point detection time by the sampling cycle is equal to or greater than the distance between the sensors from the singular point detection sensor to the camera. A camera arrival time calculation unit that calculates the cumulative time, subtracts the sampling cycle cumulative time from the singularity detection time, and calculates the camera arrival time when the singularity reaches the camera is further provided.
The display unit displays image data of the long material taken at the camera arrival time together with the graph, and further displays a third marker indicating the camera arrival time on the time axis of the graph.
The data collecting device according to claim 1. In the graph, at least the period from before the singular point passes through the physical quantity sensor and the sensor installed most upstream of the camera to passing through the singular point detection sensor is measured by the physical quantity sensor. Displaying the physical quantity at each time,
3. The data collecting device according to claim 3. A data collection device that collects data from a manufacturing line that processes long materials to be transported.
The production line
A speed sensor that measures the transport speed of the long material, and
A singularity detection sensor that detects the singularity of the long material at the installation position,
It is installed downstream of the singularity detection sensor and further has a physical quantity sensor that measures the physical quantity of the long material or the physical quantity of the device acting on the long material at the installation position.
The data collection device
The transport speed at each time measured by the speed sensor for each sampling cycle, the singular point detection time when the singular point detection sensor detects the singular point, and the physical quantity at each time measured by the physical quantity sensor for each sampling cycle. The process data storage unit that stores,
Sampling when the integrated distance obtained by multiplying the average transport speed for each sampling cycle after the singularity detection time by the sampling cycle is equal to or greater than the distance between the sensors from the singularity detection sensor to the physical quantity sensor. A sensor arrival time calculation unit that calculates the cumulative cycle time, adds the sampling cycle cumulative time to the singularity detection time, and calculates the sensor arrival time when the singularity reaches the physical quantity sensor.
The physical quantity of each time measured by the physical quantity sensor for each sampling cycle is displayed in a graph, and a first marker indicating the singular point detection time and a second marker indicating the sensor arrival time are displayed on the time axis of the graph. Display part and
A data collection device characterized by comprising. The graph displays the physical quantity at each time measured by the physical quantity sensor, at least for the period from before the singular point passes through the singular point detection sensor to when it passes through the physical quantity sensor.
5. The data collecting device according to claim 5. The production line
It is installed downstream of the singularity detection sensor and further has a camera that captures the long material at the installation position.
The data collection device
An image data storage unit that stores image data at each time taken by the camera in each sampling cycle.
Sampling cycle when the integrated distance obtained by multiplying the average transport speed for each sampling cycle after the singularity detection time by the sampling cycle is equal to or greater than the distance between the sensors from the singularity detection sensor to the camera. It further includes a camera arrival time calculation unit that calculates the cumulative time, adds the sampling cycle cumulative time to the singularity detection time, and calculates the camera arrival time when the singularity reaches the camera.
The display unit displays image data of the long material taken at the camera arrival time together with the graph, and further displays a third marker indicating the camera arrival time on the time axis of the graph.
5. The data collecting device according to claim 5. The graph was measured by the physical quantity sensor for a period from at least before the singular point passed through the singular point detection sensor until it passed through the physical quantity sensor and the sensor installed most downstream of the camera. Displaying the physical quantity at each time,
7. The data collecting device according to claim 7.

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