JP2021068983A - Gateway device, management server, setting terminal, control method of gateway device, control method of management server, control method of setting terminal, control program, and recording medium - Google Patents

Abstract

To provide a gateway device capable of easily transmitting data collected from FA apparatuses to a device based on IT technology.SOLUTION: A gateway device (1) includes: a definition acquisition unit (31) that acquires PLC specific information specifying PLC, data specific information specifying data to be acquired, and logging information specifying a logging cycle; an initial setting unit (32) that enables a communication program for communicating with the PLC; a measurement value acquisition unit (33) that acquires data from the PLC; and a log transmission unit (34) that transmits according to the logging cycle.SELECTED DRAWING: Figure 1

Description

The present invention relates to a gateway device that transmits data acquired from a desired device to another device by wireless communication, a data collection system including the gateway device, and the like.

In recent years, FA (Factory Automation) has been promoted so that products can be manufactured efficiently and stably at manufacturing sites and the like. It is desirable that the FA control system can acquire various data associated with manufacturing for maintenance, troubleshooting, and the like.

Therefore, in Patent Document 1, the control device that controls the FA device is requested to transmit the data of the controlled device, the received data of the controlled device is converted, and the converted data is transmitted to the server device. The gateway device is described.

Further, Patent Document 2 describes a data collection device connected to a PLC (Programmable Logic Controller), a data collection unit that forms periodic time-series device data, and a time-series according to a designated extraction period. A data collection device that extracts individual data from device data and assigns identification information for identifying each individual data to each extracted individual data is described.

Japanese Patent No. 6440810 (issued on December 19, 2018) Japanese Unexamined Patent Publication No. 2019-16327 (published on January 31, 2019)

In order to transmit the data collected from the FA device from the control device such as PLC to the storage or interface based on IT technology, it is necessary to make the data model transmitted from PLC etc. and the data model on the receiving IT side the same. is there.

However, in FA, various interfaces are mixed for historical reasons, and the data model of FA equipment is not uniform even if it is called FA equipment.

In addition, PLC programs are created by engineers (OT engineers) who have skills called OT (Operational Technology), while the receiving side is engineers who have IT skills (IT technology). Created by The data model on the IT side needs to be created using design information such as device configuration information designed by OT engineers, but due to differences in terms between OT and IT and differences in knowledge between engineers, etc. There is also the possibility of discrepancies.

Therefore, it is not easy to transmit the data collected from the FA device from a control device such as a PLC to a storage or an interface based on IT technology.

The above-mentioned Patent Documents 1 and 2 describe a configuration in which data is collected from an FA device and transmitted to the cloud, but the above-mentioned means for solving the difficulty of realization due to the difference between OT and IT is mentioned. Not done.

One aspect of the present invention has been made in view of the above problems, and an object of the present invention is a gateway device or the like that can easily transmit data collected from an FA device to a device based on IT technology without requiring knowledge of IT. Is to realize.

In order to solve the above problems, the gateway device according to one aspect of the present invention is a gateway device that acquires data from a PLC (Programmable Logic Controller) and transmits the acquired data to a management server, and specifies the PLC. A definition acquisition unit that acquires from the management server the PLC specific information to be specified, the data identification information that specifies the data to be acquired from the PLC, and the logging information that specifies the logging cycle that is the cycle to be transmitted to the management server, and the PLC identification. An initial setting unit that activates a communication program according to a communication protocol for communicating with the PLC based on the information, and data specified by the data identification information are acquired from the PLC using the communication program. The data acquisition unit is provided, and the data transmission unit that transmits the data acquired by the data acquisition unit to the management server according to the logging cycle specified by the logging information is provided.

According to the above configuration, a program for communicating with the PLC specified by the PLC specific information is enabled, and the program is used to communicate with the corresponding PLC. Further, based on the data specific information and the logging information, the desired data among the data acquired from the PLC is transmitted to the management server at a desired cycle. Therefore, if the user sets the PLC specific information, the data specific information, and the logging information in advance, the user simply connects the gateway device to the PLC and the management server in a communicable manner, and acquires the desired data at a desired cycle. can do. Therefore, even a user who does not have much knowledge of IT can easily transmit the data collected from the FA device to the device based on the IT technology.

The gateway device according to one aspect of the present invention includes a storage unit that stores each communication program corresponding to each PLC assumed as a data acquisition destination in advance, and the initial setting unit is stored in the storage unit. Among the communication programs, the communication program for communicating with the PLC specified by the PLC specific information may be enabled.

According to the above configuration, the communication program corresponding to each assumed PLC is stored in the own device in advance. Therefore, if the corresponding PLC is specified, the communication program for easily communicating with the PLC can be obtained. Can be used.

In order to solve the above problems, the management server according to one aspect of the present invention is a management server that receives the data from the gateway device that acquires the data from the PLC, and is connected to the gateway device and the gateway device. The PLC specific information that identifies the PLC, the data identification information that identifies the data acquired from the PLC by the gateway device, and the logging that specifies the logging cycle that is the cycle in which the gateway device transmits the data to the management server. It includes a storage unit that stores information in association with each other, and a supply unit that supplies the PLC specific information, the data specific information, and the logging information to the gateway device based on the request of the gateway device. It is characterized by that.

According to the above configuration, the PLC specific information, the data specific information, and the logging information used by the gateway device are transmitted to the gateway device that acquires the data from the PLC. Therefore, the gateway device transmits the data acquired from the PLC. Of these, desired data can be transmitted at a desired cycle. As a result, even a user who does not have much knowledge of IT can easily transmit the data collected from the FA device to the device based on the IT technology.

In order to solve the above problems, the setting terminal according to one aspect of the present invention is a setting terminal that acquires data from the PLC and sets a setting file used by the gateway device that transmits the data to the management server. PLC identification information that identifies the PLC connected to the gateway device, data identification information that identifies the data that the gateway device acquires from the PLC, and logging that is a cycle in which the gateway device transmits the data to the management server. It is characterized by including a reception unit that receives settings for logging information that specifies a cycle, and a setting transmission unit that transmits the contents received by the reception unit to the management server.

According to the above configuration, the gateway device acquires data from the corresponding PLC, and among the acquired data, PLC specific information, data specific information, and logging information necessary for transmitting desired data at a desired cycle. Can be set on the setting terminal.

In order to solve the above problems, the control method of the gateway device according to one aspect of the present invention is a control method of the gateway device that acquires data from the PLC and transmits the acquired data to the management server. The definition acquisition step of acquiring the PLC specific information to be specified, the data identification information to specify the data to be acquired from the PLC, and the logging information to specify the logging cycle which is the cycle to be transmitted to the management server from the management server, and the PLC. The initial setting step for activating the communication program according to the communication protocol for communicating with the PLC based on the specific information, and the data specified by the data specific information can be obtained from the PLC using the communication program. It is characterized by including a data acquisition step to be acquired and a data transmission step of transmitting the data acquired in the data acquisition step to the management server according to the logging cycle specified by the logging information.

In order to solve the above problems, the management server control method according to one aspect of the present invention is a control method of the management server that receives the data from the gateway device that acquires the data from the PLC. The PLC specific information that identifies the PLC connected to the gateway device, the data identification information that identifies the data acquired from the PLC by the gateway device, and the cycle in which the gateway device transmits the data to the management server. A storage unit that stores logging information that specifies a logging cycle in association with each other, a reception step that receives a request from the gateway device, and based on the request, the PLC specific information, the data specific information, and the logging information. Is included in the information transmission step of transmitting the data to the gateway device.

In order to solve the above problems, the setting terminal control method according to one aspect of the present invention is to control a setting terminal that sets a setting file used by a gateway device that acquires data from a PLC and transmits the data to a management server. The method is the PLC specific information that identifies the PLC connected to the gateway device, the data identification information that identifies the data that the gateway device acquires from the PLC, and the gateway device that sends the data to the management server. It is characterized by including a reception step for receiving a setting of logging information for specifying a logging cycle, which is a transmission cycle, and a setting transmission step for transmitting the contents received in the reception step to the management server.

The gateway device, management server, and setting terminal according to each aspect of the present invention may be realized by a computer. In this case, each part (software element) of the gateway device, management server, and setting terminal that includes the computer. A control program that realizes the gateway device, management server, and setting terminal on a computer by operating the gateway device, and a computer-readable recording medium that records the control program are also included in the scope of the present invention.

According to one aspect of the present invention, if the user sets the PLC specific information, the data specific information, and the logging information in advance, he / she only needs to connect the gateway device to the PLC and the management server in a communicable manner. It has the effect that data can be acquired at a desired cycle. Therefore, even a user who does not have much knowledge of IT can easily transmit the data collected from the FA device to the device based on the IT technology.

It is a block diagram which shows the main part structure of a gateway device. It is a figure which shows the outline of the data collection system. It is a figure which shows the installation example of the gateway device. It is a figure which shows the installation example of the gateway device. It is a figure which shows the application example of the gateway device in the manufacturing equipment of a customer. It is a block diagram which shows the main part structure of management server. It is a flowchart which shows the flow of processing which a data collection system executes in a preparation phase. It is a figure which shows an example of the management type definition screen displayed on the setting terminal in a preparation phase. It is a figure which shows an example of the steady-state logging setting screen displayed on the setting terminal in a preparation phase. It is a figure which shows the data structure of the management type definition table and management type database (DB). It is a figure which shows an example of the device registration screen displayed on the setting terminal in a registration phase. It is a figure which shows the data structure of the apparatus registration database (DB). It is a flowchart which shows the flow of the process which a data collection system executes in the initial setting phase. It is a flowchart which shows the flow of processing which a data collection system executes in a steady logging phase. It is a figure which shows the data structure of the log information. It is a figure which shows the data structure of a log database (DB).

[System overview]
FIG. 2 is a diagram showing an outline of the data collection system 100 according to the present embodiment. As an example, the data collection system 100 includes a gateway device 1, a PLC (Programmable Logic Controller) 2, a setting terminal 3, an FA device 4 and a sensor 5 as industrial devices to be monitored, a management server 6, and the like. Includes a dedicated communication network 7.

The PLC 2, the FA device 4 and the sensor 5 are directly connected by a cable according to a predetermined interface standard (for example, RS232, RS485). In addition, it may be connected so as to be communicable via a LAN (Local Area Network) (not shown). The PLC 2 and the gateway device 1 are connected by wire so as to be able to communicate with each other as described later. The gateway device 1 has a function of connecting to the dedicated communication line network 7 by wireless communication, and is communicably connected to the management server 6 via the dedicated communication line network 7. The setting terminal 3 is communicably connected to the management server 6 via a wide area communication network 8 such as the Internet or a mobile communication network.

PLC2 controls and monitors industrial equipment. In the illustrated example, the PLC2 transmits data for FA management from one or more FA devices 4 and one or more sensors 5 and other industrial devices according to the interface standard described above, or a LAN or the like of the PLC2. Obtained by communication corresponding to the communication standard.

The data for FA management is, for example, a measured value measured by a sensor built in the FA device 4 or a sensor 5 separate from the FA device 4. The measured value may indicate a physical quantity related to the operation of the FA device 4 or the surrounding environment of the FA device 4, or may be binary data indicating the state of the FA device 4 or the surrounding environment in a binarized manner. .. The measurement items measured by each sensor are not particularly limited, but are diverse, for example, current, voltage, oil pressure, water pressure, atmospheric pressure, torque, temperature, humidity, power consumption, weight, contact / non-contact, and the like.

The PLC 2 includes one or more registers, and as an example, one register stores a measured value related to one measurement item acquired from one sensor. The PLC 2 supplies the measured value stored in each register included in the own device from the gateway device 1 in response to a request.

In the present embodiment, the PLC 2 is housed in a storage box 2A such as a control panel that houses one or more devices.

The gateway device 1 is a relay device that connects communication with PLC2 by RS232, RS485 or LAN and communication with management server 6 by a dedicated communication network 7. Specifically, the gateway device 1 uploads various measured values acquired by the PLC 2 from the industrial equipment via the LAN to the management server 6 via the dedicated communication network 7. In this embodiment, the gateway device 1 and the PLC 2 have a one-to-one correspondence. Specifically, one gateway device 1 is connected to one PLC2, and the gateway device 1 is in charge of uploading the measured values collected by the attached other party's PLC2 to the management server 6. Although an example in which one PLC2 is connected to one gateway device 1 is described here, the present invention is not limited to this, and a plurality of PLC2s are connected to one gateway device 1. May be done.

As will be described later, the gateway device 1 may include an operation unit operated by an OT engineer, such as a button or a switch. The OT engineer may operate the operation unit to instruct the gateway device 1 at the timing of acquiring or uploading the measured value.

The setting terminal 3 provides an HMI (Human Machine Interface) necessary for an OT engineer to manage the entire manufacturing equipment using the data collection system 100. Specifically, the setting terminal 3 provides a UI (User Interface) for supporting various setting operations related to one or more gateway devices 1 attached to the manufacturing equipment. Further, the setting terminal 3 may provide a function as a so-called dashboard, such as displaying an outline of a huge number of measured values accumulated in the management server 6 in a list.

The setting terminal 3 is composed of, for example, a PC (Personal Computer), a tablet, a smartphone, or the like. The setting terminal 3 is a general display device for presenting information output by the data collection system 100 to an OT engineer, and a general input device (reception unit, setting) for inputting information to the data collection system 100. It has a transmitter).

The setting terminal 3 may be provided by the service provider 300 described later, or may be provided by a party different from the service provider 300.

The management server 6 periodically collects measured values from a plurality of gateway devices 1 and systematically stores a huge number of collected measured values. The management server 6 may further have a function of systematically supplying the stored measured values in response to a query specified by the setting terminal 3.

In particular, in the present embodiment, the management server 6 communicates with the setting terminal 3 and supplies necessary information to the setting terminal 3 so that the setting terminal 3 can realize a UI related to the setting of the gateway device 1.

The dedicated communication line network 7 provides a communication line for one or more gateway devices 1 having a wireless communication function to communicate with the management server 6. The gateway device 1 can upload the collected measured values to the management server 6 by wirelessly connecting to the dedicated communication network 7.

Of the above-mentioned resources constituting the data collection system 100, the management server 6 and the dedicated communication network 7 belong to the party that provides the service described later to the payer in consideration of the paid fee. This party will be referred to below as the service provider 300.

The service provider 300 does not need to own the dedicated communication network 7. For example, the dedicated communication line network 7 may belong to the service provider 300 by lending the dedicated communication line network 7 owned by another party such as a communication carrier to the service provider 300 for a fee or free of charge.

Further, the service provider 300 may be a business operator that manufactures and sells the gateway device 1.

Of the above-mentioned resources constituting the data collection system 100, the gateway device 1, the PLC 2, the setting terminal 3, the FA device 4, and the sensor 5 pay the necessary fee to the service provider 300 to enjoy the services described later. Belongs to the party to do. The party will be referred to below as Customer 200.

As an example, the services provided by the service provider 300 to the customer 200 include at least: Specifically, by (1) providing the hardware of the gateway device 1 and (2) granting the right to use the dedicated communication network 7 for uploading the measured values acquired by the gateway device 1. is there. That is, the fee paid by the customer 200 to the service provider 300 includes at least the cost of the device itself of the gateway device 1 and the cost related to the communication of the dedicated communication network 7. Then, the customer 200 can receive the above-mentioned service by contracting only with the service provider 300 and paying the cost only to the service provider 200.

The service provider 300 may further provide the following services to the customer 200 according to the contents of the contract with the customer 200. Specifically, (3) providing work tools (such as the UI described above) necessary for actually operating the gateway device 1 at the manufacturing site, and (4) responding to a query from the setting terminal 3. Therefore, necessary information is extracted and provided from the stored database of measured values.

[Installation example of gateway device]
Next, an example in which the gateway device 1 is attached to the storage box 2A in which the PLC 2 is housed will be described with reference to FIGS. 3 and 4. 3 and 4 show the gateway device 1.
It is a figure which shows the installation example of. As will be described later, the gateway device 1 has a housing divided into an antenna portion 10 and a main body portion 20, and the accommodation box is provided so that the antenna portion 10 is outside the accommodation box 2A and the main body portion 20 is inside the accommodation box 2A. It is mounted on the wall surface of 2A. The antenna portion 10 and the main body portion 20 are attached to the wall surface of the housing box 2A by a plurality of fixing screws and are fixed to each other. Further, a flat cable for connecting the antenna portion 10 and the main body 20 is provided on the wall surface of the accommodation box 2A corresponding to the surface of the antenna portion 10 on the main body 20 side and the surface of the main body 20 on the antenna portion 10 side near the center. A round hole of a predetermined size is formed so that 18 mag can pass through.

The number of PLCs 2 accommodated in the accommodation box 2A is not limited to one, and may be plural. In this case, one gateway device 1 may be attached to each PLC2, or a plurality of PLCs 2 may be attached to one gateway device 1.

[Application example]
FIG. 5 is a diagram showing an application example of the gateway device 1 in the manufacturing equipment of the customer 200. As an example, it is assumed that the customer 200 owns two factories, an Osaka factory and a Kyoto factory, as manufacturing equipment. As an example, the Osaka factory has three production lines consisting of three processes for manufacturing a certain product, and the Kyoto factory has the same production line for manufacturing the same product. It is assumed that two are laid.

In the present embodiment, one PLC2 is installed for each process of one production line. As described above, one gateway device 1 is connected to one PLC2. In another example, a plurality of PLCs 2 may be installed in one process, and when these a plurality of PLC2s are housed in one storage box 2A, the outer wall of one storage box 2A may be installed. Therefore, a plurality of gateway devices 1 for each PLC 2 may be attached.

In the present embodiment, as a management method for industrial equipment using the gateway device 1, the same management type is applied to the same process for manufacturing the same product regardless of the difference in the production line. The management type means a management style that indicates how to manage a set of manufacturing equipment that is cohesive as a monitoring target. Specifically, a mode in which the gateway device 1 acquires and uploads the measured values for each measurement item acquired from a set of manufacturing equipment belonging to one process is defined as a control type for each process.

In the illustrated example, the customer 200 owns a plurality of production lines in a plurality of factories, but each production line is the same production line for producing the same product, and the production lines are three. It consists of processes. Therefore, three control types are defined for each process. A defined management type corresponding to the process to be controlled is applied to each gateway device 1. The gateway device 1 installed so as to control each process uploads the measured value acquired from the industrial device by the communication partner PLC2 of the own device to the management server 6 according to the applied management type. The management type definition (setting file) is defined by the OT engineer operating the setting terminal 3. The method of defining the management type will be described in detail later.

[Gateway device configuration]
FIG. 1 is a block diagram showing a main configuration of the gateway device 1 according to the present embodiment.

(Hardware configuration)
As shown in FIG. 1, the gateway device 1 is divided into two housings, an antenna portion 10 and a main body portion 20, and is communicably connected via a flat cable 18. These are such that when the gateway device 1 is attached to the accommodation box 2A in which the PLC 2 is housed, the antenna portion 10 is attached to the outside of the accommodation box 2A and the main body portion 20 is attached to the inside of the accommodation box 2A. By attaching the antenna portion 10 to the outside of the accommodation box 2A, it is possible to improve the communication state in the case of wireless communication between the gateway device 1 and the external device.

The antenna unit 10 includes a communication module 11, an LTE antenna 12, a memory 13, a GPS 14, a tact switch 15, an LED (Light Emitting Diode) 16, and a connector unit 17.

The communication module 11 uses the LTE antenna 12 to communicate with an LTE (Long Term Evolution) base station.

The LTE antenna 12 is an antenna for performing LTE-based communication.

The memory 13 is a storage unit that stores a device ID that identifies the gateway device 1. The device ID is, for example, an ID specified based on a SIM (Subscriber Identity Module).

The GPS 14 identifies the position of the gateway device 1 based on a GPS (Global Positioning System) signal. For example, the GPS 14 may transmit the position information indicating the specified position to the control unit 21, and the control unit 21 may transmit the acquired position information to the management server 6 together with the measured value acquired from the PLC 2.

The tact switch 15 is a switch that receives an operation from an OT engineer. The tact switch 15 may be, for example, an abnormal switch. In this case, when the tact switch 15 is pressed, the control unit 21 of the main body 20 is notified to that effect via the flat cable 18. Then, when the control unit 21 receives the notification, it determines that there is an abnormality, and performs processing when the abnormality occurs.

The LED 16 is a display unit that shows the status of the gateway device 1 and the like. The LED 16 may be a single color or may contain a plurality of colors.

The connector portion 17 is a connection portion of a flat cable 18 that communicates with the main body portion 20.

Further, the main body unit 20 includes a connector unit 23 and a communication I / F 24 in addition to the control unit 21 and the storage unit 22.

The connector portion 23 is a connection portion of a flat cable 18 for communication connection with the antenna portion 10.

The communication interface (I / F) 24 is an interface for communication connection with the PLC 2. More specifically, the communication I / F 24 is an interface for performing serial communication with the PLC2 via the serial data bus 25, and corresponds to, for example, RS232C or RS485.

(Software configuration)
The control unit 21 of the main body 20 mounted inside the storage box 2A comprehensively controls the gateway device 1, and as an example, the definition acquisition unit 31, the initial setting unit 32, and the measurement value acquisition unit (data acquisition). A unit) 33 and a log transmission unit (data transmission unit) 34 are included.

The storage unit 22 records the control program and the OS program executed by the control unit 21, and various data to be read when the control unit 21 executes the processing related to each block of the control unit 21. The storage unit 22 is composed of, for example, a non-volatile storage device such as an EEPROM (registered trademark) (Electrically Erasable Programmable ROM).

As an example, the storage unit 22 stores the management type definition table 41, the plurality of driver information 42, and the ring buffer 43. The ring buffer 43 may be expanded into a temporary storage device (not shown) such as a RAM (random access memory) each time the power is turned on.

The definition acquisition unit 31 acquires the management type definition table corresponding to the own device from the management server 6. The management type definition table is information indicating the above-mentioned management type, and specifically, is information for defining a measurement value acquisition format and an upload format. The data structure of the management type definition table will be described in detail later.

Specifically, the definition acquisition unit 31 transmits a unique device ID to the gateway device 1 and requests the management type definition table 41 from the management server 6. The device ID is preferably unique identification information across customers, such as a manufacturing serial number. In the present embodiment, as will be described later, in the management server 6, based on the device ID, the requesting gateway device 1 determines which resource of which customer (in the application example shown in FIG. 5, which manufacturing line of which factory). It is possible to grasp which process) it is attached to. Therefore, the management server 6 can return the management type definition table 41 indicating the management type corresponding to the gateway device 1 to the definition acquisition unit 31 based on the device ID sent from the definition acquisition unit 31. The definition acquisition unit 31 stores the management type definition table 41 acquired from the management server 6 in the storage unit 22.

The initial setting unit 32 selects the driver information 42 that matches the model of the PLC2 of the communication partner to which the own device is connected from the plurality of driver information 42, and activates the selected driver information 42. Specifically, the initial setting unit 32 reads the model of the PLC2 from the management type definition table 41 stored in the storage unit 22, and specifies the model of the communication partner PLC2 to which the own device is connected. The initial setting unit 32 activates the driver information 42 corresponding to the specified PLC2 model from the plurality of driver information 42. When the driver information 42 conforming to the connected PLC2 is enabled, the control unit 21 normally communicates with the PLC2 via the communication I / F24 according to the communication protocol defined in the driver information 42. Will be possible. Then, the control unit 21 can acquire the measured value from the PLC2.

Further, the initial setting unit 32 may acquire the update data of the driver information 42 from the management server 6 and update the driver information 42. Further, when the driver information 42 is not stored in the gateway device 1, the gateway device 1 may acquire the driver information 42 from the management server 6 or another server having the driver information 42.

The measurement value acquisition unit 33 communicates with the PLC 2 and acquires the measurement value for each measurement item stored in each register of the PLC 2. The measurement value acquisition unit 33 stores each acquired measurement value in the ring buffer 43.

In the present embodiment, as an example, the measurement value acquisition unit 33 constantly acquires each measurement value of each register of the PLC 2 and sequentially stores the measurement value in the ring buffer 43. Here, "always acquire" means that the measured values of each register are continuously acquired at the same interval as the interval at which the PLC2 acquires the measured values from each sensor (for example, at 1 millisecond intervals), that is, with the same resolution as the PLC2. It may include the acquisition of the target. Alternatively, "always acquiring" means an interval (for example, 1 second interval) that is larger than the interval at which PLC2 acquires the measured value and shorter than the cycle (for example, 5 minute interval) in which the gateway device 1 uploads the measured value. It may include acquiring the measured values of each register discretely.

The ring buffer 43 is composed of an area capable of storing measured values for a predetermined time (for example, 10 minutes). The measurement value acquisition unit 33 erases or erases the oldest measurement value stored in the ring buffer 43 when the entire area of the ring buffer 43 is filled with the measurement values, that is, when 10 minutes have passed from the start of operation. Overwrite this and save the latest measurement value.

As described above, the measurement value acquisition unit 33 continues to constantly acquire the measurement value while the power is turned on to the gateway device 1 and the PLC 2 and communication is established.

The log transmission unit 34 uploads the measured values stored in the ring buffer 43 to the management server 6 according to a predetermined logging cycle. The logging cycle is information that specifies a cycle for uploading the measured value from the gateway device 1 to the management server 6. The logging cycle is defined in the management type definition table 41 acquired by the definition acquisition unit 31.

In the present embodiment, the log transmission unit 34 generates log information in which the time information indicating the upload time and the device ID are added to the measured values for each register of PLC2, that is, for each measurement item. The log information is transmitted to the management server 6. The data structure of log information will be described in detail later.

In the present embodiment, the log transmission unit 34 can transmit only the measurement values of the measurement items selected by the OT engineer among all the measurement values collected by the PLC2 in the log information. The measurement item or register name selected by the OT engineer is defined in the management type definition table 41. The log transmission unit 34 refers to the management type definition table 41 acquired by the definition acquisition unit 31, and specifies the measurement item (data identification information) of the upload target (hereinafter, logging target). When the upload timing determined by the logging cycle arrives, the log transmission unit 34 reads only the measurement values corresponding to the specified measurement items from the latest measurement values stored in the ring buffer 43 at that timing. , Generate the above log information.

[Management server configuration]
FIG. 6 is a block diagram showing a main configuration of the management server 6 according to the present embodiment.

As an example, the management server 6 includes a control unit 60, a storage unit 61, and a communication unit 62. The communication unit 62 communicates with the setting terminal 3 via the wide area communication network 8 and communicates with the gateway device 1 via the dedicated communication line network 7.

The control unit 60 comprehensively controls the operation of each unit of the management server 6. As an example, the control unit 60 includes a user interface (UI) providing unit 70, a generation unit 71, a calculation unit 72, a determination unit 73, a registration unit 74, a supply unit 75, a log management unit 76, and a simulation unit 77. There is. Each block of the control unit 60 can be realized, for example, by the CPU (central processing unit) reading a program stored in a storage device such as a ROM (read only memory) into a RAM (random access memory) or the like and executing the program. .. The configuration may be such that it can be executed on the ROM.

The storage unit 61 records the control program and the OS program executed by the control unit 60, and various data to be read when the control unit 60 executes the processing related to each block of the control unit 60. The storage unit 61 is composed of, for example, a non-volatile storage device such as a hard disk.

As an example, the storage unit 61 stores the management type database (DB) 81, the device registration database (DB) 82, and the log database (DB) 83.

The UI providing unit 70 provides a UI screen that can be viewed and operated by a general Web browser application mounted on the setting terminal 3. The UI providing unit 70 transmits various input information input from the setting terminal 3 via the UI screen to a block that requires the input information in the control unit 60. Further, the UI providing unit 70 reflects the output information output from each block in the control unit 60 on the UI screen so that it can be confirmed on the setting terminal 3.

The UI providing unit 70 may be provided in the setting terminal 3. In this case, the setting terminal 3 can acquire the UI providing unit 70 by installing, for example, a dedicated application for exchanging information with the management server 6.

As the UI screen provided by the UI providing unit 70, for example, a management type definition screen, a steady logging setting screen, a device registration screen, and the like are assumed. The management type definition screen is a UI screen for supporting the work of defining the management type performed by the OT engineer. The steady-state logging setting screen is a UI screen for supporting the work of selecting the measurement item to be logged and the work of setting the logging cycle of the measured value performed by the OT engineer. The device registration screen is a UI screen for supporting the work performed by an OT engineer to register a management type and an installation location in association with a plurality of gateway devices 1 installed in a manufacturing facility. These UI screens will be described in detail later with reference to specific examples.

The generation unit 71 generates a management type definition table based on the input information input from the setting terminal 3 via the management type definition screen and the steady logging setting screen. The management type definition table is information that defines the management type of the gateway device 1.

The generation unit 71 registers the generated management type definition table in the management type DB 81. One customer 200 can define multiple management types. Therefore, in the management type DB 81, the management type definition table is registered in association with the customer ID unique to the customer 200 and the management type name unique to the management type.

In this way, when the OT engineer operates the management type definition screen and the steady logging setting screen to define the management type, the management type definition table is generated. When the generated management type definition table is applied to the gateway device 1, the gateway device 1 can operate as intended by the OT engineer according to the management type definition table.

The calculation unit 72 calculates the amount of communication in the dedicated communication network 7 based on the above-mentioned input information. Specifically, the calculation unit 72 calculates the upper limit of the monthly communication amount in the dedicated communication network 7 that the customer 200 can use based on the conclusion of the contract with the service provider 300. In the present embodiment, the above-mentioned upper limit of the monthly communication amount is referred to as a communication amount upper limit.

As an example, the service provider 300 prepares a plurality of types of rate plans for services to be provided to the customer 200. In the charge plan, the usage period and the charge of the dedicated communication network 7 are set. For example, the price plan is set as "2 years 100,000 yen course", "2 years 200,000 yen course", and so on. The OT engineer inputs the rate plan determined based on the contract with the service provider 300 via the UI screen.

The calculation unit 72 may convert the usage period set in the charge plan into the number of months, and divide the charge set in the charge plan by the number of months to calculate the upper limit of the communication amount.

Further, the calculation unit 72 calculates the estimated communication amount for one month in the dedicated communication network 7 based on the management type definition table defined by the OT engineer. In the present embodiment, the above-mentioned estimated communication amount for one month is referred to as an estimated communication amount. For example, the management type definition table contains the assumed material information necessary for calculating the estimated communication volume. Specifically, the assumed material information includes the measurement items to be uploaded, the data length of the measurement values for each measurement item to be uploaded, the logging cycle, the number of working days per month, and the working hours per day. include.

For example, the calculation unit 72 obtains the total data length of the measured values for each measurement item to be uploaded, and obtains the amount of communication for one time generated by one upload. The calculation unit 72 obtains the number of uploads per day based on the logging cycle and the operating time per day. Then, the calculation unit 72 may calculate the estimated communication amount by (communication amount for one time) × (upload number of times per day) × (operating days per month).

Further, when the calculation unit 72 assumes that the logging cycle is the simulated cycle based on the simulated cycle set by the simulated unit 77 described later by simulating the input of the OT engineer and the above-mentioned assumed material information. The estimated monthly communication volume may be calculated as the virtual communication volume.

The determination unit 73 determines whether or not the assumed communication amount exceeds the upper limit of the communication amount. The determination unit 73 outputs the determination result. For example, the determination unit 73 outputs a determination result indicating "exceeding the upper limit" when the assumed communication amount exceeds the upper limit of the communication amount. Alternatively, the determination unit 73 outputs a determination result indicating "within the upper limit" when the assumed communication amount is equal to or less than the upper limit of the communication amount.

In addition, a configuration that does not determine whether or not the assumed communication amount exceeds the communication amount upper limit, that is, a configuration that does not include the determination unit 73 may be used. In this case, by displaying only the list of simulated cycles described later on the UI screen so as to be selectable by the UI providing unit 70, it is possible to set only the logging cycle that does not exceed the upper limit of the communication amount.

The simulation unit 77 inputs a simulation cycle that imitates the logging cycle into the calculation unit 72, obtains a virtual communication amount, and derives a logging cycle by simulation so that the estimated communication amount does not exceed the communication amount upper limit. is there. The simulation unit 77 may output all the simulation cycles in which the virtual communication volume is equal to or less than the communication volume upper limit as recommended cycles. Alternatively, the simulation unit 77 may output only the shortest simulation cycle as the recommended cycle among the simulation cycles in which the virtual communication amount is equal to or less than the communication amount upper limit. Alternatively, the simulation unit 77 may output a predetermined number of simulation cycles as recommended cycles from the shortest cycle among the simulation cycles in which the virtual communication amount is equal to or less than the communication amount upper limit.

The list of simulated cycles output by the simulated unit 77 is selectively reflected on the UI screen by the UI providing unit 70. This allows the OT engineer to easily set a logging cycle that does not exceed the upper limit of the amount of communication.

The registration unit 74 generates device information based on the input information input from the setting terminal 3 via the device registration screen, and registers the device information in the device registration DB 82. The device information and the data structure of the device registration DB 82 will be described in detail later.

The input information includes a device ID that uniquely identifies the gateway device 1, a management type name that identifies the management type defined in the customer 200, and an installation location that indicates the installation location of the gateway device 1. The registration unit 74 identifies the customer 200 based on the device ID, generates device information associated with the above-mentioned input information and the customer ID, and registers the customer 200 in the device registration DB 82.

The management server 6 holds a sales list (not shown) in the storage unit 61. At least, the device ID of the gateway device 1 sold and the customer ID of the customer who purchased the device ID are stored in the sales list in association with each other. Therefore, the registration unit 74 can identify the customer who owns the corresponding gateway device 1 based on the device ID.

By referring to the device registration DB 82, each block of the control unit 60 can identify which customer, which installation location, and which management type is applied to the gateway device 1 based on the device ID. Will be.

The supply unit 75 supplies the gateway device 1 for which communication has been established with a management type definition table to be applied to the gateway device 1. In the present embodiment, the gateway device 1 transmits a request for a management type definition table including the device ID via the dedicated communication network 7 and the communication unit 62. In response to this request, the supply unit 75 reads the management type definition table applied to the request source gateway device 1 from the management type DB 81 and supplies the management type definition table to the gateway device 1. The supply unit 75 identifies the customer ID of the customer who owns the gateway device 1 and the management type name of the management type to be applied to the gateway device 1 based on the device ID by referring to the device registration DB 82. be able to. The supply unit 75 can extract the management type definition table associated with the specified customer ID and management type name from the management type DB 81.

The gateway device 1 that has received the management type definition table from the supply unit 75 can complete the initial setting and move to normal operation.

The log management unit 76 receives log information manually transmitted from the gateway device 1 which has completed the initial settings and is normally operating, and accumulates the log information in the log DB 83. The data structure of the log DB 83 will be described in detail later.

The management server 6 may provide the accumulated data related to the manufacturing equipment accumulated in the log DB 83 to the setting terminal 3 via the wide area communication network 8 or the like in response to a request from the setting terminal 3 of the customer 200, for example. it can. The management server 6 may perform necessary analysis on the accumulated data and transmit the analysis result to the setting terminal 3. The OT engineer can utilize the knowledge obtained from the integrated data displayed on the setting terminal 3 or the analysis result for maintenance of the manufacturing equipment, response in case of trouble, and the like.

[Preparation phase after contract conclusion]
When a contract is concluded between the customer 200 and the service provider 300 and it is decided that the gateway device 1 is delivered to the customer 200, the data collection system 100 prepares before installing the gateway device 1 in the manufacturing equipment of the customer 200. The phase begins.

In the preparation phase, the OT engineer operates the setting terminal 3 to define the management type to be applied to the gateway device 1 and to set the steady logging. The data collection system 100 supports each of the above-mentioned operations of the OT engineer, for example, as follows.

FIG. 7 is a flowchart showing a flow of processing executed by each device of the data collection system 100 in the preparation phase. FIG. 8 is a diagram showing an example of a management type definition screen displayed on the above-mentioned display device in the preparation phase. FIG. 9 is a diagram showing an example of a steady logging setting screen displayed on the display device of the setting terminal 3 in the preparation phase. FIG. 10 is a diagram showing the data structures of the management type definition table 41 and the management type DB 81.

The series of processes shown in FIG. 7 is started when the setting terminal 3 of the customer 200 accesses the management server 6 via the wide area communication network 8. For example, the customer 200 is expected to be notified in advance of a URL (Uniform Resource Locator), a customer ID, a password, and the like from the service provider 300. It is assumed that the OT engineer accesses the URL and inputs the customer ID and password to display the UI screen dedicated to the customer 200 on the setting terminal 3.

In step S101, the setting terminal 3 causes the display device to display the management type definition screen provided by the UI providing unit 70 of the management server 6. For example, as shown in FIG. 8, the management type definition screen 400 has a plan input area 401, an upper limit display area 402, a type input area 403, a model input area 404, a number of days input area 405, a time input area 406, a definition list 407, and an apparatus. It is composed of each UI component of the display area 408 and the progress button 409.

In step S102, the setting terminal 3 transmits the first input information received via the management type definition screen 400 to the management server 6. The first input information is input by an OT engineer, for example, as follows. The OT technician selects the rate plan specified in the contract from the drop-down list of the plan input area 401. The OT engineer inputs a management type name for identifying the management type to be defined in the type input area 403 in text. The OT engineer selects the model (PLC specific information) of the PLC2 introduced in the manufacturing equipment from the drop-down list of the model input area 404. The OT engineer inputs the number of operating days per month for the manufacturing equipment to be monitored in the number of days input area 405. The OT engineer numerically inputs the operating hours per day for the above-mentioned manufacturing equipment in the time input area 406.

After the PLC model is selected in the model input area 404, the UI providing unit 70 reflects the register name matching the specifications of the selected PLC 2 in the register name column of the definition list 407. The OT engineer inputs the measurement items for each register in the column of the measurement items in the definition list 407 in text. Since it is only necessary for the OT engineer to be able to identify what value the measured value indicates by the text input to the column, the FA device 4 or the sensor 5 may be used in the column instead of the measurement item. You may enter the name or ID of. The OT engineer inputs the data length of each measured value stored in the register into a numerical value in the data length column.

The UI providing unit 70 may provide a drop-down list in the type input area 403 and configure the type input area 403 so that the management type name of the management type already registered is displayed as an option.

After the type input area 403 is input, if the gateway device 1 to which the input defined management type is applied is registered, the UI providing unit 70 of the registered gateway device 1 The device ID may be reflected in the device display area 408.

The setting terminal 3 uses the rate plan, management type name, PLC model, working days, working hours, measurement items for each register, and data length received via the management type definition screen 400 as the first input information. Send to the management server 6.

In step S103, the generation unit 71 of the management server 6 generates the management type definition table based on the first input information. For example, the management type definition table 41 having the data structure shown in FIG. 10 is generated. The management type definition table 41 has each item of management type name, PLC model, register name, measurement item, data length, logging cycle, working days / month, and working hours / days. The generation unit 71 stores the management type name input in the type input area 403 in the management type name item. The generation unit 71 stores the model of the PLC2 selected in the model input area 404 in the PLC model item. The generation unit 71 stores each register name reflected in the register name column of the definition list 407 in the register name item. The generation unit 71 stores each measurement item input in the measurement item column of the definition list 407 in the measurement item item. The generation unit 71 stores each data length input in the data length column of the definition list 407 in the data length item. In the item of the logging cycle, a value based on the second input information input via the steady logging setting screen described later is stored. Therefore, at this time, no value is stored in the item. The generation unit 71 stores the number of working days input in the number of days input area 405 in the item of working days / month. The generation unit 71 stores the operating time input in the time input area 406 in the operating time / day item. The generation unit 71 outputs the management type definition table 41 generated as described above. The output management type definition table 41 may be stored in, for example, a temporary storage unit (not shown).

In step S104, the calculation unit 72 calculates the upper limit of the communication amount for one month based on the charge plan selected in the plan input area 401. The UI providing unit 70 feeds back the upper limit of the communication amount calculated by the calculation unit 72 to the setting terminal 3. Specifically, the above-mentioned communication amount upper limit (for example, 10 GB) is reflected in the upper limit display area 402 of the management type definition screen 400.

In step S105, the setting terminal 3 displays the management type definition screen 400 in which the upper limit display area 402 reflects the upper limit of the communication amount.

In step S106, the setting terminal 3 determines whether or not any of the above-mentioned UI components related to the first input information has been newly operated by the OT engineer. When it is determined that the operation has been performed, the setting terminal 3 returns from YES in S106 to S102, and transmits new first input information based on the new operation to the management server 6. If the new operation as described above is not detected, the setting terminal 3 proceeds from NO in S106 to S107.

In step S107, the setting terminal 3 determines whether or not the progress button 409 for instructing to proceed to the steady logging setting screen is pressed without performing the above-mentioned new operation. Until the progress button 409 is not pressed, the setting terminal 3 returns from NO in S107 to S106 and maintains a standby state for a new operation. When the progress button 409 is pressed, the setting terminal 3 advances from YES in S107 to S108.

In step S108, the setting terminal 3 causes the display device to display the steady logging setting screen provided by the UI providing unit 70 of the management server 6. Specifically, the setting terminal 3 transmits a request for the steady logging setting screen to the management server 6 in response to the pressing of the progress button 409. The UI providing unit 70 of the management server 6 provides a steady logging setting screen to the setting terminal 3 in response to the request. As a result, the setting terminal 3 can display the steady logging setting screen on the display device.

For example, as shown in FIG. 9, the steady-state logging setting screen 420 has a type display area 421, a model display area 422, an upper limit display area 423, an assumed display area 424, a device display area 408, a selection list 425, a total display area 426, and a period. It is composed of UI components of an input area 427, a judgment display area 428, a confirmation button 429, and a back button 430.

The UI providing unit 70 may reflect various information already described up to S108 on the steady logging setting screen 420. For example, the UI providing unit 70 can reflect the existing information in the type display area 421, the model display area 422, the upper limit display area 423, and the device display area 408. Further, the UI providing unit 70 can reflect the already-existing information in each column of the register name, the measurement item, and the data length of the selection list 425.

In step S109, the setting terminal 3 transmits the second input information received via the steady logging setting screen 420 to the management server 6. The second input information is input by the OT engineer as follows, for example.

In the column to be logged in the selection list 425, a toggle button for selecting acceptance or rejection as a logging target is provided for each register. The OT engineer operates the toggle button to select the measurement item to be logged. In the illustrated example, the measurement item selected as the logging target is shown with the toggle button checked. The OT technician turns the toggle button on and off to select the measurement item that requires logging.

After the column to be logged in the selection list 425 is operated, the UI providing unit 70 reflects the communication amount required for each update in the data amount / time column of the selection list 425 for each measurement item. The UI providing unit 70 reflects the data length input in advance as it is for the measurement item selected as the logging target, that is, the toggle button is on. The UI providing unit 70 does not update the measurement item that is not selected as the logging target, that is, the toggle button is off, so that the value of zero is reflected.

Subsequently, the UI providing unit 70 reflects the total amount of data per update reflecting the on / off of the column to be logged in the total display area 426. The total data amount is the total value of the data amount reflected in the data amount / time column.

Subsequently, the OT engineer numerically inputs the cycle (logging information) for uploading the above-mentioned measured value to the management server 6 in the cycle input area 427. The UI providing unit 70 may provide a drop-down list composed of recommended cycles acquired from the simulated unit 77 in the cycle input area 427. This allows the OT engineer to easily set a logging cycle for uploading each measurement value selected in the selection list 425 so that the monthly traffic does not exceed the traffic upper limit. It becomes.

As described above, the setting terminal 3 secondly inputs the measurement item selected as the logging target and the logging cycle for uploading the measurement value of the selected measurement item, which is received via the steady-state logging setting screen 420. It is transmitted to the management server 6 as information.

In step S110, the generation unit 71 adds a value based on the second input information to the item of the logging cycle of the management type definition table 41 generated in S103. In the example shown in FIG. 9, the measurement items selected as the logging target are current, voltage, and temperature, and the logging cycle is set to 5 minutes. Therefore, in the example shown in FIG. 10, the generation unit 71 stores a value indicating “5 minutes” in the item of the logging cycle for the current, voltage, and temperature rows of the management type definition table 41. The generator 71 stores a value indicating that there is no logging period applied for the unselected oil and torque rows.

In step S111, the calculation unit 72 calculates the estimated communication volume for one month. As already described, the calculation unit 72 calculates the estimated communication amount using the assumed material information included in the management type definition table 41 completed in S110.

Here, the UI providing unit 70 may feed back the estimated communication amount calculated by the calculating unit 72 to the setting terminal 3. As a result, the estimated communication volume calculated in S111 is displayed in the assumed display area 424 of the steady logging setting screen 420.

In step S112, the determination unit 73 compares the upper limit of the communication amount calculated in S104 with the estimated communication amount calculated in S111, and determines whether or not the estimated communication amount exceeds the upper limit of the communication amount. When the assumed communication amount exceeds the communication amount upper limit, the determination unit 73 proceeds from YES in S112 to S113. When the assumed communication amount is equal to or less than the communication amount upper limit, the determination unit 73 proceeds from NO in S112 to S114.

In step S113, the determination unit 73 outputs a determination result indicating "exceeding the upper limit". The UI providing unit 70 reflects the determination result in the determination display area 428.

In step S114, the determination unit 73 outputs a determination result indicating “within the upper limit”. The UI providing unit 70 reflects the determination result in the determination display area 428.

The UI providing unit 70 may make the display mode of the determination display area 428 different depending on whether it is “exceeding the upper limit” or “within the upper limit”. For example, the UI providing unit 70 may configure the determination display area 428 so that the determination result of "exceeding the upper limit" is more conspicuous than the determination result of "within the upper limit".

In step S115, the setting terminal 3 causes the display device to display the steady-state logging setting screen 420 reflecting the above-mentioned determination result according to the UI providing unit 70. As a result, the OT engineer can determine in advance whether or not the monthly communication volume is expected to exceed the communication volume upper limit according to the contents set by the OT engineer. In this way, according to the above-mentioned method, it is possible to give the OT engineer a judgment material and an opportunity to reexamine whether or not the set contents are appropriate.

In step S116, the setting terminal 3 determines whether or not any of the above-mentioned UI components related to the second input information has been newly operated by the OT engineer. For example, the OT engineer can reselect the recommended cycle so as not to exceed the upper limit of the communication volume from the drop-down list of the cycle input area 427.

When it is determined that the selection list 425 or the periodic input area 427 has been operated, the setting terminal 3 returns from YES in S116 to S109, and transmits new second input information based on the new operation to the management server 6. In this case, a new determination result based on the new second input information is reflected in the determination display area 428. If the new operation as described above is not detected, the setting terminal 3 proceeds from NO in S116 to S117. As described above, according to the above method, it is possible to guide the OT engineer to set the steady logging setting so as not to exceed the upper limit of the communication amount.

In step S117, the setting terminal 3 determines whether or not the confirmation button 429 for instructing the confirmation of the first input information and the second input information has been pressed without performing the above-mentioned operation. .. Until the confirmation button 429 is not pressed, the setting terminal 3 returns from NO in S117 to S116 and maintains a standby state for a new operation. When the confirmation button 429 is pressed, the setting terminal 3 proceeds from YES in S117 to S118.

Although not shown, the back button 430 instructing the user to return to the management type definition screen 400 may be pressed here. In this case, the setting terminal 3 returns to S106, returns the display of the display device to the management type definition screen 400, and maintains a standby state for a new operation related to the first input information. Here, the UI providing unit 70 can reflect the logging cycle for each measurement item shown in the management type definition table 41 in the logging cycle column of the definition list 407.

In step S118, the setting terminal 3 transmits a request to the management server 6 so as to confirm the first input information and the second input information.

In step S119, the generation unit 71 registers the management type definition table 41 completed by adding the logging cycle in the management type DB 81 in response to the request. At this time, the generation unit 71 associates the management type definition table 41 with the customer ID and registers it in the management type DB 81.

[Registration phase after delivery]
When the gateway device 1 is delivered to the customer 200, after the above-mentioned preparation phase is completed, the registration phase of the gateway device 1 for associating the gateway device 1 with the management type is started in the data collection system 100.

In the registration phase, the OT engineer designs which individual gateway device 1 is attached to the PLC 2 installed in which process of which production line. Then, the OT engineer operates the setting terminal 3 according to the design contents to perform the device registration work of associating the management type with each gateway device 1. The data collection system 100 supports the registration work of the OT engineer, for example, as follows.

FIG. 11 is a diagram showing an example of a device registration screen displayed on the display device of the setting terminal 3 in the registration phase. FIG. 12 is a diagram showing a data structure of the device registration DB 82.

The OT engineer accesses the management server 6 using the setting terminal 3 and causes the setting terminal 3 to display a device registration screen for performing the registration work of the gateway device 1. The UI providing unit 70 of the management server 6 responds to the request from the setting terminal 3 and provides, for example, the device registration screen 440 shown in FIG. 11 to the setting terminal 3.

The device registration screen 440 is configured to include, for example, each UI component of the ID input area 441, the type input area 442, the location input area 443, the registration button 444, the device list 445, and the completion button 446.

The OT engineer performs the registration work of the delivered gateway device 1 by using the device registration screen 440. First, the OT engineer inputs the device ID of one gateway device 1 into the ID input area 441. The OT engineer may manually input the device ID, or may have the setting terminal 3 read the device ID using an appropriate information reading means of the setting terminal 3. For example, as the information reading means, a short-range wireless communication means such as Bluetooth (registered trademark), infrared rays or RFID tags, or an optical reading means such as a bar code reader, a two-dimensional code reader or a character recognition means is assumed. Will be done.

The OT engineer selects the management type to be applied to the gateway device 1 described above from the management types defined in the previous preparation phase shown in the drop-down list of the type input area 442.

The OT technician selects the manufacturing line to which the gateway device 1 described above is installed from the drop-down list of the location input area 443. It is assumed that the list of the production lines of the customer 200 is registered in the management server 6 in advance. The UI providing unit 70 can configure a drop-down list of the location input area 443 based on the information registered in advance.

The OT engineer presses the registration button 444 when the input of the ID input area 441, the type input area 442, and the location input area 443 is completed. The setting terminal 3 that has received this operation transmits the third input information including the device ID, the management type name, and the installation location (here, the combination of the factory name and the production line name) to the management server 6.

The registration unit 74 of the management server 6 generates device information based on the third input information, and registers the generated device information in the device registration DB 82. Specifically, the registration unit 74 reads the customer ID corresponding to the device ID included in the third input information from the sales list (not shown). The registration unit 74 generates device information in which the read customer ID is associated with the management type name and installation location included in the third input information, and registers the device ID in the device registration DB 82. As shown in FIG. 12, the device registration DB 82 is configured by accumulating a plurality of device information.

When the registration unit 74 completes the registration of one gateway device 1, the UI providing unit 70 may reflect the updated content of the device registration DB 82 on the device registration screen 440. For example, the UI providing unit 70 may add a record of the newly registered gateway device 1 to the device list 445 provided on the device registration screen 440. In the example shown in FIG. 11, the registration of the three gateway devices 1 from the device IDs "GW0001" to "GW003" to the management server 6 has been completed, and the fourth gateway device 1 will be registered from now on. It shows the state of.

The OT engineer presses the completion button 446 when the registration work for all the gateway devices 1 is completed. The setting terminal 3 may notify the management server 6 of the completion of the registration work when the completion button 446 is pressed. Upon receiving the completion notification, the registration unit 74 finally finalizes the contents registered in the device registration DB 82.

As a result, the supply unit 75 refers to the device registration DB 82 shown in FIG. 12, based on the device ID, the customer who owns the gateway device 1, the management type applied to the gateway device 1, and the gateway device. The installation location where 1 is installed can be specified.

[Initial setting phase immediately after installation]
When the registration work of each of the delivered gateway devices 1 is completed by the OT engineer and each gateway device 1 is connected to each PLC 2, the initial setting phase of the gateway device 1 is started.

In the initial setup phase, the OT technician only needs to install the gateway device 1 on a one-to-one basis with the PLC 2 and turn on the power. The gateway device 1 can automatically complete the initial settings without bothering the OT engineer and start normal operation, that is, steady logging operation.

FIG. 13 is a flowchart showing a flow of processing executed by each device of the data collection system 100 in the initial setting phase. The series of processes shown in FIG. 13 is started by the OT engineer attaching the gateway device 1 to the accommodation box 2A, making a wired connection to the PLC 2, and turning on the power of the gateway device 1 and the PLC 2 in step HS1. ..

In step S201, the control unit 21 of the gateway device 1 determines whether or not the power is turned on for the first time. When the power is turned on for the first time, the control unit 21 proceeds from YES in S201 to S202. If this is not the first time the power has been turned on, the control unit 21 proceeds from NO in S201 to S209 to establish communication with PLC2 and perform steady logging.

In step S202, the definition acquisition unit 31 of the control unit 21 transmits a request for the management type definition table applied to the own device to the management server 6. Specifically, the definition acquisition unit 31 establishes communication with the management server 6 via the antenna unit 10 and the dedicated communication network 7, and transmits a request including the device ID of the own device to the management server 6.

In step S203, the supply unit 75 of the management server 6 receives the request including the device ID from the gateway device 1.

In step S204, the supply unit 75 should refer to the device registration DB 82 shown in FIG. 12 and apply it to the customer who is the owner of the requesting gateway device 1 and the gateway device 1 based on the received device ID. Identify the management type. That is, in the device registration DB 82, the customer ID and the management type name associated with the above device ID are extracted.

In step S205, the supply unit 75 reads the management type definition table 41 associated with the customer ID and the management type name extracted in S204 from the management type DB 81 shown in FIG. 10 and supplies the management type definition table 41 to the request source gateway device 1. ..

In step S206, the definition acquisition unit 31 of the gateway device 1 receives the management type definition table 41 transmitted from the supply unit 75 and stores it in the storage unit 22.

In step S207, the initial setting unit 32 refers to the saved management type definition table 41, and based on the PLC model items included in the management type definition table 41, the model of the PLC2 to which the own device is connected is modeled. To identify.

In step S208, the initial setting unit 32 selects the driver information 42 (communication program) corresponding to the specified PLC model and activates the driver information 42 (communication program). A plurality of driver information 42s are stored in advance in the storage unit 22 so that the gateway device 1 can correspond to a plurality of types of PLCs. The initial setting unit 32 need only select one driver information 42 that matches the PLC 2 to which the device is connected and activate it. As a result, the control unit 21 can perform communication compliant with the communication protocol adopted by the connection partner PLC2 via the communication I / F 24. Here, the initial setting unit 32 may communicate with the management server 6 and download the driver information conforming to the PLC 2 from the management server 6.

In step S209, the measured value acquisition unit 33 establishes communication with the PLC 2 based on the activated driver information 42. After that, the measurement value acquisition unit 33 may execute an operation of acquiring the values stored in each register of PLC2 defined in the management type definition table 41 at predetermined intervals and storing them in the ring buffer 43. it can.

[Steady logging phase]
When the gateway device 1 connected to the PLC 2 completes the initial setting, the steady logging phase of the gateway device 1 is started. In the steady logging phase, the gateway device 1 acquires one or more measured values from PLC2 according to the management type definition table 41, and uploads the acquired measured values to the management server 6.

FIG. 14 is a flowchart showing a flow of processing executed by each device of the data collection system 100 in the steady logging phase. FIG. 15 is a diagram showing a data structure of log information. FIG. 16 is a diagram showing a data structure of the log DB 83.

The series of processes shown in FIG. 14 is repeatedly executed after the above-mentioned initial setting phase while the gateway device 1 and the PLC 2 are powered on.

In step S301, when the power of the gateway device 1 and the PLC 2 is turned on, the control unit 21 establishes the communication with the PLC 2 via the communication I / F 24. Here, the log transmission unit 34 starts monitoring the upload timing of the log information according to the logging cycle defined in the management type definition table 41.

In step S302, the measurement value acquisition unit 33 acquires the measurement value from each register defined in the management type definition table 41.

In step S303, the measurement value acquisition unit 33 stores each acquired measurement value in the ring buffer 43.

In step S304, the log transmission unit 34 determines whether or not the upload timing of the log information has arrived. While the upload timing does not arrive, the measured value acquisition unit 33 returns from NO in S304 to S302, and repeats the processes of S302 and S303. The interval of this repetition is, for example, shorter than the logging cycle described above. When the upload timing has arrived, the log transmission unit 34 proceeds from YES in S304 to S305.

In step S305, the log transmission unit 34 reads the latest measured values from the ring buffer 43 at the upload timing, generates log information including these measured values, and uploads the log information to the management server 6.

Specifically, the log transmission unit 34 reads the measurement value of the measurement item designated as the logging target in the management type definition table 41 from the ring buffer 43. In the example shown in FIG. 10, in the management type definition table 41, three measurement items of the current of the register 1, the voltage of the register 2, and the temperature of the register 5 are designated as logging targets. As an example, the logging target is determined by the fact that the item of the logging cycle is specified as a predetermined cycle (for example, "5 minutes") instead of "none".

The log transmission unit 34 reads the latest measured value from the ring buffer 43 at the upload timing among the measured values stored in the ring buffer 43. As an example, the log transmission unit 34 reads the measured value "A1" of the current of the register 1, the measured value "V1" of the voltage of the register 2, and the measured value "T1" of the temperature of the register 5 from the ring buffer 43. ..

The log transmission unit 34 generates the log information shown in FIG. As shown in FIG. 15, the log information includes the measured value for each read register. The log transmission unit 34 preferably associates each measured value with at least one of a register name and a measured item. Further, it is preferable that the log transmission unit 34 includes the time information indicating the time of reading from the ring buffer 43 or the time of uploading and the device ID of its own device in the log information. The log transmission unit 34 uploads the log information shown in FIG. 15 thus generated to the management server 6 via the dedicated communication network 7.

In step S306, the log management unit 76 of the management server 6 receives the log information from the gateway device 1.

In step S307, the log management unit 76 refers to the device registration DB 82 shown in FIG. 12, and based on the device ID included in the log information, the log management unit 76 obtains this log information from the customer and the installation location (factory and manufacturing line). ) And identify. The log management unit 76 can further specify the management type. By specifying the control type, it is possible to further specify which process of the production line is the log information.

In step S308, the log management unit 76 registers the log information in the log DB 83 shown in FIG. For example, as shown in FIG. 16, the log management unit 76 associates the log information shown in FIG. 15 with the customer ID, installation location, and management type name specified in S307, and registers the log information in the log DB 83. The log management unit 76 registers each log information in chronological order based on the time information in the log information. Further, the log management unit 76 may add a column of measurement items corresponding to the register name on a one-to-one basis at the time of registration.

By registering and accumulating the log information in the log DB 83 in this way, the control unit 60 can easily understand the log information group organized in time series in response to a request from the setting terminal 3 of the customer 200. Can be provided.

[Modification example]
In the above-described embodiment, the management server 6 generates the management type definition table of the gateway device 1 and supplies the management type definition table to the gateway device 1, and the gateway device 1 receives the data from the PLC 2. The present invention is not limited to this, and the generation of the management type definition table of the gateway device 1 and the supply to the gateway device 1 and the reception and storage of the data acquired by the gateway device 1 from the PLC 2 are performed by different servers. You may go. That is, the server A generates the management type definition table of the gateway device 1 and supplies it to the gateway device 1, and performs processing related to the setting of the gateway device 1, and the server B different from the server A is the gateway device 1. May receive the data acquired from the PLC 2 from the gateway device 1.

As described above, in the data collection system 100 according to the present embodiment, the service provider 300 is a SIM for communicating with the gateway device 1 main body and a unique identification number, and identifies the source of the acquired data. SIM that can be used for, provider contract for using communication line, management server 6, setting terminal 3 that provides a dashboard, setting tool that uses setting terminal 3, etc. All services necessary for users to make IoT It is possible to provide. As a result, the service provider 300 can cover the entire data collection system 100, thereby acquiring and managing necessary data while minimizing the amount of communication between the gateway device 1 and the management server 6. The system can be provided.

[Example of realization by software]
The control block of the gateway device 1 (particularly, the definition acquisition unit 31, the initial setting unit 32, the measurement value acquisition unit 33, and the log transmission unit 34) is a logic circuit (hardware) formed in an integrated circuit (IC chip) or the like. ) Or software.

The control block of the management server 6 (in particular, the UI providing unit 70, the generation unit 71, the calculation unit 72, the determination unit 73, the registration unit 74, the supply unit 75, the log management unit 76, and the simulation unit 77) is an integrated circuit (in particular). It may be realized by a logic circuit (hardware) formed in an IC chip or the like, or may be realized by software.

In the latter case, each of the gateway device 1 and the management server 6 includes a computer that executes a program instruction, which is software that realizes each function. This computer includes, for example, at least one processor (control device) and at least one computer-readable recording medium that stores the program. Then, in the computer, the processor reads the program from the recording medium and executes it, thereby achieving the object of the present invention. As the processor, for example, a CPU (Central Processing Unit) can be used. As the recording medium, a "non-temporary tangible medium", for example, a ROM (Read Only Memory) or the like, a tape, a disk, a card, a semiconductor memory, a programmable logic circuit, or the like can be used. Further, a RAM (Random Access Memory) for expanding the above program may be further provided. Further, the program may be supplied to the computer via an arbitrary transmission medium (communication network, broadcast wave, etc.) capable of transmitting the program. It should be noted that one aspect of the present invention can also be realized in the form of a data signal embedded in a carrier wave, in which the above program is embodied by electronic transmission.

The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the claims, and the embodiments obtained by appropriately combining the technical means disclosed in the different embodiments. Is also included in the technical scope of the present invention. Furthermore, new technical features can be formed by combining the technical means disclosed in each embodiment.

1 Gateway device 2 PLC
2A Storage box 3 Setting terminal 4 FA device 5 Sensor 6 Management server 10 Antenna part 11 Communication module 12 LTE antenna 13 Memory 14 GPS
15 tact switch 16 LED
17 Connector part 18 Flat cable 20 Main body part 21 Control part 22 Storage part 23 Connector part 24 Communication interface (I / F)
25 Serial data bus 31 Definition acquisition unit 32 Initial setting unit 33 Measured value acquisition unit (data acquisition unit)
34 Log transmission unit (data transmission unit)
41 Management type definition table 42 Driver information 43 Ring buffer 60 Control unit 61 Storage unit 62 Communication unit 70 User interface (UI) provider 71 Generation unit 72 Calculation unit 73 Judgment unit 74 Registration unit 75 Supply unit 76 Log management unit 77 Simulation unit 100 data collection system

Claims (11)

A gateway device that acquires data from a PLC (Programmable Logic Controller) and sends the acquired data to a management server.
A definition acquisition unit that acquires PLC specific information that identifies the PLC, data identification information that identifies data acquired from the PLC, and logging information that specifies a logging cycle that is a cycle of transmission to the management server. ,
An initial setting unit that activates a communication program according to a communication protocol for communicating with the PLC based on the PLC specific information, and an initial setting unit.
A data acquisition unit that acquires data specified by the data identification information from the PLC using the communication program, and a data acquisition unit.
A gateway device including a data transmission unit that transmits the data acquired by the data acquisition unit to the management server according to the logging cycle specified by the logging information. It is provided with a storage unit that stores each communication program corresponding to each PLC assumed as a data acquisition destination in advance.
The initial setting unit is characterized in that, among the communication programs stored in the storage unit, the communication program for performing communication with the PLC specified by the PLC specific information is activated. The gateway device described in. A management server that receives the data from the gateway device that acquires the data from the PLC.
The gateway device, PLC specific information that identifies the PLC connected to the gateway device, data identification information that identifies the data that the gateway device acquires from the PLC, and the gateway device that sends the data to the management server. A storage unit that stores logging information that specifies the logging cycle, which is the transmission cycle, in association with each other.
A management server including a PLC specific information, a data specific information, and a supply unit for supplying the logging information to the gateway device based on a request of the gateway device. It is a setting terminal that sets the setting file used by the gateway device that acquires data from the PLC and sends the data to the management server.
The PLC specific information that identifies the PLC connected to the gateway device, the data identification information that identifies the data acquired from the PLC by the gateway device, and the cycle in which the gateway device transmits the data to the management server. A reception unit that accepts settings for logging information that specifies the logging cycle,
A setting terminal including a setting transmission unit that transmits the contents received by the reception unit to the management server. It is a control method of the gateway device that acquires data from PLC and sends the acquired data to the management server.
With the definition acquisition step of acquiring the PLC specific information for specifying the PLC, the data identification information for specifying the data acquired from the PLC, and the logging information for specifying the logging cycle which is the cycle to be transmitted to the management server. ,
An initial setting step for activating a communication program according to a communication protocol for communicating with the PLC based on the PLC specific information, and an initial setting step.
A data acquisition step of acquiring data specified by the data identification information from the PLC using the communication program, and
A control method for a gateway device, comprising: a data transmission step of transmitting the data acquired in the data acquisition step to the management server according to the logging cycle specified by the logging information. It is a control method of the management server that receives the data from the gateway device that acquires the data from the PLC.
The gateway device, PLC specific information that identifies the PLC connected to the gateway device, data identification information that identifies the data that the gateway device acquires from the PLC, and the gateway device that sends the data to the management server. It is equipped with a storage unit that stores logging information that specifies the logging cycle, which is the cycle of transmission, in association with the logging information.
The reception step for accepting the request of the gateway device and
A control method of a management server, comprising: an information transmission step of transmitting the PLC specific information, the data specific information, and the logging information to the gateway device based on the request. It is a control method of a setting terminal that sets a setting file used by a gateway device that acquires data from a PLC and sends the data to a management server.
The PLC specific information that identifies the PLC connected to the gateway device, the data identification information that identifies the data acquired from the PLC by the gateway device, and the cycle in which the gateway device transmits the data to the management server. A reception step that accepts settings for logging information that specifies the logging cycle, and
A method for controlling a setting terminal, which includes a setting transmission step of transmitting the contents received by the reception step to the management server. The control program for operating a computer as the gateway device according to claim 1, wherein the computer functions as the definition acquisition unit, the initial setting unit, the data acquisition unit, and the data transmission unit. The control program for operating a computer as the management server according to claim 3, and the control program for operating the computer as the supply unit. The control program for operating a computer as a setting terminal according to claim 4, and the control program for operating a computer as the setting transmission unit. A computer-readable recording medium on which the control program according to any one of claims 8 to 10 is recorded.

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