JP2021174243A - Data collection device and data collection system - Google Patents

Abstract

To efficiently manage a large amount of data in a field of manufacturing industry.SOLUTION: A data collection device is interposed between an industrial machine 20 and an information device. A first communication unit 14 of the data collection device acquires a data request sent from the information device 30. A condition monitoring unit 11 monitors the condition of the industrial machine 20. A request determination unit 16 determines a sort of data request. A proxy response data production unit 12 produces proxy response data according to the conditions of the industrial machine 20 and the sort of data request. A proxy response unit 18 uses the proxy response data to respond to the data request sent from the information device 30.SELECTED DRAWING: Figure 3

Description

The present invention relates to a data collection device for collecting factory data and a data collection system.

In the manufacturing industry, production control is performed when manufacturing products. In production control, we create production schedules for products, secure equipment and personnel, manage inventory, procure parts and materials in appropriate amounts in a timely manner, grasp the progress of the production process, and smoothly proceed with daily production activities. Let me.

Proper production control can improve product quality, reduce costs and ensure delivery times. In order to deliver products on schedule, it is important not only to secure raw materials and parts, but also to maintain equipment. In production control, the operating status of equipment is monitored in order to stabilize the operating rate of the factory.

There are various industrial machines in the factory such as machine tools, industrial robots, measuring instruments, test equipment, press machines, cutting machines, packaging machines, welding machines, washing machines, painting machines, assembly equipment, etc. Various sensors are provided to monitor whether the equipment is operating normally. The operating state of these industrial machines 20 and the measurement results of the sensors are collected and analyzed and used for prevention of defects in the industrial machines, elucidation and resolution of the causes of the defects, and reduction of downtime.

As a technique for managing parts and materials, Patent Document 1 states, "Supplying workpieces, tools, oils and fats, etc. used for each manufacturing facility 11 from a plurality of manufacturing facilities 11 constructed in the manufacturing plant 16. The consumption status of goods is collected in real time. For this reason, among the plurality of manufacturing facilities 11 in the manufacturing factory, it is possible to know which manufacturing facility the supplied product needs to be replenished immediately. ”

As a technique for solving a malfunction of an industrial machine, Patent Document 2 states, "In a diagnostic service system, data on machines of a plurality of manufacturers installed in a factory are centrally and continuously collected at predetermined intervals. , It is important to have a factory monitoring system that can store and manage the stored data effectively when needed. ”,“ Users only need to use this diagnostic service system 1 to diagnose failures through the security sharing network 300. Instead, the technology of receiving comprehensive machine maintenance information services such as maintenance history management and information on maintenance parts and maintenance tools is disclosed.

Japanese Unexamined Patent Publication No. 2017-191486 Japanese Unexamined Patent Publication No. 2020-17318

In a conventional factory, as described in Patent Documents 1 and 2, a production control system is constructed in a factory or a company to respond to fluctuations in demand, grasp and manage the entire supply chain, grasp the current state of the production process, and reduce downtime. It enables reduction and abnormality detection.

A device that constantly collects and records data on industrial machines for predicting failures and detecting abnormalities in industrial machines is called a data collection device (data logger). The data collection device collects information such as the motion state and processing state of the mechanical part of the industrial machine.
As shown in FIG. 12, the industrial machine is also connected to information devices such as a personal computer, a data server, and a mobile terminal via a network. Industrial machinery must notify these information devices of the necessary information. The content of the notification is wide-ranging, such as status information such as ON / OFF and operating time of industrial machines, machining progress information such as the number of machined parts, and sensor information such as the motion state of the mechanical part, temperature, and voltage. Information for proper management of factories is increasing, and communication between industrial machines and information devices puts a load on the processors and networks of industrial machines.

In the field of manufacturing, it is desired to efficiently manage a large amount of data.

One disclosure of the present disclosure is a data collecting device, which is a data collecting device arranged between an information device and an industrial machine, a state monitoring unit for monitoring the state of the industrial machine, and a state of the industrial machine. A proxy response data generation unit that generates proxy response data based on the above, a communication unit that acquires a data request from an information device to an industrial machine, a request determination unit that determines the type of data request, and a data request type. A proxy response unit that responds by proxy to the information device is provided.

Other disclosures of the present disclosure include a first communication unit that communicates with an information device on the network and acquires a data request from the information device, and a second communication unit for communicating with an industrial machine. , A status monitoring unit that monitors the status of the industrial machine, a proxy response data generation unit that generates proxy response data according to the status of the industrial machine, a request judgment unit that determines the type of data request, and a data request type. A data collection system including a data collection device including a proxy response unit that responds by proxy to the information device accordingly.

According to one aspect of the present invention, the reusability of subprograms can be improved.

It is a block diagram of the data collection system 100. It is a schematic diagram which shows the relationship between the data collection apparatus 10, the industrial machine 20, and the information apparatus 30. It is a block diagram of the data collection device 10. It is a flowchart which shows the operation of the data collection apparatus 10. This is an example of updating proxy response data according to a state change. It is a figure which shows the flow of the proxy response processing when the proxy response data has been recorded. It is a figure which shows the flow of the update process of the proxy response data at the end of one cycle. It is a figure which shows the flow of the surrogate response processing when the industrial machine 20 is standby / stop. It is a figure which shows the flow of the surrogate response processing when the data collection apparatus 10 is recording. It is a figure which shows the flow of the surrogate response processing when the industrial machine 20 is processing. It is a figure which shows the hardware configuration of the data collection apparatus 10. It is a schematic diagram which shows the conventional relationship between a data collection apparatus 10, an industrial machine 20, and an information apparatus 30.

[First disclosure]
Hereinafter, an example of the data collection system 100 of the present disclosure will be shown. As shown in FIG. 1, the data collection system 100 includes information such as an industrial machine 20, a data collection device 10 attached to the industrial machine 20, and a personal computer or a data server that requests data from the data collection device 10. It consists of devices.

The industrial machine 20 includes a machine tool, an industrial robot, a measuring instrument, a test device, a press machine, a printing machine, a die casting machine, an injection molding machine, a food machine, a packaging machine, a welding machine, a washing machine, a coating machine, an assembly device, and a mounting machine. It is, and is not limited to, an industrial machine 20 related to the manufacture of machines, woodworking machines, sealing devices, cutting machines, belt conveyors, and the like.

The data collecting device 10 collects data such as a motion state and a processing state of the industrial machine 20. The data collection device 10 is further connected to a plurality of sensors 70 by wire or wirelessly to detect the state of industrial equipment or a processed product. The sensor 70 includes, for example, a temperature sensor, an acceleration sensor, a displacement sensor, a sound sensor, an image sensor, and the like, but is not limited thereto.

The data collection device 10 is connected to an information device 30 such as a personal computer, a data server, or a mobile phone in the factory via an internal network 40. The data collection device 10 is connected to an information device 30 such as a personal computer, a data server, or a mobile terminal outside the factory via an external network 50. In the present disclosure, the internal network 40 and the external network 50 are collectively referred to as a network 60. The information device 30 on the network 60 outputs a data request to the industrial device 20.

The configuration of the data collection system 100 in FIG. 1 is an example, and is not limited to the configuration in FIG. A plurality of industrial machines 20 may be connected to one data collecting device.

FIG. 2 is a schematic diagram showing the relationship between the data collection device 10, the industrial machine 20, and the information device 30. In the present disclosure, the data collection device 10 is provided between the industrial machine 20 and the network 60, instead of directly connecting the industrial machine 20 and the network 60. The data collection device 10 receives the data request addressed to the industrial machine, and if a proxy response is possible, the data collection device 10 makes a proxy response.
The data collection device 10 is also connected to the sensor 70 installed in the industrial machine 20, and the data from the sensor 70 also responds on behalf of the sensor 70.

FIG. 3 is a block diagram of the data collection device 10. The data collection device 10 includes a state monitoring unit 11 that monitors the state of the industrial machine 20, a proxy response data generation unit 12 that generates proxy response data, a proxy response data storage unit 13 that stores proxy response data, and an industrial machine. The first communication unit 14 that communicates with the 20 and the sensor 70, the second communication unit 15 that communicates with the information device on the network 60, and the type of data request transmitted from the network 60 to the industrial machine 20 are determined. Request determination unit 16 to perform data request, request distribution unit 17 to distribute requests according to the type of data request, proxy response unit 18 to perform proxy response to network 60, and data collected from industrial machine 20 and sensor 70. A collection data storage unit 19 for storing is provided. In the data collecting device 10, the first communication unit 14 and the second communication unit 15 may be the same.

The proxy response data generation unit 12 generates proxy response data according to the state of the industrial machine 20. The surrogate response data is data that does not require strict real-time performance. The proxy response data includes, for example, the NC program name, the total number of machined parts, and the power consumption. The proxy response data can be updated with the occurrence of an event as a trigger. For example, the NC program name is information that is determined when the operation of the industrial machine 20 is started and is not updated until the operator executes another program. The total number of machined parts is information that is not updated until the machining of one cycle of parts is completed. It is not necessary to constantly monitor the power consumption, and the information is not updated until the end of one cycle.
When an event occurs, the proxy response data generation unit 12 creates proxy response data for each type of data request and stores it in the proxy response data storage unit 13.

The proxy response data generation unit 12 generates proxy response data even while the industrial machine 20 is on standby or stopped. For example, when the rotation of the motor is stopped and made to stand by, or when the robot arm is made to stand by in a predetermined posture, the number of rotations of the motor becomes zero and the amount of movement of the arm becomes zero. The proxy response data generation unit 12 generates proxy response data of such data according to the state of the industrial machine 20.

When the data collection device 10 is collecting data, the proxy response data generation unit 12 reads the collected data and generates proxy response data. The data collection device 10 is originally a device that collects and records data from the industrial machine 20 and the sensor 70. Therefore, the data requested from the information device 30 on the network 60 may be recorded in the collection data storage unit 19. When the requested data is recorded in the data collection device 10, the proxy response data generation unit 12 reads the requested data from the collection data storage unit 19 and creates the proxy response data.

The second communication unit 15 receives a data request from the information device on the network 60. The first data request is a request addressed to the industrial machine 20, but the data collection device 10 receives the data request if it is a data request for the industrial machine 20 connected to itself.

The request determination unit 16 analyzes the structure of the data addressed to the industrial machine 20 and determines the type of data request from the network 60.
The request distribution unit 17 distributes requests according to the type of data request. For example, if the type of data request is NC program name, total number of machined parts, power consumption, etc., since proxy response data has been created, the request is distributed to the proxy response unit 18.
The request distribution unit 17 distributes requests according to the type of data request and the state of the industrial machine 20. For example, if the type of data request is a value that changes in real time, such as the actual speed of the control shaft or the rotation speed of the spindle, the request is distributed to the condition monitoring unit 11.

The state monitoring unit 11 monitors changes in the state of the industrial machine 20. The state of the industrial machine 20 includes, for example, power off, start, operation, standby, stop, alarm generation, and the like. The condition monitoring unit 11 notifies the proxy response data generation unit 12, the request distribution unit 17, and the like of the state of the industrial machine 20.
When the request is distributed from the request distribution unit 17, the condition monitoring unit 11 confirms the state of the industrial machine 20 and the state of the data collection device 10. When the industrial machine 20 is in operation and the data collection device 10 is recording the requested data, the condition monitoring unit 11 requests the proxy response data generation unit 12 to generate the proxy response data.
When the industrial machine 20 is in operation and the requested data is not recorded in the data collection device 10, the condition monitoring unit 11 connects the industrial machine 20 and the information device 30 on the network 60 without making a proxy response. Communication is performed and the requested data is directly output to the information device 30.

The proxy response unit 18 searches for proxy response data according to the type of data request, and notifies the second communication unit 15. The second communication unit 15 responds to the information device 30 with the proxy response data acquired from the proxy response unit 18.

FIG. 4 is a flowchart showing the operation of the data collection system 100 of the present disclosure. When the data request is transmitted from the information device 30 on the network 60 to the industrial machine 20, the data collecting device 10 receives the data request addressed to the industrial machine 20 on behalf of the machine (step S1). The request determination unit 16 determines the type of the received data request (step S2), and the request distribution unit 17 determines whether or not the proxy response data has been generated from the type of the data request. If the proxy response data has already been created (step S3; YES), the proxy response unit 18 reads the corresponding proxy response data from the proxy response data storage unit 13 and makes a proxy response (step S4).

On the other hand, if the proxy response data has not been generated (step S3; NO) and the value changes in real time, the request determination unit 16 distributes the request to the condition monitoring unit 11. The condition monitoring unit 11 confirms the state of the industrial machine 20, and if the industrial machine 20 is in a stopped or standby state (step S6), requests the proxy response data generation unit 12 to generate proxy response data. .. The surrogate response data generation unit 12 creates surrogate response data during stoppage or standby such as control axis actual speed = zero (step S7). The proxy response unit 18 acquires the proxy response data generated by the proxy response generation unit and makes a proxy response (step S8).

On the other hand, when the industrial machine 20 is in operation (step S6), the request determination unit 16 distributes the request to the condition monitoring unit 11. The condition monitoring unit 11 confirms whether or not the data collection device 10 is recording the requested data, and if the requested data is being recorded (step S9; YES), the proxy response data generation unit 12 is substituted. Request the generation of response data. The proxy response data generation unit 12 reads the recorded data from the collected data storage unit 19 and creates the proxy response data (step S10). The proxy response unit 18 acquires the proxy response data generated by the proxy response generation unit and makes a proxy response (step S11).
In step S9, if the requested data is not being recorded (step S9; NO), the condition monitoring unit 11 communicates the industrial machine 20 with the information device 30 on the network 60 without making a proxy response, and requests. The data is directly output to the information device 30 (step S12).

[Generation of proxy response data]
The proxy response data generation unit 12 updates the proxy response data according to the state change every time the state of the industrial machine 20 changes. FIG. 5 is an example of updating the proxy response data according to the state change. The industrial machine 20 in this example is a machine tool. (1) When the industrial machine 20 is started from a power failure, the proxy response data generation unit 12 generates all proxy response data. The data updated only at the time of function includes machine configuration information such as "model information", "number of CNC systems", "number of spindles", and "number of control axes". (2) When machining (operation of the machine tool) is started after starting the industrial machine 20, the proxy response data generation unit 12 performs machining data such as an NC program name and the total number of machined parts created so far as proxy response data. To update. (3) The actual speed of the control shaft, the rotation speed of the spindle, the temperature, the vibration, etc. during machining are data that change in real time without a proxy response. Such data is not updated. However, when the industrial machine 20 is stopped / standby, the proxy response data generation unit 12 generates proxy response data such as spindle speed = zero. (4) When the state of the industrial machine 20 changes from being machined to being machined, the proxy response data generation unit 12 inquires of the industrial machine 20 about the total number of machined parts, the power consumption required for machining, and the like, and obtains proxy response data regarding operation. Update. (5) When an alarm occurs during processing, the proxy response data generation unit 12 acquires alarm information from the industrial machine 20 and records it as proxy response data.

In this way, the data collecting device 10 of the present disclosure monitors the state of the industrial machine 20, determines which proxy response data is to be updated according to the state of the industrial machine 20, and updates the data.

[Surrogate response processing]
A specific example of proxy response processing will be described with reference to FIGS. 6 to 11. In FIG. 6, a data request for the total number of parts processed is generated from the network 60 to the industrial machine 20. (I) The data collection device 10 receives a data request addressed to the industrial machine 20 on behalf of the user, and the request determination unit 16 determines that the type of the received data request is a data request for the total number of parts processed. (II) The request distribution unit 17 requests the proxy response unit 18 to make a proxy response. Since the total number of parts machined is static data that does not change frequently, surrogate response data is generated. (III) The proxy response unit 18 acquires the corresponding data from the proxy response data storage unit 13 and makes a proxy response.
Since the data collection device 10 makes a proxy response in this way, the industrial machine 20 being processed does not need to communicate with the network 60, so that the communication load is reduced without increasing the calculation load of the industrial machine 20. can.

FIG. 7 illustrates the update of proxy response data. When the industrial machine 20 completes machining (one cycle ends), (I) the condition monitoring unit 11 detects the completion of machining, and (II) the proxy response generation unit inquires the industrial machine 20 about the total number of machined parts, and the total number of machined parts. To get. (III) The proxy response data generation unit 12 updates the proxy response data with the total number of machined parts acquired from the industrial machine 20.
In this way, the proxy response data is updated in a timely manner according to the state of the industrial machine 20.

Next, with reference to FIGS. 8 to 11, an example in which data that changes in real time (here, the spindle speed) is requested will be described. FIG. 8 shows an example in which the industrial machine 20 is on standby / stopped. In FIG. 8, when the data collection device 10 receives the data request addressed to the industrial machine 20 on behalf of the user, the request determination unit 16 (I) determines that the data request is a request for the spindle speed. (II) When the data request is a request for the spindle speed, the request is distributed to the state monitoring unit 11 because the request determines whether to respond by proxy depending on the state. (III) The condition monitoring unit 11 confirms the state of the industrial machine 20 and determines that the spindle speed is zero because the industrial machine 20 is on standby. (IV) The surrogate response data generation unit 12 generates surrogate response data with a spindle speed = zero and records it in the (V) surrogate response data storage unit 13, and the surrogate response unit 18 is in the state of the industrial machine 20. Represents spindle rotation speed = 0 until is in the process of machining.
While the industrial machine 20 is on standby, the data collection device 10 makes a proxy response, so that the calculation load of the industrial machine 20 is not increased. Further, since a fixed value such as spindle speed = zero is output, the load on the network 60 can be reduced.

FIG. 9 shows an example in which the data collection device 10 requests data from the industrial machine 20 during recording. When the data collection device 10 receives the data request addressed to the industrial machine 20 on behalf of the user, the request determination unit 16 (I) determines that the data request is a request for the spindle speed. (II) When the data request is a request for the spindle speed, the request is distributed to the state monitoring unit 11 because the request determines whether to respond by proxy depending on the state. (III) The condition monitoring unit 11 confirms the state of the industrial machine 20 and the state of the data collection device 10, and since the industrial machine 20 is being processed and the data collection device 10 records the data, the proxy response unit 11 Request a proxy response from 18. The proxy response unit 18 reads the latest data from the collected data storage unit 19 and performs a proxy response.

FIG. 10 is an example in which the industrial machine 20 receives a data request during processing. When the data collection device 10 receives the data request addressed to the industrial machine 20 on behalf of the data collection device 10, the request determination unit 16 determines that the data request is a request for the actual speed of the control axis. (II) The control axis actual speed distributes the request to the state monitoring unit 11 because the request determines whether to respond by proxy depending on the state. (III) The condition monitoring unit 11 confirms the condition of the industrial machine 20. Since the industrial machine 20 is being processed, the request distribution unit 17 passes through the data collection device 10 and communicates between the industrial machine 20 and the information device 30 without making a proxy response.

In the data collection system 100 of the present disclosure, when the data collection device 10 exists between the industrial machine 20 and the network 60 and receives a data request addressed to the industrial machine 20, the type of the data request and the state of the industrial machine 20 Make a proxy response based on. Therefore, the communication load between the industrial machine 20 and the network 60 can be reduced.

In the data collection system 100 of the present disclosure, data that changes at the same time as the state change of the industrial machine 20 is generated in advance as proxy response data in accordance with the state change of the industrial machine 20. When the data collection device 10 requests the generated data, the load on the industrial machine 20 can be reduced by reading the already recorded proxy response data and making a proxy response.

In the data collection system 100 of the present disclosure, when data that changes in real time is requested, the data collection device 10 generates proxy response data according to the state of the industrial machine 20 and performs a proxy response. As a result, for example, it is not necessary to transmit unchanged data such as the actual speed of the control axis of the stopped industrial machine 20, and the communication load can be reduced.

In the data collection system 100 of the present disclosure, when the data requested for the industrial machine is collected in the data collection device 10, the corresponding data is read from the data collection device 10 and a proxy response is made. As a result, the industrial machine 20 can transmit the data to the information device 30 on the network 60 by outputting the data only to the data collection device 10, so that the communication load can be reduced.

Hereinafter, an example of the data collection device 10 will be shown. As shown in FIG. 11, the data collection device 10 includes a CPU 111 that controls the data collection device 10 as a whole, a ROM 112 that records programs and data, and a RAM 113 that temporarily expands the data. The CPU 111 is a bus 120. The system program recorded in the ROM 112 is read through the system program, and the entire data collection device 10 is controlled according to the system program.

The non-volatile memory 114 retains its storage state even when the power of the data collection device 10 is turned off, for example, by backing up with a battery (not shown). The non-volatile memory 114 stores various data acquired from the program read from the external device 72 via the interface 115, the industrial machine 20, the sensor 70, and the like.
The proxy response processing of the present disclosure is realized by the CPU 111 executing a program recorded in the ROM 112 or the non-volatile memory 114.

100 Data collection system 10 Data collection device 11 Status monitoring unit 12 Proxy response data generation unit 13 Proxy response data storage unit 14 First communication unit 15 Second communication unit 16 Request judgment unit 17 Request distribution unit 18 Proxy response unit 19 Collection Data storage unit 20 Industrial machinery 30 Information device 70 Sensor

[Generation of proxy response data]
The proxy response data generation unit 12 updates the proxy response data according to the state change every time the state of the industrial machine 20 changes. FIG. 5 is an example of updating the proxy response data according to the state change. The industrial machine 20 in this example is a machine tool. (1) When the industrial machine 20 is started from a power failure, the proxy response data generation unit 12 generates all proxy response data. The data updated only at startup includes machine configuration information such as "model information", "number of CNC systems", "number of spindles", and "number of control axes". (2) When machining (operation of the machine tool) is started after starting the industrial machine 20, the proxy response data generation unit 12 performs machining data such as an NC program name and the total number of machined parts created so far as proxy response data. To update. (3) The actual speed of the control shaft, the rotation speed of the spindle, the temperature, the vibration, etc. during machining are data that change in real time without a proxy response. Such data is not updated. However, when the industrial machine 20 is stopped / standby, the proxy response data generation unit 12 generates proxy response data such as spindle speed = zero. (4) When the state of the industrial machine 20 changes from being machined to being machined, the proxy response data generation unit 12 inquires of the industrial machine 20 about the total number of machined parts, the power consumption required for machining, and the like, and obtains proxy response data regarding operation. Update. (5) When an alarm occurs during processing, the proxy response data generation unit 12 acquires alarm information from the industrial machine 20 and records it as proxy response data.

Claims (7)

A data collection device located between an information device and an industrial machine.
A condition monitoring unit that monitors the condition of the industrial machine,
A proxy response data generation unit that generates proxy response data based on the state of the industrial machine,
A communication unit that acquires a data request from the information device to the industrial machine, and
A request determination unit that determines the type of data request,
A proxy response unit that responds on behalf of the information device according to the type of data request,
A data collection device equipped with. The data collection device according to claim 1, wherein the proxy response data generation unit generates proxy response data of data that does not change in real time, triggered by a state change of the industrial machine. The data collecting device according to claim 1, wherein the proxy response data generation unit generates proxy response data corresponding to the state of the industrial machine when the state of the industrial machine is stopped or is on standby. A collection data storage unit for storing data output from the industrial machine is provided.
When the data requested by the data request is data that changes in real time and the data is recorded in the collected data storage unit, the proxy response data generation unit is stored in the collected data storage unit. The data collecting device according to claim 1, wherein the data is read out and the proxy response data is generated. A collection data storage unit for storing data output from the industrial machine is provided.
When the data requested by the data request is data that changes in real time and the data is not recorded in the collected data storage unit, the data is passed through the data collecting device to pass through the data collecting device and the industrial machine and the information device. The data collecting device according to claim 1, which communicates with. The data collection device according to claim 1, wherein the proxy response data includes information of a sensor indicating the state of the industrial machine. A first communication unit that communicates with an information device on a network and acquires a data request from the information device.
A second communication unit for communicating with industrial machinery,
A condition monitoring unit that monitors the condition of the industrial machine,
A proxy response data generation unit that generates proxy response data according to the state of the industrial machine,
A request determination unit that determines the type of data request,
A proxy response unit that responds on behalf of the information device according to the type of data request,
A data collection system, including a data collection device equipped with.

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