JP3666422B2 - Data monitoring device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a data monitoring apparatus that constantly monitors a status signal of an automatic machine for a production facility, etc., visualizes an abnormal operation state or a sign of abnormal operation in advance, and efficiently analyzes abnormality of facility stop and predictive maintenance.
[0002]
[Prior art]
FIG. 1 is an upper plan view of a model that is an example of an automatic machine and conveys a workpiece by two cylinders. In FIG. 1, 11 is a workpiece, 12 is a conveying jig (hereinafter referred to as knock), 13 is a table on which the workpiece is mounted, 14 is a sensor for detecting a knock return end, 15 is a sensor for detecting a knock-in end, and 16 is A sensor for detecting a workpiece conveyance backward end, and a sensor 17 for detecting a workpiece conveyance forward end.
[0003]
Next, the operation of the model of FIG. 1 will be described.
[0004]
FIG. 2 is a sequential function chart for explaining the operation of the model shown in FIG. In the figure, the knocked state Q1 is a state where the right end of the knock 12 is detected by the knocked end detection sensor 15, and at this time, the knocked end detection signal I1 output from the sensor 15 is "1". Next, the workpiece 11 is conveyed by moving the knock 12 in the direction of the workpiece conveyance advance end, and when the knock 12 is detected by the sensor 17, the workpiece conveyance advance state Q3 is entered. At this time, the workpiece conveyance advance end output by the sensor 17 is obtained. The signal I3 becomes “1”. When the workpiece 12 is supplied to the workpiece supply unit, the next workpiece is placed on the table 13. The knock 12 is moved to the left and then returned to the position of the knock return state Q0 so that the knock 12 does not collide with the work on the table 13 when returning to the knock return position. At this time, the knock return end detection signal I0 output from the sensor 14 becomes “1”. Next, the knock 12 is returned to the workpiece transfer retracted position to enter the workpiece transfer retracted state Q2. At this time, the workpiece transfer backward end detection signal I2 output from the sensor 16 becomes "1".
[0005]
In the above example, a data monitor device that monitors and displays a plurality of digital signals such as the knock return end detection signal I0, the knock insertion end detection signal I1, the workpiece transfer backward end I3, and the workpiece transfer forward end I3, for example, a logic analyzer, A signal from a measuring instrument is input, a signal converted into a binary value of “0” or “1” is sampled, stored in a storage medium, and then a digital waveform is displayed on the screen.
[0006]
FIG. 3 is a diagram showing an example of a display screen by a conventional data monitor device. In the figure, the horizontal direction of the screen indicates the time axis, and the vertical direction indicates the four detection signals I0 to I3 of the automatic machine shown in FIG. How the four detection signals change with time is displayed as a digital waveform. In the illustrated example, a knock original position (knock return end) detection signal I0, a knock operation end (knock entering end) detection signal I1, and a workpiece transfer original position (work transfer backward end) as detection signals for a plurality of positions. Only four detection signals, ie, a detection signal I2 and a workpiece transfer operation end (work transfer advance end) detection signal I3 are shown, but many of the actual automatic machines have several hundred measurement positions.
[0007]
However, with this method, there are too many measurement positions for anomaly analysis of an automatic machine that needs to monitor multiple signals over a long period of time, store their status and changes in storage media, and display them. In addition, since signals related to each other are displayed separately, there is a problem that monitoring and analysis are difficult.
[0008]
As a conventional technique for solving this problem, as described in Japanese Patent Laid-Open No. 5-249145, the result of logical product, logical sum or exclusive logical sum of a plurality of waveform data of a microprocessor is efficiently displayed as a waveform. There is a way.
[0009]
[Problems to be solved by the invention]
Conventionally, however, an enormous digital waveform over a long period of time is stored and displayed on the screen while sequentially scrolling. However, it has been very difficult to find a place to be immediately analyzed for abnormalities while scrolling.
[0010]
In addition, in the analysis of abnormalities of equipment stoppage in automatic machines of production equipment and application to predictive maintenance, as disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 5-249145, logic is simply used to monitor the state of each part of the microprocessor. There is a problem that a desired result cannot be obtained because the transient state cannot be analyzed only by displaying the waveform of the product, logical sum or exclusive logical sum.
[0011]
Further, in the method of monitoring only the special state of the microprocessor as in the technique disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 5-249145, the waveform display cannot be performed efficiently because the state of each part in the automatic machine of the production facility is monitored. There is a problem.
[0012]
Further, since the conventional display waveform is a digital waveform indicating “1” or “0”, it is difficult to immediately find a place to be analyzed for abnormality.
[0013]
Further, conventionally, since a plurality of signals related to each other are displayed as separate digital waveforms, it is still difficult to immediately find a place where an abnormality should be analyzed.
[0014]
In view of the problem of displaying a plurality of conventional waveform data as a result of logical operation of logical product, logical sum, or exclusive logical sum, the present invention performs abnormality analysis and predictive maintenance of equipment shutdown. In order to improve efficiency, signals related to the status of automatic machines are collectively displayed, and a long-time status can be collectively displayed by color, thereby providing a data monitoring device that can immediately analyze anomalies. For the purpose.
[0015]
[Means for Solving the Problems]
In order to solve the above problems, the means described in claim 1 can be employed.
[0016]
According to this means, in the data monitoring device, a single type of state waveform out of the state waveforms collected for each related signal is cut at a constant time based on the reference timing for each cycle of the cycle motion of the equipment. A two-dimensional pattern is generated and displayed by representing a horizontal line segment, color-coding the line segment in accordance with the state of the state waveform, and arranging a predetermined number of cycles of the color-coded line segment in accordance with the reference timing. Since related signals are displayed together, it is easy to find abnormal parts. In addition, since each state of a two-dimensional pattern formed over a long period of time for a single type of state waveform is displayed in different colors, an abnormal part can be found immediately.
[0017]
Moreover, in order to solve the said subject, the means of Claim 2 is employable.
[0018]
According to this means, in the data monitoring device, a plurality of types of state waveforms out of the state waveforms grouped for each related signal are cut at a constant time based on the reference timing, and are horizontal for each cycle cycle of the equipment. These line segments are color-coded according to the state of the state waveform, and a two-dimensional pattern is generated and displayed by arranging a predetermined number of cycles of the color-coded line segments in accordance with the reference timing. Since related signals are displayed together, it is easy to find an abnormal part, and many types of signals can be displayed on the screen. In addition, since each state of a two-dimensional pattern formed over a long period of time for a plurality of types of state waveforms is displayed in different colors, an abnormal part can be found immediately.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 4 is a block diagram showing the configuration of the data monitoring apparatus according to the embodiment of the present invention. In the figure, a data monitoring apparatus 1 according to an embodiment of the present invention is connected to an automatic machine 100 of a production facility. The data monitoring device 1 samples the equipment input signal from the automatic machine 100 as a digital or analog signal directly or via a network, and the communication control unit 2 and the input signal every unit time. A sampling unit 3, a signal storage unit 4 that stores the sampled signal per unit time, and a state waveform generation that generates a state waveform by collecting the waveforms of the stored signals for each related signal of the automatic machine 100 The unit 5, a two-dimensional pattern generation unit 6 that generates a two-dimensional pattern that collectively displays the generated state waveform for a long time, and a variation pattern for each state change of the state waveform generated by the state waveform generation unit 5 Which waveform data of the variation pattern generation unit 7, the state waveform generation unit 5, the two-dimensional pattern generation unit 6, and the parallax pattern generation unit 7 A display switching control unit 8 for switching whether to display the data, whereby the display switching unit 9 for switching the display, and a display unit 10 for displaying a waveform.
[0020]
Next, the operation of the data monitor device 1 will be described.
[0021]
As a simple model of the automatic machine 100, there is a workpiece supply mechanism described with reference to FIGS. In the following description, a case where the state of the workpiece supply mechanism is monitored will be described.
[0022]
FIG. 5 is a diagram showing a display screen according to the embodiment of the present invention. In FIG. 5, the four positions of the knock original position detection signal I0, the knock operation end detection signal I1, the workpiece transfer original position detection signal I2, and the workpiece transfer operation end detection signal I3 of the model shown in FIG. A screen that is combined and displayed on the display unit 10 (FIG. 4) is shown.
[0023]
FIG. 6 is a logical operation table for creating the state waveform shown in FIG.
[0024]
Outputs I0 to I3 of the sensors 14 to 17 of the workpiece supply mechanism (FIG. 1) as the automatic machine 100 are input to the signal input unit and the communication control unit 2. The sampling unit 3 samples these signals every unit time. The four sampled signals are stored in the signal storage unit 4. Next, the state waveform generation unit 5 generates four signals as state waveforms by the calculation shown in FIG. 6 and displays them on the display unit 10. As a result, the number of signals that can be displayed on one screen can be increased. That is, in the state 1, since the workpiece knock original position detection signal I0 is "0" and the knock operation end detection signal I1 is also "0", the knock 12 exists at an intermediate position that does not exist at either the knock return end or the knock entering end. Indicates that the device is operating or operating. This state waveform is set to “0”. That is, the state waveform “0” means a waveform in a state that is neither “−1” nor “+1”.
[0025]
In state 2, since the workpiece knock position detection signal I0 is "1" and the knock operation end detection signal I1 is "0", the knock 12 is present at the knock return end and its state waveform is "-1". The contents of state 2 indicate that knock 12 is in its original position.
[0026]
Further, in the state 3, since the workpiece knock original position detection signal I0 is "0" and the knock operation end detection signal I1 is "1", the knock 12 is present at the knock-in end and its state waveform is "+1". The contents of state 3 indicate that knock 12 is on the operating side.
[0027]
Further, in state 4, both the knocking position detection signal I0 and the knocking end detection signal I1 of the workpiece are both “1”, and it is impossible for both detection signals to be “1” at the same time as described above. Determined as abnormal. The state waveform is “0”.
[0028]
The workpiece conveyance original position detection signal I2 and the workpiece conveyance operation end detection signal I3 are also calculated by the same calculation as that shown in FIG. 6, and the state waveform “0” and the state waveform “−1” as shown in the lower waveform data in FIG. ”And a single waveform having a state waveform“ +1 ”.
[0029]
In this way, two related signals (I0 and I1, and I2 and I3) stored in the signal storage unit 4 are generated in the state waveform unit 5 as one state waveform based on the calculation example shown in FIG. By displaying on the display unit 10, what was conventionally two waveforms is displayed as one waveform, so the number of signals that can be displayed on one screen can be increased.
[0030]
Further, in order to increase efficiency, attention is paid to the time that can be displayed.
[0031]
FIG. 7 is a diagram illustrating an example of a two-dimensional pattern waveform generated by converting the knock state waveform generated by the state waveform generation unit 5 in FIG. 4 by the two-dimensional pattern generation unit 6.
[0032]
The two-dimensional pattern generation unit 6 generates a single type of state waveform out of the state waveforms collected for each related signal in the state waveform output from the state waveform generation unit 5 based on a reference timing. The line segment is represented by a horizontal line for each cycle of the equipment cycle movement, and the line segment is color-coded according to the state of the state waveform, and the predetermined number of cycles of the color-coded line segment is arranged in accordance with the reference timing. Generate a dimensional pattern.
[0033]
In FIG. 7, reference numerals 200 to 203 denote each cycle when the reciprocating motion from the original position of the knock 12 to the operating end is defined as one cycle. Each state of the knock 12 in each cycle is represented by the color of a horizontal line segment. That is, the color of each line segment of the cycles 200 to 203 is green in the state 2 where the knock 12 is in the original position, and the knock 12 exists in the middle position between the original position and the operation end or is in operation between them. It is yellow in state 1 and blue in state 3 with knock 12 at the operating end.
[0034]
By arranging these line segments in the vertical direction to generate a two-dimensional pattern 204 and displaying the two-dimensional pattern 204 on the display unit 10, it is possible to collectively display a long-time state. Although FIG. 7 shows an example in which only four cycles are collectively displayed, many more cycles can be collectively displayed on one screen.
[0035]
210 in the cycle 202 indicates an abnormal operation of the knock 12. For example, although the knock 12 is once moved to the operating end, it is reflected too much by the operation end because it is pushed too much, and it is moved again to the operating end. Because of this abnormal operation, the blue end of state 3 and the yellow end of state 1 are behind the other normal cycles. When this is displayed in a two-dimensional pattern, the yellow portion 211 of state 1 is visualized in the blue of state 3, and the blue portion 212 of state 3 extends to the yellow portion of state 1 in other normal cycles. Furthermore, since the yellow portion 213 in the state 1 extends to the green portion in the state 2 in another normal cycle, an abnormality analysis can be easily performed from a long-time equipment state.
[0036]
FIG. 8 is a diagram illustrating another example of the waveform of the two-dimensional pattern generated by converting the knock state waveform generated by the state waveform generation unit 5 in FIG. 4 by the two-dimensional pattern generation unit 6. In FIG. 8, 300-303 shows each cycle when the reciprocating motion from the original position of the knock 12 to the operating end is taken as one cycle. Each state of the knock 12 in each cycle is represented by a color of a horizontal line segment as in FIG.
[0037]
These line segments are arranged in the vertical direction to generate a two-dimensional pattern 304, and the two-dimensional pattern 304 is displayed on the display unit 10.
[0038]
In FIG. 8, the time until the knock 12 returns from the operating end to the original position extends as the cycle progresses. This phenomenon appears when, for example, the back side of the knock is rusted and the time required to move from the operating end to the original position is longer than the time required to move from the original position to the operating end. In the conventional display method, the knock original position and the waveform of the knock operation end for each cycle are separately displayed in sequence, so that it is difficult to understand the change with time. However, when the two-dimensional pattern 304 is displayed, the yellow area 311 is displayed. The increase with time can be visualized, and it is possible to easily analyze abnormality over time.
[0039]
7 and 8, only the state of the knock 12 is displayed as a two-dimensional pattern, but the workpiece conveyance state may be displayed on the same screen as a two-dimensional pattern different from the knock state.
[0040]
FIG. 9 is a diagram showing still another example of the waveform of the two-dimensional pattern generated by converting the state waveform generated by the state waveform generation unit 5 in FIG. 4 by the variation pattern generation unit 7. In FIG. 9, in addition to the state of the knock 12, the workpiece conveyance state is also displayed in one two-dimensional pattern. Green, yellow, and blue indicate the same states as in FIGS. 7 and 8, respectively. However, yellow also indicates a state in which the workpiece conveyance state is in the middle between the operation end and the original position. Gray indicates that the knock 12 is at the operating end and the workpiece is between the original position and the operating end. Black indicates that the knock 12 is in the middle between the operating end and the original position, and the work is at the operating end.
[0041]
In the variation pattern generation unit 7, a plurality of types of state waveforms among the state waveforms grouped for each related signal in the state waveform grouped for each related signal in the state waveform output from the state waveform generation unit 5. Is represented by horizontal line segments for each cycle of the equipment cycle movement, based on the reference timing, and these line segments are color-coded according to the state of the state waveform. The number of cycles is arranged according to the reference timing, and the two-dimensional pattern is generated. The waveform data of each cycle is cut with a certain span based on the reference timing, and line segments color-coded for each state are obtained for each cycle, and they are perpendicular. A two-dimensional pattern arranged in the direction is generated. The two-dimensional pattern is displayed on the display unit 10. Thereby, the state of the whole automatic machine can be collectively displayed on the display unit 10 for a long time.
[0042]
As can be seen from the pattern 400 shown in FIG. 9, when the time reference t0 is displayed together with the start time of the state 1 (yellow), the cycle time of each cycle varies. In the illustrated example, it can be easily determined visually that the cycle time of the fifth cycle is the longest.
[0043]
The location where the cycle time of the fifth cycle is extended may not be known only by analyzing the pattern 400.
[0044]
Therefore, when the pattern 401 combined with the time reference t1 is displayed at the start of the state 3 (blue), it can be seen that the fifth cycle of the blue state is extended, and this delays the entry to the gray state. After that, it suffices to search for the mechanical cause of delay in entering the gray state. That is, the cause of the delay of the knock 12 from starting from the work transfer original position toward the operation end is searched.
[0045]
Similarly, by adjusting the reference time at the start of the gray state, the start of the black state, and the start of the green state, it is possible to analyze the abnormality after that color.
[0046]
The embodiment of the present invention described above is merely an example, and various modifications are possible within the scope of the present invention. For example, the automatic machine is not limited to that shown in FIG. Further, various states of the automatic machine displayed on the display device are possible other than knock-back, knock-on, workpiece transfer backward, and workpiece transfer forward. Furthermore, the displayed colors are not limited to those illustrated.
[Brief description of the drawings]
FIG. 1 is an upper plan view of a model that is an example of an automatic machine and transports a workpiece by two cylinders.
FIG. 2 is a sequential function chart for explaining the operation of the model shown in FIG.
FIG. 3 is a diagram showing an example of a display screen by a conventional data monitor device.
FIG. 4 is a block diagram showing a configuration of a data monitoring apparatus according to an embodiment of the present invention.
FIG. 5 is a diagram showing a display screen according to the embodiment of the present invention.
[Fig. 6]
6 is a logical operation table for creating the state waveform shown in FIG. 5.
7 is a diagram illustrating an example of a waveform of a two-dimensional pattern generated by converting the knock state waveform generated by the state waveform generation unit 5 in FIG. 4 by the two-dimensional pattern generation unit 6. FIG.
8 is a diagram showing another example of the waveform of the two-dimensional pattern generated by converting the knock state waveform generated by the state waveform generation unit 5 in FIG. 4 by the two-dimensional pattern generation unit 6. FIG.
9 is a diagram showing still another example of the waveform of the two-dimensional pattern generated by converting the state waveform generated by the state waveform generation unit 5 in FIG. 4 by the variation pattern generation unit 7. FIG.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Data monitoring apparatus 2 ... Signal input and communication control part 3 ... Sampling part 4 ... Signal storage part 5 ... State waveform generation part 6 ... Two-dimensional pattern generation part 7 ... Variation pattern generation part 10 ... Display part

Claims (2)

In a data monitoring device for monitoring a status signal indicating the status of equipment that performs cycle motion,
A sampling unit for sampling the state signal every unit time;
A signal storage unit for storing the signal sampled by the sampling unit every unit time;
A state waveform generating unit for collecting signals stored in the signal storage unit into state waveforms for each related signal of the equipment;
A state waveform of a single type of state waveforms collected for each related signal by the state waveform generator is cut at a constant time based on a reference timing, and a horizontal line for each cycle of the cycle motion of the equipment. A two-dimensional pattern generation unit that generates a two-dimensional pattern by color-coding the line segment according to the state of the state waveform and arranging a predetermined number of cycles of the color-coded line segment according to the reference timing ,
A data monitor apparatus comprising: a display unit that displays the two-dimensional pattern. In a data monitoring device for monitoring a status signal indicating the status of equipment that performs cycle motion,
A sampling unit for sampling the state signal every unit time;
A signal storage unit for storing the signal sampled by the sampling unit every unit time;
A state waveform generating unit for collecting signals stored in the signal storage unit into state waveforms for each related signal of the equipment;
A plurality of types of status waveforms among the status waveforms collected for each related signal by the status waveform generation unit are cut at a constant time based on a reference timing, and a horizontal line segment for each cycle of the cycle motion of the equipment. A variation pattern generation unit that generates a two-dimensional pattern by color-coding the line segment according to the state of the state waveform and arranging a predetermined number of cycles of the color-coded line segment in accordance with the reference timing;
A data monitor apparatus comprising: a display unit that displays the two-dimensional pattern.

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