JP5845944B2 - Manufacturing process operation support apparatus, method and program - Google Patents

Description

  The present invention relates to an operation support apparatus, method, and program suitable for supporting the operation of a manufacturing process in which a continuous product continuously flows, such as a continuous casting process.

  In order to realize a stable operation of continuous casting, it is necessary for an operator to always judge and select an appropriate operation. For that purpose, it is important to accurately predict the state of equipment and products.

  For the above prediction, operators, particularly experts, have constructed a cognitive model of the continuous casting process by integrating piecewise information about the state of steel in the continuous casting process through causal relationships. And since operators have knowledge of the cognitive model of the continuous casting process in their heads, they have avoided trouble by estimating the state of the steel, predicting the future state, and performing appropriate operations.

  On the other hand, in recent years, productivity decline due to a decrease in skilled workers, operation trouble occurrence, and the like are increasing, and it is demanded to support appropriate operations even if they are not skilled workers.

  As a countermeasure to the above-mentioned decrease in skilled persons, there is a method of predicting an operation state by performing a simulation using a numerical model expressing a physical phenomenon by a statistical analysis method. For example, Patent Document 1 predicts an operation state using a numerical model created by applying any one of principal component analysis, independent component analysis, and wavelet analysis. Since various operating factors can be incorporated into the model, a numerical model can be created even for complex processes.

  Furthermore, there is a method for searching for similar cases of past operation states from a time series database and predicting the future of operation states. For example, Patent Document 2 discloses a complicated process in which a large number of operation factors having a short period with respect to a time scale are included by reducing noise in time series data as preprocessing for searching for similar cases. It is said that a practically sufficient prediction accuracy can be obtained.

JP 2010-214417 A JP 2009-76037 A

Tadao Murata: Petri net analysis and application, Modern Science (1992)

  However, in general, in a continuous process, the state of a product takes various forms depending on temperature and components, and the state changes depending on the time and operation of the equipment. The product state changes the state of the equipment. , It also affects the condition of the product, etc. There are complex mutual interferences. The techniques disclosed in Patent Document 1 and Patent Document 2 are aimed at predicting the operation state by a simple method, but the above-described model of the phenomenon in which the state of the equipment or product interferes in a complicated manner is accurate. It is difficult to build high.

  Therefore, paying attention to the fact that the cognitive model in the expert's head takes into account the complex mutual interference of the equipment and product states as described above, There is a need to make the cognitive model of the continuous casting process objective, that is, to model causal relationships in the state transition of steel so that it can provide guidance on avoiding operational troubles and actions when operational troubles occur.

  The present invention has been made in view of the above points, and discretely models a manufacturing process in which a continuous product continuously flows, and uses the discrete model to support the operation of the manufacturing process. For the purpose.

An operation support apparatus for a manufacturing process according to the present invention is an operation support apparatus for supporting an operation of a manufacturing process in which a continuous product continuously flows. The manufacturing process is processed by receiving input from the operator about the attribute and state of the product, the transition path of the state of the product attribute, the equipment and the state of each stage, and the transition path of the state of the equipment. The product attribute state transition model and the equipment state transition model are created for each stage, and the state between the product attribute state and the equipment state in each stage is created. effects and storage means for storing discrete model created by defining a relationship, defined by a plurality of combinations of states of the attributes of the stage and product, troubles of the manufacturing process A designation means for designating a crisis state that is a high risk of life, and an initial stage based on the discrete model and limited to the stage and product attributes specified by the crisis condition designated by the designation means A state transition diagram creating means for creating a state transition diagram representing a route from a state to the crisis state; a state transition diagram representing a route to one crisis state created by the state transition diagram creating means; When an operation is performed on the manufacturing process in the path leading to the one crisis state based on the state transition diagram representing the path leading to another crisis state, the operation is performed in the other crisis state. And determining means for determining whether or not to affect the route up to.
Another feature of the manufacturing process operation support device according to the present invention is that the state transition diagram created by the state transition diagram creating means is used to determine the occurrence probability and danger of each state constituting the state transition diagram. There is a risk matrix creating means for creating a risk matrix representing the relationship with the degree.
Further, another feature of the operation support apparatus of the manufacturing process according to the present invention is that the determination means performs a state of an attribute of a product included in a path from the execution of the operation to the one crisis state. To determine whether the state of the attribute of the product included in the path leading to the other critical state changes based on the discrete model, When the attribute state of the product included in the route changes, it is determined that the operation affects the route leading to the other crisis state.
In addition, another feature of the operation support device of the manufacturing process according to the present invention is that the state transition diagram for the plurality of crisis states created by the state transition diagram creation unit is from the initial state to each crisis state. The shortest path of each is extracted and listed, and is provided with a bird's-eye view information creation means.
Another feature of the manufacturing process operation support device according to the present invention is that, in the discrete model, between the attributes of the products between the stages, which is the influence received from the products existing in different stages at the same time. This is in the point of further defining the influence relationship.
Further, another feature of the manufacturing process operation support device according to the present invention is that, in the discrete model, the state of the product attribute in the upstream stage is changed to the downstream stage as the product moves. This is in the point of further defining the relationship passed to.
The manufacturing process operation support method of the present invention is an operation support method for supporting the operation of a manufacturing process in which a continuous product continuously flows, and is defined by a plurality of combinations of stages and product attribute states. A designation step for designating a crisis state in which there is a high risk of occurrence of trouble in the manufacturing process, a method of dividing the stage of the manufacturing process, an attribute and a state of the product for each stage, a state of the product The manufacturing process is divided into a plurality of stages in the flow direction of the product in response to input by the operator regarding the transition path of the attribute state, the equipment for each stage and its state, and the transition path of the equipment state. Create a state transition model for product attributes and a state transition model for equipment at the same time, and between the state of product attributes and the state of equipment within each stage. Based on the discrete model created by defining the impact relationship, the path from the initial state to the critical state is limited to the stage and product attributes specified by the critical state specified in the specifying step. A state transition diagram creating step for creating a state transition diagram representing the state, a state transition diagram representing a route leading to one crisis state created by the state transition diagram creating step, and a route leading to another crisis state When an operation for the manufacturing process is performed in the path leading to the one crisis state based on the state transition diagram to be expressed, the operation has an effect on the path leading to the other crisis state. And a determination step for determining whether or not to give.
The program of the present invention is a program for supporting the operation of a manufacturing process in which a continuous product continuously flows, the method of dividing the stage of the manufacturing process, the attribute of the product for each stage, and its state In response to input by an operator regarding the transition path of the attribute state of the product, the equipment and the state of each stage, and the transition path of the equipment state, the manufacturing process is performed in a plurality of stages in the product flow direction. The product attribute state transition model and the equipment state transition model are created for each stage, and the influence relationship between the product attribute state and the equipment state in each stage is defined. storage means for storing discrete models created, defined by a plurality of combinations of states of the attributes of the stage and product, troubles possibility is high like the manufacturing process The critical state is specified from the initial state to the critical state based on the discrete model and the stage and product attributes specified by the critical state specified by the specific unit based on the discrete model. A state transition diagram creating means for creating a state transition diagram representing a route to the state, a state transition diagram representing a path to one crisis state created by the state transition diagram creating means, and another crisis state When a certain operation for the manufacturing process is performed in the path leading to the one crisis state based on the state transition diagram representing the path to the path, the operation is routed to the other crisis state. The computer is made to function as a determination unit that determines whether or not it has an influence on the computer.

  According to the present invention, it is possible to create a state transition diagram representing a route from the initial state to the crisis state while reducing the amount of calculation, and extract only information related to the crisis state necessary for the operator. The route to the crisis can be presented and the operation of the manufacturing process can be supported.

It is a figure which shows the outline | summary of a continuous casting process. It is a flowchart which shows the procedure of the discrete modeling of a continuous casting process. It is a figure explaining the attribute of the product of each stage. It is a figure explaining a Petri net. It is a figure which shows the state transition model of the attribute of the product in a TD stage, and the state transition model of an installation. It is a figure which shows the state transition model of the temperature and hot_water | molten_metal surface level of the product in a casting_mold | template stage, and the state transition model of the bulging of the product in a vertical area | region stage. It is a figure which shows the state transition model of the flow volume of the product in a nozzle stage, and the state transition model of the hot_water | molten_metal surface level of the product in a casting_mold | template stage. It is a figure which shows the structural example of the operation support apparatus of the continuous casting process suitable for performing the operation support 1. FIG. It is a flowchart which shows the procedure of the operation support 1 by the operation support apparatus. It is a figure which shows the reachable tree created from the state transition model of the TD stage. It is a figure which shows the reachable tree produced from the state transition model of the temperature of a product in a casting_mold | template stage and a hot_water | molten_metal surface level, and the reachable tree created from the state transition model of the bulging of the product in a vertical area | region stage. It is a figure which shows the reachable tree of the casting_mold | template stage and vertical area | region stage corresponding to FIG. It is a figure which shows the state transition model of the temperature and hot_water | molten_metal surface level of the product in a casting_mold | template stage, and the state transition model of the bulging of the product in a vertical area | region stage. It is a figure which shows the reachable tree of the casting_mold | template stage and vertical area | region stage corresponding to FIG. It is a figure which shows the example of a risk matrix. It is a figure which shows the example of a risk matrix. It is a schematic diagram which shows the reachable tree which isolate | separated and produced the state transition model of the attribute of a product, and the state transition model of an installation. It is a schematic diagram which shows a reachable tree when a certain crisis state is designated. It is a schematic diagram which shows a risk matrix when a certain crisis state is designated. It is a schematic diagram which shows the risk matrix about two crisis states. It is a schematic diagram which shows the risk matrix of the reachable tree showing the path | route to one crisis state, and is a figure which shows a mode that "state" changes by operation. It is a figure which shows the relationship between the attribute of the product in the discrete model of a continuous casting process. It is a schematic diagram which shows the risk matrix of the reachable tree showing the path | route to other crisis states. It is a schematic diagram which shows overhead view information. It is a figure for demonstrating whether the path | route to other crisis states is affected when performing the operation for avoiding a certain crisis state in overhead information. It is a figure for demonstrating conversion which reduces the state of the attribute of a product. It is a figure which shows the structural example of the operation support apparatus of the continuous casting process suitable for performing the operation support 2. FIG. It is a figure which shows the example of the screen which an operation support apparatus displays on an output device. It is a figure which shows the example of the screen which an operation support apparatus displays on an output device. It is a figure which shows the bird's-eye view information of case 1. It is a figure which shows the bird's-eye view information of case 2. It is a figure which shows the bird's-eye view information of case 3. It is a figure which shows the bird's-eye view information of case 3.

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.
[Outline of continuous casting process]
In the continuous casting process, as shown in FIG. 1, molten steel made in a converter (not shown) is put into a ladle 100 through secondary refining and is transported to the top of a continuous casting facility. Molten steel is poured from the bottom of the ladle 100 to the lower tundish 200. The molten steel poured into the tundish 200 is poured from the bottom of the tundish 200 into the mold 400 via the nozzle 300. The molten steel that has contacted the mold 400 is cooled while being precisely adjusted and solidified to form a steel slab, which is cut to an appropriate length by a gas cutting machine (not shown) at the end of the roll row while being carried by a roll (not shown). The

[Discrete modeling of continuous casting process]
First, discrete modeling of the continuous casting process as shown in FIG. 1 will be described. In the continuous casting process, a continuous (physically linked) product (molten steel, billet) flows continuously (moves). Discrete modeling of a continuous casting process having the feature of “continuous” in this way is equivalent to extracting the causal relationship recognized in “continuous” and defining it as a discrete model. Therefore, the state of the product is defined for each stage and discretized.

  FIG. 2 shows a procedure for discrete modeling of the continuous casting process. First, the continuous casting process is divided into a plurality of stages in the direction in which the product flows (step S101). In this embodiment, as shown in FIG. 3, the tundish stage (TD stage), the nozzle stage, the mold stage, and the vertical region stage are divided from the upstream side.

  Next, the attribute of the product and its state are defined for each stage (step S102). For example, as shown in FIG. 3, temperature (high / common / low) and viscosity (high / common) are defined as attributes and states of the product in the TD stage. Moreover, the temperature (high / normal / low), the flow rate (appropriate / low), and the flow (rectification / diffusion) are defined as attributes and states of the product in the nozzle stage. In addition, the attributes of the product at the mold stage and its state include temperature (high, ordinary, low), temperature uniformity (uniform / non-uniform), shell thickness (appropriate / thin), shell uniformity (uniform / non-uniform). ), Inclusions (with / without), surface tensile stress (strong / weak), and level (appropriate / low). In addition, as attributes and states of the product in the vertical region stage, temperature (high / normal / low), shell thickness (appropriate / thin), and presence / absence of bulging (presence / absence) are defined. In addition, the attribute of the product mentioned here and its state are examples, and are not limited to this.

  Next, a transition path of the attribute state of the product is defined for each stage (step S103). For example, in each stage, for the temperature of the product, a transition path is defined such that the movement between the high temperature and low temperature always moves after passing through the temperature.

  Next, a state transition model M1 of product attributes is created for each stage (step S104). In the present embodiment, the state transition model M1 of the product attribute is created by a Petri net. A Petri net is a graphical and executable mathematical model that expresses a discrete event system consisting of multiple processes that run in parallel and asynchronously simultaneously. As shown in FIG. 4, a state is described as a place P and a transition as a transition T. By firing T, the token moves from the input-side places P1 and P2 to the output-side place P3, thereby expressing the target behavior. The Petri net is described in detail in Non-Patent Document 1 and the like.

  FIG. 5 shows a state transition model TD-M1 of product attributes at the TD stage. Regarding the temperature, a place where the temperature is high, a place where the temperature is normal, and a place where the temperature is low are connected via transitions T9 to T12. If there is a token in the place where the temperature is low, the transition T11 can be ignited, and when it is ignited, the token moves to a place where the temperature is normal. In addition, when there is a token at a place where the temperature is normal, the transition T9 can be ignited, and when it is ignited, the token moves to a place where the temperature is high. In addition, when there is a token in a place where the temperature is high, the transition T10 can be ignited, and when it is ignited, the token moves to a place where the temperature is normal. In addition, when there is a token in a place where the temperature is normal, the transition T12 can be ignited, and when ignited, the token moves to a place where the temperature is low.

  In addition, with regard to viscosity, a place with high viscosity and a place with high viscosity are connected via transitions T13 and T14. When there is a token in a place with high viscosity, the transition T14 can be ignited, and when ignited, the token moves to a place where the viscosity is normal. In addition, when there is a token in the viscous place, the transition T13 can be ignited, and when ignited, the token moves to a viscous (high) place.

  Here, the state transition model TD-M1 of the product attribute at the TD stage has been described in detail. However, the state transition model NOZ-M1 of the product attribute is also respectively applied to the nozzle stage, the mold stage, and the vertical region stage. MD-M1 and V-M1 are created.

  If the state transition model M1 of the product attribute is created for all stages (step S105), the equipment and its state are defined for each stage (step S106). In this embodiment, a plasma heating device (ON / OFF / failure) and bubbling (ON / OFF / failure) are defined as equipment and its state on the TD stage. In addition, nozzles (stationary (non-clogging), non-stationary, failure (uneven clogging), failure (clogging)), slide (stationary / non-stationary (wide), failure) ) Is defined. In addition, the equipment and conditions at the mold stage include powder feeders (steady / unsteady (separate pattern) / failure), sprinklers (steady / unsteady (strong) / failure), rollers (steady / Non-stationary use (slow withdrawal speed / failure) is defined. In addition, the facilities mentioned here and the state are examples, and are not limited to this.

  Next, a transition path of equipment state is defined for each stage (step S107). For example, in the TD stage, for the plasma heating device (ON / OFF / failure), a transition path is defined such that the plasma heating device (failure) always moves from the plasma heating device (OFF).

  Next, an equipment state transition model M2 is created for each stage (step S108). In the present embodiment, the equipment state transition model M2 is also created by a Petri net.

  FIG. 5 shows a state transition model TD-M2 of the equipment at the TD stage. In the plasma heating apparatus, an ON place, an OFF place, and a failure place are connected via transitions T1 to T3. When there is a token in the OFF place, the transition T1 can be ignited, and when ignited, the token moves to the place of failure. Further, when there is a token in the OFF place, the transition T3 can be fired, and when fired, the token moves to the ON place. In addition, when there is a token in the ON place, the transition T2 can be ignited, and when ignited, the token moves to the OFF place.

  For bubbling, an ON place, an OFF place, and a failure place are connected via transitions T5 to T7. If there is a token in the OFF place, the transition T5 can be ignited, and when ignited, the token moves to the place of failure. Further, when there is a token in the OFF place, the transition T7 can be fired, and when fired, the token moves to the ON place. Further, when there is a token in the ON place, the transition T6 can be fired, and when fired, the token moves to the OFF place.

  Here, the equipment state transition model TD-M2 at the TD stage has been described in detail. However, the equipment state transition models NOZ-M2, MD-M2, and V for the nozzle stage, the mold stage, and the vertical region stage, respectively. -Create M2.

  If the equipment state transition model M2 is created for all stages (step S109), the influence relationship within the stage is defined for each stage (step S110). Table 1 shows the contents defining the influence relationship between the state of the equipment in the TD stage and the state of the attribute of the product. As shown in Table 1, when the plasma heating device is ON, the temperature of the product attribute changes to a normal temperature if the temperature is low, and to a high temperature if the temperature is normal. Defined. Further, when bubbling is ON, it is defined that, among the attributes of the product, the temperature transitions to a normal temperature when the temperature is high and transitions to a low temperature when the temperature is normal.

  Next, the influence relationship between the state of the equipment and the state of the product attribute defined in step S110 is incorporated into the state transition model (the state transition model M1 of the product attribute and the state transition model M2 of the equipment) (step S111). ). As shown in FIG. 5, when there is a token at the ON place in the state transition model of the plasma heating apparatus, the transition T4 is ignited via the conditional arc. As a result, when there is a token at a place where the temperature is low in the temperature state transition model, the transition T11 connected with the transition T4 by the permission synchronization arc is ignited, and the token moves to the place where the temperature is normal. In addition, when there is a token at a place where the temperature is normal, the transition T9 connected to the transition T4 by the permission synchronization arc is ignited, and the token moves to the place where the temperature is high. Further, when there is a token in the ON place in the bubbling state transition model, the transition T8 is ignited via the conditional arc. As a result, when there is a token at a place where the temperature is high in the temperature state transition model, the transition T10 connected with the transition T8 by the permission synchronization arc is ignited, and the token moves to the place where the temperature is normal. In addition, when there is a token in a place where the temperature is normal, the transition T12 connected with the transition T8 by the permission synchronization arc is ignited, and the token moves to the place where the temperature is high. The permitted synchronization arc indicates that the end point transition always fires when the start point transition fires. The conditional arc indicates that the token can be ignited when a token is present at the starting place.

  Here, the state transition model TD-M1 of the attribute of the product in the TD stage and the equipment state transition model TD-M2 are described in detail. However, the nozzle stage, the mold stage, and the vertical region stage are also staged respectively. The influence relationship between the state of the equipment and the state of the product attribute is incorporated into the state transition model (the state transition model M1 of the product attribute and the state transition model M2 of the equipment).

  Further, here, the influence relationship between the state of the equipment in the stage and the state of the product attribute has been described. However, for example, the influence relationship between the product attributes in the stage may be defined. For example, the temperature uniformity affects the shell uniformity in the mold stage (if the temperature is uniform, the shell is uniform, and if the temperature is not uniform, the shell is not uniform), the state transition model (state of the product attribute) It may be incorporated in the transition model M1).

  If the influence relationship within the stage is taken in for all stages (step S112), the influence relationship between the attributes of the product between the stages is defined (step S113). The influence relationship between the attributes of the product between the stages is an effect received from the product existing in another stage at substantially the same time. For example, it is known that when bulging occurs in the vertical region, the molten metal surface vibration is generated in the upstream mold at approximately the same time, affecting the molten metal surface level. Therefore, as indicated by the broken line arrow 31 in FIG. 3, the presence or absence of bulging in the vertical region stage is defined as affecting the level of the molten metal surface in the upstream mold stage. That is, when there is bulging in the vertical region stage, it is defined that the level shifts to low if the molten metal level at the mold stage is appropriate. Further, it is defined that when there is no bulging on the vertical region stage, an appropriate transition is made if the molten metal level at the mold stage is low.

  Next, the influence relationship between the product attributes between the stages (arrow 31 in FIG. 3) defined in step S113 is expressed as a state transition model (the product attribute state transition model M1 and the equipment state transition model M2). (Step S114). FIG. 6 shows part of the state transition model MD-M1 of the product attribute at the mold stage (temperature and hot water level) and one of the state transition model V-M1 of the product attribute at the vertical region stage. Part (bulging). These state transition models M1 are created in step S104. Regarding the temperature at the mold stage, if there is a token in a place where the temperature is low, the transition T301 can be ignited, and when ignited, the token moves to a place where the temperature is high. In addition, when there is a token in a place where the temperature is high, the transition T302 can be ignited, and when ignited, the token moves to a place where the temperature is low. Although it has been described that (high / normal / low) is defined as the temperature state, only the (high / low) state is illustrated in FIG. 6 in order to simplify the description. With respect to the level of the molten metal surface at the mold stage, when there is a token in an appropriate place, the transition T303 can be ignited, and when ignited, the token moves to a place where the token is low. In addition, when there is a token in a low place, the transition T304 can be fired, and when fired, the token moves to an appropriate place. As for bulging in the vertical region stage, when there is a token in a place without bulging, the transition T401 can be fired, and when fired, the token moves to a place with bulging. In addition, when there is a token in a place where there is a token, the transition T402 can be ignited, and when it is ignited, it moves to a place where there is no token.

  As shown in FIG. 6, when there is a token at a place in the state transition model for bulging in the vertical region stage, a transition T501 is ignited via a conditional arc. As a result, when there is a token at an appropriate place in the state transition model at the molten metal level at the mold stage, the transition T303 connected with the transition T501 by the permission synchronization arc is ignited, and the token moves to a place with a low token. Further, when there is a token in a place where there is no bulging state transition model in the vertical region stage, the transition T502 is ignited via a conditional arc. As a result, when there is a token in a low place in the state transition model of the molten metal level at the mold stage, the transition T304 connected to the transition T501 by the permission synchronization arc is ignited, and the token moves to an appropriate place.

  In the present embodiment, the example in which the attribute of the product at the downstream stage affects the attribute of the product at the upstream stage, but the opposite, that is, the product at the upstream stage. Can affect the attributes of the product at the downstream stage.

  Next, a relationship is defined in which the attribute state of the product in the upstream stage is transferred to the downstream stage as the product moves (step S115). As shown by the solid line arrow 32 in FIG. 3, for example, the temperature at the TD stage is defined as being transferred to the temperature at the nozzle stage on the downstream side. That is, if the temperature at the TD stage increases, the temperature at the downstream nozzle stage also increases, and if the temperature at the TD stage becomes normal, the temperature at the downstream nozzle stage also becomes normal, If the temperature at the TD stage decreases, the temperature at the nozzle stage on the downstream side also decreases. Similarly, it is defined that the temperature at the nozzle stage is transferred to the temperature at the mold stage, and the temperature at the mold stage is transferred to the temperature at the vertical region stage.

  Further, it is defined that the flow rate at the nozzle stage is transferred to the molten metal level at the downstream mold stage. That is, if the flow rate at the nozzle stage is appropriate, the level of the molten metal level at the downstream mold stage is also appropriate, and if the flow rate at the nozzle stage is reduced, the molten metal level at the downstream mold stage. Also lower.

  Further, it is defined that the flow at the nozzle stage is transferred to the temperature uniformity at the downstream mold stage. That is, if the flow at the nozzle stage is rectified, the temperature uniformity at the downstream mold stage is also uniform, and if the flow at the nozzle stage is uneven, the temperature is uniform at the downstream mold stage. The characteristics are also uneven.

  Next, the state transition model defines the relationship (arrow 32 in FIG. 3) in which the state of the product attribute at the upstream stage defined in step S115 is transferred to the downstream stage as the product moves. They are incorporated into (attribute state transition model M1 and facility state transition model M2) (step S116). FIG. 7 shows a part (flow rate) of the state transition model NOZ-M1 of the product attribute at the nozzle stage and a part (water surface level) of the state transition model MD-M1 of the product attribute at the mold stage. ). These state transition models M1 are created in step S104. As for the flow rate at the nozzle stage, when there is a token in an appropriate place, the transition T201 can be ignited, and when ignited, the token moves to a place with few tokens. In addition, when there are tokens in a small number of places, the transition T202 can be fired, and when fired, the tokens move to an appropriate place. The hot water level on the mold stage is as described with reference to FIG.

  Then, as shown in FIG. 7, an appropriate place of the state transition model of the flow rate at the nozzle stage and an appropriate place of the state transition model of the molten metal level at the downstream mold stage are transferred via the transition T601. Further, a small number of places in the state transition model of the flow rate at the nozzle stage and a low place in the state transition model at the molten metal level at the downstream mold stage are connected via the transition T602. Hereinafter, the transition defined in step S116 is referred to as a transfer transition. If there is a token at an appropriate place in the state transition model of the flow rate at the nozzle stage, the transfer transition 601 can be ignited, and when ignited, the state transition model at the molten metal level at the mold stage on the downstream side is ignited. The token moves. In addition, when there are tokens in a small number of places in the state transition model of the flow rate at the nozzle stage, the transfer transition 602 can be ignited, and when ignited, the low state transition model at the mold surface level on the downstream side of the mold stage is low. The token moves to the place.

  In addition, when connecting to the downstream stage, the corresponding place is connected via a transfer transition. In the example of FIG. 7, since the hot water level does not connect to the downstream stage, delivery transitions T603 and T604 in which no place is connected to the outlet side are defined.

  The transfer transitions defined in step S116 (the transfer transitions T601 to T604 in the example of FIG. 7) are not ignited alone, and all of them are ignited simultaneously when the state of the product attribute changes in any stage. . For example, in the state shown in FIG. 7 (a token is in an appropriate place in the state transition model of the flow rate at the nozzle stage and a token is in an appropriate place in the state transition model of the mold level at the mold stage) When the flow rate is low (when a token moves to a place with a low flow rate), all transfer transitions fire simultaneously. As a result, the token of the place with a small flow rate moves to a place with a low hot water level due to the firing of the transfer transition T602, and the token of the appropriate place at the hot water level disappears due to the firing of the passing transition T603. Again, when the product attributes change at any stage, all delivery transitions fire simultaneously.

  Further, for example, in the state shown in FIG. 7, if the temperature of the product of any stage changes, all the transfer transitions are ignited simultaneously. As a result, the token of the place with the appropriate flow rate moves to the appropriate place of the hot water level due to the ignition of the transfer transition T601, and the token of the appropriate place of the hot water level disappears due to the ignition of the transfer transition T603. In this arrangement, the flow rate of the nozzle stage and the state of the mold surface level of the mold stage are not affected by the change in temperature and do not change from the previous state.

  The discrete modeling described above can be performed using a computer device that can execute an algorithm of discrete modeling. That is, when an operator inputs through a stage dividing method, a product attribute and its state for each stage, and a transition path of a product attribute state (steps S101 to S103), the computer apparatus automatically performs the stage. A state transition model for each product attribute is created (step S104). Similarly, when the operator inputs the equipment for each stage and its state, and the transition path of the equipment state (steps S106 to S107), the computer apparatus automatically creates the equipment state transition model for each stage (step S106). S108). When the operator inputs an influence relationship within the stage (step S110), the computer apparatus automatically incorporates the influence relationship into the state transition model (step S111). When the operator inputs the influence relationship between the attributes of the product between the stages (step S113), the computer apparatus automatically incorporates the influence relationship into the state transition model (step S114). Further, when the operator inputs a relationship in which the attribute state of the product at the upstream stage is transferred to the downstream stage as the product moves (step S115), the computer device automatically The relationship is incorporated into the state transition model (step S116).

  Although the Petri net has been described in this embodiment, the present invention is not limited to this as long as it models a discrete event system, and the present invention is applied to other graph models such as a directed graph and an undirected graph. Is also possible. For example, in a directed graph, a place in a Petri net model is represented by a point, and a transition is represented by a line with an arrow. A line with an arrow is a moving operation end for moving a product, that is, a token from point to point, and serves as a moving path. The arrow indicates the direction in which the token moves from line to point or from point to line. Even when the present invention is applied to a graph model having such characteristics, a series of operations are the same as the operations in the above-described Petri net model, and detailed description thereof is omitted.

[Operation support 1 using discrete models created by discrete modeling 1]
FIG. 8 is a diagram illustrating a configuration example of an operation support apparatus for a continuous casting process suitable for performing the operation support 1. 1 is a discrete modeling unit, and as described above, the continuous casting process is divided into a plurality of stages in the product flow direction, and a state transition model of product attributes and a state transition model of equipment are created for each stage. Create and store a discrete model created by defining the influence relationship in each stage. In addition, if necessary, the influence relationship between the attributes of the product between the stages (arrow 31 in FIG. 3), which is an influence received from the product existing in another stage at the same time, the above-mentioned relationship in the upstream stage. The state of the attribute of the product defines a relationship (arrow 32 in FIG. 3) that is transferred to the downstream stage as the product moves.

  Reference numeral 2 denotes a reachable tree creation unit, which is a state transition diagram of each stage showing a state reachable from the initial state by setting an initial state for each stage using the discrete model created by the discrete modeling unit 1. Create a reachable tree. Reference numeral 3 denotes an overall reachable tree creation unit, which creates a reachable tree that is a state transition diagram of the entire continuous casting process using the reachable trees of all stages created by the reachable tree creation unit 2.

  4 is a risk matrix creation unit, which uses the reachable tree of the entire continuous casting process created by the overall reachable tree creation unit 3 to represent a risk assessment matrix that represents the relationship between the occurrence accuracy and the risk level (in this application, simply the risk matrix). To create). Reference numeral 5 denotes an input device. For example, the discrete modeling unit 1 inputs and sets various definitions when creating a discrete model, and the initial state when the reachable tree creating unit 2 creates a reachable tree is input and set. To do. An output device 6 corresponds to, for example, a display device that displays a risk matrix created by the risk matrix creation unit 4 on the screen.

  Although illustrated as one device in FIG. 8, for example, discrete modeling is executed by another device, and the operation support device stores a created discrete model. The functional configuration shown in FIG. 8 may be realized.

  FIG. 9 shows a procedure of the operation support 1 by the operation support apparatus. First, a discrete model is created and stored by the above-described discrete modeling (step S201). In the case of this example, the purpose is to present in detail the risks that may occur in the near future, including risks that are unlikely to occur, so we do not consider the risks that will occur in the distant future, that is, with the movement of the product . That is, a discrete model is created in steps S101 to S114 in FIG. 2, and steps S115 and S116 in FIG. 2 are not performed. That is, the state of the attribute of the product in the upstream stage changes with the movement of the product. A discrete model is created without incorporating the relationship (arrow 32 in FIG. 3) passed to the downstream stage.

  Next, using the discrete model created in step S201, an initial state is set for each stage, for example, the current state of each stage, and a reachable tree that can be transitioned (reachable) from the initial state is created (step) S202). As shown in FIG. 10, the reachable tree is configured by connecting “state” (an ellipse describing the state) via “transition (corresponding to the contents of the operation)” (an ellipse with dots). . FIG. 10 shows a reachable tree created from the state transition model of the TD stage (see FIG. 5). Here, the initial state is “low temperature, high viscosity, plasma heating device OFF, bubbling failure”, and the next “state” that can be reached is “low temperature, high viscosity, plasma heating when transition T1 ignites. “Device failure, bubbling failure” or “Temperature normal, high viscosity, plasma heating device ON, bubbling failure” when transition T3 is ignited (accordingly, transitions T4, T11 are also ignited). In this way, the “state” that can be reached next is sequentially obtained to create a reachable tree.

  Although the reachable tree in the TD stage has been described in detail here, the initial state is set for each of the nozzle stage, the mold stage, and the vertical region stage, and a reachable tree is created. FIG. 11 shows a reachable tree created from a state transition model (see FIG. 6) of the product temperature and the molten metal level at the mold stage, and a state transition model (FIG. 11) of the product bulging at the vertical region stage. 6)). In the mold stage, when the initial state is “low temperature, appropriate level of molten metal level”, the “state” that can be reached next is “high temperature, appropriate level of molten metal level” when transition T301 ignites, or transition T303. "Low temperature, low water level" when the fire ignites. In the vertical region stage, when the initial state is “no bulging”, the next “state” that can be reached is “with bulging” when the transition T401 is ignited. In this way, the “state” that can be reached next is sequentially obtained to create a reachable tree.

  In the meantime, the reachable tree of the TD stage in FIG. 10 is a state transition diagram in which the state transitions only in one direction (cannot return to the original state), whereas the mold stage and the vertical region stage in FIG. The reachable tree is a state transition diagram that can be freely returned to the original state. This is a state transition diagram in which the transition state T12 cannot be fired even if the state transitions due to the firing of the transition T11 because the “bubble failure” is the initial state in the TD stage, and the transition is only in one direction. . Thus, the reachable tree differs depending on how the initial state is given.

  Next, a reachable tree (one reachable tree) of the entire continuous casting process is created using the reachable trees of all stages created in step S202 (step S203).

  Here, depending on the stage, there may be a case where the influence relationship (the arrow 31 in FIG. 3) between the attributes of the product is defined between the stages, and a case where it is not defined. First, with reference to FIG. 11, a description will be given of how to create reachable trees for both stages when an influence relationship between product attributes is defined between stages. FIG. 11 uses a reachable tree created from the state transition model of the product temperature and the molten metal level at the mold stage and a reachable tree created from the state transition model of the product bulging at the vertical region stage. This shows how to create reachable trees for both stages.

  As described above with reference to FIG. 6, when there is a token at a certain place in the bulging state transition model in the vertical region stage, the transition T501 is ignited via the conditional arc. As a result, when there is a token at an appropriate place in the state transition model at the molten metal level at the mold stage, the transition T303 connected with the transition T501 by the permission synchronization arc is ignited, and the token moves to a place with a low token. Further, when there is a token in a place where there is no bulging state transition model in the vertical region stage, the transition T502 is ignited via a conditional arc. As a result, when there is a token in a low place in the state transition model of the molten metal level at the mold stage, the transition T304 connected to the transition T501 by the permission synchronization arc is ignited, and the token moves to an appropriate place.

  In this case, as shown in FIG. 11, the “state” of the mold stage and the vertical region stage is regarded as a place, “transition” is regarded as a transition, and transitions T501 and T502 that connect the stages are regarded as transitions T700 to T703. Transition ”and places P701 and P702. Modeling the “switching” where the hot water level transitions from “appropriate” to “low” only when bulging is “present” and the hot water level transitions from “low” to “appropriate” only when bulging is not present Yes. Although it does not exist in this example, the hot water level changes from “low” to “appropriate” only when the bulging is changed from “present” to “other” (for example, “somewhat present”). do not do. In order to make the transition to the “appropriate” level, the bulging state must always transit to “none”. In order to express this, modeling as shown in FIG. 11 is performed. The transition T501 is a transition that always fires when a token exists with bulging, and the transition T502 is a transition that always fires when a token exists without bulging. The place P701 is a place that becomes a condition for firing the transition T700, and the place P702 is a place that becomes a condition for firing the transition T701. The transition T700 is a transition that always fires when a token exists in the place P701, and the transition T701 is a transition that always fires when a token exists in the place P702. Further, when there is a token in the place P701, the transition T702 is ignited via the conditional arc, and as a result, the transition T304 connected to the transition T702 by the permission synchronization arc is ignited. Further, when there is a token in the place P702, the transition T703 is ignited via the condition arc, and as a result, the transition T303 connected to the transition T703 by the permission synchronization arc is ignited.

  Thereby, as shown in FIG. 12, reachable trees of both stages having the initial state “low temperature, appropriate level of molten metal level, no bulging” are created.

  Next, with reference to FIG. 13 and FIG. 14, a description will be given of how to create reachable trees of both stages when the influence relationship between the attributes of the product between the stages is not defined. Here, including the meaning of the comparison, as shown in FIG. 13, it is assumed that the influence relationship between the attributes of the product is not defined between the mold stage and the vertical region stage, and the reachable trees of both stages are defined. The case of creating will be described. In this case, the reachable tree is created with all combinations of the “state” of the mold stage and the “state” of the vertical area stage as “states”, respectively. That is, in the case of the example of FIG. 14, a reachable tree having eight “states” that are all combinations of the four “states” of the mold stage and the two “states” of the vertical region stage is created. Thereby, as shown in FIG. 14, reachable trees of both stages having the initial state “low temperature, appropriate level of molten metal level, no bulging” are created.

  As shown in FIG. 12, when the influence relationship between product attributes is defined between stages, transition is possible among all combinations of “state” of the mold stage and “state” of the vertical area stage. Only “state” will be selected. That is, the combination of “states” is limited, and the number of “states” is reduced as compared with the case where the influence relationship between the attributes of the product between the stages is not defined as shown in FIG.

  According to the above algorithm, the reachable tree of the entire continuous casting process is created using the reachable trees of all stages. This single reachable tree means a set of states in which the products and equipment of the entire continuous casting process can transition from an initial state.

  Next, using the reachable tree of the entire continuous casting process created in step S203, a risk matrix representing the relationship between the occurrence probability and the risk is created (step S204). FIG. 15 shows an example of the risk matrix. In the illustrated example, for simplicity of explanation, an example is shown in which a risk matrix is created using reachable trees of the mold stage and the vertical region stage. Create a matrix.

  The horizontal axis of the risk matrix represents the probability of occurrence, and the vertical axis represents the degree of risk. The “state” of the reachable tree of the entire continuous casting process (the reachable tree of the mold stage and the vertical area stage in the example of FIG. 15) is rearranged. It is a thing. In the horizontal axis direction, an initial state is first positioned, and then a “state” that can be reached from the initial state is positioned. The minimum number of transitions required to reach each “state” from the initial state is defined as the “distance” from the “initial state” to each “state”. The smaller the “distance”, the lower the probability of occurrence. Position to be. Here, the number of executions of transitions from the initial state is defined as “distance”. However, considering the probability of each “transition” being executed (probability of firing), etc., each “state” from the initial state is You may make it prescribe | regulate a distance.

  In the transitions connecting the initial state and each “state” in FIG. 12, transitions other than the transition of the minimum distance are removed, and the “state” is generated with a lower probability of occurrence as the “distance” from the initial state is smaller. To do.

  Further, a risk level is determined in advance for each attribute of the product, and the risk level is determined according to the combination. Here, the “state” of “high temperature, appropriate level of hot water level, no bulging” is the safest state of operation, whereas “state” of “low temperature, low hot water level, with bulging” is It becomes the most dangerous state in operation.

  By displaying and presenting such a risk matrix on the screen, it is possible to present information that is effective in operator decision making, such as estimation of trouble occurrence. In the reachable tree mapped to the risk matrix, “state of high occurrence accuracy and low risk”, “state of low occurrence accuracy and low risk”, etc. are shown, and any “state” Is comprehensively visualized, it is easy to look down on the cause of the trouble. For example, it can be recognized that the “state” located at the lower left of the risk matrix is “a state where the occurrence probability is high and the degree of danger is high”, and that attention should be paid together with the route to that state. In other words, “transition” in which the degree of danger is reduced from the initial state “low temperature, appropriate level of molten metal level, no bulging” means an operation to be performed.

  When the risk matrix is displayed on the screen, for example, the “highest occurrence probability and high risk state” may be displayed prominently. Further, as indicated by a box 1501 in FIG. 15, a route (scenario) to reach a dangerous state may be surrounded and displayed. Or, conversely, a route (scenario) up to a safe state may be surrounded and displayed.

  Although the number of “states” is large as described above, the reachable tree of the entire continuous casting process can be obtained without defining the influence relationship between the attributes of the product between the stages (arrow 31 in FIG. 3). Can be created. That is, based on the discrete model created only in steps S101 to S112 in FIG. 2, a reachable tree for each stage is created, and a reachable tree for the entire continuous casting process is created using them to create a risk matrix. You may make it do. For reference, FIG. 16 shows an example of creating a risk matrix using reachable trees of the mold stage and the vertical region stage when the influence relationship between product attributes between stages is not defined.

  Up to this point, as shown in FIG. 10, it has been explained that a reachable tree is created without dividing a product and equipment, and both the attribute state of the product and the state of the equipment are represented as “state”. However, in order to satisfy the purpose of presenting a route (scenario) to reach a dangerous or safe state, information on the state transition of the product attribute is necessary, and the state of the product attribute is necessary. The state of the equipment is required as “the cause of the state transition of the product attribute”. In a reachable tree, “state” generally has information about the state, “transition” has information about the state transition, and the state of the equipment should be “transition”. That is, it is desirable to calculate a reachable tree using the state transition model M1 of the product attribute, and to set the information held by the “state” in the reachable tree as the state of the product attribute.

  Therefore, the reachable tree is calculated using the state transition model M1 of the product attribute, and the information of the “state” in the reachable tree is set as the product attribute state. Therefore, the state transition model M1 of the product attribute and the state transition model M2 of the equipment are separated at each stage, and the reachable tree of the product attribute for each stage is obtained from the state transition model M1 of the product attribute. create. Next, the reachable trees of each stage are connected to create a reachable tree for the entire continuous casting process. The reachable tree creation method itself is the same as that described in steps S202 and S203 of FIG.

  On the other hand, in the reachable tree of the entire continuous casting process created from the state transition model M1 of the product attribute using the state transition model M2 of the separated facility, the cause of the state transition of the product attribute and the facility Need to be matched. Since it is necessary to give the information to “transition” in the reachable tree of the entire continuous casting process, as shown in FIG. 17, the “transition” of the reachable tree of the entire continuous casting process and the state transition model M2 of the equipment Are connected by a network. Thereby, it becomes possible to give information on the state transition of the attribute of the product from the created reachable tree.

[Operation support 2 using discrete models created by discrete modeling 2]
In the operation support 1 described above, an example in which a reachable tree indicating a state transition that can be reached from the initial state is created by exhaustive calculation and presented as a risk matrix has been described. In practice, however, as the number of product attributes and their states increases, exhaustive calculations not only make the amount of calculations enormous, but are also not necessary for operators and trouble-free stages and productions. Information on the attributes of the object is also included. Therefore, it is desired that only the information necessary for the operator can be extracted and presented while suppressing the calculation amount.

  Therefore, the operation support 2 introduces a recognition of a crisis state that is directly related to a trouble among combinations of product attribute states, that is, defined as a state in which there is a high risk of occurrence of a trouble in the manufacturing process. Then, by creating a state transition diagram that represents the path from the initial state to the crisis state, specifically, a reachable tree that represents the “state” that can transition to the crisis state, it is represented in the crisis state. The route (scenario) leading to the trouble is displayed.

  The crisis state is defined by specifying the state of the stage and product attributes. That is, in order to set one crisis state, it is defined which abnormality is observed in the attribute state of which product at which stage. For example, a combination of a state where the viscosity is high on the TD stage, the temperature is low on the nozzle stage, and the flow rate is low is defined as “nozzle clogging 1”. Also, it is conceivable that the same nozzle clogging may be caused by a combination of different states, and the combination of the state of low temperature on the TD stage, low temperature on the nozzle stage, and drift is defined as “nozzle clogging 2”. Table 2 shows an example of combinations of stages and product attribute states identified for each crisis state. Crisis status can be set by referring to the operation stop criteria in the on-site work manual, or by extracting and setting the combination of steel conditions at the time of trouble that an experienced operator has sensuously, What is necessary is just to extract and set the combination of the steel state at the time of a trouble.

By introducing such a concept of a crisis state, it is possible to limit the stages to be considered when considering a certain crisis state. For example, nozzle clogging 1 and 2 can be limited to two stages, a TD stage and a nozzle stage.
It is also possible to limit the attributes of the products that are considered when considering certain crisis conditions. For example, nozzle clogging 1 can be limited to three attributes: viscosity at the TD stage, temperature at the nozzle stage, and flow rate.
These two features reduce the amount of calculation of the reachable tree, and the path to the crisis state does not include information on the stage and product attributes not related to the trouble represented by the crisis state. The advantage is obtained.

(Presentation of route from initial state to crisis state)
First, consider the path from the initial state to the crisis state. When a certain critical state is designated, as shown in FIG. 18, a reachable tree is created in a form limited to the stage and product attributes specified by the critical state. This indicates what kind of “state” is passed from the current state to the crisis state, and can be said to be a path from the current state to the crisis state. This reachable tree is different from that created by exhaustive calculation as described in the operation support 1, and extracts and presents only the information on the attribute of the product directly related to the crisis state.

  In the reachable tree representing the path to the crisis state created in this way, in order for the operator to know at a glance the likelihood of the state of the attribute of each product and the degree of danger, FIG. As shown in FIG. 6, a risk matrix representing the relationship between the occurrence accuracy and the risk is created in the same manner as described in the operation support 1. In this risk matrix, if a state transition occurs from the current state, that is, in a higher risk direction, it will be closer to the crisis state from the current state, and it is understood that the possibility of the trouble is increasing can do. On the other hand, if a state transition occurs from the current state, that is, in a direction with a lower risk level, it will move away from the crisis state compared to the current state, and the trouble is unlikely to occur and it becomes a safe state. I can understand. Further, it is considered that the number of necessary state transitions increases as it goes to the right from the current state, and it becomes difficult to reach the attribute state of the product.

(Indication of whether the operations performed in the path leading to one crisis will affect the path leading to another crisis)
Next, consider how the operations performed in the path leading to one crisis state will affect the path leading to another crisis state. It is relatively easy to assume a single crisis and take measures to avoid it, but in reality, operations that were performed to avoid a certain crisis in a variety of crisis situations. It is very important to consider whether it triggers another crisis.

  Therefore, as shown in FIG. 20, the risk matrix of the reachable tree representing the path to one crisis state (“nozzle clogging 1” in the illustrated example) and the other crisis states (“breakout 2” in the illustrated example). And a risk matrix of a reachable tree representing a route to “)”.

  Then, regarding the paths leading to these two crisis states, consider the effect that the operation performed to avoid one crisis state has on the route leading to another crisis state. The current situation is that the temperature at the nozzle stage is low and there is a danger of nozzle clogging, so it is considered to perform an operation called plasma heating to increase the temperature. As shown in FIG. 21, due to plasma heating, in the path leading to the critical state “nozzle clogging 1”, nozzle clogging is less likely to occur due to the high temperature at the nozzle stage, that is, farther from the critical state. Transition to a less frequent “state”.

  In this case, based on a discrete model of the continuous casting process, in order to consider how the temperature up to the critical state “breakout 2” will be affected by the temperature at the nozzle stage being increased, Consider the relationship between the state of the product attribute considered in “nozzle clogging 1” and the state of the product attribute considered in “breakout 2”. As shown in FIG. 22, in the discrete model of the continuous casting process, the temperature (high / normal / low) at the nozzle stage and the shell thickness (thickness / normal / thin) at the vertical region stage are respectively defined. It is defined that the temperature at the nozzle stage is transferred to the shell thickness at the downstream vertical region stage as the product moves. In this case, there is a relationship that the temperature at the nozzle stage is high, and the steel flows to the downstream vertical region stage, so that the shell thickness at the vertical region stage is reduced.

  Thus, in the path leading to the crisis state “breakout 2”, the location of the “state” in which the shell thickness in the vertical region stage is reduced due to the influence of plasma heating is considered. FIG. 23 is a schematic diagram showing a risk matrix of a reachable tree representing a route to the crisis state “breakout 2”, and circles the “state” in which the shell thickness in the vertical region stage is reduced. Show. Since the current state is a stable state without an abnormal product attribute state in particular, as shown by a circle in FIG. 23, the current state is closer to a crisis state than the current state due to the influence of plasma heating. It can be seen that the state transitions. Note that there are multiple “states” that are affected by plasma heating because the shell thickness at the vertical region stage is reduced due to the effect of plasma heating, but the attributes of the other two products (hot water at the mold stage). This is because the bulging on the surface level and vertical area stage) is not affected and takes an arbitrary state.

  The operator can grasp how easily the trouble of breakout is likely to occur by the operation of plasma heating by looking at how close the “state” affected by the plasma heating is to the critical state. If the "state" affected by the plasma heating is close to the critical state, nozzle clogging can be avoided by plasma heating, but the possibility of triggering a breakout increases, so the operation should not be easy. . On the other hand, if the "state" affected by the plasma heating remains close to the initial state, which is a stable state, nozzle clogging can be avoided by plasma heating, and the possibility of inducing breakout does not increase. It can be said that the operation is recommended.

  In addition, by comparing the state of the attribute of the product indicated by the “state” affected by the plasma heating, the product to be noted in order not to induce breakout when performing the operation called plasma heating Attributes can be extracted. For example, the “state” that is particularly close to the crisis state includes “low mold level at the mold stage” in common, and the “state” that is relatively far from the crisis state does not include it. . The attribute of the mold level at the mold stage is not directly affected by plasma heating. That is, in the path leading to the crisis state “breakout 2”, the shell thickness at the vertical region stage becomes thin due to the influence of the plasma heating, and the current state shifts to the “state” approaching the crisis state. However, by performing the operation with care so that the level of the molten metal surface on the mold stage does not become low, it is possible to prevent the critical state “breakout 2” from being approached so much even under the influence of plasma heating.

  As described above, depending on the relationship between the attributes of products specified by two crisis states, what kind of route is used to reach another crisis state when an operation is performed as a countermeasure for one crisis state? It is possible to grasp whether a state transition occurs. In addition, by extracting common elements from “states” that may transition, information on the state of product attributes that should be noted in order to prevent other crisis states from being induced when performing operations Can be obtained. By presenting these in an easy-to-understand manner for operators, it is possible to generate operation support information related to the execution of operations.

(Presentation of overhead information)
Next, let us consider a bird's-eye view of the relationship between the current state and the path to multiple crisis states. For example, for a plurality of crisis states 1 to 4, a reachable tree representing a route to each crisis state is created. Then, as shown in FIG. 24, the shortest paths to the crisis state are extracted and listed in each reachable tree. The initial state in this case is a summary of the initial states of the reachable tree for each crisis state. Thereby, it is possible to determine the most likely (short distance) crisis state from the current state. In the example of FIG. 24, it can be said that crisis state 1 is the most likely (short distance) crisis state from the current state.

  Once you have determined the most likely crisis situation from the current situation, consider performing operations to avoid that crisis situation. At that time, as described above, by looking in detail at the relationship between the paths leading to the two crisis states, it is possible to determine the crisis state that is likely to occur under the influence of the operation to be performed, and Judge the quality of the.

  If you select a critical state of interest from each of the listed critical states and decide on an operation that you want to consider to avoid it, you can determine how likely another critical state is likely to occur by that operation. Overlook. Therefore, as described above, by looking at the relationship between the most likely crisis state 1 and the other state variables considered in each of the other crisis states 2 to 4, Among the state transitions in the extracted shortest path, those that may occur under the influence of operations are presented.

  For example, as shown in FIG. 25, it is assumed that an operation for avoiding the crisis state 1 is considered. On the other hand, crisis states 2 and 4 do not include state transitions affected by the operation under consideration, but crisis states 3 include two state transitions affected by the operation under consideration. (State transitions circled in the figure). In the critical state 3, the current state reaches the critical state 3 by four state transitions at the shortest. However, when the operation under consideration is executed, there is a possibility that the critical state 3 is reached by the two state transitions. There will be.

  In this way, the more the state transitions that can occur due to an operation are included in the shortest path to each crisis state, the more easily it is affected by the operation and the more likely it is to fall into that crisis state. Become. That is, by comparing the number of state transitions that may occur due to an operation in the shortest path to each crisis state, it is possible to generate information indicating which crisis state is likely to be induced.

(Granularity of product attribute status)
As described above, the stage attribute and the product attribute to be considered are limited depending on the crisis state, but the granularity of the product attribute state is considered to vary depending on the crisis state. Here, the granularity refers to the states of “very high”, “very low”, etc., rather than having three levels of “high”, “normal”, and “low” when defining the state of the attribute of temperature. In addition, it is assumed that the granularity is finer if it is described as five stages. For example, when considering the state of the attribute of temperature in two crises such as nozzle clogging and breakout, a fine difference in temperature affects the occurrence of troubles in nozzle clogging, but it is necessary to grasp in detail in breakout Absent. That is, the temperature at the nozzle clogging needs to be finer, whereas the temperature at the breakout may be coarser.

  Therefore, the discrete model of the continuous casting process may be described with the most detailed granularity, and when creating a reachable tree up to the critical state, it may be converted to the required granularity according to the critical state. . For example, three levels of “high”, “normal”, and “low” have been explained as the attribute status of temperature in each stage, but it is further divided into “very high” and “very low” states. To do.

  Then, in order to create a reachable tree that represents the path to the crisis state, when extracting the product attribute specified according to the crisis state from the discrete model, the product described in the discrete model is extracted. By reducing the number of attribute states, the granularity set for each crisis state is converted. For example, in the discrete model of the continuous casting process, it is assumed that the temperature state is described in five stages of “very high”, “high”, “normal”, “low”, and “very low”. In this case, when creating a reachable tree representing the path leading to the critical state, the temperature state in the critical state “nozzle clogged 1, 2” is left as it is in five stages, whereas the critical state “break” The temperature state at “Out 1” is reduced to three stages. As shown in FIG. 26, the standard of correspondence between the small granularity and the large granularity is set for each attribute of the product. For example, in FIG. 26, “When tokens are placed in the upper two places with smaller granularity, tokens are placed in the upper places with larger granularity, and tokens are placed in the lower two places with smaller granularity. If there is, set a standard such as “Place token in place under larger granularity”.

(Configuration of operation support equipment for continuous casting process)
So far, the outline of the operation support 2 has been described. FIG. 27 is a diagram illustrating a configuration example of an operation support apparatus for a continuous casting process suitable for performing the operation support 2. 11 is a discrete modeling unit, and as described above, the continuous casting process is divided into a plurality of stages in the product flow direction, and a state transition model of product attributes and a state transition model of equipment are created for each stage. Create and store a discrete model created by defining the influence relationship in each stage. In addition, if necessary, the influence relationship between the attributes of the product between the stages (arrow 31 in FIG. 3), which is an influence received from the product existing in another stage at the same time, the above-mentioned relationship in the upstream stage. The state of the attribute of the product defines a relationship (arrow 32 in FIG. 3) that is transferred to the downstream stage as the product moves.

  Reference numeral 12 denotes a reachable tree creation unit which is a state transition diagram creation unit. Based on the discrete model created by the discrete modeling unit 1, the stage and the product specified by the designated critical state are input by the input device 16. A reachable tree that is a state transition diagram representing a path from the initial state to the crisis state is created as shown in FIG.

  Reference numeral 13 denotes a risk matrix creation unit, which creates a risk matrix representing the relationship between the occurrence probability and the degree of risk, as shown in FIG. 19, using the reachable tree created by the reachable tree creation unit 12.

  Reference numeral 14 denotes a determination unit. As shown in FIGS. 20 to 23, regarding a route to two crisis states, an operation performed to avoid one crisis state is a route to another crisis state. It is judged whether it has an influence on it. The determination unit 14 changes the attribute state of the product included in the path leading to one crisis state after the operation is performed, so that the attribute of the product included in the path leading to another crisis state is determined. It is determined based on a discrete model whether the state of changes. As a result, when the state of the attribute of the product included in the path leading to another critical state changes, it is determined that the operation affects the path leading to another critical state.

  Reference numeral 15 denotes a bird's-eye information creation unit that extracts and lists the shortest paths from the initial state to each crisis state using reachable trees for a plurality of crisis states, as shown in FIG.

  Reference numeral 16 denotes an input device. For example, the discrete modeling unit 11 inputs and sets various definitions when creating a discrete model, or the crisis state and initial state when the reachable tree creating unit 12 creates a reachable tree. Input and set.

  Reference numeral 17 denotes an output device. For example, the reachable tree created by the reachable tree creation unit 12 and the risk matrix created by the risk matrix creation unit 4 are displayed on the screen, the determination result of the determination unit 14 is displayed on the screen, A display device that displays the bird's-eye view information created by the bird's-eye information creation unit 15 on the screen corresponds to this.

  In FIG. 27, although illustrated as one device, for example, discrete modeling is performed by another device, and the operation support device stores a created discrete model. The functional configuration shown in FIG. 27 may be realized.

  FIG. 28 shows an example of a screen displayed on the output device 17 by the operation support device. The screen shown in FIG. 28 is an example of a screen that displays the reachable tree created by the reachable tree creation unit 12 and the risk matrix created by the risk matrix creation unit 13. Reference numeral 2801 denotes a steel status column, which displays the current steel status acquired by the operation support apparatus from a higher-level process computer. In this steel state column 2801, according to the discrete model of the continuous casting process, it is divided into four stages, that is, a TD stage, a nozzle stage, a mold stage, and a vertical region stage. The status is displayed.

  Reference numeral 2802 denotes a crisis state designation field, and the operator inputs and designates the crisis state via the input device 16. For the crisis state designated in the crisis state input field 2802, the reachable tree creation unit 12 creates a reachable tree representing a route from the initial state to the crisis state, and the risk matrix creation unit 13 stores the risk matrix. create.

  Reference numeral 2803 denotes a “state” display portion, which displays the risk level and the contents of each “state” based on the risk matrix for the crisis state designated in the crisis state input field 2802. The risk of “state” is the value on the vertical axis shown in FIG. 19 and is displayed as, for example, risk 0, risk 1,... From the safest side. The content of “state” is the state of the attribute of the product included in “state”. For example, in the case of crisis state “nozzle clogging 2”, “TD temperature low, nozzle temperature normal, nozzle rectification” Is displayed.

  In the uppermost item “initial state”, the risk level and the contents of the initial state are displayed. In the item “1 step” in the second row, the risk level of “state” that can be changed from the initial state and its contents are displayed. In the example of FIG. 19, the three “states” leading to the initial state, that is, the three “states” having the second occurrence probability from the left, the risk levels and the contents thereof are listed. Similarly, the item “2 steps” lists the risk levels and the contents of the four “states” connected to the “state” of the first step. The item “3 steps” (not shown in FIG. 28) lists the risk levels and the contents of the three “states” connected to the “state” of the second step. The item “4 steps” (not shown in FIG. 28) lists the risk levels and contents of the three “states” connected to the “state” at the third step.

  Reference numeral 2804 denotes a reachable tree display field, which displays a reachable tree and a risk matrix for the crisis state designated in the crisis state input field 2802. In this case, the entire reachable tree and the risk matrix may be displayed, or only a part thereof may be displayed. For example, a desired “state” can be selected in the “state” display portion 2803, and the “state” before and after the selected “state” is displayed in the reachable tree display field 2804. It may be.

  FIG. 29 shows an example of a screen displayed on the output device 17 by the operation support device. The screen illustrated in FIG. 29 is an example of a screen that displays the overhead information created by the overhead information creation unit 15. Each item 2901 displays a plurality of crisis states used to create the overhead view information. In the example of FIG. 24, “crisis state 1”, “crisis state 2”, “crisis state 3”, and “crisis state 4” are displayed in each item 2901.

  Each display field 2902 displays the distance from the initial state to the crisis state, that is, the number of state transitions. In the example of FIG. 24, since the number of state transitions from the initial state up to “crisis state 1” is 2, it is displayed as “distance: two state transitions”. In addition, the contents of the state transition are displayed. For example, in the case of “distance: two-state transition”, the state transition from the initial state to the next “state” is a change from the nozzle temperature normal to the nozzle temperature low, and the state from the next “state” to the critical state If the transition is a change from the absence of nozzle drift (rectification) to the presence of nozzle drift, it is displayed as “(nozzle temperature: normal → low), (nozzle: rectification → drift)”.

  In addition, although not shown in the screen of FIG. 29, it is possible to select a crisis state and determine an operation for avoiding it. When a critical state is selected and an operation is determined, the determination unit 14 determines whether or not the operation for the selected critical state has an influence on the route leading to each other critical state. Each display field 2902 displays the distance after the operation and the contents of the state transition. In the example of FIG. 25, when an operation for “crisis state 1” is performed, the state change of 4 times in “crisis state 3” is a state change of 2 times under the influence of the operation. Will come. In this case, as shown in FIG. 29, in the display column 2902 for “crisis state 3”, it is displayed that “distance: 4 state transition” is shortened to “distance: 2 state transition”. Therefore, the operator can know that “crisis state 3” is likely to be triggered when the operation for “crisis state 1” is performed.

  Hereinafter, with reference to FIG. 30 to FIG. 33, the overhead information for four of the crisis states shown in Table 2, “nozzle clogging 1”, “nozzle clogging 2”, “breakout 1”, and “overflow”. Explain the case of creating In the description of FIG. 3, an example of defining the flow rate (appropriate / low) at the nozzle stage and the level (appropriate / low) at the mold (MD) stage is given. It is assumed that the flow rate at the nozzle stage (many / normal / low) and the level of water at the mold stage (high / normal / low) are defined in detail.

  In the discrete model of the continuous casting process, the temperature at the TD stage is transferred to the temperature at the downstream nozzle stage, and similarly, the temperature at the nozzle stage is transferred to the temperature at the mold stage. It is defined that the temperature at the mold stage is transferred to the temperature at the vertical region stage. Further, it is defined that the temperature at the nozzle stage is transferred to the shell thickness at the mold stage on the downstream side. Further, it is defined that the flow rate at the nozzle stage is transferred to the molten metal level at the downstream mold stage.

  In the following description, the state of the attribute of which product at which stage is expressed as “stage + product attribute {state}”.

  Example 1 shown in FIG. 30 assumes a situation in which molten steel having a low temperature is poured from the ladle 100 to the tundish 200, and the current state as the initial state is “TD temperature {low}, “Normal”. Other than normal, TD viscosity {Pun}, nozzle temperature {Pun}, nozzle flow rate {Pun}, nozzle drift {No (rectification)}, MD temperature {Pun}, MD shell thickness {Pun ( Appropriate)}, MD shell uniformity {uniform}, MD hot water level {normal}.

  In this case 1, “nozzle clogging 2” is the most likely (short distance) crisis state from the current state. Even when compared with past trouble cases, there was a case where nozzle clogging occurred when casting was continued without plasma heating in the same state, and consistency with troubles that were likely to occur was confirmed.

  Therefore, plasma heating is examined to avoid “nozzle clogging 2”. When plasma heating is performed, the nozzle temperature changes from {normal} to {high}, and as a result, the MD shell thickness changes from {common} to {thin}, and the MD temperature changes from {common} to {high}. To do. Therefore, it can be understood that state transitions a and b occur in “breakout 1”, and that there are three state transitions, “breakout 1” may be induced in one more state transition.

  In this case, in the critical state “breakout 1”, the “state” close to the critical state includes “MD shell uniformity {non-uniform}”, but the “state” on the relatively far safety side does not include it. Is not included. In other words, by performing the operation with care so that the uniformity of the shell on the mold stage does not become non-uniform, it is possible to keep away from the critical state “breakout 1” even under the influence of plasma heating. Recognize.

  Example 2 shown in FIG. 31 assumes a situation where the nozzle is clogged and the flow rate is low, and the current state, which is the initial state, is “nozzle flow rate {low}, others are normal”. . Other than normal, TD viscosity {Pun}, nozzle temperature {Pun}, TD temperature {Pun}, nozzle drift {No (rectification)}, MD temperature {Pun}, MD shell thickness {Pun ( Appropriate)}, MD shell uniformity {uniform}, MD hot water level {normal}.

  In this case 2, “nozzle clogging 1” is the most likely (short distance) crisis state from the current state.

  Therefore, nozzle pecking is studied to avoid “nozzle clogging 1”. When nozzle pecking is performed, the nozzle flow rate changes from {small} to {common}, and then {many}, and the MD level changes from {normal} to {high} under the influence. Therefore, it can be seen that the state transitions a, b, and c occur in “overflow”, and that there are four state transitions may cause “overflow” in one more state transition.

  In this case, in the crisis state “overflow”, the “state” close to the crisis state includes “nozzle drift {Yes}”, but the “state” on the relatively far safety side does not include it. . That is, it can be seen that by performing the operation with care so that the flow at the nozzle stage does not drift, it is possible not to approach the crisis state “overflow” so much even under the influence of nozzle pecking. Even when compared with past trouble cases, there was a case where overflow occurred when nozzle pecking was performed even though there was a drift in the nozzle stage in the same state, and consistency with troubles that are likely to occur was confirmed.

  Case 3 shown in FIG. 32 and FIG. 33 assumes a situation in which two signs of nozzle clogging and breakout are observed. The current state as the initial state is “nozzle drift (present), MD shell uniformity” {Non-uniformity, others are normal]. Other than normal, TD viscosity {general}, nozzle temperature {general}, nozzle flow rate {general}, TD temperature {general}, MD temperature {general}, MD shell thickness {general (appropriate)} , MD hot water level {normal}.

  Therefore, as shown in FIG. 32, plasma heating is examined to avoid “nozzle clogging 2”. When plasma heating is performed, the nozzle temperature changes from {normal} to {high}, and as a result, the MD temperature changes from {normal} to {high}, and the MD shell thickness changes from {common} to {thin}. To do. Therefore, it can be seen that state transitions a and b occur in “breakout 1”, and “breakout 1” may be induced.

  Further, as shown in FIG. 33, a bubbling for lowering the temperature of the steel in the tundish 200 is examined in order to avoid “breakout 1”. When the bubbling is performed, the TD temperature changes from {normal} to {low}, and the nozzle temperature changes from {normal} to {low} under the influence. Therefore, it can be seen that the state transition a occurs in “nozzle clogging 1”, and that there are three state transitions may cause “nozzle clogging 1” to be induced in one more state transition. In addition, it can be seen that state transitions b and c occur in “nozzle clogging 2”, and “nozzle clogging 2” may be induced.

  When multiple operations are considered in this way, information on state transitions that should be noted when performing each operation separately can be extracted.

  As described above, it is possible to predict the action to be taken for each cause and the phenomenon that will occur as a result, or to predict the phenomenon that will occur if no action is taken. It is possible to support the operation of the continuous casting process, for example, by guiding the actions.

  In the present invention, software (program) for realizing the functions of the present invention is supplied to a system or apparatus via a network or various storage media, and a computer (or CPU, MPU, etc.) of the system or apparatus reads the program. It can also be realized by executing.

  In the above embodiment, the continuous casting process has been described as an example. However, the present invention is applicable to any manufacturing process in which a continuous product flows continuously. For example, hot rolling (a steel plate flows continuously) or petroleum It can also be applied to plants (liquid flows continuously).

11: Discrete modeling unit 12: Reachable tree creation unit 13: Risk matrix creation unit 14: Determination unit 15: Overhead information creation unit 16: Input device 17: Output device

Claims (8)

An operation support device for supporting operation of a manufacturing process in which continuous products continuously flow,
About how to divide the stages of the manufacturing process, the attribute and state of the product for each stage, the transition path of the state of the attribute of the product, the equipment and the state for each stage, and the transition path of the state of the equipment The manufacturing process is divided into a plurality of stages in the product flow direction, and a state transition model of product attributes and a state transition model of equipment are created for each stage. Storage means for storing a discrete model created by defining an influence relationship between the state of the attribute of the product and the state of the facility;
A designation means which is defined by a plurality of combinations of stages and product attribute states, and designates a crisis state which is a state in which there is a high risk of occurrence of trouble in the production process;
Based on the discrete model, a state transition diagram representing the path from the initial state to the critical state is created in a form limited to the stage and product attributes specified by the critical state specified by the specifying means State transition diagram creation means for
Based on the state transition diagram representing the path leading to one crisis state created by the state transition diagram creating means and the state transition diagram representing the path leading to another crisis state, the one crisis state is established. A determination means for determining whether or not the operation has an influence on the path leading to the other crisis state when an operation is performed on the manufacturing process in the path leading to Operation support device for the manufacturing process.   Using a state transition diagram created by the state transition diagram creating means, comprising a risk matrix creating means for creating a risk matrix representing the relationship between the probability of occurrence of each state constituting the state transition diagram and the risk level; The operation support apparatus for a manufacturing process according to claim 1, wherein the operation support apparatus is a manufacturing process. The determination means includes
The state of the attribute of the product included in the path leading to the other crisis state by changing the state of the attribute of the product included in the path leading to the one crisis state after performing the operation Is determined based on the discrete model,
When the state of the attribute of the product included in the path leading to the other critical state changes, it is determined that the operation affects the path leading to the other critical state The operation support apparatus of the manufacturing process according to claim 1 or 2.   Characterized in that it comprises overhead information creation means for extracting and enumerating the shortest paths from the initial state to each of the crisis states in a state transition diagram for a plurality of crisis states created by the state transition diagram creation means. An operation support apparatus for a manufacturing process according to any one of claims 1 to 3.   5. The discrete model further defines an influence relationship between product attributes between stages, which is an effect received from a product existing in another stage at the same time. The operation support apparatus of the manufacturing process of any one of Claims 1.   The discrete model further defines a relationship in which the attribute state of the product in the upstream stage is transferred to the downstream stage as the product moves. 6. An operation support apparatus for a manufacturing process according to any one of 5 above. An operation support method for supporting operation of a manufacturing process in which a continuous product continuously flows,
A designation step that is defined by a plurality of combinations of stage and product attribute states, and that designates a crisis state that is a high risk of occurrence of trouble in the production process;
About how to divide the stages of the manufacturing process, the attribute and state of the product for each stage, the transition path of the state of the attribute of the product, the equipment and the state for each stage, and the transition path of the state of the equipment The manufacturing process is divided into a plurality of stages in the product flow direction, and a state transition model of product attributes and a state transition model of equipment are created for each stage. Based on the discrete model created by defining the influence relationship between the product attribute state and the equipment state, it is limited to the stage and product attribute specified by the crisis state specified in the specifying step. In this way, a state transition diagram creating step for creating a state transition diagram representing a path from the initial state to the crisis state,
Based on the state transition diagram representing the path leading to one crisis state created in the state transition diagram creating step and the state transition diagram representing the path leading to another crisis state, the one crisis state is established. A determination step for determining whether or not the operation affects the route to the other critical state when an operation is performed on the manufacturing process in the route up to A manufacturing process operation support method. A program for supporting the operation of a manufacturing process in which a continuous product flows continuously,
About how to divide the stages of the manufacturing process, the attribute and state of the product for each stage, the transition path of the state of the attribute of the product, the equipment and the state for each stage, and the transition path of the state of the equipment The manufacturing process is divided into a plurality of stages in the product flow direction, and a state transition model of product attributes and a state transition model of equipment are created for each stage. Storage means for storing a discrete model created by defining an influence relationship between the state of the attribute of the product and the state of the facility;
A designation means which is defined by a plurality of combinations of stages and product attribute states, and designates a crisis state which is a state in which there is a high risk of occurrence of trouble in the production process;
Based on the discrete model, a state transition diagram representing the path from the initial state to the critical state is created in a form limited to the stage and product attributes specified by the critical state specified by the specifying means State transition diagram creation means for
Based on the state transition diagram representing the path leading to one crisis state created by the state transition diagram creating means and the state transition diagram representing the path leading to another crisis state, the one crisis state is established. When a certain operation is performed on the manufacturing process in the route up to, the computer functions as a determination unit that determines whether the operation affects the route up to the other crisis state. Program to let you.

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