JP5942395B2 - Product defect information tracking device - Google Patents

Description

  The present invention relates to a product defect information tracking device used in industrial plants such as steel and non-ferrous metals.

  In industrial plants such as steel and non-ferrous metals, various types of plant data are collected and accumulated. When a defect occurs in a product, the accumulated plant data is used to analyze the cause of the defect. .

  There are a great many items that can be collected in plant data. Conventionally, items necessary for analyzing defect factors are selected in advance from plant data, and only the plant data of the selected items is collected and accumulated. For example, when a defect occurs in a product, an item necessary for factor analysis of the defect is further selected from the accumulated plant data, and only the plant data of the selected item is output.

  For example, the following Patent Document 1 proposes that in a steel plant, information when a product passes through the process and information when the product passes through another process are simultaneously displayed on the same display device. Has been.

JP 2000-107992 A

  In conventional apparatuses, including those described in Patent Document 1, the items of plant data collected in the upstream process and the downstream process have to be selected and defined in advance. In addition, when a defect occurs in a product, it is necessary to further select from the accumulated plant data what is expected as the cause of the defect.

  For this reason, knowing about plant operation, process control, and equipment maintenance is required to select data items to be stored and select data items to be output. Depending on the skill of the user, the cause of defects must be analyzed correctly. There was a case that could not be. In addition, if a shortage of data items to be collected / stored is known later, or a defect has occurred due to a complicated phenomenon, it is not possible to realize that the data items to be collected / stored are insufficient. Sometimes happened.

  The present invention has been made to solve the above-described problems, and its purpose is to require know-how related to plant operation, process control, and equipment maintenance when a defect occurs in each process in the plant. It is an object of the present invention to provide a product defect information tracking apparatus that can easily grasp useful information that can be related to the defect.

The product defect information tracking device according to the present invention is provided in each of a plurality of processes of an industrial plant, and includes a tracking device connected to a predetermined communication network together with devices constituting the process . A data collection device that collects plant data of the process in time series, a data storage device that accumulates plant data collected by the data collection device, and that occurred in the process based on the plant data stored in the data storage device Based on the product defect detection device that detects a predetermined defect and outputs the product defect information including the position of the defect in the product of the process in question to the other tracking device and the product defect information input from the other tracking device. The defect position information conversion device that converts the position of the defect generated in another process into the position in the product of the process and the data storage device Create a defect related information extracting apparatus for extracting the relevant information candidate or found defects in the plant data, the display list based on the information regarding defect extracting information regarding defect candidates extracted by the device to display a predetermined display terminal A defect-related information editing device, and the defect-related information extracting device includes plant data of a defect position converted by the defect position information conversion device, plant data in a predetermined range before the position of the defect, and Comparison is made with at least one of plant data in a predetermined range, and plant data in which a predetermined change has occurred in the position of the defect converted by the defect position information conversion device is extracted as a defect-related information candidate .

  With the product defect information tracking device according to the present invention, when a defect occurs in each process in the plant, usefulness that can be related to the defect without requiring know-how regarding plant operation, process control, and facility maintenance It becomes possible to easily grasp such information.

It is a block diagram which shows the product defect information tracking apparatus in Embodiment 1 of this invention.

The present invention will be described in detail with reference to the accompanying drawings . The overlapping description will be simplified or omitted as appropriate.

Embodiment 1 FIG.
FIG. 1 is a block diagram showing a product defect information tracking apparatus according to Embodiment 1 of the present invention.
This product defect information tracking device is applied to an industrial plant provided with a plurality of processes for producing a predetermined product, for example, an industrial plant such as steel and non-ferrous metal.

  One process of the industrial plant is provided with a process computer 1, a process controller 2, a drive means (electric motor / drive device, etc.) 3, a process sensor 4, and an operator operation terminal 5. The tracking device 6 constituting the main part of the present invention is connected to the process computer 1 and the operator operation terminal 5 via a predetermined information LAN 7. The tracking device 6 is connected to the process computer 1, the process controller 2, the drive means 3, and the process sensor 4 via a predetermined control LAN 8.

  Other processes of the industrial plant have the same configuration. That is, in each process of an industrial plant, a product or a semi-finished product for manufacturing the product using a plurality of devices connected to a predetermined communication network (hereinafter, what is manufactured in each process is Manufacturing process). And the tracking apparatus 6 is provided in at least 2 process among the processes which comprise an industrial plant. In this Embodiment, the case where the tracking apparatus 6 is each incorporated in the control system of each process which comprises an industrial plant is shown as an example.

  Below, one process of an industrial plant is demonstrated concretely, and the process is called the said process. Further, a process on the upstream side of the process is referred to as an upstream process, and a process on the downstream side of the process is referred to as a downstream process. For example, a steel plant is provided with a plurality of processes such as a casting line, a hot rolling line, a pickling cold rolling line, a continuous annealing line, and a galvanizing line from the upstream side. If the pickling cold rolling line is the process, the casting line and the hot rolling line correspond to the upstream process, and the continuous annealing line and the galvanizing line correspond to the downstream process.

  The tracking device 6 is for collecting, accumulating and processing plant data covering a number of items from each device constituting the process of the industrial plant (for example, the pickling and cold rolling line in the above example). . The tracking device 6 includes a data collection device 9, a data storage device 10, a product defect detection device 11, a defect position information conversion device 12, a defect related information extraction device 13, a defect related information editing device 14, and a display terminal 15. Yes.

  The data collection device 9 has a function of collecting plant data from each device used in the process. As described above, each device in the process is connected to a predetermined communication network (in this embodiment, the information LAN 7 and the control LAN 8). The data collection device 9 collects all plant data that can be collected via the communication network in time series.

  The information LAN 7 is an information network related to operations and product manufacturing. The data collection device 9 collects information on operations and products from the process computer 1 via the information LAN 7. For example, the data collection device 9 collects, from the process computer 1 via the information LAN 7, product manufacturing instructions, control amount settings for each device, product quality results, and the like as plant data for each event (operation event). The data collection device 9 collects operation histories as plant data from the operator operation terminal 5 via the information LAN 7.

The data collection device 9 collects real-time data as plant data from the process controller 2, the drive unit 3, and the process sensor 4 via the control LAN 8.
The control LAN 8 is a process control network that provides a data area shared between nodes. The high-speed data area of the control LAN 8 enables data transmission with a cycle of 2 [ms], for example. The control output of the process controller 2, the control data of the driving means 3, and the measurement output value of the process sensor 4 are output to the shared data area of the control LAN 8. The data collection device 9 collects all data in the shared data area of the control LAN 8 according to the transmission cycle.

  The data collection device 9 is composed of one or a plurality of units. Since the number and speed of items of plant data to be collected differ depending on the scale of the process, the data collection device 9 has a configuration that matches the installation environment.

The data storage device 10 includes a large-capacity database that stores plant data collected by the data collection device 9. In the data storage device 10, all plant data collected by the data collection device 9, for example, control information of each facility, event information, operation history information, alarm information, operation information such as product manufacturing instructions and product results are stored. In a time series, it is accumulated for a predetermined period. The capacity required for the data storage device 10 is determined by, for example, the number of items of plant data to be stored, the collection cycle, and the storage period. For example, if the process is a pickling and cold rolling line of a steel plant, the period in which the data storage device 10 stores the plant data is required from about three months to six months.
In addition, the data storage device 10 has a function of retrieving and providing stored data in response to a request from another device.

  The product defect detection device 11 has a function of detecting a predetermined defect that has occurred in the process. The product defect detection device 11 detects defects based on the plant data stored in the data storage device 10. The definition of the defect in the process is registered in advance in the tracking device 6. The product defect detection device 11 detects the plant data as a defect when the plant data stored in the data storage device 10 corresponds to the registered definition.

  For example, if the process is a pickling and cold rolling line in a steel plant, the product quality items (plate thickness, plate width, temperature, shape, etc.) may deviate from the target value or nominal value, or the product may be damaged or deformed. Or the like, the product defect detection device 11 detects the defect. For example, when a specific event (coil winding completion or predetermined information input indicating wrinkles or deformation from the operator operation terminal 5) occurs, the product defect detection device 11 extracts the actual data of the manufactured product. And check for defects. When the product defect detection device 11 detects a defect in the inspection, the product defect detection device 11 converts the predetermined product defect information into a defect position information conversion device 12 (of the tracking device 6) in the process and a defect position (of the tracking device 6) in another process. It outputs to the information converter 12.

  The product defect information output by the product defect detection device 11 includes, for example, information for specifying the process, key information (for example, a coil number) for specifying the product in which the defect has occurred, and defect information. Is included. The defect information includes, for example, a data item in which a defect has occurred and a position of the defect in the product in the process (a position in which the defect has occurred). When the process is a pickling and cold rolling line of a steel plant, for example, in the pickling and cold rolling line, the crown value of the coil number 0077 deviates from the allowable value within a range of 50 m to 60 m from the tip. Product defect information to the effect is output from the product defect detection device 11 to each defect position information conversion device 12.

  The defect position information conversion device 12 has a function of converting the position of the defect detected by each product defect detection device 11 into the position of the product in the process.

  Product defect information is input to the defect position information conversion device 12 from the product defect detection device 11 in the process. The product defect information includes the position of the detected defect in the product in the process. For this reason, when product defect information is input from the product defect detection device 11 in the process, it is not necessary to use the position conversion function by the defect position information conversion device 12. In such a case, the defect position information conversion device 12 uses the key information for identifying the product in which the defect has occurred and the defect position information input from the product defect detection device 11 (in the relevant process) as defect related information. Output to the extractor 13.

  The tracking device 6 provided in a process other than the process also has the same configuration as the tracking apparatus 6 of the process. For this reason, the product defect information is also input to the defect position information conversion device 12 from the product defect detection device 11 of the tracking device 6 provided in another process. The product defect information input from the product defect detection device 11 of another process includes the position of the detected defect in the product of that (other) process. For this reason, when the product defect information is input from the product defect detection device 11 in another process, the defect position information conversion device 12 determines the position of the defect generated in that (other) process in the product in the process. Convert to

  For example, consider a case where the process is a hot rolling line of a steel plant and product defect information is input from the tracking device 6 of the pickling / cold rolling line in the downstream process. The product of the hot rolling line (hot coil) is 100m long, and the product becomes a product of 1000m length (cold coil) in the pickling cold rolling line which is the downstream process, and is included in the input product defect information It is assumed that the position of the defect to be detected is 100 m to 200 m from the tip. Further, when the tip in the hot rolling line becomes a product (hot coil), it is arranged at the center of the coil and is finally rewound in the pickling cold rolling line. That is, the tip in the hot rolling line becomes the tail in the pickling cold rolling line. For this reason, the defect position information conversion device 12 calculates the input defect position as 10 m to 20 m from the tail end, that is, 80 m to 90 m from the tip, in the product of the process.

  When the defect position information conversion device 12 converts the position of a defect generated in another process into a position in a product in the process, key information for specifying the product in which the defect has occurred, and information on the position of the converted defect Is output to the defect-related information extracting device 13.

  The defect-related information extracting device 13 is configured so that when a predetermined change occurs in the value of the plant data when the defect portion detected by each product defect detecting device 11 passes through the process, the plant data ( Is extracted as a defect-related information candidate. For example, the defect related information extraction device 13 compares the plant data at the defect position converted by the defect position information conversion device 12 with the plant data in a predetermined range before the defect position. Further, the defect related information extraction device 13 compares the plant data at the defect position converted by the defect position information conversion device 12 with plant data in a predetermined range after the defect position. Only one of the comparisons may be performed, or both may be performed.

  In the comparison, for example, the defect-related information extracting device 13 calculates the maximum value and the minimum value of the plant data at the position of the defect, and the maximum value and the minimum value of the plant data in the preceding and following ranges. Then, the defect-related information extracting device 13 converts the plant data into a defect when the maximum value of the defect position is larger than the maximum value before or after the defect, or when the minimum value of the defect position is smaller than the minimum value before and after the defect. Extract as related information candidates. The defect-related information candidates may be extracted based on a comparison of an average value and a variance value of plant data. Moreover, you may carry out based on these combination.

  The data storage device 10 stores all plant data collected by the data collection device 9. The defect-related information extraction device 13 includes all the data items that can be compared among the plant data stored in the data storage device 10 (that is, all the data items associated with the position in the product of the process). ), It is determined whether or not a value change has occurred. For example, the data storage device 10 also stores material and product identification numbers, time information such as slab extraction completion time, and integrated values of electricity, water and gas consumption for the entire process. Such a data item cannot be associated with a position in the product of the process. For this reason, the defect related information extraction device 13 does not perform the determination for extracting defect related information candidates for these data items.

  The defect-related information extraction device 13 detects the position of the defect converted by the defect position information conversion device 12 from the plant data stored in the data storage device 10 (in the present embodiment, the product defect detection in this process). Those that have undergone a predetermined change (including the positions of defects detected by the apparatus 11) are extracted as defect-related information candidates. When the defect related information extracting device 13 extracts defect related information candidates, the defect related information extracting device 13 outputs the extracted contents to the defect related information editing device 14.

  The defect related information editing device 14 creates a display list based on the defect related information candidates extracted by the defect related information extracting device 13. Then, the defect related information editing device 14 causes the display terminal 15 to display the created display list.

  If the product defect information tracking device having the above configuration is used, if a defect occurs in each process in the plant, it is useful to be able to relate to the defect without requiring know-how related to plant operation, process control, and equipment maintenance. It is possible to easily grasp the information displayed on the display terminal 15.

  That is, in the tracking device 6 having the above configuration, all the plant data that can be collected via the information LAN 7 and the control LAN 8 are stored in the data storage device 10. For this reason, it is not necessary to select data items to be stored in advance, and there is no shortage of stored data items as in the past. In the tracking device 6, the defect-related information extracting device 13 performs a determination for extracting defect-related information candidates for all data items that can be compared. For this reason, it is possible to perform appropriate data extraction without various know-how. Moreover, there is no fear that important data items that may cause defects are excluded due to preconceptions and assumptions of the user.

  By using this product defect information tracking device, it is possible to reduce the time for analyzing the cause of the defect and improving the product. In addition, it is possible to grasp factors that were not noticed before, and it can be expected to improve product quality and operational efficiency.

DESCRIPTION OF SYMBOLS 1 Process computer 2 Process controller 3 Drive means 4 Process sensor 5 Operator operation terminal 6 Tracking apparatus 7 Information LAN
8 Control LAN
DESCRIPTION OF SYMBOLS 9 Data collection device 10 Data storage device 11 Product defect detection device 12 Defect position information conversion device 13 Defect related information extraction device 14 Defect related information editing device 15 Display terminal

Claims (4)

A tracking device provided in each of a plurality of processes of an industrial plant and connected to a predetermined communication network together with devices constituting the process;
With
Each of the tracking devices is
A data collection device for collecting plant data of the process in time series;
A data storage device for storing plant data collected by the data collection device;
A product defect that detects a predetermined defect generated in the process based on the plant data stored in the data storage device and outputs product defect information including the position of the defect in the product in the process to another tracking device A detection device;
Based on product defect information input from another tracking device, a defect position information conversion device that converts the position of a defect generated in another process into a position in the product of the process,
A defect-related information extracting apparatus for extracting the relevant information candidate Recessed in one we deleted the plant data stored in the data storage device,
A defect-related information editing device for creating a display list based on the defect-related information candidates extracted by the defect-related information extracting device and displaying the list on a predetermined display terminal;
Equipped with a,
The defect-related information extraction device includes at least plant data at a defect position converted by the defect position information conversion device, plant data in a predetermined range before the defect position, and plant data in a predetermined range after the defect position. A product defect information tracking device that compares the other and extracts plant data that has undergone a predetermined change in the position of the defect converted by the defect position information conversion device as a defect-related information candidate .   The defect-related information extraction device is configured to obtain a predetermined value at the position of the defect converted by the defect position information conversion device for all plant data associated with the position in the product of the process and stored in the data storage device. The product defect information tracking device according to claim 1, wherein it is determined whether or not a change has occurred.   The defect-related information extraction device is a candidate for defect-related information that has a predetermined change in the position of the defect detected by the product defect detection device among the plant data stored in the data storage device. The product defect information tracking device according to claim 1 to be extracted. The product defect information tracking according to any one of claims 1 to 3 , wherein the data collection device collects all plant data that can be collected from the equipment in the process via the communication network in time series. apparatus.

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