JP6955851B2 - Factory monitoring system, factory monitoring method, and factory monitoring program - Google Patents

Description

The present invention relates to a factory monitoring system, a factory monitoring method, and a factory monitoring program.

As a typical configuration example of a diagnostic service system using a conventional network, there are three systems shown in FIGS. 1A, 1B, and 1C. The system shown in FIG. 1A transmits the operating status of the machines 11, 12, and 13 directly from the machines 11, 12, and 13 to the diagnostic center 20 via the network, and takes into account the status of the machines 11, 12, and 13 for failure diagnosis. I do. Patent documents describing this system include, for example, Patent Documents 1, 2, and 3. In the system shown in FIG. 1B, the management device 30 monitors the operating status of the machines 11, 12, and 13, and the diagnosis center 20 makes a diagnosis in consideration of the log data stored in the management device 30 at the time of an alarm. Patent Document 4 is a patent document that describes this system. The system shown in FIG. 1C has a management device 31 provided with an inquiry system and a diagnostic center 21 provided with an inquiry system. The management device 31 incorporates an inquiry system, and the inquiry system is used when an alarm occurs. The diagnosis center 21 makes a diagnosis by combining the information and the log data accumulated in the management system 31. Patent documents describing this system include, for example, Patent Documents 5 and 6.

Japanese Unexamined Patent Publication No. 10-228311 Japanese Unexamined Patent Publication No. 5-284573 Japanese Unexamined Patent Publication No. 11-119815 Japanese Unexamined Patent Publication No. 10-222220 Japanese Unexamined Patent Publication No. 5-11834 Japanese Unexamined Patent Publication No. 2001-236115

The conventional system is characterized in that when analyzing the details of a failure when an alarm occurs, the details of the failure can be quickly grasped by using actual machine operation data and historical data.
However, in an actual service center, when a plurality of failures occur at the same time, whether or not they can be dealt with promptly depends on the actual operation system in many cases.
Specifically, it is important to know the details of the failure in a short time, deliver it to the customer in the shortest time even if parts need to be replaced, and dispatch a field service person as soon as possible to repair the failure at an early stage. In addition, it is important to have a system that comprehensively provides the items necessary for machine maintenance.

In addition, since these systems are usually operated as security systems for paying members, it is important to improve the satisfaction of members that there are user merits other than failure diagnosis. Therefore, as a user merit other than failure diagnosis, it is important how the failure data and diagnosis data accumulated in the network can be utilized for member users.
As a premise of such a system, a factory monitoring system capable of collecting data on machines of a plurality of manufacturers and storing the data so that it can be effectively used is desired.
Hereinafter, unless otherwise specified, the member user is referred to as a user.

The present invention provides a factory monitoring system, a factory monitoring method, and a factory monitoring method that can centrally and continuously collect data on machines of a manufacturer installed in a factory and store and manage the data so that the data can be effectively used when necessary. The purpose is to provide a factory monitoring program.

The factory monitoring system according to the present invention is a factory monitoring system that is connected to at least one machine and stores data from the machine.
A data acquisition means for acquiring data that can be used for failure diagnosis from the machine after being converted from the communication standard of the machine to the communication standard of the factory monitoring system.
A storage means for storing data converted by communication standards,
It is a factory monitoring system equipped with.

The factory monitoring method according to the present invention is a monitoring method of a factory monitoring system that is connected to at least one machine and stores data from the machine.
Data that is converted from the communication standard of the machine to the communication standard of the factory monitoring system and can be used for failure diagnosis is acquired from the machine.
This is a factory monitoring method that stores data converted from communication standards in a storage means.

The factory monitoring program according to the present invention is connected to at least one machine and is connected to a computer as a factory monitoring system that stores data from the machine.
A process of acquiring data that can be used for failure diagnosis from the machine after being converted from the communication standard of the machine to the communication standard of the factory monitoring system.
This is a factory monitoring program that executes the process of storing the converted data in the storage means.

According to the present invention, data on a manufacturer's machine installed in a factory is centrally continuously collected and stored at predetermined intervals, and the stored data can be stored when necessary regardless of where the factory is located. It is possible to obtain a factory monitoring system, a factory monitoring method, and a factory monitoring program that can store and manage data so that they can be effectively used.

It is a block showing an example of a diagnostic service system including a machine and a diagnostic center. It is a block showing an example of a diagnostic service system including a machine, a management device, and a diagnostic center. This block shows an example of a diagnostic service system including a machine, a management device, a diagnostic center, and an inquiry system. It is a block diagram which shows the structure of one Embodiment of the diagnostic service system which concerns on this invention. It is a block diagram which shows the structure of the service center management apparatus 401. It is a block diagram which shows the structure of the service terminal 700. It is a block diagram which shows the structure of a machine and a factory monitoring system. It is a block diagram which shows the structure of a machine and a factory monitoring system. It is a flowchart which shows the operation of a factory monitoring system. It is explanatory drawing which shows the outline of the machine tool provided with the mechanism which converts a rotary motion into a linear motion. It is a characteristic diagram which shows the relationship between the frequency of use and a stroke. It is a characteristic figure which shows the relationship between a drive current and a stroke. It is a flowchart which shows the control which obtains the distribution of the disturbance load torque of a machine 200. It is a figure which shows the divided stroke. It is a figure which shows the screen of the diagnostic service system menu. It is a figure which shows the authentication screen. It is a figure which shows the selection screen of a diagnostic service system menu. It is a figure which shows the screen and the input example of the manual search system. It is a figure which shows the screen of a failure diagnosis system, the input example, and the diagnosis system information confirmation screen. It is a figure which shows the detail of the diagnostic system information confirmation screen. This is an evaluation information input screen for answers from the diagnostic system. It is a figure which shows the flow of the diagnostic service system when the knowledge diagnostic system is selected. It is a figure which shows the flow of the diagnosis service system when the failure diagnosis system is selected. It is a figure which shows the diagnosis request screen which is displayed to a respondent. It is a figure which shows the screen of the diagnosis request menu. It is a figure which shows the screen of the history search. It is a figure which shows the screen of a keyword search. It is a figure which shows the screen of knowledge search. It is a figure which shows the screen of the sensor information. It is a figure which shows the screen of a part information. It is a figure which shows the screen of the field service person information. It is a figure which shows an example of a machine tool.

First, prior to the description of the embodiment of the present invention, the background leading to the present invention will be described by taking an obstacle in a machine tool arranged in a factory as an example.
There are roughly three patterns of causes for machine tool alarms inquired by users.
(1) When a failure occurs in a specific part of a machine tool, for example, in a machine tool equipped with a mechanism for converting a rotary motion into a linear motion with a ball screw or the like, the ball screw may be worn.
(2) When machining under stricter machining conditions than the machining conditions assumed by the machine tool (when it looks like an obstacle, but it is not an obstacle due to a failure of a specific part of the machine), for example, the rating of the motor In some cases, it is processed in excess of torque.
(3) When the processing tool (for example, a knife, etc.) is worn (when it looks like an obstacle, but it is not an obstacle due to a failure of a specific part of the machine)

Then, the response differs depending on the cause of the alarm occurrence. In particular,
In the case of (1) above, identification of the failed part (selection of the optimum part) and identification of whether the cause of the alarm generation is a control system failure or a manufacturer system failure (so-called category). It is necessary to do.
By identifying these, the optimum parts and the optimum field service personnel can be selected and dispatched.

In the case of (2) above, the alarm can be eliminated by specifying the machining conditions on the user side and reviewing the machining conditions. Therefore, it is not necessary to order machine tool parts and dispatch field service personnel.
In the case of (3) above, the alarm can be resolved by finding a defect in the machining tool on the user side and replacing the machining tool. Therefore, it is not necessary to order machine tool parts and dispatch field service personnel.

In the cases of (2) and (3) above, it is not necessary to dispatch a skilled engineer, and it is preferable to provide an environment in which the user can quickly resolve the error.
Further, in the case of the above (1), that is, when a failure occurs in a specific part of the machine tool, it is possible to arrange the optimum parts and promptly dispatch the optimum field service person.
In this way, when an alarm occurs in a machine machine located in the user's factory, an integrated system that can quickly identify the cause of the alarm and take appropriate measures based on the cause of the alarm (hereinafter referred to as the integrated system). It is important to provide a "diagnostic service system").
For that purpose, a factory that can centrally and continuously collect data on machines of multiple manufacturers installed in the factory at predetermined cycles and store and manage the stored data so that it can be effectively used when needed. Surveillance systems are important.

By providing a factory monitoring system, in the case of a machine tool equipped with a mechanism for converting a rotary motion into a linear motion with the above-mentioned ball screw or the like, it is possible to infer the cause of the alarm generation as follows.
In the case of (1) above, based on the information stored and managed in the factory monitoring system, in the case of wear of the ball screw, the usage stroke status and the load status of the ball screw are clarified from the characteristic diagram of FIG. 6B described later. By comparing this data with, for example, the data when the full stroke is operated in the shipping inspection at the factory, it can be estimated that the ball screw is worn at a specific part.

In the case of (2) above, for example, in the factory monitoring system, when machining exceeds the rated torque of the motor, in all machining, the machining machine and machining program, the motor command speed at the time of machining, It is configured to store motor current and information from various sensors at regular intervals.
By doing so, from the relationship between the command speed at the time of shipment from the factory and the motor current, and the relationship between the command speed at the time of machining and the motor current, the motor current at the time of machining exceeds the rated torque of the motor used. You can grasp the situation. The motor used can be ascertained from the factory records.

In the case of (3) above, for example, in the machine as shown in FIG. 24 described later, in addition to the information of the machine and processing program being processed in the factory monitoring system, the motor command speed at the time of processing, the motor current and various sensors, By equipping a vibration sensor in a place where the status of the machining tool can be detected, the vibration during machining is memorized at regular intervals.
By doing so, the vibration during machining can be compared with the threshold value. More specifically, for example, by comparing the waveform when machining without problems in the past with the current waveform, the wear of the machining tool can be compared with higher accuracy than the threshold value created for the sample with a small N value. Can be inferred.

The present invention has been made based on such a request, and the present invention will be described in detail below based on embodiments.
Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. In the embodiment described below, an example in which a machine such as an injection molding machine, a cutting machine, an electric discharge machine, and a machine tool including a robot or the like is used as the machine will be described.
FIG. 2A is a block diagram showing a configuration of an embodiment of the diagnostic service system according to the present invention. 3 and 4 are block diagrams showing the configurations of machine and factory monitoring systems. FIG. 5 is a flowchart showing the operation of the factory monitoring system. FIG. 6A is an explanatory diagram showing an outline of a machine tool provided with a mechanism for converting a rotary motion into a linear motion. FIG. 6B is a characteristic diagram showing the distribution of the disturbance load torque. FIG. 6C is an explanatory diagram illustrating uneven wear detection of the ball screw. It should be noted that n used in the following description indicates a positive integer of 1 or more unless it is stated that there are a plurality of n. The number of machines, the number of factory monitoring systems, the number of service centers, and the number of service terminals are all indicated by n, but unless otherwise stated in the following explanation, the number of machines and the number of factory monitoring systems are the same. The number, the number of service centers, and the number of service terminals can be set arbitrarily.

<Overall configuration of diagnostic service system 1>
The overall configuration of the diagnostic service system 1 will be described with reference to FIG. 2A. As shown in FIG. 2, the service center management device 401 is connected to one or more factory monitoring systems 100 via a security shared network 300, and is connected to one or more service centers 600 via a network. Each of the one or more factory monitoring systems 100 is connected to the one or more machines via a network. In FIG. 2, the factory monitoring system 100 is composed of a plurality of factory monitoring systems 100-1, 100-2, ..., 100-n, and the factory monitoring system 100-1 is composed of various machines 200-1, 200-2, ... ..., Indicates that it is connected to 200-n.

One or more service terminals 700 are connected to each of the one or more service centers 600 by a network via a service control. In FIG. 2, the service center 600 is composed of a plurality of service centers 600-1, 600-2, ..., 600-n, and a plurality of service terminals 700-1 are connected to each service center 600 via a network via the service control 601. , 700-2, ..., 700-n are connected. The service control 601 may be realized as a function in the service center 600.

When a failure occurs in a machine installed in a factory, the user inputs a questionnaire via the factory monitoring system 100 to diagnose the failure and solve the problem with respect to the service center 600 via the service management device 401. You can ask for a law.
In addition, the service center 600 can be requested to diagnose the failure and solve the problem by transmitting the inquiry mail 104 or the inquiry IP telephone to the service management device 401 via a personal computer, a smartphone, a mobile phone, or the like. can. More specifically, instead of the user inputting the questionnaire, the operator of the service center 600 inputs the questionnaire based on the contents of the declaration acquired via the inquiry mail 104 or the inquiry IP telephone, thereby inputting the questionnaire 600. You can request a failure diagnosis and its solution.

The service center management device 401 is connected to a customer service server 402, a manual server 403, a social network system (SNS) 404, a sales data server 405, a factory data server 406, a field serviceman location information system 407, and a knowledge system 408. NS.
The knowledge system 408 is connected to the fault know-how data 409. Each of the service centers 600 is connected to the parts shipping center 500 and the personnel dispatch center 501. FIG. 2A shows that the service center 600-1 is connected to the parts shipping center 500 and the personnel dispatch center 501.

In this way, the service center management device 401 can manage the parts status and personnel data, and can quickly perform the personnel dispatch plan for parts replacement and repair adjustment after the failure diagnosis is completed.

Each service center 600 can be a globally arranged service center. For example, service center 600-1 is located in Tokyo, service center 600-2 is located in New York, and service center 600-3 is located in Beijing. By doing so, the service center located in the area corresponding to the location of the factory may be prioritized. The failure inquiry (questionnaire) delivered to the service center management device 401 may be delivered to the service terminal of the respondent who has the fewest inquiries on hand by the service control 601.
Further, the respondent specified by the user may be selected by specifying the respondent ID by the user.
FIG. 2A shows that the service center 600-1 is connected to the service control 601 and the service control 601 is connected to the plurality of service terminals 700-1, 700-2, ..., 700-n. The failure inquiry delivered to the service center management device 401 is delivered to the service terminal (for example, service terminal 700-1) of the respondent who has the fewest inquiries on hand.

<Configuration and operation of machine and factory monitoring system>
Each user and the service provider exchange a maintenance contract for the maintenance of each machine in the factory, and this maintenance contract includes, for example, a failure repair contract (contract for abnormalities) that repairs when a failure occurs. In addition to repairing failures, preventive maintenance contracts (normal contracts) that perform preventive maintenance by periodically performing failure diagnosis to predict the occurrence of abnormalities and replacing parts, life parts, and consumable parts that are expected to cause abnormalities. And so on.
In this way, the maintenance contract between each user and the service provider can be made for each factory, and each factory is provided with a factory monitoring system for monitoring each machine in the factory.
Factories may be located globally. Therefore, the factory monitoring system is configured to acquire information from an arbitrary machine and convert the acquired information into a preset common format (referred to as "global format").

Further, as a premise when performing a failure diagnosis in the diagnosis service system 1, it is required to store machine data in the factory monitoring system.
Machine tools are often used in user factories for a long period of time (for example, about 35 years). Since it is premised on any manufacturer as a machine tool, the machine number, manuals related to the machine, maintenance history, operation information operated at the user's factory from the time the machine is shipped from the manufacturer's factory, etc. can be quickly obtained. It is important to be able to obtain it.
Machine tools are used in two cases: continuous production (for example, the same product is continuously produced for 24 hours) and intermittent production. In particular, in the case of intermittent production, when an alarm occurs, it is desirable to know the history of when it was operated last time.

Machine tools do not always apply the same parameters, but often modify and apply the previously applied parameters.
Therefore, it is required to collect and manage information (data) about each machine tool so that the information can be immediately referred to when an alarm occurs. Here, as the information about the machine tool, the following information can be mentioned in addition to the machine information of FIG. 3 described later.

(1) Operating state of the machine (for example, machining program, motor command speed at the time of machining, motor current and information of various sensors) (for example, in the case of an injection molding machine, the number of shots from the start of operation, the injection screw during injection) The maximum current value of the motor that drives the mold, the maximum current value of the motor that drives the mold clamping mechanism during molding, the maximum current value of the motor that drives the ejector shaft, the maximum current value of the motor that rotates and drives the screw, Peak injection pressure, current cycle time of one molding cycle, weighing time, injection time, alarm code, etc.
(2) Transition of operating state (for example, temporal transition of the above operating state),
(3) Failure history (for example, each data such as previously generated alarm contents, occurrence time, repair completion time, failure repair contents, etc.),
(4) Maintenance history (for example, periodic inspection contents and implementation time, replaced consumable parts and life parts, replacement time, etc.),
(5) Production control information (total operating time, total number of strokes (number of slides), etc.).

<Factory monitoring system 100>
Hereinafter, the control device constituting the factory monitoring system of the present embodiment will be described. Hereinafter, unless otherwise specified, the control device constituting the factory monitoring system is simply referred to as a "factory monitoring system".
FIG. 3 is a configuration diagram for realizing the operation of the factory monitoring system 100 by software, and FIG. 4 shows the functions in blocks. Each part shown in FIG. 4 may be composed of software or hardware.
In FIG. 3, the factory monitoring system 101 includes a CPU 1001, a storage unit 1003 that stores software executed by the CPU 1001, and an internal converter 1004 that is connected to the machine 200. Instead of the internal converter 1004, the machine 200 may be connected via the external converter 800.

As shown in FIG. 4, the factory monitoring system 100 communicates with the storage unit 1002, the internal converter 1004, the data acquisition unit 1011, the storage data management unit 1012, the control unit 1013, the service center management device 401, and the security sharing network 300. A communication unit 1014 and a format conversion unit 1015 are provided. Instead of the internal converter 1004, it may be connected to the machine 200 via an external converter 800. The control unit 1013 controls the internal converter 1004, the external converter 800, the data acquisition unit 1011, the storage data management unit 1012, the communication unit 1014, and the format conversion unit 1015.

The factory monitoring system 100 has one or more factory terminals (non-standard) for displaying information such as screen information of FIGS. 7 to 13 described later, which is transmitted from the service center management device 401 via the security sharing network 300. (Shown) is connected.
The factory terminal includes a control unit (not shown) and a display display (not shown) such as a liquid crystal display provided with a touch panel. A key operation screen is displayed on the display and characters can be input, but an input unit such as a keyboard may be provided separately. The control unit displays information such as screen information of FIGS. 7 to 13 transmitted from the service center management device 401 on the display display. The data input by the touch panel (or the input unit such as a keyboard) is transmitted to the service center management device 401. Further, the factory monitoring system 100 receives display screen information in which necessary data is displayed from the service center management device 401.
The service center management device 401 may be provided with a Web server, and the factory terminal may be provided with a Web browser to control the display of the screens of FIGS. 17 to 23.

Although one factory monitoring system 100-1 is shown in FIGS. 3 and 4, each factory monitoring system 100-2, ..., 100-n also has the same configuration. As shown in FIG. 2, each of the factory monitoring systems 100 is provided in each factory, connected to machines via a network, and monitors the machines in the factories. Although only machines 200-1 and 200-2 are shown in FIGS. 3 and 4, the factory monitoring system 100-1 monitors one or more machines 200. The plurality of machines 200-1, 200-2, ..., 200-n are not limited to products of a specific manufacturer, and may include machines of any plurality of manufacturers. Sensors for detecting position, acceleration, current value, temperature, humidity, etc. are attached to each of the plurality of machines 200-1, 200-2, ..., 200-n. FIG. 3 shows a case where one or more sensors 2001-1, 2001-2, ..., 2000-n are attached to the machine 200-1. The information from the sensors 2000-1, 2000-2, ..., 2000-n is read by the control device of the machine 200-1 and transmitted to the factory monitoring system 100-1. The information measured by the sensor is an interface (for example, a cycle of 100 milliseconds or less) set by the factory monitoring system 100 for each machine 200 together with parameter data indicating the operating state of the machine. Obtained via the communication protocol (data structure) described later.

FIG. 6A shows an example of sensor data. In the control system as shown in FIG. 6A, the sensor data may be a disturbance load torque or the like calculated by the control device of the machine 200. For example, as shown in FIG. 6A, in the case of a mechanism in which the machine converts the rotational motion of the motor 3002 into a linear motion with the ball screw 3004 and linearly moves the table 3001 of the work, the movement distribution within the operating limit of the table 3001 is determined. It can be represented by the position signal of the pulse coder 3003 attached to the motor 3002 and the distribution of the disturbance load torque calculated in the control device of the machine 200 (FIG. 6B).

This distribution is sent to the factory monitoring system 100-1 from each of the machines 200-1, 200-2, ..., 200-n in the factory, and by totaling with the factory monitoring system 100-1, the ball screw throat It is possible to detect at which position the load torque is large (Fig. 6C) when it is often used at a position or when it is moved at a constant speed, and it is also possible to detect uneven wear of the ball screw (bias of the ball screw). Wear detection). The detection of uneven wear of the ball screw is performed by the factory monitoring system 100-2, ..., 100-n as well as the factory monitoring system 100-1.

FIG. 6D is a flowchart showing the control for obtaining the distribution of the disturbance load torque of the machine 200. FIG. 6A shows a machine 200 having one axis, but FIG. 6D shows a flow chart of control in the case of the machine 200 having multiple axes. FIG. 6E shows a divided stroke, and the normally divided stroke is a distance between ball screw pitches (for example, several millimeters or more).
As shown in FIG. 6D, the analysis of data from each machine is started at a predetermined cycle. In step S120, the number of axes n of the machine is 1, and the number of divisions m of the stroke of the ball screw is 1 (n = 1, m = 1).
Next, in step S121, it is determined whether or not the n-axis is moving. At the start, n = 1. When the n-axis is moving (Yes in step S121), in step S122, the current position X (n) of the n-axis is larger than the position L (m-1) of the divided stroke, and the divided stroke. It is judged whether or not it is equal to or less than the position L (m) of. If the current position X (n) of the n-axis is larger than the position L (m-1) of the divided stroke and is equal to or less than the position L (m) of the divided stroke, the sample is sampled in a predetermined cycle in step S123. 1 is added to the cumulative number S (n, m) at the m-th stroke division position of the n-axis, and 1 is further added to the stroke division number m of the ball screw in step S124. The cumulative number S (n, m) is reset to 0 at the time of shipment from the factory and when the ball screw is replaced. The cumulative number S (n, m) is counted only while moving, not when stopped.
Then, in step S125, it is determined whether or not the number of divisions m of the stroke of the ball screw with which 1 is added is equal to or greater than the maximum value Mmax of the number of divisions of the stroke of the ball screw. If it is equal to or greater than the maximum value Mmax of the number of stroke divisions (Yes in step S12), the process proceeds to step S127. If the number of divisions of the ball screw stroke m is not equal to or greater than the maximum value Mmax of the number of divisions of the ball screw stroke, the process returns to step S122. Steps S122 to S125 are repeated until the number of divisions of the ball screw stroke m becomes equal to or greater than the maximum value Mmax of the number of divisions of the ball screw stroke.
When it is determined in step S121 that the n-axis is not moving (No in step S121), 1 is added to the number of axes n of the machine in step S126, and the number of axes n of the machine is the maximum axis of the machine in step S127. Determine if it is greater than or equal to a few Nmax. If the number of axes n of the machine is not equal to or greater than the maximum number of axes Nmax of the machine, the process returns to step S121. Steps S121, S126, and S127 are repeated until the number of axes n of the machine becomes equal to or greater than the maximum number of axes Nmax of the machine. If the number of axes n of the machine is equal to or greater than the maximum number of axes Nmax of the machine, the process ends. The positions L (m) of the divided strokes (for example, L (0), ..., L (5) in FIG. 6E), the maximum value Nmax, and the maximum value Mmax are set at the time of shipment from the factory according to the machine use.

The machine information of one or more machines 200-1, 200-2, ..., 200-n is sent to the factory monitoring system 100-1 to the machines 200-1, 200-2, ..., 200-n. Is registered in the factory monitoring system 100-1 for each machine in advance when connecting. Specifically, the factory monitoring system 100-1 registers metadata about each machine for each machine number that identifies each machine. As shown in the machine information of FIG. 3, for example, the metadata includes a machine maker name, a machine model name, a machine serial number, a control device name used, a control device maker serial number, a communication interface, a communication protocol (data structure), and the like. Is. The machine manufacturer name, model name, serial number, etc. are data for identifying the machine. The machine number may be a unique number within each factory. Further, the machine manufacturer name, model name, and serial number may be used as the machine number.
Here, the communication protocol (data structure) is a command system for the factory monitoring system 100 to acquire information measured by a sensor installed in the machine, parameter data indicating the operating state of the machine, alarm data, and the like. Is.

The factory monitoring system 100 includes the data acquisition unit 1011 shown in FIG. 4, and the control unit 1013 specifies a machine number and passes through the data acquisition unit 1011 every predetermined cycle (for example, a cycle of 100 milliseconds or less). ) To get the operating status of the machine. The data acquisition unit 1011 acquires the operating state and the like of the machine based on the communication protocol (data structure) of the machine corresponding to the machine number.
The acquired information such as the operating state of the machine is stored in the storage unit 1002 together with the acquisition time (time stamp).
As described above, each factory monitoring system 100 acquires the data that is the basis of the diagnostic service system.

Multiple machines 200-1, 200-2, ..., 200-n can be connected to machines with different hardware and protocols such as Ethernet (registered trademark), Ether Cat (registered trademark), RS485, RS232C, etc. be. As shown in FIG. 4, the electrical difference is unified to the Ethernet communication standard by using the internal converter 1004 of the factory monitoring system 100-1. Instead of the internal converter 1004, the conversion from RS485, RS232C or the like to Ethernet may be configured so that an external converter 800 such as a commercially available converter is connected to the machine. The same applies to the other factory monitoring systems 100-2, ..., 100-n.

In addition, the operation data, machine history data, operation history data, etc. input from various machines 200-1, 200-2, ..., 200-n are the upper service centers 600-1, 600-2, ... The factory monitoring system has a function (global format) for standardizing data sequences and units so that it can be judged as the same type of data when viewed from 600-n, and is stored in the storage unit 1002 in the global format. do. For this electrical / software conversion, when a machine is connected to the factory monitoring system, machine information such as the manufacturer name and model name in FIG. 3 is registered and used in advance.

Specifically, as shown in FIG. 3, in the storage unit 1002 in the factory monitoring system 100, the software protocols P1, P2, ..., Pn, etc. that communicate with each machine number are described in advance. In this protocol, metadata such as data sequences and units related to temperature, speed, operation data, etc. are stored. The control unit 1001 such as a CPU refers to the protocol stored in the storage unit 1002 by using the software stored in the storage unit 1003, and outputs data from the machines 200-1, 200-2, ..., 200-n. Take it out and replace it with the data structure (global format) used by the entire system. Further, it has a function of adding a time when data communication is performed and sending the data to the storage unit 1002. The storage unit 1002 is installed on a circuit that can be read from other CPUs. Protocols P1, P2, ..., Pn, machine information I1, I2, ..., In stored in the storage unit 1003 correspond to machines 200-1, 200-2, ..., 200-n. ing.

The operation of the factory monitoring system 100 will be described with reference to the block diagram showing the configuration of the machine and the factory monitoring system 100 of FIG. 4 and the flowchart of FIG.

As shown in FIG. 5, the data acquisition unit 1011 of the factory monitoring system 100 sends an instruction (command) to each machine 200 in order to periodically acquire data from each machine 200 in step S110. Each machine 200 sends data according to an instruction (command). As already mentioned, it is possible to connect to machines with different communication protocols (physical layer) such as Ethernet (registered trademark), Ether Cat (registered trademark), RS485, RS232C, etc. As shown in FIG. 4, the electrical difference uses the internal converter 1004 of the factory monitoring system 100, and the inside is unified to the Ethernet electrical standard. Further, for conversion from RS485, RS232C or the like to Ethernet, an external converter 800 such as a commercially available converter can also be used.

In step S111, the internal converter 1004 or the external converter 800 is used to convert the electrical standard, and the data acquisition unit 1011 acquires data from each machine 200. Data acquisition is performed at predetermined intervals (for example, a cycle of 100 milliseconds or less).

When there is data processing as described with reference to FIGS. 6B and 6C (YES in step S112), the data processing is performed in step S113, and in step S114, the format conversion unit 1015 uses the common format (global format). Convert.

If there is no data processing (NO in step S112), the process proceeds to step S114. After that, the data converted into the common format is stored in the storage unit 1002 by the storage data management unit 1012 (step S115). When storing the data, the time information (type stamp) when the data was acquired is also stored. The time information may be the time information at the time of storage.

<Configuration and operation of service center management device 401>
The service center management device 401 is a management device when one or more service centers 600-1, 600-2, ..., 600-n are globally arranged. When one service center is connected, this service center may also serve as a service center management device and execute the same function. FIG. 2B is a block diagram showing the configuration of the service center management device 401.

The service management device 401 includes a first communication unit 4001 that communicates with the factory monitoring system 100 via the security sharing network 300, a second communication unit 4002 that communicates with the service center 600 via the network, and a paid membership system. Controls storage unit 4003 that stores data for configuring the system, customer service server 402, manual server 403, SNS404, sales data server 405, factory data server 406, interface unit 4004 connected to the knowledge system 408, and each unit. It is provided with a control unit 4005.
The control unit 4005 accesses the customer service server 402, the manual server 403, the SNS 404, the sales data server 405, the factory data server 406, or the knowledge system 408 based on the request from the factory monitoring system 100 or the service terminal 700. , Obtain necessary data and send it to the factory monitoring system 100 and the service center 600.

When the function of the control unit 4005 of the service center management device 401 is configured by software, the storage unit such as a hard disk, ROM, etc., which stores the program describing the operation of the control unit 4005 of the service center management device 401, and the data required for the calculation. In a computer composed of a DRAM, a CPU, and a bus connecting each unit, information necessary for calculation can be stored in the DRAM, and the program can be operated by the CPU.

The service center management device 401 is used as a sales data server 405 that stores sales data when an order for a machine 200 is received from a customer (factory) of this system, inspection data, a shipping date, and a shipping date when each machine 200 is manufactured. It is connected to the factory data server 406 that stores factory data such as data of existing parts.
Further, the service center management device 401 is connected to the field serviceman position information system 407, and can track the position of the field serviceman all over the world from the GPS data of the mobile phone or the like possessed by the field serviceman. be.

Further, the service center management device 401 is connected to the knowledge system 408. The knowledge system 408 automatically analyzes the machine status by free text input by the user, accesses the database 409 that records the failure know-how according to the content, and automatically creates the analysis information corresponding to the machine status at the service center. It is transmitted to the management device 401.

Further, the service center management device 401 monitors the communication load status of each service center and automatically distributes the communication load to the service center having a small load. Alternatively, a response request is sent to all service centers 600-1, 600-2, ..., 600-n, and the service center that responds earliest is judged to be the center with the least communication load, and an inquiry is made from a unique customer. It is also possible to perform the failure diagnosis at this service center.
Further, it is also possible to request a connection to a familiar respondent by designating the respondent when the user makes an inquiry to the service center management device 401 by the factory monitoring system, the inquiry mail, or the inquiry IP telephone.
The diagnostic service system 1, which will be described later, can be a membership-based paid service. A membership system that provides the member with the diagnostic service system 1 for a fee can be constructed by providing a storage unit 4003 in the service center management device 401 and recording the number of accesses or the access time of the user. For example, when a user makes an inquiry to the service center management device 401 by the factory monitoring system 100, the inquiry mail 104, or the inquiry IP telephone 105, the number of inquiries or the connection time from the factory monitoring system 100 to the service center management device 401, the inquiry mail 104 The number of inquiries to the service center management device 401, the call time when making an inquiry to the service center management device 401 by the inquiry IP phone 105, etc. are associated with the user ID of the inquiry source and stored in the storage unit 4003 of the service center management device 401. do. A pay-as-you-go system can be constructed by charging a fee according to the number of times and time. The diagnostic service system 1 can also be provided as a fixed fee.

In addition, the service center management device 401 is connected to a social network system (SNS) 404, a manual server 403 that is a system for managing manuals by different manufacturers, and a customer service server 402 that records information about customer service. ing.
The customer service server 402 stores information for which security management is important, such as member information such as a member ID, machine information, maintenance history, and warranty history.

<Diagnostic service system menu>
The service center management device 401 has a function of providing the user with the diagnostic service system menu shown in FIG. 7. To receive the diagnostic service system shown in FIG. 7, first enter the user ID and password on the authentication screen shown in FIG. Here, the user ID is associated with the factory to which the user belongs, and the service center management device 401 can specify the factory by the user ID.
When the user ID and password are entered, the company name (factory name) and its address are displayed. When OK is input by the user, the screen of the diagnostic service system menu shown in FIG. 7 is displayed. When the system number to be used is input on the screen displaying the diagnostic service system menu shown in FIG. 7, one of the screens (submenu) shown in FIG. 9 is displayed. When the required information is input by the user and execution is selected, the selected service is provided, and the program processing for executing the function provided by each service is executed.

The diagnostic service system can be used by users and service center operators (respondents). When the user uses it, for example, he / she uses "3. Knowledge Diagnosis System" to perform knowledge diagnosis by himself / herself. Furthermore, based on the machine number, the operating status of the machine immediately before the failure declaration time (alarm occurrence time) of the machine, the operating status (usage) of the machine, the maintenance history of the machine, etc. 4. Acquire by "Maintenance history search", "5. Periodic maintenance history", etc., and use your own knowledge to perform failure diagnosis.
Next, the main submenus provided by the diagnostic service system menu will be described.

<Manual search system>
When "1. Manual search system" is selected, the machine number and the keyword to be searched are input to the screen of the manual search system of FIG. 9, and are stored in advance as shown in FIG. 3 based on the input information. Based on the machine information such as the maker name and the model name, the contents that hit the keyword are searched from the maker manual of the specified machine recorded in the manual server 403 and displayed in a list. The user can select the necessary items from the list display and achieve the purpose.

More specifically, when "20" is entered as the machine number and "override" is entered as the keyword to be searched on the screen of the manual search system displayed as shown in FIG. 10, the machine number is changed to "20". Based on this, the machine manufacturer and model name are specified, and the manual suitable for this model is selected from the manual server 403. Next, the selected manual is searched based on the keyword "override", and the hit pages are displayed from the beginning. Select "Next Keyword" to display the next hit page. The page is scrolled with "↑" and "↓", and when the information you want to know is obtained from the manual you want to know, press the end key to return to the diagnostic service system menu shown in FIG.

<Failure diagnosis system>
"2. Failure diagnosis system" is selected when, for example, when an alarm of the machine 200 occurs, the user requests a reply from the respondent (operator of the service center).
In "2. Failure diagnosis system", the user inputs the machine number and the situation on a predetermined questionnaire as shown in FIG. For example, as shown in FIG. 11, on the screen of the failure diagnosis system (screen of a predetermined questionnaire) of FIG. 9, "20" is input as the machine number, and "tool wear is fast, the cutting edge is chipped" as the status input. Is input (fault report), and a respondent who can answer more easily by the service control 601 via the service center management device 401 and the service center 600 is selected. Specifically, by referring to the table that manages the work status of the operator of the service center, the respondents (candidates) who can answer more easily are selected. The user can specify the respondent ID on the input screen. In that case, the respondent specified by the user is selected.
When the user specifies the respondent ID, it is delivered to the corresponding service terminal. If there is no designated respondent, the reason is notified to the user and delivered to the other respondents who can answer the earliest. If it takes time for the specified respondent to reply, the user is notified to that effect.

When the user uses the failure diagnosis system of FIG. 9, the operation data of the target machine at that time, which is necessary for the failure diagnosis, can be transmitted to the service center management device 401. Whether to select automatic or manual transmission can be selected at the time of membership contract. If automatic transmission is not selected, the user can manually send according to the respondent's instructions.

In addition to this, there is a route via e-mail or inquiry IP telephone as a failure report route from the user. In the case of receiving an email, the counter (operator) creates a questionnaire based on the content of the received email, and in the case of receiving an IP phone, the counter (operator) asks the user while listening to the user's story via the IP phone. Create a vote.

By making an inquiry based on the machine number sent to the respondent, the respondent can grasp the operating status of the machine corresponding to the machine number in the factory and the status at the time of sale. In addition, the analysis of the failure content is started from the sent message. Respondents operate the service terminal 700 to perform failure diagnosis. The operation of the service terminal 700 for performing the failure diagnosis will be described later.
If the respondent determines that it is necessary to replace the parts and dispatch a field engineer to replace the parts as a result of the failure diagnosis, the service terminal inquires at the service center, and the parts delivery date and the arrangement and arrival of the field service person are made. The answer such as time can be notified to the questioner (user).

The questioner (user) can confirm the answer from the respondent by selecting "9. Confirmation of diagnostic system information" from the diagnostic service system menu of FIG.
Specifically, the questioner (user) selects the execution key on the screen for confirming the diagnostic system information shown in FIG. 11 and confirms the answer from the respondent.
When confirming the answer message from the respondent, the questioner (user) selects the confirmation key. As shown in FIG. 12, the response message from the respondent includes diagnostic information, parts, and information such as dispatch of field service personnel. When the questioner (user) accepts the dispatch of the field serviceman, the field serviceman is arranged by selecting the arrangement key.
If the user selects the arrangement key and agrees with the service center's proposal, the parts and field service personnel will be dispatched immediately.
When the field serviceman arrives at the site, he begins work. The interaction between the operator and the user in this practice is registered in the customer service server 402 in chronological order. The field serviceman can also diagnose the status of another machine of the visiting user. The record at that time is also recorded in the customer service server 402.
As described above, by using this failure diagnosis system, the user can use the shortest and most accurate failure diagnosis and quickly repair the failure part.

<Knowledge diagnostic system>
"3. Knowledge diagnosis system" provides the function of the knowledge diagnosis system to the user. By doing so, the user can diagnose the cause of the alarm by himself / herself without requesting a reply from the respondent (service center operator).
When the machine number and the situation are input by the user through the screen of "3. Knowledge diagnosis system" shown in FIG. 9, the knowledge system 408 automatically analyzes the situation by free text and knows the failure according to the contents. The database 409 in which the above is recorded is accessed, and the content of the automatic response is answered via the service center management device 401. As a result of the answer, if the cause of the failure is machining conditions, wear of the machining tool, etc., it is not necessary to order machine tool parts or dispatch a field service person, but in other cases, "2. Failure" in Fig. 9 Select the "Diagnostic System" screen, and if it is necessary to order parts or dispatch a field serviceman as a result of failure diagnosis, secure the above-mentioned parts and field serviceman. In addition, by saving the answers of the knowledge system, it is possible to create user-specific failure diagnosis guidance.
The "3. Knowledge Diagnosis System" is basically a self-service diagnostic investigation by the user, and does not request the service center 600 to perform a failure diagnosis. The knowledge diagnostic system can prioritize and respond to diagnostic results.

<Maintenance history search>
By selecting "4. Maintenance history search" by the user and inputting the machine number on the "Maintenance history search" screen shown in FIG. 9, the service center management device 401 is maintained on the customer service server 402. Refer to the history. With this function, the user can automatically manage a specific machine failure log, a parts delivery log, and a field service worker dispatch log of a factory without having to manage them in-house. In addition, by accumulating and referring to machine failure logs, it is possible to build a unique knowledge system.

<Sales of maintenance parts>
When the user selects "5. Can be purchased from the Parts Shipping Center 500. Users can easily purchase maintenance parts required for machines without error, even if they own equipment from different manufacturers.

<Introduction of maintenance tools>
By selecting "6. Introduction of maintenance tools" by the user and entering the machine number on the "Introduction of maintenance tools" screen shown in FIG. 9, the user can purchase the maintenance tools required for the machine. .. In addition, by using a social network, it is possible to refer to tools that are effective for maintenance.

<Regular maintenance history>
The user selects "7. Periodic maintenance history", and by inputting the machine number on the "Periodic maintenance history" screen shown in FIG. 9, the past of each machine manufacturer recorded in the factory data server 406 is recorded. You can refer to the time when the regular maintenance was performed and the contents of the maintenance. In this way, the periodic maintenance history is managed collectively, so even if machines from different manufacturers and different maintenance concepts coexist, users can use it with peace of mind without being aware of the differences between manufacturers. can.

<Others>
By selecting "8. E-mail (SNS)" by the user and selecting either sending an e-mail or confirming the e-mail via the "E-mail" screen shown in FIG. 9, the user himself / herself. It is possible to send an e-mail directly to the service center management device 401 from the PC, smartphone, or this system, or to receive an e-mail from the service center management device 401. As a result, the user can manage the mail sent from his / her PC, smartphone, and this system to the service center management.
In addition to email, it provides social network (SNS) functions. By doing so, it is possible to exchange business information and technical information between members managed by security.

<Diagnostic service system information>
When "9. Diagnostic system information" is selected by the user and the execution of the "Diagnostic system information confirmation" screen shown in FIG. 9 is selected, the diagnostic service system information notified to the user from the diagnostic service system side is confirmed. can do. The diagnostic service system information includes, for example, important failure information (including bug information), recall information, diagnostic service system version upgrade information, and the like.
For example, when a critical failure that requires a recall occurs in the diagnostic service system itself, the service center or the service center management can send the recall information. As a result, the user can quickly refer to the recall information to be transmitted. In addition, it is possible to confirm notifications such as version upgrades of the diagnostic service system. As a method of notifying the diagnostic service system information, it is also possible to send an e-mail to a user's mobile phone (or smartphone or the like) registered in advance by a push method according to the urgency of the diagnostic service system information.

<Evaluation of answers>
FIG. 13 is an “evaluation information input screen” for inputting a user's evaluation for a response from the diagnostic service system. In this way, it is possible to raise the level of the respondents and carry out additional learning of the knowledge system based on the input information from the user.
The diagnostic service system menu has been described above.

<Processing flow related to "2. Failure diagnosis system" and "3. Knowledge diagnosis system">
Next, the processing flow of the diagnosis service system when the user selects "2. Failure diagnosis system" and when the user selects "3. Knowledge diagnosis system" will be described with reference to FIGS. 14 and 15.

[When the user selects "3. Knowledge Diagnostic System"]
As shown in FIG. 14, when a machine tool alarm occurs in step S210, the user selects “3. Knowledge diagnosis system” in step S211 in the factory monitoring system 100-1.
When "3. Knowledge diagnosis system" is selected in the service center management device 401, the knowledge system 408 starts diagnosis based on the input from the user in step S212. At step 213, the knowledge system 408 sends the diagnosis result to the user when the diagnosis is completed. In step S214, the user acquires the diagnosis result by the knowledge diagnosis system.

[When the user selects "2. Failure diagnosis system"]
As shown in FIG. 15, when the machine tool alarm is generated in step S310, the failure diagnosis system is selected by the user in step S311, and when the questionnaire is input, the optimum service center is selected in step S312. The service terminal to which the most suitable respondent belongs is selected by the service center selected in step S313. The respondent of the service terminal selected in step S314 makes a diagnosis using, for example, "3. Knowledge diagnosis system", sends the diagnosis result to the factory monitoring system 100-1 in step S315, and the factory monitoring system 100-1 Receive the diagnosis result in step 316.

<Configuration and operation of service terminal 700>
Next, regarding the configuration of the service terminal 700 and the terminal operation when the respondent who diagnoses the failure diagnoses the failure of the machine when the failure report is received from the user, including the operator on the service center side. This will be further described with reference to FIGS. 16 to 24.

FIG. 2C is a block diagram showing the configuration of the service terminal 700. The service terminal 700 displays the communication unit 7001 that communicates with the service control 601 via the network, the screen information of FIGS. 17 to 23 transmitted from the service control 601 and the like, and displays 7002 such as a liquid crystal display provided with a touch panel. And a control unit 7003 that controls the communication unit 7001 and the display display 7002. A key operation screen is displayed on the display 7002 and characters can be input, but an input unit such as a keyboard may be provided separately. The control unit displays the failure diagnosis request (inquiry content) screen shown in FIG. 16 on the display display 7002, which is distributed from the service center management device 401, and is distributed from the service center management device 401 by operating the touch panel or the input unit. The screen information of FIGS. 17 to 23 is displayed on the display display 7002. The data input via the touch panel or the input unit is transmitted to the service center management device 401 via the service control 601 and the service center 600. Further, the service terminal 700 receives necessary data from the service center management device 401 via the service center 600 and the service center 600.
The service center management device 401 (or service center) may be provided with a Web server, and the service terminal 700 may be provided with a Web browser to control the display of the screens of FIGS. 17 to 23.

When the function of the control unit of the service terminal 700 is configured by software, a storage unit such as a hard disk or ROM that stores a program describing the operation of the control unit of the service terminal 700, a DRAM or a CPU that stores data required for calculation. , And in a computer configured by a bus connecting each part, it can be realized by storing the information necessary for the calculation in the DRAM and operating the program on the CPU.

As shown in FIG. 16, the service terminal 700 provides a function of displaying a list of failure diagnosis requests (inquiry contents) delivered from the service control 601 to the respondent. Respondents can select an unanswered failure diagnosis request (inquiry content) by selecting the selection key.
Respondents can also search for failure diagnosis requests (inquiry details) that have been processed in the past by selecting the processed search key.
When the respondent selects a failure diagnosis request from a certain user from the failure diagnosis request (inquiry content) displayed in a list, the failure diagnosis request screen from the user is displayed as shown in FIG.
When the "diagnosis start" button is selected by the respondent, the "diagnosis request menu" screen shown in FIG. 17 is displayed, the function to be used for diagnosis is selected, and the execution key is selected. On the screen of the diagnosis request menu shown in FIG. 17, history search, keyword search, knowledge search, sensor information, component information, and field serviceman information are selected as functions used for diagnosis. By doing so, the respondent can use these functions to perform a failure diagnosis. Respondents can also use the "diagnosis service system menu" shown in FIG.

As shown in FIG. 18, the service terminal 700 provides a function of searching the history of failure diagnosis requests received so far. As shown in FIG. 18, on the "diagnosis request (history search)" screen, the user's company name and machine number can be referred to, and a list of past inquiry history related to the machine can be generated from the customer service server 402 or the like. .. Here, the past failure display is set to one year, but the number of years of the past failure display can be arbitrarily selected.

As shown in FIG. 19, the service terminal 700 provides a keyword search function. As shown in FIG. 19, based on the keyword (tool wear) input by the respondent, the past cases are searched from the customer service server 402 and the like, and a list of cases that hit the keyword (tool wear) is displayed. indicate. Respondents can select a search range such as machine manufacturer and machine model. By doing so, a list of cases that hit the keyword (tool wear) is displayed, and the respondent can inquire the details of the selected case by entering the number to be referred to and selecting the selection key. It will be possible.

As shown in FIG. 20, the service terminal 700 provides a knowledge search function. As shown in FIG. 20, the knowledge search shows the knowledge search screen, the inquiry content is automatically decomposed into keywords, and the search keyword is created.
Keyword creation
1) The same character string as the index described in the machine manual 2) Consecutive Chinese characters 3) Consecutive numbers, etc. In this case, "tool wear", "cutting edge", etc. are the keywords. Cases are resolved and only those that are answered are selected. This is to support automatic response later. The knowledge search can be performed using the knowledge system 408.

As shown in FIG. 21, the service terminal 700 provides an inquiry function for sensor information arranged in the machine. FIG. 21 is an example of a screen in which sensor information that can be used as a reference for an inquiry keyword is extracted from the factory monitoring system 100 and displayed. In addition, in order to compare with the factory shipment data and the basic specifications of the machine, the display period indicating when to display the sensor information can be selected on this screen.
The machine referred to in FIG. 21 is shipped with a sensor attached to a spindle as shown in FIG. 24, for example. FIG. 24 is an explanatory view showing a machine tool in which a sensor is attached to a spindle portion. In FIG. 24, a vibration sensor 4002 is attached to the spindle mechanism 4001 to measure acceleration and amplitude. The tool (cutting tool) 4004 is attached to the spindle mechanism 4001 via the tool clamper 4003. The work 4005 is machined by the tool (cutting tool) 4004.

As shown in FIG. 22, the service terminal 700 provides a component search function. FIG. 22 is an example of a screen showing the component search result. In the search for parts, the customer service server 402 is referred to, the repair parts are searched from the repair record data so far, and the shipability of the parts is determined from the factory database 406.

As shown in FIG. 23, the service terminal 700 provides a search function for a field service person who can travel. FIG. 23 shows a screen showing a list of field servicemen who can travel, and displays a list of field servicemen who can be dispatched by field servicemen who have experience of spindle exchange from the field serviceman database of the service center 600.

By doing so, if the respondent determines that it is necessary to replace the parts and dispatch a field engineer to replace the parts as a result of the failure diagnosis, the parts from the service terminal to the parts shipping center 500 and the parts from the factory data 406 From the dispatch center 501 and the field serviceman location information system 407, the field serviceman suitable for the fault category that can be reached earliest is identified, and the user is informed as described above. , It is possible to notify the questioner (user) of the answer such as the parts delivery date, the arrangement of the field service person, and the arrival time.
If the failure report route from the questioner (user) is an email or an inquiry IP phone, the respondent can notify the questioner (user) by email or IP phone.

Although the diagnostic service system 1 including the factory monitoring system 100 has been described above, all or part of the factory monitoring system 100 can be realized by hardware, software, or a combination thereof. Here, what is realized by software means that it is realized by a computer reading and executing a program. When configured with hardware, a part or all of the factory monitoring system shown in the block diagram of FIG. 4 may be, for example, an LSI (Large Scale Integrated circuit), an ASIC (Application Specific Integrated Circuit), a gate array, or an FPGA (Field Programmable). It can be configured by an integrated circuit (IC) such as Gate Array).

When all or part of the factory monitoring system 100 is configured by software, a hard disk or ROM storing a program describing all or part of the operation of the factory monitoring system shown in the block diagram of FIG. 4 and the flowchart of FIG. In a computer composed of a storage unit such as a storage unit, a DRAM that stores data required for calculation, a CPU, and a bus that connects each unit, information necessary for calculation is stored in the DRAM, and the program is operated by the CPU. It can be realized.

Programs can be stored and supplied to a computer using various types of computer readable medium. Computer-readable media include various types of tangible storage media. Examples of computer-readable media include magnetic recording media (eg, flexible disks, magnetic tapes, hard disk drives), magneto-optical recording media (eg, magneto-optical disks), CD-ROMs (Read Only Memory), CD-Rs, CD-. It includes R / W and semiconductor memory (for example, mask ROM, PROM (Programmable ROM), EPROM (Erasable PROM), flash ROM, RAM (random access memory)).

The effect of the factory monitoring system 100 of the present embodiment described above will be described.
The machine information stored in the storage unit 1002 of the factory monitoring system 100 includes differences between manufacturers. By doing so, it becomes possible to centrally search machine information regardless of the manufacturer.
The factory monitoring system 100 absorbs the unique sensor information shown in FIG. 3 and the difference in the protocol due to the difference in the machine shown in FIG. 3 by converting it with an internal converter or an external converter. By doing so, the internal processing of the factory monitoring system 100 can be centrally processed by a standard protocol, and an efficient system can be constructed.
In the factory monitoring system 100, even if the machines are manufactured by different manufacturers, the format conversion unit 1015 shown in FIG. 4 converts the communication specifications and protocol usage into global data. By doing so, it becomes possible to evaluate all machines equally regardless of the manufacturer. In addition, the data conversion work by the user becomes unnecessary, and efficient evaluation management becomes possible.
The factory monitoring system 100 periodically transmits an instruction for data acquisition to the machine, and stores the machine operation data, operation history data, and the like in the storage unit. By doing so, it is possible to quickly acquire operation information, etc. of operating the machine in the factory. For example, when an alarm occurs when the machine is performing intermittent production, when the last operation was performed It becomes possible to know the achievements accurately.
The factory monitoring system 100 collects and manages data such as parameters applied to the machine. By doing so, it becomes possible to quickly and accurately know information such as parameters when an alarm occurs.

100-1, 100-2, ..., 100-n Factory monitoring system 104 Inquiry mail 105 Inquiry IP phone 200-1, 200-2, ..., 200-n Machine 300 Security shared network 401 Service center management device 402 Customer service server 403 Manual server 404 SNS
405 Sales Data Server 406 Factory Data Server 407 Field Serviceman Location Information System 408 Knowledge System 409 Failure Know-how Database 500 Parts Shipping Center 501 Personnel Dispatch Center 600-1, 600-2, ..., 600-n Service Center 601 Service Control 700-1, 700-2, ..., 700-n service terminal

Claims (9)

A factory monitoring system that is connected to at least one machine tool and stores data from that machine tool.
A data acquisition means for acquiring data that is converted from the communication standard of the machine tool to the communication standard of the factory monitoring system and can be used for failure diagnosis from the machine tool.
And data converted into the communication standard of the plant monitoring system, storage means for storing the communications software protocol corresponding to the machine tool,
The data stored in the storage means, and format conversion unit for converting a format data sequence or units are normalized,
A control unit that acquires the data by the data acquisition means and converts the data into the format by the format conversion unit with reference to the protocol stored in the storage means.
Factory monitoring system equipped with. The factory monitoring system according to claim 1, wherein the machine tool includes an injection molding machine, a cutting machine, an electric discharge machine, or a robot. The factory monitoring system according to claim 1 or 2, further comprising a conversion means for converting a communication standard between the communication standard of the machine tool and the communication standard of the factory monitoring system. The factory according to claim 1 or 2, which is connected to the machine tool via an externally provided conversion means for converting the communication standard between the communication standard of the machine tool and the communication standard of the factory monitoring system. Monitoring system. The factory monitoring system according to any one of claims 1 to 4, wherein the data acquisition means periodically transmits an instruction for data acquisition to the machine tool. A monitoring method for a factory monitoring system that is connected to at least one machine tool and stores data from that machine tool.
Data that is converted from the communication standard of the machine tool to the communication standard of the factory monitoring system and can be used for failure diagnosis is acquired from the machine tool.
The factory and data converted into the communication standard of the monitoring system, and stored in the storage means and the communication software protocol corresponding to the machine tool,
By referring to the protocol stored in the storage unit, the acquired said from the machine tool data, the data stored in the storage means, into a format in which the data sequences or units are normalized,
Factory monitoring method. The factory monitoring method according to claim 6, wherein the data acquisition is performed by periodically transmitting an instruction for data acquisition to the machine tool. A computer as a factory monitoring system that is connected to at least one machine tool and stores data from that machine tool.
A process of acquiring data that can be used for failure diagnosis from the machine tool after being converted from the communication standard of the machine tool to the communication standard of the factory monitoring system.
And data converted into the communication standard of the plant monitoring system, a process of storing in the storage means and the communication software protocol corresponding to the machine tool,
By referring to the protocol stored in the storage unit, the data to which the acquired said from the machine tool data, stored in the storage means, a process of converting the format in which the data sequences or units are normalized,
A program for factory monitoring to execute. The factory monitoring program according to claim 8, wherein the data acquisition is performed by periodically transmitting an instruction for data acquisition to the machine tool.

Images