JP7474017B2 - Operational Data Collection System - Google Patents

Description

An embodiment of the present invention relates to an operational data collection system for industrial equipment such as cranes.

In a system that controls industrial equipment such as cranes, operational data such as the operation information of the operator who operates the equipment, the cause of the equipment failure, and detailed status are stored in a storage device within the control system installed within the equipment.

When investigating failures or conducting regular or irregular inspections of such equipment, it is necessary to collect operational data stored in a storage device within the control system. Collecting operational data requires specialized technical knowledge that is different from the techniques used to operate a crane, so it is difficult to have the equipment operator collect the operational data. On the other hand, with large industrial equipment such as cranes, each time operational data is needed, an investigator with specialized technical knowledge must climb onto the crane and access the control system to retrieve the operational data. This makes it difficult to collect operational data frequently.

One possible solution would be to lay a wired communication cable between the device and a location where the operational data stored in the device is retrieved and processed, and collect the operational data at the desired time. However, laying a communication cable between the device that has already been installed and the data collection location would require a great deal of cost and time.

There is known an operation data collection device that uses a mobile terminal to collect operation history data of industrial machinery, transmits the collected operation history to a management server via a public wireless communication network, and manages the data (see, for example, Patent Document 1). Therefore, if operation data is collected using such wireless communication technology instead of wired communication technology, it is possible to reduce the costs required for laying communication cables. If high-speed wireless communication technology such as 5G is used as the wireless communication technology, it becomes possible to collect large amounts of operation data quickly.

However, even when wireless communication technology is applied, it is often necessary to build a system for data transmission from scratch. Furthermore, the operational data collected may include the operating status of the equipment or alarm status due to a malfunction, and there is a strong demand to obtain such data in real time. To collect data in real time, the mobile terminal needs to maintain a constant communication state, which can cause problems such as operating life and communication costs. Another problem is that large cranes are often installed in places where there is no public wireless communication network or where radio waves are weak. Furthermore, with wireless communication, problems such as external interference and data tampering or theft can occur.

JP 2016-208245 A

The present invention is intended to solve the problems described above, and aims to provide an operational data collection system that can reliably collect operational data without making major changes to existing equipment or control systems.

The operation data collection system according to an embodiment of the present invention includes a first communication connection means provided in an apparatus to be operated and capable of being communicatively connected to a mobile terminal having a storage unit for storing operation data, a PLC provided in the apparatus to be communicatively connected to the first communication connection means and electrically control the operation of the apparatus, a second communication connection means provided in a location different from the apparatus and capable of being communicatively connected to the mobile terminal, and a server provided in the different location and communicatively connected to the second communication connection means. The PLC enables the apparatus to be operated after communication between the first communication connection means and the mobile terminal is established. The PLC transfers the operation data to the mobile terminal with which communication with the first communication connection means is established . After a connection between the second communication connection means and the mobile terminal is established, the server requests the mobile terminal to transmit the operation data. The mobile terminal transmits the operation data to the server based on the request. When a connection between the first communication connection means and the mobile terminal is established, a connection between the second communication connection means and the mobile terminal is not established.

In this embodiment, an operational data collection system is realized that can reliably collect operational data without making major changes to existing equipment or control systems.

FIG. 1 is a schematic block diagram illustrating an operation data collection system according to a first embodiment. FIG. 1 is a schematic side view illustrating an industrial crane. FIG. 2 is a schematic block diagram for explaining the operation of the operation data collection system of the first embodiment. 4 is an example of a flowchart for explaining an operation of the operation data collection system according to the first embodiment. FIG. 2 is a schematic diagram for explaining a method of using the operation data collection system of the first embodiment. FIG. 11 is a schematic block diagram illustrating a portion of an operation data collection system according to a second embodiment.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
In addition, the drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between parts, etc. are not necessarily the same as those in reality. Even when the same part is shown, the dimensions and ratios of each part may be different depending on the drawing.
In this specification and each drawing, elements similar to those described above with reference to the previous drawings are given the same reference numerals and detailed description thereof will be omitted as appropriate.

First Embodiment
FIG. 1 is a schematic block diagram illustrating an operation data collection system according to the present embodiment.
As shown in FIG. 1, the operation data collection system 100 of this embodiment includes an access point (A) (first communication connection means) 10, a PLC 20, an access point (B) 30 (second communication connection means), and a server 40. The access point (A) 10 and the PLC 20 are provided in a device from which operation data is collected. In this example, the device from which operation data is collected is an industrial crane, and the operation data collection system 100 of this embodiment is preferably used in a device that requires skill to operate, such as an industrial crane. The access point (A) 10 and the PLC 20 are provided in a crane on-board equipment 102. As will be described in detail later, an industrial crane includes an operator's cab and an electrical room as the crane on-board equipment 102, and the access point (A) 10 and the PLC 20 are arranged together with a controller 22 and a drive device 24.

The access point (B) 30 and the server 40 are installed in the office facility 106. The office facility 106 is installed in an office that is located at a different location from where the crane is installed. Here, the office is a facility where the operator who operates the crane on a daily basis manages attendance and performs other clerical tasks. Therefore, when the operator is engaged in work that involves operating the crane, he or she always enters the office and then moves to the crane that he or she is to operate. Then, when the operator has finished operating the crane, he or she always returns to the office.

In the operation data collection system 100 of this embodiment, the operator carries a mobile terminal 104. The mobile terminal 104 carried by the operator can be communicatively connected to the access point (A) 10 and the access point (B) 30. For example, the access point (A) 10 and the access point (B) 30 are equipped with an interface that enables wireless data communication, and when the mobile terminal 104 carried by the operator is within a specified range, wireless communication can be established, enabling data communication with the PLC 10 and the server 40.

The mobile terminal 104 is equipped with a storage device, and when it is connected to the PLC 20 via the access point (A) 10, operation data is transferred (downloaded) to the storage device by a program installed in the PLC 10, and the operation data is read from the storage device of the PLC 10. When the mobile terminal 104 is connected to the server 40 via the access point (B) 30, the operation data stored in the storage device of the mobile terminal 104 can be transferred (uploaded) to the server 40 by a program installed in the server 40.

The access point (A) 10 and the access point (B) 30 have unique identification data. If the mobile terminal 104 has the same identification data, the access point (A) 10 and the access point (B) 30 allow the download and upload of operation data after establishing communication with the mobile terminal 104.

The mobile terminal 104 may be any terminal capable of wireless communication with the access point (A) 10 and the access point (B) 30 and capable of downloading and uploading operation data. The mobile terminal 104 may be, for example, a general-purpose portable terminal such as a smartphone or tablet terminal, or may be a dedicated wireless terminal designed for this system.

The configuration of the operation data collection system 100 of this embodiment will be described in detail.
The crane on-board equipment 102 is provided with an access point (A) 10 and a PLC 20, as well as a controller 22 and a drive device 24. The controller 22 is connected to the PLC 20. The controller 22 is a device operated by an operator, and the operator can traverse, hoist, and lower the load suspended by the crane by operating the controller 22. When the operator operates the controller 22, a control signal corresponding to the operation is generated, and the generated control signal is transmitted to the PLC 20.

The drive device 24 is connected to the PLC 20. The drive device 24 drives an electric motor that moves the load laterally, hoisting, and lowering it. The PLC 20 receives control signals from the controller 22 and motor speed and torque signals acquired by the drive device 24, and transmits appropriate control signals to the drive device 24 to control the operation of the electric motor.

When the operator turns on the power to the crane, the access point (A) 10 becomes capable of communicating with the mobile terminal 104. When the mobile terminal 104 approaches, the access point (A) 10 establishes wireless communication, enabling data communication between the PLC 20 and the mobile terminal 104. When the mobile terminal 104 is communicatively connected to the access point (A) 10, the mobile terminal 104 becomes capable of communicating with the PLC 20 via the access point (A) 10. The PLC 20 becomes capable of transferring operational data, including control signals, to the mobile terminal 104.

The type and frequency of operation data transferred to the mobile terminal 104 is determined by a program pre-installed in the PLC 20. For example, among the multiple pieces of operation data required for the operation of the crane control system, some pre-set operation data may be transferred from the PLC 20 to the mobile terminal 104, or all operation data may be transferred to the mobile terminal 104. The PLC 20 may constantly transfer the operation data to the mobile terminal 104, or may temporarily store the operation data in a storage device (not shown) connected to the PLC 20 and transfer the temporarily stored operation data to the mobile terminal 104 when a predetermined data capacity is reached.

The access point (B) 30 of the office equipment 106 is connected to the server 40. The access point (B) 30 and the server 40 are constantly powered and ready for communication. When the mobile terminal 104 carried by the operator approaches the access point (B) 30, wireless communication is established and the server 40 requests the mobile terminal 104 to transmit operation data. The operation data stored in the mobile terminal 104 is transferred to the server 40 via the access point (B) 30. A database is set up in advance in the server 40, and the transferred operation data is stored in the database by a previously installed program.

FIG. 2 is a schematic side view illustrating an industrial crane.
As shown in FIG. 2, the crane 1 is, for example, a container crane installed in a port. The crane 1 includes a cab 2a, an electric room 2b, a pair of legs 4, and a girder 5. Although not shown, the crane 1 is also provided with a traverse trolley and a spreader. The crane 1 is used to unload a transport ship docked at a quay W to a container yard Y, or to load a container loaded in the container yard Y onto a docked transport ship. The crane 1 is not limited to such a container crane, but may be other cranes, such as a construction crane, a cable crane, an overhead crane, a Goliath crane, etc. As described above, the operation data collection system 100 is not limited to the crane 1, but can be applied to cases where a work site and an office are provided separately, such as other industrial equipment or plants, and an operator who works travels back and forth between the work site and the office.

In this example, the cab 2a is provided on the girder 5. The cab 2a travels, for example, along a traverse rail provided on the girder 5 together with a traverse trolley or the like, or independently of the traverse trolley. Alternatively, the cab 2a may be fixed at any position on the girder 5.

The operator's cab 2a is provided with operation levers and various display panels for operating the traverse trolley, winding up and down the spreader, and operating rail travel. The operation levers are provided in the controller 22, which generates control signals according to the movement of the operation levers. The display panel displays data such as the spreader height, and the speed and height during winding up and down, based on detection signals, control signals, etc. input and output by the PLC 20. The detection signals, control signals, etc. are used for these operations and displays, and can be the subject of collected operational data.

In this example, the electrical room 2b is located at the rear and upper part of the crane 1. Specifically, the electrical room 2b is located on a girder 5 that is supported approximately horizontally with the container yard Y by a pair of legs 4.

The electrical room 2b houses the motors, drive mechanisms, and drive units 24 that operate the traverse trolley and spreader.

The operation of the operation data collection system 100 of this embodiment will be described.
FIG. 3 is a schematic block diagram for explaining the operation of the operation data collection system of this embodiment.
As shown in Fig. 3, the crane on-board equipment 102 includes an operator's cab 102a and an electrical room 102b. The access point (A) 10 and the PLC 20 described in Fig. 1 are provided in the operator's cab 102a and the electrical room 102b, respectively. That is, the operator's cab 102a is provided with the access point (A) 10a, the PLC 20a, and the controller 22. The electrical room 102b is provided with the access point (A) 10b, the PLC 20b, and the drive device 24.

The PLC 20a in the cab 102a receives a control signal from the controller 22, and based on this generates the necessary control signals, control commands, etc., and transmits them to the PLC 20b in the electrical room 102b. The PLC 20b in the electrical room 102b generates speed commands, etc., to be supplied to the drive device 24, based on the received control signals, control commands, etc., and supplies them to the drive device 24.

The PLC 20b in the electrical room 102b receives detection signals from the drive unit 24 and other sensors, and transmits them to the PLC 20a in the cab 102a. The PLC 20a in the cab 102a displays information such as the position and height of the suspended load on a display panel, etc., based on the received signals, etc.

In this way, when multiple PLCs 20a, 20b are installed in multiple locations, it is sufficient to connect an access point to at least one of the PLCs. The access point (A) 10 and the mobile terminal 104 each have unique identification data, and by matching the identification data, the interlock of the control system including the PLCs 20a, 20b is released. For this reason, it is preferable to install the access point (A) 10 in a location where the operator performs daily operations on the crane 1.

When an access point is provided for each PLC, even if an investigator other than the operator carries a mobile terminal 104 and heads to the electrical room 102b, it becomes possible to transfer operation data without stopping by the cab 102a. This has the advantage that it is possible to collect operation data while inspecting the drive unit 24 and other devices and equipment in the electrical room 102b.

When the mobile terminal (represented as terminal in FIG. 3) 104 reaches the communication range of the access point (A) 10a connected to the PLC, communication with the access point (A) 10a is established. The mobile terminal 104 establishes communication with the access point (A) 10a and is able to communicate with the PLC 20a. Since the PLC 20a is communicatively connected to the PLC 20b in the electrical room 102b, the operational data handled by the PLC 20b can also be obtained from the PLC 20b and transferred to the mobile terminal 104.

When an investigator carrying a mobile terminal 104 enters the electrical room 102b, the mobile terminal 104 establishes communication with access point (B) 10b, enabling communication with PLC 20b. When it is necessary to obtain operation data from PLC 20a, PLC 20b can obtain the operation data from PLC 20a according to a program previously set in PLC 20b and transfer it to the mobile terminal 104.

The office equipment 106 is installed somewhere in the office, for example in the electrical room. The access point (B) 30 does not necessarily have to be installed inside the office equipment 106, as long as it is within communication range when the mobile terminal 104 approaches and is located in a position where it can receive power.

FIG. 4 is an example of a flowchart for explaining the operation of the operation data collection system of this embodiment.
FIG. 4 shows an operational flow of the operation data collection system 100 in the crane on-board equipment 102.
As shown in Fig. 4, in step S1, the power supply to the crane is turned on manually by an operator.

In step S2, when the mobile terminal 104 enters the communication range of the access point (A) 10a, communication is established between the mobile terminal 104 and the access point (A) 10a, and the mobile terminal 104 is connected so that communication is possible.

In step S3, the access point (A) 10a receives the identification data of the mobile terminal 104 and determines whether the identification data matches that of the registered operator. If they match, the access point (A) 10a transitions the process to the next step S4. If they do not match, the access point (A) 10a waits until it receives matching identification data.

In step S4, PLC 20a releases the interlock of crane 1, enabling operation of crane 1.

In step S5, PLC 20a starts the system of crane 1. For example, the system of crane 1 may be set to a startable state in step S4 and started by an operator pressing a push button, or the system may be automatically started simultaneously with the interlock release in step S4 or after a predetermined time has elapsed. In the case of an internal combustion engine as the power source, the engine is started by the operator pressing a push button.

In step S6, PLC 20a causes the mobile terminal 104 to download data. If the operation data to be downloaded is handled by PLC 20b, PLC 20a causes the operation data handled by PLC 20b to be transferred to the mobile terminal 104.

Although not shown, after the operator has finished the work, he or she shuts down the crane 1 system by shutting off the power to the crane 1. By shutting off the power, the connection with the mobile terminal 104 is severed and the crane 1 system is interlocked. The operator can then leave the cab 102a.

A method of using the operation data collection system 100 of this embodiment will be described.
FIG. 5 is a schematic diagram for explaining a method of using the operation data collection system of this embodiment.
As shown in FIG. 5 , in the operation data collection system 100 of this embodiment, an operator OP carries a mobile terminal 104 and travels between an office F and a crane 1 .

(1) The mobile terminal 104 is preferably located within the communication range of the access point (B) 30. When the operator OP arrives at the office F, he picks up and carries the mobile terminal 104 located at a predetermined position in the office F. The operator OP moves to the crane 1 with the mobile terminal 104 in his hand.

(2) The operator OP boards the crane 1 while carrying the mobile terminal 104. The operator OP heads to the electrical room 102b or the driver's cab 102a while carrying the mobile terminal 104.

(3) The operator OP, carrying the mobile terminal 104, enters the cab 102a. According to the operational flow described in FIG. 4, the mobile terminal 104 and the access point (A) 10a are connected by communication, the interlock is released, and the crane system is started. After that, the downloading of the operation data from the PLC 20a to the mobile terminal 104 is started or made possible.

(4) When the operator OP has finished working with the crane 1, he or she shuts off the power and leaves the cab 102a. The power shutoff causes the crane system to be interlocked, but the download of operation data from the PLC 10a has already been completed before the power was shut off.

(5) The operator OP, still carrying the mobile terminal 104, gets off the crane 1 and returns to the office F.

(6) When the operator OP approaches the access point (B) 30 and the mobile terminal 104 enters the communication range of the access point (B) 30, the access point (B) 30 determines whether the identification data of the mobile terminal 104 matches the identification data registered in advance. If the identification data matches, the access point (B) 30 establishes communication with the mobile terminal 104. After communication is established, the server 40 requests the mobile terminal 104 to upload the collected operation data via the access point (B) 30, and the mobile terminal 104 transmits the operation data to the server 40.

In this way, the operation data collection system 100 of this embodiment allows the operator OP to collect operation data using the mobile terminal 104 carried by the operator OP.

In the above description, the PLC 20 and the server 40 are connected to the mobile terminal 104 using a wireless communication interface via the access point (A) 10 and the access point (B) 30, but this is not limited to the above. Instead of a key or the like required for the operator OP to drive and operate the crane 1, the operator OP may carry the mobile terminal 104 having the identification data with him/her on a daily basis and incorporate it into the business routine. For example, the PLC 20 and the server 40 may be provided with a dedicated or general-purpose wired connection terminal or connector, and the interlock of the crane 1 may be released by inserting the plug of the mobile terminal 104, etc., via a wired communication connection, and then operation data may be downloaded, etc.

The effects of the operation data collection system 100 of this embodiment will be described.
In the operation data collection system 100 of this embodiment, an access point (A) 10a is provided in a cab 102a or the like where an operator enters for daily work, and the identification data of the access point (A) 10 is collated with the identification data of a mobile terminal 104. By collation of the identification data at the daily work site, the control system of the crane 1 is started up, enabling the operation of the crane 1, so the operator OP always carries the mobile terminal when boarding the crane 1.

The mobile terminal 104 is connected to the control system as a storage device for the control system of the crane 1, including the PLCs 20a and 20b, so that operation data can be collected reliably.

When the operator OP finishes working with the crane 1, he returns to the office F carrying the mobile terminal 104. Since an access point (B) 30 with identification data set is also installed in the office F, the mobile terminal 104 can be connected to the server 40 via the access point (B) 30, and the saved operation data can be reliably uploaded to the server 40.

After the connection between the access point (A) 10 and the mobile terminal 104 is established, the sequence of the control system including the PLC 20 can be realized by introducing a control program into the access point (A) 10 and the PLC 20. The establishment of a communication connection and data transmission between the server 40 and the mobile terminal 104 via the access point (B) 30 can be realized by introducing a control program into the server 40. Therefore, this can be easily realized without making major changes to the configuration of the current control system or data management system.

Communication between the access point (A) 10 and the mobile terminal 104 is via a short-range wireless LAN and can be encrypted, preventing data tampering or theft during communication.

In this way, the operational data collection system 100 of this embodiment can reliably collect operational data every time an operator works with equipment such as a crane 1, without the operator having to acquire specialized technical knowledge.

As in this example, by providing access point (A) 10b in an electrical room 102b or the like where the operator OP does not normally enter but where investigators do, it becomes possible for investigators to collect operational data when inspecting other equipment. For example, if a test program is temporarily introduced into PLC 20b, the test results can be collected as operational data, allowing for efficient investigation of defects.

Second Embodiment
FIG. 6 is a schematic block diagram illustrating a part of the operation data collection system according to this embodiment.
In this embodiment, the configuration of the server 240 is different from that of the other embodiments described above. In the other embodiments described above, the collected operation data is stored in a database of any suitable format. In this embodiment, the server 240 periodically reads the database and generates and outputs an electronic operation log based on the operation data.

The server 240 is connected to the access point (B) 30. When the operator OP returns to the office F carrying the mobile terminal 104 and enters the communication range of the access point (B) 30, the access point (B) 30 establishes communication with the mobile terminal 104, as in the other embodiments described above. The server 240 requests the mobile terminal 104 to transmit operation data, and the mobile terminal 104 uploads the collected operation data to the server 240.

The server 240 stores the received operation data in a database and outputs, for example, format data for the electronic operation log 242. The format data for the electronic operation log 242 is set in advance in the server 240. This format data is a frame for allocating each piece of data in the data server to a specified position.

For example, the server 240 reads the day's operation data from the database and inputs it into the format data. This allows an electronic operation log 242 for each operation day to be generated and output.

The frequency of generating and outputting the electronic operation log 242 may be every operation day, every operation week, or every operation month. Preferably, the electronic operation log 242 is generated and output every operation day, so that a business routine can be established to ensure that the operation data collected by the mobile terminal 104 is uploaded.

By outputting operational data showing the operation history of each operator OP as an item output in the electronic operation log 242, it can also be useful for quantifying the skills of the operator OP.

According to the embodiment described above, it is possible to realize an operational data collection system that can reliably collect operational data without making major changes to existing equipment or control systems.

Although several embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the gist of the invention. These embodiments and their variations are included within the scope and gist of the invention, as well as within the scope of the invention and its equivalents described in the claims. In addition, the above-mentioned embodiments can be implemented in combination with each other.

1 Crane, 2a Cab, 2b Electric room, 10, 10a, 10b Access point (A), 20, 20a, 20b PLC, 22 Controller, 24 Drive device, 30 Access point (B), 40, 240 Server, 100 Operation data system, 104 Mobile terminal, 242 Electronic operation logbook

Claims (5)

A first communication connection means provided in the device to be operated and capable of being communicatively connected to a mobile terminal having a memory unit for storing operation data;
a PLC provided within the device so as to be communicatively connected to the first communication connection means and electrically control the operation of the device;
A second communication connection means capable of being communicatively connected to the mobile terminal and provided at a different location from the device;
A server that is communicatively connected to the second communication connection means and is provided at the different location;
Equipped with
the PLC enables the device to operate after communication between the first communication connection means and the mobile terminal is established;
The PLC transfers the operation data to the mobile terminal with which communication with the first communication connection means is established ;
the server requests the mobile terminal to transmit the operation data stored in the mobile terminal after a connection between the second communication connection means and the mobile terminal is established;
The mobile terminal transmits the operation data to the server based on the request;
An operational data collection system , wherein when a connection between said first communication connection means and said mobile terminal is established, a connection between said second communication connection means and said mobile terminal is not established . The operation data collection system according to claim 1, wherein the first communication connection means and the second communication connection means have the same identification data set to permit communication, and when the identification data held by the mobile terminal match, communication is established with the mobile terminal. 3. The operation data collection system according to claim 2, wherein the interlock of the device is released after the communication between the first communication connection means and the mobile terminal is established. The server,
constructing a database based on the operation data transferred from the mobile terminal;
4. An operation data collection system according to claim 1, further comprising: a generating section for generating an electronic operation log based on said database at a preset frequency . An operation data collection system according to any one of claims 1 to 4, wherein the first communication connection means and the second communication connection means include a wireless communication station, and the working location of an operator carrying the mobile terminal is within the communication range.

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