KR101748282B1 - Plant diagnosis system and diagnosis method using the same - Google Patents

Abstract

The present invention relates to a facility diagnosis system and a facility diagnosis method using the system, and more particularly, to a facility management system and a facility management system, And a diagnostic module (120) comprising hardware equipped with software for diagnosing the presence or absence of an abnormality of the facility, the facility diagnosis system (100) comprising: The image module 110 includes an internal or external image device 100 of the facility diagnosis system 100 and stores image data of the facility at all times; The diagnostic module 120 receives a digital setting signal D, an analog voltage / current signal A and an external signal separated by a PLC memory map access signal P to generate a diagnostic event, 110) is stored for each diagnostic event file and the image data is analyzed and used for diagnosis of the presence or absence of a facility abnormality; The diagnostic event is generated selectively in parallel with one or more of a specific operation section monitoring, a material condition monitoring, a standby status monitoring and an image analysis monitoring diagnosis event, and an alarm signal is outputted to the facility controller to correspond to the diagnosis result , It is characterized by providing simpler and more efficient facility diagnosis system, and more accurate and reliable facility diagnosis method.

Description

TECHNICAL FIELD [0001] The present invention relates to an apparatus diagnosis system and an apparatus diagnosis method using the system,

The present invention relates to a facility diagnosis system and a facility diagnosis method using the system. More particularly, the present invention relates to a facility diagnosis system and a facility diagnosis method using the system, And to provide a facility diagnosis system and a facility diagnosis method using the system.

Generally, facilities are collectively referred to as manufacturing or manufacturing facilities, whole plants, and mainly means production machines or devices or all of them. The facility plays a pivotal role in the production and manufacturing of products in most industrial fields such as machinery, steel, and chemicals.

In recent years, facilities for automating the control, management, and operation of products have been implemented through factory automation using machine tools, robots, and computers. In addition to automation of devices, process control that controls the devices programmably by computer Automation is also progressing gradually.

Therefore, in recent industrial equipments such as automation parts assembly machine, various tester, processing machine, etc., a built-in PCB board with PLC, computer, and microprocessor is embedded and the controller is finally programmed.

For example, a configuration of a car assembly facility known in the Japanese Patent Registration No. 10-0867773 includes a central management server for storing and managing vehicle information necessary for assembling a car, and a plurality of And a plurality of control PCs connected to each of the plurality of facility control units and communicating with the central management server, wherein the plurality of control PCs are connected to each of the plurality of facility control units, The control unit includes PLC devices of different models.

Meanwhile, the above-mentioned industrial equipment may cause various unexpected problems such as malfunction of the equipment or non-assembling of manufactured parts in the process of operation.

In particular, if the errors of such facilities are repeatedly produced, the production efficiency is remarkably lowered, thereby increasing the economic burden. Moreover, the reliability of the product quality can not be ensured and the technology development and industrial development are adversely affected.

In the end, in order to identify the cause of the above-mentioned equipment failure, engineers are constantly performing surveillance work around the facility. However, inefficiency due to accumulation of work fatigue and visual surveillance system dependent on the naked eye can cause problems It is a reality that it is difficult to respond.

Accordingly, a variety of facility diagnosis technologies have been developed and provided so as to accurately and promptly identify and respond to the causes of various errors occurring in the development or operation of the facility. For example, a production line disclosed in Registration No. 10- 0084195 The following is a brief description of the configuration of the fault diagnosis system.

A method of diagnosing a facility in a production line, the method being characterized in that a plurality of operations executed by equipment in the production line are performed in a steady state of the equipment in order to execute a plurality of operation steps in each operation block in a predetermined order A step of classifying each of the plurality of operation blocks into a plurality of operation steps for each of a series of operation units independently executed from the start to the end of the operation; Comprising the steps of: measuring an operation time taken from the start to the end of a series of operation steps in the operation block; storing completion of operation in each operation step in each operation block; Comparing the time and the measured time of operation; and comparing the state of the completion of operation in each operation step with the phase For each block in response to a time difference in the comparison step comprises a step of specifying a broken operation step.

Patent No. 10-0867773 Patent No. 10- 0084195 Registration No. 10 - 1351309 Published Patent No. 10 - 1996 - 0074298

A method for diagnosing a facility of a production line to which the related art is applied includes a vehicle assembly line (hereinafter referred to as a facility), a line fault diagnosis unit installed in the entire facility to diagnose a line fault, Area to diagnose faults Fault diagnosis unit, which is installed for each area-mounted device, and which has a device fault diagnosis unit to diagnose the fault of the device, constitutes a fault diagnosis device for sequentially diagnosing.

However, the above-described prior art failure diagnosing apparatus measures the operation time of each line, area, and mounting device, that is, IN-OUT time, compares with the reference time, and takes a form in which a diagnostic result is outputted as a failure if it is determined to be abnormal.

Therefore, the above-described prior art is configured to perform diagnosis by installing a fault diagnosis apparatus for every line, area, and apparatus of the facility, so that the configuration of the fault diagnosis apparatus can not help but be very complicated and can not be universally applied to various kinds of facilities .

In particular, it is only at the level of diagnosing normal or abnormal conditions by simply measuring the process progress time of each part of the equipment, and it is difficult to clearly grasp whether the direct cause of the failure is due to the equipment itself or other external factors such as material .

In addition, even if a facility error occurs, it is difficult to ensure the accuracy of the fault diagnosis in the prior art because the IN-OUT time is normally maintained during line operation.

Accordingly, the present invention has been made to solve the above-mentioned problems,

A video module 110 for capturing image data of a facility incorporating a PLC, a computer or a facility controller mounting a microprocessor to control the operation of the facility, and hardware equipped with software for diagnosing the abnormality of the facility 1. A facility diagnostic system (100) comprising a diagnostic module (120) comprising:

The image module 110 may include an internal diagnostic system 100 or an external image device, and may store image data of the equipment at all times;

The diagnostic module 120 receives a digital setting signal D, an analog voltage / current signal A, and an external signal separated by a PLC memory map access signal P to generate a diagnostic event, The image data photographed by the module 110 is stored for each diagnostic event file, the image data is analyzed and used for diagnosing whether or not there is a facility error;

The diagnosis event is generated selectively in parallel with one or more of a specific operation section monitoring, a work state monitoring, a standby state monitoring, and an image analysis monitoring and diagnosis event and outputs an alarm signal to the facility controller to respond to the diagnosis result .

In the facility diagnosis method using the facility diagnosis system 100,

The facility diagnosis method includes the steps of generating a diagnostic event by receiving a digital setting signal (D), an analog voltage / current signal (A), and an external signal separated by a PLC memory map access signal (P) and;

The diagnostic event may include:

A specific operation section monitoring (S10) method in which a user sets a specific operation section monitoring event signal to the diagnosis module 120 during operation of the facility, diagnoses a specific operation section of the facility and outputs an alarm signal to the facility controller,

A material condition monitoring (S20) method in which a user sets a material condition monitoring event signal in a diagnostic module (120) during operation of a facility, diagnoses the material condition and outputs an alarm signal to the facility controller,

How the user sets the stand-by state monitoring event signal to the diagnosis module 120 in operation before the standby state of the plant, and a standby state to monitor and diagnose the condition of the plant outputs an alarm signal to the plant controller (S30) and,

By an image analysis monitoring (S40) method of analyzing the image data stored in the diagnosis module 120 according to the image setting value set by the user in the diagnosis module 120, diagnosing the condition of the facility, and outputting an alarm signal to the facility controller Lt; / RTI &

The user diagnoses and responds to the abnormality of the equipment by generating one or a plurality of diagnostic events by the different methods (S10 to S40) through the diagnosis module 120, It is possible to achieve the purpose of effectively overcoming the trouble.

The present invention has the effect of overcoming the problems such as malfunction of the equipment or non-assembling of the parts caused by failure of the equipment or omission of the material, which is difficult to grasp the cause in developing and operating various industrial facilities.

In particular, it is possible to construct an equipment diagnosis system composed of hardware that receives various external signals such as digital, analog, and PLC communication methods and has hardware for diagnosing the abnormality of facilities through diagnosis module and image module, There is an advantage to realize a remarkable simplification.

Therefore, the facility diagnosis system of the present invention has an effect of facilitating on-site installation and movement and efficiently performing facilities diagnosis work by providing a wired / wireless signal input / output interface.

In addition, by using the above-described facility diagnosis system, it is possible to monitor a specific operation section of the facility, monitor the operation from the standby state to the end of one cycle, and monitor the state of the material input to the facility, There is an advantage in that accuracy and reliability of facility diagnosis can be ensured by providing a facility diagnosis method.

1 is a schematic block diagram according to an embodiment of a facility diagnosis system of the present invention;
2 is a schematic process flow diagram according to an embodiment of a facility diagnosis method using the facility diagnosis system of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a configuration and operation of a facility diagnosis system and an apparatus diagnosis method using the system according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a schematic block diagram according to an embodiment of the facility diagnosis system of the present invention, and FIG. 2 is a schematic process flow diagram according to an embodiment of a facility diagnosis method using the facility diagnosis system of the present invention.

The facility diagnosis system to which the technique of the present invention is applied and the facility diagnosis method using the system are designed to prevent the malfunction of the equipment or the non-assembly of the parts due to the failure or defect of the equipment, The present invention relates to a technique for diagnosing an abnormality of equipment by inputting various external signals to effectively overcome the problems caused by the abnormality.

The facility diagnosis system 100 of the present invention includes a video module 110 for capturing image data of a facility incorporating a PLC, a computer or a facility controller for mounting a microprocessor to control the operation of the facility, And a diagnostic module 120 configured to include software for diagnosing the presence or absence of abnormality.

The facility controller is a built-in device for automation facility control and includes a PCB (Programmable Logic Controller), a computer, and a PCB with a microprocessor.

The user program memory of the PLC stores end-user programmed software. In the data memory, information such as input / output relays, auxiliary relays, contact states of the timers and counters, and set values are stored. The OS program is stored in the system memory.

The customization program is a control program created by the user in accordance with the facility to be controlled and inputs / outputs signals through the input / output module of the PLC to perform various control functions by connecting and communicating with the interface.

The PLC I / O module basically includes a signal control method using a digital unit and an analog unit that incorporates a converter to control voltage and current, and it is possible to communicate by input / output of a PLC memory map. Other detailed technical matters concerning the PLC will be referred to well-known technologies, and a detailed description thereof will be omitted.

The image module 110 includes an internal diagnostic system 100 or an external image device and continuously stores the latest image data of an appropriate capacity,

The imaging device includes a camera or CCTV built in or remotely installed in the facility diagnosis system 100 and includes an imaging device 111 and a lighting device 112. The imaging device 100 includes a connection port One or more video devices 111 and a lighting device 112 may be connected to the video camera 121 to transmit and receive signals.

The diagnosis module 120 includes a plurality of terminal terminal blocks 122, a plurality of communication ports 123 for communicating with the PLC and the image module 110, And a display device 125 for setting and changing various parameters through the software interface and confirming stored image data. The system diagnosis system 100 includes a central processing unit It is lumbar.

The diagnosis module 120 receives a digital setting signal D, an analog voltage / current signal A and an external signal separated by a PLC memory map access signal P to generate a diagnostic event, The image data photographed by the camera 110 is stored for each diagnostic event file, and the image data is analyzed and used for diagnosis of the presence or absence of a facility error.

The diagnostic event is selectively generated in parallel with one or more of a specific operation section monitoring, a work condition monitoring, a standby status monitoring, and an image analysis monitoring diagnostic event.

Accordingly, the diagnostic module 120 stores and software-processes the image data received from the image module 110 according to an external signal and a diagnostic event generated by the set parameter, and uses the image data to diagnose whether there is a facility error. For example, when it is diagnosed that an abnormality has occurred in the facility, an alarm signal is outputted to the facility controller so as to correspond to the diagnosis result.

Hereinafter, an apparatus diagnosis method using the facility diagnosis system 100 will be described in order to grasp the concrete operation process of the facility diagnosis system 100 of the present invention as described above.

As described above, in the facility diagnosis method, the diagnostic module 120 receives an external signal distinguished by the digital setting signal D, the analog voltage / current signal A, and the PLC memory map access signal P And generates a diagnostic event.

For example, when receiving the digital setting signal D, the diagnostic module 120 stores the image data when the user satisfies a desired condition using various parameters (setting time, etc.) set in the diagnostic module 120 And outputs an alarm signal.

The diagnostic module 120 receiving the analog voltage / current signal A similarly outputs various parameters (setting time, voltage / current size to be recognized as a signal, number of signals, etc.) set in the diagnostic module 120 When the user satisfies the desired condition using the condition, the image data is stored and an alarm signal is outputted.

The diagnosis module 120 receives the PLC memory map access signal P through the PLC communication. The diagnosis module 120 determines various parameters (setting time, type and number of memories to read, bits to be used as signals) And stores the image data and outputs an alarm signal when the user satisfies the desired condition.

The diagnosis event generated by the facility diagnosis method of the present invention can be largely divided into a specific operation section monitoring method S10, a material condition monitoring method S20, a waiting state monitoring method S30, ) Method.

In the specific operation section monitoring method (S10), a user sets a specific operation section monitoring event signal to the diagnosis module 120 during operation of the facility, diagnoses a specific operation section of the facility, and outputs an alarm signal to the facility controller.

In the material condition monitoring (S20), a user sets a material condition monitoring event signal to the diagnosis module 120 during operation of the facility, diagnoses the material condition, and outputs an alarm signal to the facility controller.

The standby state monitoring (S30) method sets a standby state monitoring event signal to the diagnosis module 120 in a standby state before the operation of the facility, diagnoses the state of the facility, and outputs an alarm signal to the facility controller.

The image analysis monitoring method (S40) analyzes the image data stored in the diagnosis module 120 according to the image setting value set by the user in the diagnosis module 120, diagnoses the condition of the facility, and outputs an alarm signal to the facility controller do.

Accordingly, the user may diagnose and respond to the abnormality of the equipment by generating one or a plurality of diagnostic events by the different methods (S10 to S40) through the diagnosis module 120. [

The facility diagnosis system to which the technology of the present invention is applied and the facility diagnosis method using the system as described above can be implemented by monitoring a specific operation section of the facility using a simplified facility diagnosis system as compared with the prior art, And more precise and detailed equipment diagnosis method such as monitoring the operation of the equipment up to the point of time, monitoring the condition of the material input to the equipment, and analyzing and monitoring the image data.

Therefore, it is advantageous to improve the accuracy and reliability of the facility diagnosis by overcoming the problems such as the malfunction of the equipment or the unassembling of the parts caused by the failure of the equipment or the omission of the material, which is difficult to grasp the cause.

Therefore, it is possible to optimize the setting conditions individually for new or existing facilities with built-in controller, such as automation parts assembly machine, various tester and processing equipment, so that it can be applied to production line or maintenance team of domestic and foreign manufacturers, The verification team can expect to be able to utilize it effectively.

100: Facility diagnosis system
110: image module
111: Imaging device
112: Lighting device
120: Diagnostic module
121: connection port
122: Terminal terminal block
123: Communication port
124: PCB
125: Display device
D: Digital parameter setting signal
A: analog voltage / current signal
P: PLC memory map access signal
S10: How to monitor specific operation section
S20: How to monitor the status of the material
S30: Standby status monitoring method
S40: Image analysis monitoring method

Claims (3)

An equipment diagnosis system 100 equipped with a video module 110 for capturing image data of a facility incorporating the facility controller and a diagnosis module 120 comprising hardware equipped with software for diagnosing the presence or absence of an abnormality of the facility ;
The image module 110 includes an imaging device 111 and an illumination device 112 that are comprised of a facility diagnosis system 100 or a remote camera or a CCTV. The imaging module 110 is connected to the diagnosis module 120, Transmitting image data;
The diagnosis module 120 includes a plurality of terminal terminals 122 for processing the digital setting signal D and the analog voltage / current signal A and a plurality of communication ports 123 for communicating with the PLC and the external device, A PCB 124 having software for analyzing inputted data to diagnose the abnormality of equipment, a display device 125 for setting and changing parameters and checking stored image data through the software interface );
The diagnostic module (120)
And a PLC memory map access signal (P) according to a monitoring event condition for setting a desired point in time, and performs a specific operation section monitoring, A monitoring status monitor, a standby status monitoring, and an image analysis monitoring event in parallel with one or a plurality of diagnostic events, storing image data taken by the image module 110 for each diagnostic event file, Wherein the image data stored at a time point that meets the condition is analyzed and used for facility diagnosis, and an alarm signal is output to the facility controller so as to correspond to the diagnosis result. delete An equipment diagnosis system 100 equipped with a video module 110 for capturing image data of a facility incorporating the facility controller and a diagnosis module 120 comprising hardware equipped with software for diagnosing the abnormality of the facility, A method for diagnosing a facility using the same;
The facility diagnosis method includes a digital setting signal D, an analog voltage / current signal A and a PLC memory map access signal P in accordance with a monitoring event condition for setting a desired time point for use by the diagnostic module 120. [ To generate a diagnostic event;
The diagnostic event may include:
A specific operation section monitoring (S10) method in which a user sets a specific operation section monitoring event signal to the diagnosis module 120 during operation of the facility, diagnoses a specific operation section of the facility and outputs an alarm signal to the facility controller,
A material condition monitoring (S20) method in which a user sets a material condition monitoring event signal in a diagnostic module (120) during operation of a facility, diagnoses the material condition and outputs an alarm signal to the facility controller,
How the user sets the stand-by state monitoring event signal to the diagnosis module 120 in operation before the standby state of the plant, and a standby state to monitor and diagnose the condition of the plant outputs an alarm signal to the plant controller (S30) and,
By an image analysis monitoring (S40) method of analyzing the image data stored in the diagnosis module 120 according to the image setting value set by the user in the diagnosis module 120, diagnosing the condition of the facility, and outputting an alarm signal to the facility controller Lt; / RTI &
The user generates one or a plurality of diagnostic events performed by the different methods (S10 to S40) through the software interface of the diagnostic module 120, And analyzing the stored image data for use in diagnosis of the facility.

Images