WO2011052534A1 - 設備状態検知装置、設備状態検知方法、およびコンピュータ読み取り可能な記録媒体 - Google Patents
設備状態検知装置、設備状態検知方法、およびコンピュータ読み取り可能な記録媒体 Download PDFInfo
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- WO2011052534A1 WO2011052534A1 PCT/JP2010/068842 JP2010068842W WO2011052534A1 WO 2011052534 A1 WO2011052534 A1 WO 2011052534A1 JP 2010068842 W JP2010068842 W JP 2010068842W WO 2011052534 A1 WO2011052534 A1 WO 2011052534A1
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- state
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- 238000001514 detection method Methods 0.000 title claims abstract description 147
- 238000000034 method Methods 0.000 claims description 21
- 238000005259 measurement Methods 0.000 claims description 18
- 230000002776 aggregation Effects 0.000 claims description 9
- 238000004220 aggregation Methods 0.000 claims description 9
- 230000004931 aggregating effect Effects 0.000 claims description 4
- 238000003825 pressing Methods 0.000 abstract description 13
- 238000003754 machining Methods 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 13
- 238000012545 processing Methods 0.000 description 7
- 238000004891 communication Methods 0.000 description 5
- 238000009434 installation Methods 0.000 description 4
- 230000005856 abnormality Effects 0.000 description 3
- 238000005070 sampling Methods 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
-
- G—PHYSICS
- G07—CHECKING-DEVICES
- G07C—TIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
- G07C3/00—Registering or indicating the condition or the working of machines or other apparatus, other than vehicles
- G07C3/02—Registering or indicating working or idle time only
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37348—Power, wattmeter voltage times current
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- the present invention relates to an equipment state detection device, an equipment state detection method, and a computer-readable recording medium, and in particular, an equipment state detection device, an equipment state detection method, and a computer readable medium used for equipment that holds a plurality of operating states.
- the present invention relates to a simple recording medium.
- Patent Document 1 discloses an apparatus that detects such an operation state of equipment by measuring a physical quantity with respect to the operation state of the equipment.
- the apparatus includes an integrated wattmeter, and measures an integrated power value consumed by the facility as a physical quantity, for example, every 10 minutes. Then, the difference between the two measured power integration values is calculated by the processor to obtain the average power amount. Accordingly, it is determined which operating state the obtained average power amount falls within the allowable detection range of the operating state, and the operating state of the equipment is detected.
- JP 2001-52221 A paragraph numbers 0021 to 0023, etc.
- the operating state of the facility is detected by obtaining the average electric energy. Therefore, in order to detect the operating state of the equipment, it is necessary to calculate a difference between two integrated power values measured by the processor.
- the measured integrated power value is stored in the auxiliary storage device and reported to the facility manager as a daily report or a monthly report.
- the situation surrounding the facilities is changing every moment, it is difficult for such reports to cope with the changes.
- An object of the present invention is to provide an equipment state detection device capable of accurately detecting the operation state of equipment by a simple method.
- Another object of the present invention is to provide a facility state detection method capable of accurately detecting the operation state of a facility by a simple method.
- Still another object of the present invention is to provide a computer-readable recording medium which records a facility state detection program capable of accurately detecting the operation state of the facility by a simple method.
- the equipment state detection apparatus is an equipment state detection apparatus capable of detecting the operation state of the equipment, and the operation state of the equipment includes an operating state in which work is being performed and a non-working state in which work is not being performed.
- Acquisition means for acquiring real-time status data relating to the operating state of the equipment, first detection means for detecting that the equipment is in operation based on the status data acquired by the acquisition means, and acquisition by the acquisition means Second state detecting means for detecting that the facility is in a non-operating state based on the state data.
- Such an equipment state detection device acquires real-time state data regarding the operation state of the equipment, and detects the operation state of the equipment from the acquired state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the facility can be accurately detected by a simple method.
- reporting the operating status of equipment it can be based on real-time status data.
- the equipment state detection device when the equipment state detection device is connected to the server via the network and notifies the server of the operation state of the equipment, data based on real-time state data can be notified.
- the acquisition means includes a start signal receiving means for receiving an input of a start signal output when the work is started by the equipment, and an end signal receiving means for receiving an input of an end signal output when the work is ended by the equipment.
- the first detecting means detects that the facility is in operation by the start signal received by the start signal receiving means, and the second detecting means is based on the end signal received by the end signal receiving means. Detecting that the equipment is not in operation. By doing so, it is possible to accurately detect the operating state only by determining the signal output by the facility during work.
- the non-operating state includes a standby state for waiting for work and a stop state for stopping work, and the end signal receiving means receives an input of a standby signal output when waiting for work by the equipment.
- the acquisition unit includes a measurement unit that measures a physical quantity that changes according to the operating state of the facility, and a setting unit that sets a predetermined threshold, and the detection unit includes at least one of a start signal and an end signal. If either one cannot be acquired, the operating state of the equipment is detected by comparing the physical quantity measured by the measuring means with a predetermined threshold set by the setting means. By doing so, even if the signal cannot be acquired, the operating state of the facility can be easily detected using the measured physical quantity.
- the acquisition unit includes a measurement unit that measures a physical quantity that changes in accordance with the operating state of the facility, and a setting unit that sets a predetermined threshold, and the detection unit sets the physical quantity measured by the measurement unit.
- the operation state of the equipment is detected by comparing with a predetermined threshold set by the means. By doing so, it is possible to easily detect the operating state of the facility only by comparing with a predetermined threshold value.
- the physical quantity includes a statistic converted based on the physical quantity. By doing so, it is possible to detect the operating state of the equipment based on various data.
- the physical quantity changes periodically, and the detection means compares the waveform of the first cycle with the waveform of the second cycle different from the first cycle, and the difference in waveform is within a predetermined range.
- a judging means for judging whether or not. By doing so, it is possible to detect an abnormality of the facility in accordance with the operating state of the facility.
- the detection means compares the waveform in the operating state of the first period waveform with the waveform in the operating state of the second period waveform.
- the equipment state detection device is connectable to a server via a network, and aggregates the operation state of the equipment detected by the detection means, and the operation state of the equipment collected by the aggregation means at a predetermined timing. And notification means for notifying to.
- the measured integrated power value is stored in the auxiliary storage device, and the data is aggregated and reported to the facility manager as daily and monthly reports.
- the situation surrounding the facilities is changing every moment, such a report is not sufficient.
- the predetermined timing is, for example, a predetermined time interval, an equipment operation cycle, or the like, and is an arbitrary timing according to the convenience of a user such as an equipment manager.
- running state of an installation can be notified.
- the operation data indicating the operation state of the equipment is gathered and notified, not just the output of the pulse signal, the amount of data communicated to the server is suppressed even when the sampling period becomes fine. be able to. Therefore, in a factory or the like where the equipment is installed, even when the number of equipment to be detected is large and the scale is large, the server can be stably notified. It is also effective from the viewpoint of energy saving.
- the present invention relates to a facility state detection method capable of detecting the operation state of a facility.
- the operating state of the equipment has an operating state in which work is being performed and a non-operating state in which work is not being performed, and the process of acquiring real-time state data regarding the operating state of the equipment and the acquired state data And a process of detecting that the facility is in a non-operating state based on the acquired state data.
- Such an equipment state detection method acquires real-time state data regarding the operation state of the equipment, and detects the operation state of the equipment from the acquired state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the facility can be accurately detected by a simple method.
- Still another aspect of the present invention relates to a computer-readable recording medium that records a facility state detection program that operates a computer as an facility state detection device that can detect the operation state of the facility.
- the equipment status detection program is provided with a step of acquiring real-time status data regarding the operating status of equipment including an operating status in which work is being performed and a non-operating status in which work is not being performed, and the acquired status data. And a step of detecting that the equipment is in an operating state and a step of detecting that the equipment is in a non-operating state based on the acquired state data.
- the computer-readable recording medium in which such an equipment state detection program is recorded is obtained by operating the computer as an equipment state detection device and acquiring real-time state data regarding the operation state of the equipment. By this, the operating state of the equipment is detected. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the equipment can be accurately detected by a simple method.
- the equipment state detection apparatus acquires real-time state data regarding the operation state of the equipment, and detects the operation state of the equipment from the acquired state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the facility can be accurately detected by a simple method.
- reporting the operating status of equipment it can be based on real-time status data.
- the equipment state detection device when the equipment state detection device is connected to the server via the network and notifies the server of the operation state of the equipment, data based on real-time state data can be notified.
- the facility state detection method acquires real-time state data related to the operation state of the facility, and detects the operation state of the facility from the acquired state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the facility can be accurately detected by a simple method.
- the computer-readable recording medium in which the equipment state detection program according to the present invention is recorded is obtained by operating the computer as an equipment state detection device and acquiring real-time state data relating to the operation state of the equipment.
- the operating state of the equipment is detected based on the state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the equipment can be accurately detected by a simple method.
- FIG. 7 is a block diagram illustrating a case where a waveform determination unit is added to a control unit in the equipment state detection device illustrated in the embodiment of FIG. 6.
- FIG. 7 is a block diagram illustrating a case where a notification unit and an aggregation unit are added to a control unit in the equipment state detection device illustrated in the embodiment of FIG. 6.
- It is a block diagram which shows the structure of the equipment state detection apparatus which measures an electric energy while using a signal.
- FIG. 1 is a perspective view showing an equipment state detection apparatus 10 according to an embodiment of the present invention.
- FIG. 2 is a block diagram illustrating a configuration of the equipment state detection apparatus 10.
- the equipment state detection apparatus 10 is attached to equipments, such as a processing machine, and detects the driving
- the operating state is a configuration including an operating state in which work is being performed and a non-operating state in which work is not being performed.
- the non-operating state includes a stop state in which work is stopped and a standby state in which work is waited.
- the equipment state detection device 10 has a quadrangular prism shape, and stores a control unit 11 that controls the whole equipment state detection device 10, an acquisition unit 16 that acquires predetermined data from the outside, data acquired by the acquisition unit 16, and the like. And a display unit 18 that displays data stored in the storage unit 13.
- the control unit 11 includes a detection unit 17 that detects the operating state of the equipment based on the data acquired by the acquisition unit 16.
- the acquisition unit 16 is connected to a logical terminal of the facility, has an input reception unit 12 that receives an input of a state signal from the facility, an operation button, and the like, and receives an operation input to the facility state detection device 10 from a user.
- the display unit 18 can display characters including numbers and alphabets.
- the display unit 18 can display symbols such as circles and triangles. Then, each operation state of the equipment is displayed in each color, the accumulated time of each operation state of the equipment is displayed, the contents operated by the user via the setting unit 15 are displayed, the equipment state detection An error or the like when the device 10 is attached to the facility is displayed. Thereby, the information which the equipment state detection apparatus 10 hold
- FIG. 3 is a diagram illustrating a case where the equipment state detection device 10 is attached to the press machine 9.
- the press machine 9 will be described with reference to FIG.
- the press machine 9 is connected to, for example, a roller conveyor 26 and the like, and processes the plate material 20 and the like conveyed by the roller conveyor 26. Then, when the processing is completed, the plate material 20 is conveyed onto the roller conveyor 26 again.
- plate material 20 is a direction which goes to the right from the left.
- the press working machine 9 has a plate member 20 mounted thereon and supports the plate member 20, a pressing unit 21 that presses a predetermined portion of the plate member 20 supported by the support unit 23, and a support unit 23.
- the equipment state detection device 10 is attached to the control unit 25. Then, the operating state of the press machine 9 is detected.
- the support part 23 is provided with a recessed part 23a having a predetermined shape, and the plate member 20 is placed so as to cover the recessed part 23a.
- the pressing unit 21 is connected to the control unit 25 via an input terminal, and can be moved up and down as indicated by an arrow III in FIG. And when moving downward, the location applicable to the recessed part 23a of the board
- the sensor 24 is a photoelectric sensor, for example, and is connected to the control unit 25 via an input terminal and notifies the detection result. Specifically, it is detected that the plate material 20 has been transported from the support portion 23 onto the roller conveyor 26, and the control portion 25 is notified accordingly.
- the control unit 25 controls the entire press machine 9. For example, the number of rotations of the motor is controlled, and power on and off for operating the press machine 9 is controlled. When the power is turned on, the rotation of the motor is started. When the power is turned off, the rotation of the motor is stopped.
- the control unit 25 outputs a status signal to the equipment status detection device 10.
- a start signal and an end signal are output.
- the start signal is a signal that is output when the press machine 9 starts work. Specifically, the start signal is a signal that is output when the pressing portion 21 starts to move downward.
- the end signal is a signal output when the press machine 9 ends the work, and the end signal includes a standby signal and a stop signal.
- the standby signal is a signal that is output when the pressing portion 21 finishes the upward movement.
- the stop signal is a signal that is output when notified from the sensor 24, that is, a signal that is output when the plate member 20 is transported from the support portion 23 onto the roller conveyor 26.
- FIG. 4 is a flowchart showing a case where the operation state of the press machine 9 is detected using the equipment state detection device 10.
- FIG. 5 is a diagram showing changes in the operating state of the press machine 9. This will be described with reference to FIGS.
- the power source of the press machine 9 is turned on at the time point P 0 in FIG. 5, and the plate material 20 is conveyed to the press machine 9 by the roller conveyor 26 at the time point P 1 in FIG. 5.
- the press machine 9 will output a start signal and will move the press part 21 below.
- the input reception part 12 receives the input of a start signal (in step S11 of FIG. 4, YES, and a step is abbreviate
- the equipment state detection apparatus 10 acquires real-time state data regarding the operation state of the press machine 9. That is, the status signal from the press machine 9 is status data regarding the operating state of the press machine 9.
- the input reception unit 12 operates as a start signal reception unit.
- the detection part 17 detects that the operation state of the press machine 9 is an operation state by reception of a start signal (S12).
- the operating state is a state in which the pressing member 21 is moved to process the plate material 20.
- the detection unit 17 operates as a first detection unit. At this time, the time of the P 2 in FIG.
- the press work machine 9 will output a standby signal.
- the input receiving unit 12 receives an input of a standby signal (NO in S11, YES in S13).
- the input reception unit 12 operates as a standby signal reception unit among the end signal reception units. If it does so, the detection part 17 will detect that the driving
- the standby state is a state where, for example, the plate member 20 is placed on the support portion 23, but the operation of the pressing portion 21 is finished, and the plate member 20 is not processed.
- the detection unit 17 operates as a second detection unit. At this time, the time of P 3 in FIG.
- the press machine 9 will output a stop signal.
- the input receiving unit 12 receives an input of a stop signal (NO in S11, NO in S13).
- the input reception unit 12 operates as a stop signal reception unit among the end signal reception units. If it does so, the detection part 17 will detect that the driving
- the stop state is, for example, a state where the plate material 20 is not placed on the support portion 23 and a state where the plate material 20 is not processed.
- the detection unit 17 operates as a second detection unit. At this time, the time of the P 4 in FIG.
- a plurality of plate materials 20 are sequentially transported to the press machine 9 at predetermined intervals. Then, as shown in FIG. 5, the start signal, the standby signal, and the stop signal are output every time the plate member 20 is processed, and the operation state, the standby state, and the stop state change periodically.
- the equipment state detection device 10 acquires real-time state data regarding the operation state of the equipment, and detects the operation state of the equipment based on the acquired state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the facility can be accurately detected by a simple method.
- the facility state detection apparatus 10 maintains the same operation state until the next state signal is output. Therefore, the detection of the operation state of the equipment is based on only the change in the signal, and the real-time state data is data on only the change in the signal. That is, in this embodiment, the real time is a time based only on a change in a signal output from the equipment, and can be distinguished from an operating state, a standby state, and a stopped state only by a signal output from the equipment. It is.
- the real-time state data is current facility state data.
- such an equipment state detection method acquires real-time state data regarding the operation state of the equipment, and detects the operation state of the equipment from the acquired state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the facility can be accurately detected by a simple method.
- the computer-readable recording medium in which the facility state detection program is recorded is obtained by operating the computer as the facility state detection device and acquiring real-time state data regarding the operation state of the facility.
- the operating state of the equipment is detected based on the state data. Therefore, it is possible to detect the operating state of the equipment based on real-time state data. In this case, it is not necessary to calculate the difference between the state data. As a result, the operating state of the equipment can be accurately detected by a simple method.
- the standby state and the stop state as the non-operating state can be detected, and the operation state of the equipment can be classified and detected in detail.
- the roller conveyor 26 may be configured to output a signal, and when the roller conveyor 26 operates, the operation signal may be output to accept the input, or when the roller conveyor 26 stops, a stop signal is output. By doing so, the input may be accepted.
- a sensor that detects that the plate material 20 is placed on the support portion 23 may be provided, and the sensor may notify the control unit 25 of the detection result to accept the input.
- FIG. 6 is a block diagram showing a configuration of an equipment state detection device 50 according to another embodiment of the present invention.
- the equipment state detection device 50 is configured to include a measurement unit 51 in the acquisition unit 55 as a difference from the above-described embodiment.
- the measuring unit 51 measures the power consumption of the equipment to which the equipment state detection device 50 is attached. Specifically, the power consumption of the facility is measured at predetermined intervals, for example, at intervals of 1 second. By doing so, the power consumption of the facility can be measured in detail.
- the measurement unit 51 operates as measurement means.
- the input receiving unit 52 receives input of power consumption data measured by the measuring unit 51.
- the setting unit 54 receives settings of the first threshold value and the second threshold value from the user.
- the setting unit 54 operates as setting means.
- the storage unit 53 stores power consumption data measured by the measurement unit 51.
- the storage unit 53 stores the first threshold and the second threshold set via the setting unit 54 as the predetermined threshold.
- the first threshold value and the second threshold value indicate predetermined power values, and are values serving as a reference for detecting the operating state of the facility.
- the display unit 58 also displays power consumption data and a threshold value via the control unit 56.
- solid line arrows in FIG. 6 indicate the flow of power consumption data
- alternate long and short dash line arrows indicate the signal flow in the operation received from the user.
- FIG. 7 is a diagram illustrating a case where the equipment state detection device 50 is attached to the wattmeter 37.
- the wattmeter 37 will be described with reference to FIG.
- the wattmeter 37 is attached to, for example, the control unit 25 of the press machine 9 described above, and measures the power consumption of the press machine 9. Specifically, the wattmeter 37 includes a terminal that serves as an interface with the outside, and measures the power consumption of the press machine 9. A plurality of wattmeters 37 are connected to the hub 35 via a communication line such as RS-485.
- the equipment state detection device 50 is attached to each wattmeter 37 and detects the operation state of each of the plurality of press machines 9.
- the hub 35 is connected to the server 36 via a communication line such as Ethernet (registered trademark).
- the server 36 is managed by, for example, a user who uses the equipment state detection device 50.
- the measuring unit 51 measures power consumption and constitutes a part of the wattmeter 37.
- FIG. 8 is a flowchart showing a case where the operation state of the press machine 9 is detected using the equipment state detection device 50.
- FIG. 9 is a graph showing the power consumption of the press machine 9.
- the first threshold value w 0 is indicated by a one-dot chain line
- the second threshold value w 1 is indicated by a two-dot chain line.
- the first threshold value w 0 is 0.4 kW
- the second threshold value w 1 is 0.7 kW. This will be described with reference to FIGS.
- the measurement unit 51 starts measuring power consumption at a predetermined interval, for example, at intervals of 1 second (S21), and the input receiving unit 52 receives input of measured power consumption data.
- the equipment state detection apparatus 50 acquires real-time state data regarding the operation state of the press machine 9. That is, the power consumption data of the press machine 9 is state data regarding the operating state of the press machine 9.
- the measurement unit 51 operates as an acquisition unit. One data of power consumption measured is indicated by t 0 in FIG. 9, a 0.3 kW.
- the detection unit 57 compares the data of the power consumption with the first threshold value w 0. Then, the data of the power consumption is determined as the first threshold value w 0 is smaller than (in S22, YES), the operation state of the press machine 9 is detected as the stop state (S23).
- the stopped state is a state immediately after the power of the press machine 9 is turned on, for example, and is a state in which the plate material 20 is not being conveyed by the roller conveyor 26.
- the plate material 20 is conveyed to the press machine 9 by the roller conveyor 26.
- one data of power consumption measuring unit 51 has measured is indicated by t 1 in FIG. 9, a 0.6 kW.
- the detection unit 57 compares the data of the power consumption with the first threshold value w 0. Then, the data of the power consumption is determined to be larger than the first threshold value w 0 (in S22, NO), the detection unit 57 compares the data of the power consumption with the second threshold value w 1. Then, the data of the power consumption is determined with a second threshold value w 1 is smaller than (in S24, YES), the operation state of the press machine 9 is detected as the standby state (S25).
- the standby state is a state in which, for example, the plate material 20 is being conveyed by the roller conveyor 26, but has not reached the support portion 23 and the plate material 20 is not processed.
- the detection unit 57 operates as a second detection unit.
- the detection unit 57 compares the data of the power consumption with the first threshold value w 0. Then, the data of the power consumption is determined to be larger than the first threshold value w 0 (in S22, NO), the detection unit 57 compares the data of the power consumption with the second threshold value w 1. Then, the data of the power consumption is determined with a second larger threshold value w 1 (at S24, NO), the operation state of the press machine 9 is detected as the operating state (S26).
- the operating state is a state in which the pressing member 21 is moved to process the plate material 20.
- the detection unit 57 operates as first detection means.
- the press machine 9 moves the pressing portion 21 upward, and finishes the processing of the plate material 20.
- one data of power consumption measuring unit 51 has measured is indicated by t 3 in FIG. 9, a 0.6 kW.
- the detection unit 57 compares the data of the power consumption with the first threshold value w 0. Then, the data of the power consumption is determined to be larger than the first threshold value w 0 (in S22, NO), the detection unit 57 compares the data of the power consumption with the second threshold value w 1. Then, the data of the power consumption is determined with a second threshold value w 1 is smaller than (in S24, YES), the press machine 9 is detected as the standby state (S25).
- the equipment state detection device 50 acquires real-time state data regarding the operation state of the equipment, and detects the operation state of the equipment based on the acquired state data. That is, in this embodiment, the operating state of the facility is detected based on the power consumption data measured by the measuring unit 51. Therefore, since it is only necessary to compare with a predetermined threshold value, the operating state of the facility can be easily detected.
- the equipment state detection device 50 detects the operation state of the equipment by comparing the power consumption data measured at intervals of 1 second with a threshold value each time. Therefore, the operation state of the equipment is detected regardless of whether or not the operation state has changed, and real-time state data is a fixed time shorter than the duration of each operation state regardless of whether or not the operation state has changed. It is the data notified by. That is, in this embodiment, the real time is a time in which the operating state, the standby state, and the stopped state can be distinguished at intervals shorter than the duration of each operation state of the equipment.
- a plurality of plate materials 20 are sequentially conveyed to the press machine 9 at predetermined intervals. If it does so, as shown in FIG. 9, as for the data of power consumption, a standby state and an operation state will change periodically for every process of the some board
- the operating state of the press machine 9 may be detected by comparing changes in power consumption. Specifically, a change in power consumption during processing of the first plate material, that is, a waveform of the first period in standby a and operation a in FIG. 9 and a change in power consumption during processing of the second plate material. That is, the waveform of the second period in standby b and operation b in FIG. 9 is compared. Then, it is determined whether the waveforms are the same. If the waveforms are the same, for example, it can be determined that the quality of the processed product processed by the press machine 9 is stable, and if the waveforms are different, it is determined that the quality varies. be able to. As a result, it is possible to detect abnormalities such as a fatigue state and a load state of the press machine 9.
- FIG. 10 is a block diagram illustrating a case where the waveform determination unit 59 is added to the control unit 56 in the equipment state detection device 50 illustrated in the embodiment of FIG.
- symbol is attached
- the waveform determination unit 59 determines whether or not the waveform difference is within a predetermined range.
- the waveform determination unit 59 operates as a determination unit.
- the waveform determination unit 59 calculates a maximum value and a minimum value of power consumption per cycle, so that at least one of the maximum value and the minimum value of power consumption is a predetermined amount of power. It may be determined whether or not. Also, by calculating an average value of power consumption per cycle, the average value of the first cycle is compared with the average value of the second cycle, and it is determined whether or not the same value is obtained. May be. Further, a ratio between the operating state and the standby state may be calculated for one cycle, and it may be determined whether or not the ratio becomes a constant value. For example, the elapsed time between standby a and operation a in FIG.
- the ratio A between the time of standby a and the time of operation a is calculated. Further, the elapsed time between the standby b and the operation b in FIG. 9 is calculated, and the ratio B between the standby b time and the operation b time is calculated. Then, it may be determined whether the ratio A and the ratio B are constant values.
- only the operating state of the waveform may be determined. That is, it may be determined whether or not the waveforms are the same by comparing the waveform in operation a of the first cycle in FIG. 9 with the waveform in operation b of the second cycle in FIG. . By doing so, it is possible to easily detect the wear of the press machine 9 when the press machine 9 is in operation, the situation change with respect to the press machine 9 not intended by the user using the press machine 9, and the like. it can.
- the period may change based on the maximum value of power consumption.
- the example in which the first threshold value w 0 is 0.4 kW and the second threshold value w 1 is 0.7 kW has been described.
- a value corresponding to the press machine 9 may be obtained by performing a test or the like in advance.
- the present invention is not limited to this, and for example, according to the operating state of the press machine 9.
- a plurality of thresholds such as three or four types may be provided.
- a waveform pattern statistic such as an RMS (Root Mean Square) value, Skewness, or Flatness may be used, or detection may be performed using a specific power spectrum.
- RMS Root Mean Square
- rush power may be generated.
- Such noise may be removed and the driving state may be detected.
- the measured power consumption is inrush power
- the power consumption data after elapse is used without using the power consumption data while the inrush power is generated.
- the timing for starting the measurement of the power consumption is the timing when the power of the press machine 9 is turned on.
- the present invention is not limited to this example. Measurement may be started before 9 is turned on.
- the present invention is not limited to this, and may be performed at intervals of less than 1 second, and can be arbitrarily set. It's okay. And according to a driving
- the present invention is not limited to this, and a physical quantity that changes according to the operating state of the press machine 9 may be measured. Good. For example, it may be a current value.
- the operating state of the press machine 9 may be detected using a statistic converted based on a physical quantity. By doing so, it is possible to detect the operating state of the equipment based on various data.
- a statistic a time average value, an RMS value, a short time power spectrum value, etc. are employable, for example.
- the present invention is not limited to this, and the measured power consumption is used for a predetermined time such as 5 minutes.
- the integrated power value may be compared with a predetermined threshold value to detect the operating state of the press machine 9.
- the display unit 58 has been described with respect to the example of displaying power consumption data via the control unit 56.
- the display unit 58 is not limited to this, and the display unit 58 displays the power consumption data.
- the data may be displayed by notifying the directly measured data. Further, when it is not necessary for the user, it may not be displayed on the display unit 58.
- notification may be made via the control unit 56.
- the equipment state detection device 50 may collect the operation state of the equipment and notify the server 36 via the hub 35 of the integrated operation state at a predetermined timing.
- the predetermined timing is, for example, a predetermined time interval, an equipment operation cycle, or the like, and is an arbitrary timing according to the convenience of a user such as an equipment manager. Thereby, according to a user's convenience, the driving
- FIG. 11 is a block diagram showing a case where the notification unit 49 and the aggregation unit 48 are added to the control unit 56 in the equipment state detection device 50 shown in the embodiment of FIG. In addition, since it is the same as that of FIG.
- the notification unit 49 is connected to a network or the like, and notifies the operation state of the equipment detected by the equipment state detection device 50 to the outside.
- the aggregating unit 48 aggregates data on the operation state of the equipment.
- the operation state becomes non-operation state after 10 minutes of continuous operation
- the operation state is not notified every minute but at the timing when the operation state ends for 10 minutes. Notify that the operating status of is finished.
- the aggregation of the operating state of equipment means that if the operating state is continued for 10 minutes, the operating state is not notified every minute, but is notified all at once for 10 minutes. is there. Therefore, the aggregating unit 48 aggregates a plurality of notifications at a time. Thereby, the amount of data communicated to the server 36 can be suppressed.
- the aggregation unit 48 operates as an aggregation unit
- the notification unit 49 operates as a notification unit.
- the notification of the operating state of the equipment to the server 36 is not limited to data based on power consumption, but may include data based on signals such as a start signal and an end signal.
- the equipment state detection apparatus 50 demonstrated the example connected with the server 36 via the hub 35, a structure provided with an equipment state detection apparatus and a server in this way. It is good also as an equipment state detection system.
- the operation state may be notified as data to be notified to the server, or the above integrated power value may be notified according to the communication state or the like.
- FIG. 12 is a block diagram showing a configuration of an equipment state detection device 60 that uses a signal and measures the amount of electric power. That is, the configuration of the equipment state detection apparatus 10 shown in FIG. 2 and the construction of the equipment state detection apparatus 50 shown in FIG. 6 are combined.
- the dotted arrow indicates the flow of the status signal
- the solid line arrow indicates the power consumption data flow
- the alternate long and short dash arrow indicates the signal in the operation received from the user. The flow is shown.
- the detection result of the driving state is different, it is possible to adopt a high priority result by giving a priority in advance, and for each result The result to be adopted may be selected by weighting according to the site. Also, in the embodiment using the signal as shown in FIGS. 2 to 5, if the signal cannot be acquired from the facility, such as failure to acquire the signal from the facility, the amount of power as shown in FIGS. May be measured to detect the operating state of the equipment.
- FIG. 13 is a flowchart showing a case where the amount of electric power is measured and the operating state of the facility is detected when a signal from the facility cannot be obtained.
- Steps S31 to S34 are the same as steps S11 to S14 of FIG.
- the input receiving unit 62 measures the power consumption (S35).
- the input receiving unit 62 receives input of measured power consumption data. If the detection unit 67 compares the power consumption data with the first threshold value and determines that the power consumption data is smaller than the first threshold value (YES in S36), the operation state of the equipment is in the stopped state. It is detected that there is (S37).
- the detection unit 67 determines in S36 that the power consumption data is greater than the first threshold value (NO in S36), the power consumption data is compared with the second threshold value. If it is determined that the power consumption data is smaller than the second threshold (YES in S38), the operating state of the equipment is detected as a standby state (S39).
- the detection unit 67 determines in S38 that the power consumption data is larger than the second threshold value (NO in S38), the operation state of the equipment is detected as being in an operating state (S40).
- the threshold value may be adjusted.
- the equipment state detection devices 10, 50, 60 can accurately detect the operation state of the equipment, for example, the power consumption in the non-operating state is reduced, and the operation rate of the equipment is improved. Can do. For example, when the power consumption in the standby state is large, it can be grasped that there are many plate materials 20 waiting to be processed on the roller conveyor 26 in front of the press machine 9. In such a case, a predetermined measure can be taken and wasteful power consumption can be reduced. As a result, power saving of the facility can be achieved.
- the equipment state detection apparatus 10,50,60 demonstrated the example which is a structure provided with the memory
- the equipment state detection devices 10, 50, 60 are configured to include the input receiving units 12, 52, 62 .
- the present invention is not limited to this, and FIG.
- the data can be directly acquired from the measurement units 51 and 61 such as detection by the power consumption of the facility as in the embodiment shown in FIG.
- the non-operating state includes the stopped state and the standby state has been described.
- the present invention is not limited to this, and the stop state may be only the standby state or only the standby state. May be.
- the equipment state detection devices 10, 50, 60 may be configured to include a buzzer or the like. Thereby, for example, when the standby state continues, a warning can be easily issued.
- This invention is effectively used when detecting the operating state of the equipment.
- Press processing machine 10, 50, 60 equipment state detection device, 11, 56, 66 control unit, 12, 52, 62 input reception unit, 13, 53, 63 storage unit, 15, 54, 64 setting unit, 16, 55, 65 acquisition unit, 17, 57, 67 detection unit, 18, 58, 68 display unit, 51, 61 measurement unit, 20 plate material, 21 pressing unit, 23 support unit, 23a recess, 24 sensor, 25 control unit, 26 Roller conveyor, 35 hub, 36 server, 37 power meter, 48 aggregation unit, 49 notification unit, 59 waveform determination unit.
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Abstract
Description
Claims (11)
- 設備の運転状態を検知可能な設備状態検知装置であって、
前記設備の運転状態は、作業を行っている稼動状態と、作業を行っていない非稼動状態とを有し、
前記設備の運転状態に関するリアルタイムの状態データを取得する取得手段と、
前記取得手段により取得した前記状態データにより、前記設備が前記稼動状態であることを検知する第一の検知手段と、
前記取得手段により取得した前記状態データにより、前記設備が前記非稼動状態であることを検知する第二の検知手段とを備える、設備状態検知装置。 - 前記取得手段は、前記設備により、前記作業を開始する際に出力される開始信号の入力を受け付ける開始信号受付手段と、前記設備により、前記作業を終了する際に出力される終了信号の入力を受け付ける終了信号受付手段とを含み、
前記第一の検知手段は、前記開始信号受付手段により受け付けた前記開始信号により、前記設備が前記稼動状態であることを検知し、
前記第二の検知手段は、前記終了信号受付手段により受け付けた前記終了信号により、前記設備が前記非稼動状態であることを検知する、請求項1に記載の設備状態検知装置。 - 前記非稼動状態は、前記作業を待機する待機状態と、前記作業を停止する停止状態とを含み、
前記終了信号受付手段は、前記設備により、前記作業を待機する際に出力される待機信号の入力を受け付ける待機信号受付手段と、前記設備により、前記作業を停止する際に出力される停止信号の入力を受け付ける停止信号受付手段とを含み、
前記第二の検知手段は、前記待機信号受付手段により受け付けた前記待機信号により、前記設備が前記待機状態であることを検知し、前記停止信号受付手段により受け付けた前記停止信号により、前記設備が前記停止状態であることを検知する、請求項2に記載の設備状態検知装置。 - 前記取得手段は、前記設備の運転状態に応じて変化する物理量を計測する計測手段と、所定の閾値を設定する設定手段とを含み、
前記検知手段は、前記開始信号および前記終了信号のうちの少なくともいずれか一方を取得できなければ、前記計測手段により計測した前記物理量を、前記設定手段により設定した前記所定の閾値と比較することにより、前記設備の運転状態を検知する、請求項2に記載の設備状態検知装置。 - 前記取得手段は、前記設備の運転状態に応じて変化する物理量を計測する計測手段と、所定の閾値を設定する設定手段とを含み、
前記検知手段は、前記計測手段により計測した前記物理量を、前記設定手段により設定した前記所定の閾値と比較することにより、前記設備の運転状態を検知する、請求項1に記載の設備状態検知装置。 - 前記物理量は、前記物理量に基づいて変換された統計量を含む、請求項5に記載の設備状態検知装置。
- 前記物理量は、周期的に変化し、
前記検知手段は、第一の周期の波形と、前記第一の周期とは異なる第二の周期の波形とを比較して、波形の差が所定の範囲内であるか否かを判断する判断手段を含む、請求項5に記載の設備状態検知装置。 - 前記検知手段は、前記第一の周期の波形のうちの前記稼動状態における波形と、前記第二の周期の波形のうちの前記稼動状態における波形とを比較する、請求項7に記載の設備状態検知装置。
- 前記設備状態検知装置は、ネットワークを介してサーバに接続可能であって、
前記検知手段により検知した前記設備の運転状態を集約する集約手段と、
前記集約手段により集約した前記設備の運転状態を、所定のタイミングで前記サーバへ通知する通知手段とを備える、請求項1に記載の設備状態検知装置。 - 設備の運転状態を検知可能な設備状態検知方法であって、
前記設備の運転状態は、作業を行っている稼動状態と、作業を行っていない非稼動状態とを有し、
前記設備の運転状態に関するリアルタイムの状態データを取得する過程と、
取得した前記状態データにより、前記設備が前記稼動状態であることを検知する過程と、
取得した前記状態データにより、前記設備が前記非稼動状態であることを検知する過程とを備える、設備状態検知方法。 - コンピュータを、設備の運転状態を検知可能な設備状態検知装置として作動させる設備状態検知用プログラムを記録したコンピュータ読み取り可能な記録媒体であって、
前記設備状態検知用プログラムは、コンピュータに、
作業を行っている稼動状態と、作業を行っていない非稼動状態とを含む設備の運転状態に関するリアルタイムの状態データを取得するステップと、
取得した状態データにより、設備が稼動状態であることを検知するステップと、
取得した状態データにより、設備が非稼動状態であることを検知するステップとを実行させる、コンピュータ読み取り可能な記録媒体。
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CN2010800385343A CN102483623A (zh) | 2009-10-30 | 2010-10-25 | 设备状态检测装置、设备状态检测方法、以及计算机可读取的记录介质 |
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EP2495629A4 (en) | 2013-04-10 |
US20120191414A1 (en) | 2012-07-26 |
KR101413896B1 (ko) | 2014-06-30 |
JP2011118874A (ja) | 2011-06-16 |
JP5402896B2 (ja) | 2014-01-29 |
EP2495629A1 (en) | 2012-09-05 |
CN102483623A (zh) | 2012-05-30 |
KR20120032569A (ko) | 2012-04-05 |
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