WO2016143072A1 - Programmable logic controller - Google Patents

Programmable logic controller Download PDF

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Publication number
WO2016143072A1
WO2016143072A1 PCT/JP2015/057035 JP2015057035W WO2016143072A1 WO 2016143072 A1 WO2016143072 A1 WO 2016143072A1 JP 2015057035 W JP2015057035 W JP 2015057035W WO 2016143072 A1 WO2016143072 A1 WO 2016143072A1
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data
storage unit
normal
data storage
input
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PCT/JP2015/057035
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French (fr)
Japanese (ja)
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啓文 甲斐
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三菱電機株式会社
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Priority to PCT/JP2015/057035 priority Critical patent/WO2016143072A1/en
Priority to JP2016513936A priority patent/JPWO2016143072A1/en
Priority to TW105105635A priority patent/TW201638684A/en
Publication of WO2016143072A1 publication Critical patent/WO2016143072A1/en

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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
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
    • 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

Definitions

  • the present invention relates to a programmable logic controller that controls a control target system by executing a control program transferred from a programming tool.
  • the programmable logic controller controls the entire control target system by exchanging various control data with the control target system, but monitors the control data in order to confirm that the control is correctly performed. To do.
  • a production apparatus when a series of processing is performed while parts are conveyed by a belt conveyor, the torque control of the motor that is the power of the belt conveyor is performed in conjunction with the position detection timing by the sensor. At this time, input data from the sensor and output data to the motor are monitored to check whether the control is normally performed. If it is determined by monitoring that the state of the controlled system is abnormal, the controlled system is stopped and the cause is investigated.
  • control data as described above is stored in the programmable logic controller and the data collected from the system to be controlled is stored internally, and the value is compared with a predetermined threshold value.
  • a predetermined threshold value There is a method of automatically determining whether or not the process is being performed.
  • many of the conventional programmable logic controllers determine whether the collected data at a certain time is normal or abnormal based only on whether or not it exceeds a predetermined threshold, and based on the trend of time-series data over a certain period. It is not judged whether it is normal or abnormal. For this reason, if the difference between the collected data at a certain time and the threshold value is small, even if the control system has an abnormality, the abnormality may not be detected.
  • it is not enough to determine the state at a certain time to determine whether the system to be controlled is normal or abnormal and it is possible to determine whether it is normal or abnormal by evaluating trends over a certain period. It can be done with high accuracy.
  • Patent Document 1 the trend graph of the measurement data of the control target system and the trend graph of the normal measurement data measured in the past are displayed on the same screen so that the monitor can view the current measurement data. It is possible to determine whether it is normal or abnormal.
  • Patent Document 2 measurement data of a control target system is collected and stored, normal data serving as a determination criterion is stored from the stored measurement data, measurement data and normal data are extracted, compared by statistical processing, When a change is determined, a portion determined as a state change in the trend graph of the evaluation index is highlighted.
  • Patent Document 1 determines whether the monitor is normal or abnormal by visually checking the trend graph, the monitor may miss it even if an abnormal state occurs on the trend graph.
  • the said patent document 2 can determine automatically whether it is normal or abnormal, it displays a trend graph with respect to the evaluation index which performed the statistical process with respect to normal data and measurement data Therefore, it is impossible to intuitively confirm what kind of trend divergence has occurred between normal data and measurement data.
  • the present invention has been made in view of the above, and can determine whether a normal state or an abnormal state without manual intervention, and easily determine what kind of trend divergence has occurred between normal data and measurement data.
  • An object of the present invention is to obtain a programmable logic controller that can be recognized.
  • the present invention is a programmable logic controller that controls a system to be controlled by executing a control program transferred from a programming tool, and during execution of the control program,
  • a data collection unit that collects input / output data with the control target system, a collection data storage unit that stores input / output data collected by the data collection unit, and a specified portion of the input data stored in the collection data storage unit Is stored as normal input / output data, the input / output data is acquired from the collected data storage unit and the normal data storage unit, the input / output data acquired from the collected data storage unit, and the normal data.
  • An abnormality determination unit that determines whether Luke, characterized by comprising a display control unit for displaying the determination result display screen for displaying the determination result by the abnormality determination unit graphically engineering tool.
  • the programmable logic controller according to the present invention can determine whether it is in a normal state or an abnormal state without human intervention, and can easily recognize what kind of trend divergence has occurred between normal data and measurement data. There is an effect.
  • the block diagram which shows the structure of the programmable logic controller concerning embodiment of this invention The figure which shows the hardware constitutions of the programmable logic controller concerning embodiment.
  • the figure which shows an example of the system which used the programmable logic controller concerning embodiment for control of the component processing apparatus which performs a series of processes, conveying components with a belt conveyor The figure which shows an example of the data collection setting of the programmable logic controller concerning embodiment
  • the flowchart which shows the data registration procedure to the normal data storage part of the programmable logic controller concerning an embodiment The figure which shows an example of the registration screen which the normal data registration part of the programmable logic controller concerning embodiment displays on a programming tool
  • the flowchart which shows the procedure of the abnormality determination setting of the programmable logic controller concerning an embodiment The figure which shows an example of the abnormality determination setting screen of the programm
  • FIG. 1 is a diagram showing a configuration of a system that controls a system to be controlled by a programmable logic controller according to an embodiment of the present invention.
  • the programmable logic controller 1 holds the control program transferred from the programming tool 2 and executes the held control program to control the control target system 3.
  • the programming tool 2 is a computer in which a programming tool program is installed, and is realized by the computer executing the programming tool program.
  • the programming tool 2 does not necessarily need to be connected to the programmable logic controller 1 at all times, except when transferring a control program and when setting data collection settings, abnormality determination settings and abnormality determination described later. Alternatively, the programmable logic controller 1 may be disconnected.
  • FIG. 2 is a block diagram showing the configuration of the programmable logic controller according to the embodiment of the present invention.
  • the programmable logic controller 1 includes a data collection unit 14 that collects input / output data with the control target system according to the data collection setting 13 during execution of the control program, and a collected data storage that stores the input / output data collected by the data collection unit 14 11, a specified portion of the input data stored in the collected data storage unit 11 is stored as normal input / output data, and the input data stored in the collected data storage unit 11 is stored.
  • Input / output data is acquired from the normal data registration unit 15 for registering the output data in the normal data storage unit 12, the collected data storage unit 11 and the normal data storage unit 12, and input / output data for a certain period is obtained according to the abnormality determination setting 16.
  • the abnormality determination unit 17 that determines whether the control target system is normal or abnormal and the determination by the abnormality determination unit 17 Results and a display control unit 18 to be displayed on the programming tool 2 graphically.
  • the data collection unit 14 collects two types of data, that is, input data input from the control target system 3 and output data output to the control target system 3 according to the data collection setting 13, and stores the collected data in the collected data storage unit 11. .
  • the input data and the output data are collectively referred to as input / output data.
  • FIG. 3 is a diagram illustrating a hardware configuration of the programmable logic controller according to the embodiment.
  • the programmable logic controller 1 includes a storage device 22 that stores the control program 26, an arithmetic device 21 that executes the control program 26, output data that is output to the control target system 3 during execution of the control program 26, and the control target system 3. It has an internal memory 23 that holds input data to be input, and a communication device 25 for communication with other devices.
  • the data collection unit 14, normal data registration unit 15, abnormality determination unit 17, and display control unit 18 illustrated in FIG. 2 are realized by the arithmetic device 21 and the internal memory 23.
  • a plurality of arithmetic devices and a plurality of memories may cooperate to execute the above function.
  • the collected data storage unit 11 and the normal data storage unit 12 are realized by the storage device 22.
  • FIG. 4 is a diagram illustrating an example of a system in which the programmable logic controller according to the embodiment is used to control a component processing apparatus that performs a series of processes while conveying components by a belt conveyor.
  • the component processing apparatus 4 that is the control target system 3 includes a belt conveyor 41 that conveys the component 40, a sensor 42 that detects the position of the component 40, and a motor 43 that serves as power for the belt conveyor 41.
  • the component processing apparatus 4 that performs a series of processing while conveying the component 40 by the belt conveyor 41 is the control target system 3
  • data input from the sensor 42 and written in the internal memory 23 and processed by the control program 26 are stored. The data acquired from the controlled system 3.
  • the torque control value data of the motor 43 written to the internal memory 23 by the control program 26 and output from the programmable logic controller 1 to the motor 43 is data output to the control target system 3.
  • Data acquired from the control target system 3 and data output to the control target system 3 are stored at specific addresses in the internal memory 23.
  • FIG. 5 is a diagram illustrating an example of data collection setting of the programmable logic controller according to the embodiment.
  • the data collection setting 13 indicates the setting contents for the operation of collecting the input / output data of the data collection unit 14. As shown in FIG. 5, the data collection setting 13 specifies data to be collected from the control target system 3 and defines a period for collecting data. The period for collecting data is defined so as to be synchronized with the scan that is the operation cycle of the programmable logic controller 1.
  • the data collection setting 13 can be set by the programming tool 2. That is, the programmable logic controller 1 can set the data collection setting 13 by an operation on the programming tool 2.
  • FIG. 6 is a flowchart showing the data collection operation of the programmable logic controller according to the embodiment.
  • the data collection unit 14 reads the data collection setting 13.
  • the data collection unit 14 collects input / output data from the internal memory 23 according to the data collection setting 13.
  • the data collecting unit 14 stores the input / output data collected from the internal memory 23 in the collected data storage unit 11 together with the collection time information.
  • the data collection unit 14 acquires the input data input from the control target system 3 and the output data output to the control target system 3 at preset intervals, and the collected data storage unit together with the collection time information 11.
  • the normal data registration unit 15 registers, in the normal data storage unit 12, the collection data stored in the collection data storage unit 11 during the period specified in the data collection setting 13 as determined by the system administrator. To do. Registration of data from the collected data storage unit 11 to the normal data storage unit 12 is executed in the following procedure.
  • FIG. 7 is a flowchart illustrating a data registration procedure in the normal data storage unit of the programmable logic controller according to the embodiment.
  • FIG. 8 is a diagram illustrating an example of a registration screen displayed on the programming tool by the normal data registration unit of the programmable logic controller according to the embodiment.
  • the normal data registration unit 15 causes the programming tool 2 to display a normal data registration screen 151 including the trend graph 152 of the collected data stored in the collected data storage unit 11.
  • step S ⁇ b> 12 the normal data registration unit 15 receives an operation for specifying a period by the system administrator on the normal data registration screen 151 on the programming tool 2 through the communication device 25. On the programming tool 2, the period can be specified in units of days, hours, minutes, and seconds.
  • the start time may be specified by inputting date / time / minute / second in the start time column 153 or may be specified by performing an operation of moving the start time display bar 154.
  • the end time may be specified by inputting date / time / minute / second in the end time column 155 or may be specified by performing an operation of moving the end time display bar 156.
  • the registration button 157 is pressed after designating the start time and end time, the setting of the start time and end time is completed.
  • step S ⁇ b> 13 the normal data registration unit 15 acquires data for the period specified on the normal data registration screen 151 from the collected data storage unit 11 and registers it in the normal data storage unit 12.
  • the abnormality determination unit 17 acquires the data stored in the collected data storage unit 11 and the data stored in the normal data storage unit 12 in accordance with the abnormality determination setting 16, and compares them to obtain the collected data storage unit 11 Determine whether the data stored in is normal or abnormal.
  • the abnormality determination unit 17 determines whether the difference between normal data and collected data during a certain period is equal to or less than a threshold value set prior to the determination. A determination method for performing the determination and a period for comparing the data during the determination are set.
  • the abnormality determination setting 16 can be set by the programming tool 2. That is, the programmable logic controller 1 can set the abnormality determination setting 16 by an operation on the programming tool 2.
  • the determination method set in the abnormality determination setting 16 can be selected from a plurality of methods.
  • the abnormality determination unit 17 compares the input / output data acquired from the collected data storage unit 11 and the normal input / output data acquired from the normal data storage unit 12 by a method selected from a plurality of methods. Is possible.
  • One of the determination methods that can be set in the abnormality determination setting 16 is a method for detecting a pattern in which the amount of change in the trend of collected data exceeds a predetermined threshold with respect to the amount of change in the trend of normal data to be compared. By using this method, it is possible to detect an abnormality of the control system based on the threshold value without relying on human hands.
  • FIG. 9 is a flowchart illustrating a procedure for setting abnormality determination in the programmable logic controller according to the embodiment.
  • FIG. 10 is a diagram illustrating an example of an abnormality determination setting screen of the programmable logic controller according to the embodiment.
  • the abnormality determination unit 17 causes the programming tool 2 to display the abnormality determination setting screen 161, and the normal data by the system administrator in the normal data designation field 162 in the abnormality determination setting screen 161 displayed on the programming tool 2 is displayed.
  • a selection operation is accepted through the communication device 25. That is, a list of normal data registered in the normal data storage unit 12 can be confirmed by the programming tool 2 and normal data to be compared can be selected from the list of normal data.
  • the abnormality determination unit 17 receives an operation of selecting a comparison start time by the system administrator in the comparison start time designation field 163 in the abnormality determination setting screen 161 displayed on the programming tool 2 through the communication device 25.
  • the comparison start time is a time at which the comparison between the selected normal data and the collected data is started. In the present embodiment, since comparison is made with respect to the data trend, it is necessary to match the comparison start point.
  • a comparison start time is designated for each of normal data and collected data. Note that when the abnormality determination is performed while causing the programmable logic controller 1 to control the control target system 3, the start time of the collected data is a future time.
  • step S23 the abnormality determination unit 17 accepts an operation of selecting a determination method by the system administrator in the determination method designation field 164 in the abnormality determination setting screen 161 displayed on the programming tool 2 through the communication device 25.
  • step S ⁇ b> 24 the abnormality determination unit 17 performs an operation of specifying a time interval when calculating the trend change amount in the time interval specification field 165 in the abnormality determination setting screen 161 displayed on the programming tool 2 through the communication device 25. Accept.
  • the abnormality determination unit 17 is the absolute value of the difference between the change amount of normal data and the change amount of collected data in the threshold value designation field 166 in the abnormality determination setting screen 161 displayed on the programming tool 2.
  • An operation for designating an allowable upper limit value as a threshold value is accepted through the communication device 25.
  • the threshold is a setting item that needs to be adjusted depending on the target system.
  • the abnormality determination unit 17 stores the contents set in the abnormality determination setting screen 161 in the storage device 22 and stores the abnormality determination setting 16. To.
  • the abnormality determination unit 17 determines whether the collected data is normal or abnormal according to the abnormality determination setting 16. When the abnormality determination unit 17 determines by detecting a pattern in which the trend change amount of the collected data exceeds the predetermined threshold value with respect to the trend change amount of the normal data to be compared as described above, Determine whether the procedure is normal or abnormal.
  • FIG. 11 is a flowchart illustrating a flow of processing in which the programmable logic controller according to the embodiment determines whether the collected data is normal or abnormal.
  • the abnormality determination unit 17 acquires normal data at the current time from the normal data storage unit 12 and acquires collected data from the collected data storage unit 11.
  • the abnormality determination unit 17 confirms whether the time ti has elapsed. If the time ti has not elapsed, No is returned in step S32, and step S32 is repeated. If the time ti has elapsed, Yes is determined in step S32, and the process proceeds to step S33.
  • step S33 the abnormality determination unit 17 acquires normal data after the elapse of time ti from the normal data storage unit 12, and acquires collected data after the elapse of time ti from the collected data storage unit 11.
  • step S34 the abnormality determination unit 17 calculates the change amount of the normal data trend and the change amount of the collected data trend.
  • the amount of trend change in the period from time t1 to time t2 after time t1 can be calculated by the following equation (1).
  • step S35 the abnormality determination unit 17 calculates the difference between the change amount of the normal data trend and the change amount of the collected data trend.
  • step S36 the abnormality determination unit 17 confirms whether the absolute value of the difference between the change amount of the normal data trend and the trend change amount of the collected data exceeds the threshold value. If the absolute value of the difference between the change amount of the normal data trend and the change amount of the collected data trend exceeds the threshold value, Yes is made in step S36, and the display control unit 18 warns the programming tool 2 in step S37. Is displayed and an abnormal warning is notified. The warning is displayed by highlighting the corresponding part and the difference on the trend graph of normal data and the trend graph of collected data. After step S37, the process ends. If the absolute value of the difference between the change amount of the trend of normal data and the change amount of the trend of the collected data does not exceed the threshold value, No is returned in step S36, and the process is terminated.
  • the display control unit 18 superimposes the trend graph of normal data acquired from the normal data storage unit 12 and the trend graph of data currently being collected by the data collection unit 14 in accordance with the abnormality determination setting 16. In addition, when the abnormality determination unit 17 determines whether the abnormality is normal or not as a result of the determination, the corresponding part determined to be abnormal on the trend graph is highlighted.
  • FIG. 12 is a diagram illustrating an example of a determination result display screen displayed on the programming tool when the abnormality determination unit of the programmable logic controller according to the embodiment determines an abnormality.
  • the determination result display screen 181 a trend graph 182 of normal data and a trend graph 183 of collected data are displayed. Further, a change amount calculation period 184 when the abnormality determination unit 17 determines that the absolute value of the difference between the change amount of the normal data trend and the change amount of the collected data trend exceeds the threshold is set by the pointer 185. It is emphasized.
  • the warning comment field 186 a warning comment indicating the abnormality occurrence time is displayed. Further, the difference between the input / output data and the normal data is highlighted by arrows 187 and 188.
  • the system administrator can easily confirm that an abnormality has occurred within the period of change amount calculation 184. Further, based on the interval between the normal data trend graph 182 and the collected data trend graph 183 and the arrows 187 and 188, it can be determined how much the normal data and the collected data are different.
  • One of the determination methods that can be set in the abnormality determination setting 16 is a method for detecting a pattern in which the accumulation of the difference between the collected data and the normal data over a certain period exceeds a predetermined threshold. If the monitoring data shows the “quantity” of the target handled by the control system, such as mass, volume, quantity, or consumption, even if it does not show a sudden change from the normal time, there is a difference from the normal time. Accumulating may result in abnormal output. In such a case, an abnormality cannot be detected by the above-described method of detecting a sudden change.
  • the difference from normal is accumulated for a preset period, and the accumulated value exceeds a preset threshold.
  • One of the determination methods that can be set in the abnormality determination setting 16 is a method for detecting an abnormality based on the correlation between input data and output data for the control system.
  • a control system a plurality of devices are linked to realize a series of operations. Therefore, between linked devices, there is a correlation between control data given to the device by the programmable logic controller and control data acquired from the device.
  • the programmable logic controller 1 outputs a specific value to the torque control value of the motor 43 at the timing when the position of the component 40 is detected by the sensor 42. At this time, there is a correlation between the signal indicating that the position has been detected and the torque control value to be output.
  • the programmable logic controller manages the correlated input / output data in association with each other, so that the abnormality determination unit 17 determines whether the correlated input / output data is normal or abnormal in a batch. Determine. The judgment result is displayed in parallel with the trend graph of each input / output data in the display control unit 18 so that it can be understood which data is the first data in which the abnormality has occurred in the target system. The cause can be investigated efficiently.
  • the programmable logic controller 1 is configured so that the input data input from the control target system 3 within a predetermined period and the output data output to the control target system 3 within a predetermined period are during normal operation. Since the abnormality determination unit 17 automatically detects an abnormality when showing a different trend, the abnormality can be detected easily and with high accuracy compared to the case of determining whether it is normal or abnormal based on data at a specific time point. It can be detected. Further, not only the input data input from the control target system 3 but also the output data output to the control target system 3 can be monitored and used to determine whether the control output of the programmable logic controller 1 is normal or abnormal.
  • the determination method of whether the collected data is normal or abnormal can be selected from a plurality of methods according to the target system, an abnormality can be detected with higher accuracy than in the case of a single determination method.
  • the monitoring data collection method and the determination method for determining whether the monitoring data is normal or abnormal can be set from the programming tool 2, it is possible to reduce the number of work steps when adjusting the settings at the time of starting the system.
  • the display control unit 18 displays a trend graph 182 of normal data and a trend graph 183 of collected data on the same screen on the same screen on the programming tool 2, and when an abnormality is detected, an abnormality location and a difference between normal data and collected data are displayed. Highlight it. Therefore, the difference between the normal data and the collected data and the abnormal part can be visually and intuitively recognized, which can lead to early investigation of the cause of the abnormality and recovery to the normal state.
  • the setting operation can be easily performed by receiving the data collection setting 13 and the abnormality determination setting 16 from the programming tool 2.
  • the configuration described in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and can be combined with other configurations without departing from the gist of the present invention. It is also possible to omit or change the part.

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Abstract

Provided is a programmable logic controller (1), comprising: a data collection unit (14) which, during the execution of a control program, collects I/O data passing between the system being controlled and the programmable logic controller (1); a collected data storage unit (11) which saves the I/O data which is collected with the data collection unit (14); a correct operation data storage unit (12) which stores as correct operation data, a designated portion of the input data saved in the collected data storage unit (11), which is I/O data during correct operations; a malfunction determination unit (17) which acquires I/O data from the collected data storage unit (11) and the correct operation data storage unit (12), compares for a given period the I/O data acquired from the collected data storage unit (11) with the I/O data during correct operations acquired from the correct operation data storage unit (12), and determines whether the control of the system is being correctly carried out; and a display control unit (18) which causes to be displayed in a programming tool (2) a determination result display screen which graphically displays the result of the determination from the malfunction determination unit (17).

Description

プログラマブルロジックコントローラProgrammable logic controller
　本発明は、プログラミングツールから転送された制御プログラムを実行して制御対象システムを制御するプログラマブルロジックコントローラに関する。 The present invention relates to a programmable logic controller that controls a control target system by executing a control program transferred from a programming tool.
　一般に、プログラマブルロジックコントローラは、制御対象システムと様々な制御データをやりとりすることにより、制御対象システム全体の制御を行うが、制御が正しく行われていることを確認するために、上記制御データを監視する。 In general, the programmable logic controller controls the entire control target system by exchanging various control data with the control target system, but monitors the control data in order to confirm that the control is correctly performed. To do.
　生産装置においては、ベルトコンベアで部品を搬送しがら一連の加工を行う場合、ベルトコンベアの動力となるモータのトルク制御は、センサによる位置検出のタイミングに連動して行われる。この際、センサからの入力データとモータへの出力データとを監視し、制御が正常に行われているか否かを確認する。監視により制御対象システムの状態が異常であると判定された場合は、制御対象システムを停止し、原因の究明を行う。 In a production apparatus, when a series of processing is performed while parts are conveyed by a belt conveyor, the torque control of the motor that is the power of the belt conveyor is performed in conjunction with the position detection timing by the sensor. At this time, input data from the sensor and output data to the motor are monitored to check whether the control is normally performed. If it is determined by monitoring that the state of the controlled system is abnormal, the controlled system is stopped and the cause is investigated.
　上記のような制御データの監視は、目視で監視する以外に、プログラマブルロジックコントローラにおいて、制御対象システムから収集したデータを内部に記憶し、その値を既定の閾値と比較することにより、制御が正常に行われているか否かを自動判断する方法がある。しかし、従来のプログラマブルロジックコントローラの多くは、ある時刻における収集データが既定の閾値を超えているか否かのみを基に正常か異常かを判断しており、一定期間にわたる時系列データの傾向を基に、正常か異常かを判断していない。そのため、ある時刻の収集データと閾値との差異が小さければ、制御システムが異常を来していても、異常を検出できない場合がある。制御分野では、制御対象システムが正常か異常かを判定するためにある時刻における状態の判定のみでは不十分であり、一定期間における傾向に対して評価を行うことで、正常か異常かの判定を高精度に行える。 In addition to visual monitoring, the control data as described above is stored in the programmable logic controller and the data collected from the system to be controlled is stored internally, and the value is compared with a predetermined threshold value. There is a method of automatically determining whether or not the process is being performed. However, many of the conventional programmable logic controllers determine whether the collected data at a certain time is normal or abnormal based only on whether or not it exceeds a predetermined threshold, and based on the trend of time-series data over a certain period. It is not judged whether it is normal or abnormal. For this reason, if the difference between the collected data at a certain time and the threshold value is small, even if the control system has an abnormality, the abnormality may not be detected. In the control field, it is not enough to determine the state at a certain time to determine whether the system to be controlled is normal or abnormal, and it is possible to determine whether it is normal or abnormal by evaluating trends over a certain period. It can be done with high accuracy.
　上述の課題に対し、一定期間にわたり制御対象システムのデータを監視し、正常か異常かの判定を行うための手法が提案されている。特許文献１では、制御対象システムの計測データのトレンドグラフと、過去に測定した正常時の計測データのトレンドグラフとを、視認できるように同一画面に表示することで、監視者が現在の計測データに対して正常か異常かを判定できるようにしている。特許文献２では、制御対象システムの計測データを収集保存し、保存した計測データから判定基準となる正常時データを記憶し、計測データと正常時データとを取り出して統計処理により比較して、状態変化が判定された場合に、評価指標のトレンドグラフで状態変化と判定された部分を強調表示している。 In response to the above problems, a method has been proposed for monitoring the data of the system to be controlled over a certain period and determining whether it is normal or abnormal. In Patent Document 1, the trend graph of the measurement data of the control target system and the trend graph of the normal measurement data measured in the past are displayed on the same screen so that the monitor can view the current measurement data. It is possible to determine whether it is normal or abnormal. In Patent Document 2, measurement data of a control target system is collected and stored, normal data serving as a determination criterion is stored from the stored measurement data, measurement data and normal data are extracted, compared by statistical processing, When a change is determined, a portion determined as a state change in the trend graph of the evaluation index is highlighted.
特開２０００－１０６２０号公報JP 2000-10620 A 特開２０１１－８４０３号公報JP 2011-8403 A
　しかしながら、上記特許文献１は、監視者がトレンドグラフを目視で確認することにより正常か異常かを判定するため、トレンドグラフ上に異常な状態が発生した場合でも、監視者が見逃してしまう可能性がある。また、上記特許文献２は、正常か異常かの判定を自動的に行うことが可能であるが、正常データと計測データとに対して統計処理を行った評価指標に対してトレンドグラフを表示するため、正常データを計測データとの間でどのようなトレンドの乖離が発生したのかを直感的に確認することができない。 However, since the above-mentioned Patent Document 1 determines whether the monitor is normal or abnormal by visually checking the trend graph, the monitor may miss it even if an abnormal state occurs on the trend graph. There is. Moreover, although the said patent document 2 can determine automatically whether it is normal or abnormal, it displays a trend graph with respect to the evaluation index which performed the statistical process with respect to normal data and measurement data Therefore, it is impossible to intuitively confirm what kind of trend divergence has occurred between normal data and measurement data.
　本発明は、上記に鑑みてなされたものであって、正常状態か異常状態かを人手によらず判定でき、正常データと計測データとの間でどのようなトレンドの乖離が発生したのかを容易に認識可能なプログラマブルロジックコントローラを得ることを目的とする。 The present invention has been made in view of the above, and can determine whether a normal state or an abnormal state without manual intervention, and easily determine what kind of trend divergence has occurred between normal data and measurement data. An object of the present invention is to obtain a programmable logic controller that can be recognized.
　上述した課題を解決し、目的を達成するために、本発明は、プログラミングツールから転送された制御プログラムを実行して制御対象システムを制御するプログラマブルロジックコントローラであって、制御プログラムの実行中に、制御対象システムとの入出力データを収集するデータ収集部と、データ収集部で収集した入出力データを保存する収集データ記憶部と、収集データ記憶部に保存した入力データのうちの指定された一部分を記憶して、正常時の入出力データとする正常データ記憶部と、収集データ記憶部及び正常データ記憶部から入出力データを取得し、収集データ記憶部から取得した入出力データと、正常データ記憶部から取得した正常時の入出力データとを一定期間分比較して、制御対象システムの制御が正常に行われているか否かを判定する異常判定部と、異常判定部による判定結果をグラフィカルに表示する判定結果表示画面をエンジニアリングツールに表示させる表示制御部とを備えることを特徴とする。 In order to solve the above-described problems and achieve the object, the present invention is a programmable logic controller that controls a system to be controlled by executing a control program transferred from a programming tool, and during execution of the control program, A data collection unit that collects input / output data with the control target system, a collection data storage unit that stores input / output data collected by the data collection unit, and a specified portion of the input data stored in the collection data storage unit Is stored as normal input / output data, the input / output data is acquired from the collected data storage unit and the normal data storage unit, the input / output data acquired from the collected data storage unit, and the normal data. Compare the normal input / output data acquired from the storage unit for a certain period of time, and control the controlled system normally An abnormality determination unit that determines whether Luke, characterized by comprising a display control unit for displaying the determination result display screen for displaying the determination result by the abnormality determination unit graphically engineering tool.
　本発明にかかるプログラマブルロジックコントローラは、正常状態か異常状態かを人手によらず判定でき、正常データを計測データとの間でどのようなトレンドの乖離が発生したのかを容易に認識可能であるという効果を奏する。 The programmable logic controller according to the present invention can determine whether it is in a normal state or an abnormal state without human intervention, and can easily recognize what kind of trend divergence has occurred between normal data and measurement data. There is an effect.
本発明の実施の形態にかかるプログラマブルロジックコントローラによって制御対象システムを制御するシステムの構成を示す図The figure which shows the structure of the system which controls a control object system by the programmable logic controller concerning embodiment of this invention. 本発明の実施の形態にかかるプログラマブルロジックコントローラの構成を示すブロック図The block diagram which shows the structure of the programmable logic controller concerning embodiment of this invention 実施の形態にかかるプログラマブルロジックコントローラのハードウェア構成を示す図The figure which shows the hardware constitutions of the programmable logic controller concerning embodiment 実施の形態にかかるプログラマブルロジックコントローラを、ベルトコンベアで部品を搬送しながら一連の加工を行う部品加工装置の制御に用いたシステムの一例を示す図The figure which shows an example of the system which used the programmable logic controller concerning embodiment for control of the component processing apparatus which performs a series of processes, conveying components with a belt conveyor 実施の形態にかかるプログラマブルロジックコントローラのデータ収集設定の一例を示す図The figure which shows an example of the data collection setting of the programmable logic controller concerning embodiment 実施の形態にかかるプログラマブルロジックコントローラのデータ収集動作を示すフローチャートA flowchart showing data collection operation of the programmable logic controller according to the embodiment 実施の形態にかかるプログラマブルロジックコントローラの正常データ記憶部へのデータ登録手順を示すフローチャートThe flowchart which shows the data registration procedure to the normal data storage part of the programmable logic controller concerning an embodiment 実施の形態にかかるプログラマブルロジックコントローラの正常データ登録部がプログラミングツールに表示させる登録画面の一例を示す図The figure which shows an example of the registration screen which the normal data registration part of the programmable logic controller concerning embodiment displays on a programming tool 実施の形態にかかるプログラマブルロジックコントローラの異常判定設定の手順を示すフローチャートThe flowchart which shows the procedure of the abnormality determination setting of the programmable logic controller concerning an embodiment 実施の形態にかかるプログラマブルロジックコントローラの異常判定設定画面の一例を示す図The figure which shows an example of the abnormality determination setting screen of the programmable logic controller concerning embodiment 実施の形態にかかるプログラマブルロジックコントローラが、収集データが正常か異常かを判定する処理の流れを示すフローチャートThe flowchart which shows the flow of the process in which the programmable logic controller concerning embodiment determines whether collection data is normal or abnormal 実施の形態にかかるプログラマブルロジックコントローラの異常判定部にて異常と判定された場合にプログラミングツールに表示される判定結果表示画面の一例を示す図The figure which shows an example of the determination result display screen displayed on a programming tool, when it determines with abnormality in the abnormality determination part of the programmable logic controller concerning embodiment
　以下に、本発明の実施の形態にかかるプログラマブルロジックコントローラを図面に基づいて詳細に説明する。なお、この実施の形態によりこの発明が限定されるものではない。 Hereinafter, a programmable logic controller according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiments.
実施の形態．
　図１は、本発明の実施の形態にかかるプログラマブルロジックコントローラによって制御対象システムを制御するシステムの構成を示す図である。プログラマブルロジックコントローラ１は、プログラミングツール２から転送された制御プログラムを保持し、保持した制御プログラムを実行して、制御対象システム３を制御する。プログラミングツール２は、プログラミングツールプログラムがインストールされたコンピュータであり、コンピュータがプログラミングツールプログラムを実行することによって実現される。なお、プログラミングツール２は、常時プログラマブルロジックコントローラ１に接続されている必要はなく、制御プログラムの転送時と、後述するデータ収集設定、異常判定設定の設定時及び異常判定の実行時とを除いて、プログラマブルロジックコントローラ１から切り離されていても良い。 Embodiment.
FIG. 1 is a diagram showing a configuration of a system that controls a system to be controlled by a programmable logic controller according to an embodiment of the present invention. The programmable logic controller 1 holds the control program transferred from the programming tool 2 and executes the held control program to control the control target system 3. The programming tool 2 is a computer in which a programming tool program is installed, and is realized by the computer executing the programming tool program. The programming tool 2 does not necessarily need to be connected to the programmable logic controller 1 at all times, except when transferring a control program and when setting data collection settings, abnormality determination settings and abnormality determination described later. Alternatively, the programmable logic controller 1 may be disconnected.
　図２は、本発明の実施の形態にかかるプログラマブルロジックコントローラの構成を示すブロック図である。プログラマブルロジックコントローラ１は、制御プログラム実行中に、データ収集設定１３に従い制御対象システムとの入出力データを収集するデータ収集部１４と、データ収集部１４で収集した入出力データを保存する収集データ記憶部１１と、収集データ記憶部１１に保存した入力データのうちの指定された一部分を記憶して、正常時の入出力データとする正常データ記憶部１２と、収集データ記憶部１１に保存した入出力データを、正常データ記憶部１２に登録する正常データ登録部１５と、収集データ記憶部１１及び正常データ記憶部１２から入出力データを取得し、異常判定設定１６に従って一定期間の入出力データを比較することにより、制御対象システムが正常か異常かを判定する異常判定部１７と、異常判定部１７による判定結果をプログラミングツール２にグラフィカルに表示させる表示制御部１８とを有する。 FIG. 2 is a block diagram showing the configuration of the programmable logic controller according to the embodiment of the present invention. The programmable logic controller 1 includes a data collection unit 14 that collects input / output data with the control target system according to the data collection setting 13 during execution of the control program, and a collected data storage that stores the input / output data collected by the data collection unit 14 11, a specified portion of the input data stored in the collected data storage unit 11 is stored as normal input / output data, and the input data stored in the collected data storage unit 11 is stored. Input / output data is acquired from the normal data registration unit 15 for registering the output data in the normal data storage unit 12, the collected data storage unit 11 and the normal data storage unit 12, and input / output data for a certain period is obtained according to the abnormality determination setting 16. By comparing, the abnormality determination unit 17 that determines whether the control target system is normal or abnormal and the determination by the abnormality determination unit 17 Results and a display control unit 18 to be displayed on the programming tool 2 graphically.
　データ収集部１４は、制御対象システム３から入力された入力データと、制御対象システム３に出力した出力データとの２種類のデータをデータ収集設定１３に従って収集し、収集データ記憶部１１に格納する。なお、入力データと出力データとを合わせて入出力データという。 The data collection unit 14 collects two types of data, that is, input data input from the control target system 3 and output data output to the control target system 3 according to the data collection setting 13, and stores the collected data in the collected data storage unit 11. . The input data and the output data are collectively referred to as input / output data.
　図３は、実施の形態にかかるプログラマブルロジックコントローラのハードウェア構成を示す図である。プログラマブルロジックコントローラ１は、制御プログラム２６を格納する記憶装置２２と、制御プログラム２６を実行する演算装置２１と、制御プログラム２６の実行中に制御対象システム３へ出力する出力データ及び制御対象システム３から入力される入力データを保持する内部メモリ２３と、他の装置との通信用の通信装置２５とを有する。 FIG. 3 is a diagram illustrating a hardware configuration of the programmable logic controller according to the embodiment. The programmable logic controller 1 includes a storage device 22 that stores the control program 26, an arithmetic device 21 that executes the control program 26, output data that is output to the control target system 3 during execution of the control program 26, and the control target system 3. It has an internal memory 23 that holds input data to be input, and a communication device 25 for communication with other devices.
　図２に示したデータ収集部１４、正常データ登録部１５、異常判定部１７及び表示制御部１８は、演算装置２１及び内部メモリ２３により実現される。また、複数の演算装置及び複数のメモリが連携して上記機能を実行してもよい。収集データ記憶部１１及び正常データ記憶部１２は、記憶装置２２により実現される。 The data collection unit 14, normal data registration unit 15, abnormality determination unit 17, and display control unit 18 illustrated in FIG. 2 are realized by the arithmetic device 21 and the internal memory 23. A plurality of arithmetic devices and a plurality of memories may cooperate to execute the above function. The collected data storage unit 11 and the normal data storage unit 12 are realized by the storage device 22.
　図４は、実施の形態にかかるプログラマブルロジックコントローラを、ベルトコンベアで部品を搬送しながら一連の加工を行う部品加工装置の制御に用いたシステムの一例を示す図である。制御対象システム３である部品加工装置４は、部品４０を搬送するベルトコンベア４１と、部品４０の位置を検出するセンサ４２と、ベルトコンベア４１の動力となるモータ４３とを有する。ベルトコンベア４１で部品４０を搬送しながら一連の加工を行う部品加工装置４が制御対象システム３である場合、センサ４２から入力されて内部メモリ２３に書き込まれ、制御プログラム２６によって処理されるデータが、制御対象システム３から取得したデータである。また、制御プログラム２６によって内部メモリ２３に書き込まれ、プログラマブルロジックコントローラ１からモータ４３へ出力されるモータ４３のトルク制御値のデータが、制御対象システム３に出力したデータである。制御対象システム３から取得したデータ及び制御対象システム３に出力したデータは、内部メモリ２３の特定のアドレスに格納される。 FIG. 4 is a diagram illustrating an example of a system in which the programmable logic controller according to the embodiment is used to control a component processing apparatus that performs a series of processes while conveying components by a belt conveyor. The component processing apparatus 4 that is the control target system 3 includes a belt conveyor 41 that conveys the component 40, a sensor 42 that detects the position of the component 40, and a motor 43 that serves as power for the belt conveyor 41. When the component processing apparatus 4 that performs a series of processing while conveying the component 40 by the belt conveyor 41 is the control target system 3, data input from the sensor 42 and written in the internal memory 23 and processed by the control program 26 are stored. The data acquired from the controlled system 3. Further, the torque control value data of the motor 43 written to the internal memory 23 by the control program 26 and output from the programmable logic controller 1 to the motor 43 is data output to the control target system 3. Data acquired from the control target system 3 and data output to the control target system 3 are stored at specific addresses in the internal memory 23.
　図５は、実施の形態にかかるプログラマブルロジックコントローラのデータ収集設定の一例を示す図である。データ収集設定１３は、データ収集部１４の入出力データを収集する動作についての設定内容を示している。図５に示すように、データ収集設定１３は、制御対象システム３から収集するデータを指定し、データを収集する期間を規定する。データを収集する期間は、プログラマブルロジックコントローラ１の動作周期であるスキャンに同期するように規定される。 FIG. 5 is a diagram illustrating an example of data collection setting of the programmable logic controller according to the embodiment. The data collection setting 13 indicates the setting contents for the operation of collecting the input / output data of the data collection unit 14. As shown in FIG. 5, the data collection setting 13 specifies data to be collected from the control target system 3 and defines a period for collecting data. The period for collecting data is defined so as to be synchronized with the scan that is the operation cycle of the programmable logic controller 1.
　データ収集設定１３は、プログラミングツール２によって設定可能である。すなわち、プログラマブルロジックコントローラ１は、プログラミングツール２上での操作によりデータ収集設定１３を設定可能である。 The data collection setting 13 can be set by the programming tool 2. That is, the programmable logic controller 1 can set the data collection setting 13 by an operation on the programming tool 2.
　図６は、実施の形態にかかるプログラマブルロジックコントローラのデータ収集動作を示すフローチャートである。ステップＳ１において、データ収集部１４は、データ収集設定１３を読み込む。ステップＳ２において、データ収集部１４は、データ収集設定１３に従って内部メモリ２３から入出力データを収集する。ステップＳ３において、データ収集部１４は、内部メモリ２３から収集した入出力データを収集時刻情報とともに収集データ記憶部１１に格納する。 FIG. 6 is a flowchart showing the data collection operation of the programmable logic controller according to the embodiment. In step S <b> 1, the data collection unit 14 reads the data collection setting 13. In step S <b> 2, the data collection unit 14 collects input / output data from the internal memory 23 according to the data collection setting 13. In step S3, the data collecting unit 14 stores the input / output data collected from the internal memory 23 in the collected data storage unit 11 together with the collection time information.
　上記のようにして、データ収集部１４は、制御対象システム３から入力された入力データ及び制御対象システム３に出力した出力データを、予め設定した間隔で取得し、収集時刻情報とともに収集データ記憶部１１に格納する。 As described above, the data collection unit 14 acquires the input data input from the control target system 3 and the output data output to the control target system 3 at preset intervals, and the collected data storage unit together with the collection time information 11.
　正常データ登録部１５は、収集データ記憶部１１に格納された収集データのうち、システム管理者が正常と判断しデータ収集設定１３に規定された期間の収集データを、正常データ記憶部１２に登録する。収集データ記憶部１１から正常データ記憶部１２へのデータの登録は、以下の手順で実行される。 The normal data registration unit 15 registers, in the normal data storage unit 12, the collection data stored in the collection data storage unit 11 during the period specified in the data collection setting 13 as determined by the system administrator. To do. Registration of data from the collected data storage unit 11 to the normal data storage unit 12 is executed in the following procedure.
　図７は、実施の形態にかかるプログラマブルロジックコントローラの正常データ記憶部へのデータ登録手順を示すフローチャートである。図８は、実施の形態にかかるプログラマブルロジックコントローラの正常データ登録部がプログラミングツールに表示させる登録画面の一例を示す図である。ステップＳ１１では、正常データ登録部１５は、収集データ記憶部１１に格納されている収集データのトレンドグラフ１５２を含んだ正常データ登録画面１５１をプログラミングツール２に表示させる。ステップＳ１２では、正常データ登録部１５は、プログラミングツール２上での正常データ登録画面１５１におけるシステム管理者による期間指定の操作を、通信装置２５を通じて受け付ける。プログラミングツール２上では、期間の指定は、日、時間、分、秒単位で行うことができる。開始時刻は、開始時刻欄１５３に日時分秒を入力することによって指定しても良いし、開始時刻表示バー１５４を移動させる操作を行って指定しても良い。同様に、終了時刻は、終了時刻欄１５５に日時分秒を入力することによって指定しても良いし、終了時刻表示バー１５６を移動させる操作を行って指定しても良い。開始時刻及び終了時刻を指定した後に登録ボタン１５７が押下されると、開始時刻及び終了時刻の設定が完了する。ステップＳ１３では、正常データ登録部１５は、正常データ登録画面１５１において指定された期間のデータを、収集データ記憶部１１から取得し、正常データ記憶部１２に登録する。 FIG. 7 is a flowchart illustrating a data registration procedure in the normal data storage unit of the programmable logic controller according to the embodiment. FIG. 8 is a diagram illustrating an example of a registration screen displayed on the programming tool by the normal data registration unit of the programmable logic controller according to the embodiment. In step S <b> 11, the normal data registration unit 15 causes the programming tool 2 to display a normal data registration screen 151 including the trend graph 152 of the collected data stored in the collected data storage unit 11. In step S <b> 12, the normal data registration unit 15 receives an operation for specifying a period by the system administrator on the normal data registration screen 151 on the programming tool 2 through the communication device 25. On the programming tool 2, the period can be specified in units of days, hours, minutes, and seconds. The start time may be specified by inputting date / time / minute / second in the start time column 153 or may be specified by performing an operation of moving the start time display bar 154. Similarly, the end time may be specified by inputting date / time / minute / second in the end time column 155 or may be specified by performing an operation of moving the end time display bar 156. When the registration button 157 is pressed after designating the start time and end time, the setting of the start time and end time is completed. In step S <b> 13, the normal data registration unit 15 acquires data for the period specified on the normal data registration screen 151 from the collected data storage unit 11 and registers it in the normal data storage unit 12.
　異常判定部１７は、異常判定設定１６に従い、収集データ記憶部１１に格納されたデータと正常データ記憶部１２に格納されたデータとを取得し、両者を比較することにより、収集データ記憶部１１に格納されたデータが正常か異常かを判定する。 The abnormality determination unit 17 acquires the data stored in the collected data storage unit 11 and the data stored in the normal data storage unit 12 in accordance with the abnormality determination setting 16, and compares them to obtain the collected data storage unit 11 Determine whether the data stored in is normal or abnormal.
　異常判定設定１６には、一定期間中の正常データと収集データとの差分が、判定に先立って設定した閾値以下であるか否かに基づいて、異常判定部１７で正常か異常かの判定をする際の判定方式と、判定の際にデータを比較する期間とが設定される。 In the abnormality determination setting 16, the abnormality determination unit 17 determines whether the difference between normal data and collected data during a certain period is equal to or less than a threshold value set prior to the determination. A determination method for performing the determination and a period for comparing the data during the determination are set.
　異常判定設定１６は、プログラミングツール２によって設定可能である。すなわち、プログラマブルロジックコントローラ１は、プログラミングツール２上での操作により異常判定設定１６を設定可能である。 The abnormality determination setting 16 can be set by the programming tool 2. That is, the programmable logic controller 1 can set the abnormality determination setting 16 by an operation on the programming tool 2.
　異常判定設定１６に設定される判定方式は、複数の方式の中から選択可能である。換言すると、異常判定部１７は、収集データ記憶部１１から取得した入出力データと正常データ記憶部１２から取得した正常時の入出力データとを、複数の中から選択された方式で比較することが可能である。 The determination method set in the abnormality determination setting 16 can be selected from a plurality of methods. In other words, the abnormality determination unit 17 compares the input / output data acquired from the collected data storage unit 11 and the normal input / output data acquired from the normal data storage unit 12 by a method selected from a plurality of methods. Is possible.
　異常判定設定１６に設定可能な判定方式の一つは、収集データのトレンドの変化量が、比較対象の正常データのトレンドの変化量に対し、既定の閾値を超えるパターンを検出する方式である。この方式を用いることにより、制御システムの異常を閾値に基づいて人手によらずに検出することができる。 One of the determination methods that can be set in the abnormality determination setting 16 is a method for detecting a pattern in which the amount of change in the trend of collected data exceeds a predetermined threshold with respect to the amount of change in the trend of normal data to be compared. By using this method, it is possible to detect an abnormality of the control system based on the threshold value without relying on human hands.
　上述のベルトコンベアによる部品加工装置４では、モータのトルク制御値が正常時に比べて明らかに急激に変化している場合、制御対象システム３である部品加工装置４に異常が生じていると想定される。収集データのトレンドの変化量が、比較対象の正常データのトレンドの変化量に対し、既定の閾値を超えるパターンを検出する方式を用いる場合、プログラミングツール２から異常判定設定１６に以下の設定を行う。 In the above-described component processing device 4 using the belt conveyor, if the torque control value of the motor is clearly abruptly changed as compared with the normal time, it is assumed that an abnormality has occurred in the component processing device 4 that is the control target system 3. The When using a method for detecting a pattern in which the amount of change in the trend of collected data exceeds a predetermined threshold with respect to the amount of change in the trend of normal data to be compared, the following settings are made from the programming tool 2 to the abnormality determination setting 16. .
　図９は、実施の形態にかかるプログラマブルロジックコントローラの異常判定設定の手順を示すフローチャートである。図１０は、実施の形態にかかるプログラマブルロジックコントローラの異常判定設定画面の一例を示す図である。ステップＳ２１で、異常判定部１７は、プログラミングツール２に異常判定設定画面１６１を表示させ、プログラミングツール２上に表示された異常判定設定画面１６１内の正常データ指定欄１６２におけるシステム管理者による正常データ選択の操作を、通信装置２５を通じて受け付ける。すなわち、正常データ記憶部１２に登録した正常データの一覧は、プログラミングツール２により確認でき、正常データの一覧の中から比較対象となる正常データを選択可能である。 FIG. 9 is a flowchart illustrating a procedure for setting abnormality determination in the programmable logic controller according to the embodiment. FIG. 10 is a diagram illustrating an example of an abnormality determination setting screen of the programmable logic controller according to the embodiment. In step S21, the abnormality determination unit 17 causes the programming tool 2 to display the abnormality determination setting screen 161, and the normal data by the system administrator in the normal data designation field 162 in the abnormality determination setting screen 161 displayed on the programming tool 2 is displayed. A selection operation is accepted through the communication device 25. That is, a list of normal data registered in the normal data storage unit 12 can be confirmed by the programming tool 2 and normal data to be compared can be selected from the list of normal data.
　ステップＳ２２で、異常判定部１７は、プログラミングツール２に表示させた異常判定設定画面１６１内の比較開始時刻指定欄１６３におけるシステム管理者による比較開始時刻選択の操作を、通信装置２５を通じて受け付ける。比較開始時刻は、選択した正常データと収集データとの比較を開始する時刻である。本実施の形態では、データのトレンドに対して比較を行うため、比較開始ポイントを合わせる必要がある。正常データ及び収集データの各々に対し、比較開始時刻を指定する。なお、プログラマブルロジックコントローラ１に制御対象システム３の制御を行わせながら異常判定を行う場合には、収集データの開始時刻は、未来の時刻となる。 In step S22, the abnormality determination unit 17 receives an operation of selecting a comparison start time by the system administrator in the comparison start time designation field 163 in the abnormality determination setting screen 161 displayed on the programming tool 2 through the communication device 25. The comparison start time is a time at which the comparison between the selected normal data and the collected data is started. In the present embodiment, since comparison is made with respect to the data trend, it is necessary to match the comparison start point. A comparison start time is designated for each of normal data and collected data. Note that when the abnormality determination is performed while causing the programmable logic controller 1 to control the control target system 3, the start time of the collected data is a future time.
　ステップＳ２３で、異常判定部１７は、プログラミングツール２に表示させた異常判定設定画面１６１内の判定方式指定欄１６４におけるシステム管理者による判定方式選択の操作を、通信装置２５を通じて受け付ける。 In step S23, the abnormality determination unit 17 accepts an operation of selecting a determination method by the system administrator in the determination method designation field 164 in the abnormality determination setting screen 161 displayed on the programming tool 2 through the communication device 25.
　ステップＳ２４で、異常判定部１７は、プログラミングツール２に表示させた異常判定設定画面１６１内の時間間隔指定欄１６５におけるトレンドの変化量を計算する際の時間間隔指定の操作を、通信装置２５を通じて受け付ける。 In step S <b> 24, the abnormality determination unit 17 performs an operation of specifying a time interval when calculating the trend change amount in the time interval specification field 165 in the abnormality determination setting screen 161 displayed on the programming tool 2 through the communication device 25. Accept.
　ステップＳ２５で、異常判定部１７は、プログラミングツール２に表示させた異常判定設定画面１６１内の閾値指定欄１６６における、正常データの変化量と収集データの変化量との差分の絶対値であって許容できる上限値を閾値に指定する操作を、通信装置２５を通じて受け付ける。閾値は、対象システムによって調整が必要な設定項目である。各欄への入力が完了したのち、設定ボタン１６７を押下する操作が行われると、異常判定部１７は、異常判定設定画面１６１において設定された内容を記憶装置２２に記憶して異常判定設定１６にする。 In step S25, the abnormality determination unit 17 is the absolute value of the difference between the change amount of normal data and the change amount of collected data in the threshold value designation field 166 in the abnormality determination setting screen 161 displayed on the programming tool 2. An operation for designating an allowable upper limit value as a threshold value is accepted through the communication device 25. The threshold is a setting item that needs to be adjusted depending on the target system. When an operation of pressing the setting button 167 is performed after the input to each column is completed, the abnormality determination unit 17 stores the contents set in the abnormality determination setting screen 161 in the storage device 22 and stores the abnormality determination setting 16. To.
　異常判定設定１６の設定終了後、異常判定部１７は異常判定設定１６に従い、収集データが正常か異常かの判定を行う。異常判定部１７において、上記のように、収集データのトレンドの変化量が、比較対象の正常データのトレンドの変化量に対し、既定の閾値を超えるパターンを検出することで判定する場合、下記の手順で正常か異常かの判定を行う。 After completing the setting of the abnormality determination setting 16, the abnormality determination unit 17 determines whether the collected data is normal or abnormal according to the abnormality determination setting 16. When the abnormality determination unit 17 determines by detecting a pattern in which the trend change amount of the collected data exceeds the predetermined threshold value with respect to the trend change amount of the normal data to be compared as described above, Determine whether the procedure is normal or abnormal.
　図１１は、実施の形態にかかるプログラマブルロジックコントローラが、収集データが正常か異常かを判定する処理の流れを示すフローチャートである。ステップＳ３１において、異常判定部１７は、現時刻の正常データを正常データ記憶部１２から取得し、収集データを収集データ記憶部１１から取得する。ステップＳ３２において、異常判定部１７は、時間ｔｉが経過したかを確認する。時間ｔｉが経過していなければ、ステップＳ３２でＮｏとなり、ステップＳ３２を繰り返す。時間ｔｉが経過していれば、ステップＳ３２でＹｅｓとなり、ステップＳ３３に進む。 FIG. 11 is a flowchart illustrating a flow of processing in which the programmable logic controller according to the embodiment determines whether the collected data is normal or abnormal. In step S <b> 31, the abnormality determination unit 17 acquires normal data at the current time from the normal data storage unit 12 and acquires collected data from the collected data storage unit 11. In step S32, the abnormality determination unit 17 confirms whether the time ti has elapsed. If the time ti has not elapsed, No is returned in step S32, and step S32 is repeated. If the time ti has elapsed, Yes is determined in step S32, and the process proceeds to step S33.
　ステップＳ３３において、異常判定部１７は、時間ｔｉ経過後の正常データを正常データ記憶部１２から取得し、時間ｔｉ経過後の収集データを収集データ記憶部１１から取得する。 In step S33, the abnormality determination unit 17 acquires normal data after the elapse of time ti from the normal data storage unit 12, and acquires collected data after the elapse of time ti from the collected data storage unit 11.
　ステップＳ３４において、異常判定部１７は、正常データのトレンドの変化量及び収集データのトレンドの変化量を計算する。 In step S34, the abnormality determination unit 17 calculates the change amount of the normal data trend and the change amount of the collected data trend.
　時刻ｔ１から時刻ｔ１よりも後の時刻ｔ２までの期間でのトレンドの変化量は、下記式（１）で算出できる。 The amount of trend change in the period from time t1 to time t2 after time t1 can be calculated by the following equation (1).
　変化量＝（（ｔ２のデータ）－（ｔ１のデータ））／（ｔ２－ｔ１）　・・・（１） Change amount = ((t2 data) − (t1 data)) / (t2−t1) (1)
　ここで、本実施形態では、変化量を計算する際の時間間隔ｔｉ＝ｔ２－ｔ１を指定するため、時刻ｔ１からの変化量を計算する場合、上記式（１）は、下記式（２）に変形できる。 Here, in this embodiment, since the time interval ti = t2−t1 when calculating the change amount is designated, when calculating the change amount from the time t1, the above equation (1) is expressed by the following equation (2). Can be transformed into
　変化量＝（（ｔ１＋ｔｉのデータ）－（ｔ１のデータ））／ｔｉ　・・・（２） Change amount = ((data of t1 + ti) − (data of t1)) / ti (2)
　ステップＳ３５において、異常判定部１７は、正常データのトレンドの変化量と収集データのトレンドの変化量との差分を計算する。 In step S35, the abnormality determination unit 17 calculates the difference between the change amount of the normal data trend and the change amount of the collected data trend.
　ステップＳ３６において、異常判定部１７は、正常データのトレンドの変化量と収集データのトレンドの変化量との差分の絶対値が閾値を超えているかを確認する。正常データのトレンドの変化量と収集データのトレンドの変化量との差分の絶対値が閾値を超えていれば、ステップＳ３６でＹｅｓとなり、ステップＳ３７において、表示制御部１８は、プログラミングツール２に警告を表示させ、異常警告を通知する。警告の表示は、正常データのトレンドグラフ上及び収集データのトレンドグラフ上において、該当箇所及び差分を強調表示することによって行う。ステップＳ３７の後、処理を終了する。正常データのトレンドの変化量と収集データのトレンドの変化量との差分の絶対値が閾値を超えていなければ、ステップＳ３６でＮｏとなり、処理を終了する。 In step S36, the abnormality determination unit 17 confirms whether the absolute value of the difference between the change amount of the normal data trend and the trend change amount of the collected data exceeds the threshold value. If the absolute value of the difference between the change amount of the normal data trend and the change amount of the collected data trend exceeds the threshold value, Yes is made in step S36, and the display control unit 18 warns the programming tool 2 in step S37. Is displayed and an abnormal warning is notified. The warning is displayed by highlighting the corresponding part and the difference on the trend graph of normal data and the trend graph of collected data. After step S37, the process ends. If the absolute value of the difference between the change amount of the trend of normal data and the change amount of the trend of the collected data does not exceed the threshold value, No is returned in step S36, and the process is terminated.
　表示制御部１８は、異常判定設定１６に従い、正常データ記憶部１２から取得した正常データのトレンドグラフと、現在データ収集部１４にて収集中のデータのトレンドグラフとを重畳表示する。また、異常判定部１７にて、正常か異常かの判定を行った結果、異常と判定した場合に、トレンドグラフ上において異常と判定された該当箇所を強調表示する。 The display control unit 18 superimposes the trend graph of normal data acquired from the normal data storage unit 12 and the trend graph of data currently being collected by the data collection unit 14 in accordance with the abnormality determination setting 16. In addition, when the abnormality determination unit 17 determines whether the abnormality is normal or not as a result of the determination, the corresponding part determined to be abnormal on the trend graph is highlighted.
　図１２は、実施の形態にかかるプログラマブルロジックコントローラの異常判定部にて異常と判定された場合にプログラミングツールに表示される判定結果表示画面の一例を示す図である。判定結果表示画面１８１内には、正常データのトレンドグラフ１８２と収集データのトレンドグラフ１８３とが表示される。また、正常データのトレンドの変化量と収集データのトレンドの変化量との差分の絶対値が閾値を超えていると異常判定部１７が判断した時の変化量の計算期間１８４が、ポインタ１８５によって強調されている。また、警告コメント欄１８６には、異常発生時刻を示す警告コメントが表示される。さらに、入出力データと正常データとの差分が矢印１８７，１８８によって強調表示されている。従って、表示制御部１８がプログラミングツール２に表示させる判定結果表示画面１８１を見ることで、システム管理者は、変化量の計算期間１８４の期間内に異常が発生したことを容易に確認できる。また、正常データのトレンドグラフ１８２と収集データのトレンドグラフ１８３との間隔及び矢印１８７，１８８に基づいて、正常データと収集データとがどの程度乖離しているかを判断できる。 FIG. 12 is a diagram illustrating an example of a determination result display screen displayed on the programming tool when the abnormality determination unit of the programmable logic controller according to the embodiment determines an abnormality. In the determination result display screen 181, a trend graph 182 of normal data and a trend graph 183 of collected data are displayed. Further, a change amount calculation period 184 when the abnormality determination unit 17 determines that the absolute value of the difference between the change amount of the normal data trend and the change amount of the collected data trend exceeds the threshold is set by the pointer 185. It is emphasized. In the warning comment field 186, a warning comment indicating the abnormality occurrence time is displayed. Further, the difference between the input / output data and the normal data is highlighted by arrows 187 and 188. Therefore, by viewing the determination result display screen 181 that the display control unit 18 displays on the programming tool 2, the system administrator can easily confirm that an abnormality has occurred within the period of change amount calculation 184. Further, based on the interval between the normal data trend graph 182 and the collected data trend graph 183 and the arrows 187 and 188, it can be determined how much the normal data and the collected data are different.
　異常判定設定１６に設定可能な判定方式の一つは、収集データと正常データとの差分の一定期間における累積が、既定の閾値を超えるパターンを検出する方式である。監視データが質量、体積、数量又は消費量といった、制御システムが扱う対象の“量”を示している場合、正常時に対して急激な変化を示していない場合であっても、正常時に対する差異が累積することで、異常な出力となる場合がある。このような場合、上述の急激な変化を検出する方式では異常を検出することができない。 One of the determination methods that can be set in the abnormality determination setting 16 is a method for detecting a pattern in which the accumulation of the difference between the collected data and the normal data over a certain period exceeds a predetermined threshold. If the monitoring data shows the “quantity” of the target handled by the control system, such as mass, volume, quantity, or consumption, even if it does not show a sudden change from the normal time, there is a difference from the normal time. Accumulating may result in abnormal output. In such a case, an abnormality cannot be detected by the above-described method of detecting a sudden change.
　収集データと正常データとの差分の一定期間における累積が、既定の閾値を超えるパターンを検出する方式では、正常時に対する差異を、予め設定した期間累積し、累積値が予め設定した閾値を超えるか否かを確認することにより、正常時に対して急激な変化を示していない場合でも異常を検出できる。 In a method for detecting a pattern in which the accumulation of the difference between collected data and normal data over a certain period exceeds a predetermined threshold, the difference from normal is accumulated for a preset period, and the accumulated value exceeds a preset threshold. By confirming whether or not, an abnormality can be detected even when a sudden change is not shown in the normal state.
　異常判定設定１６に設定可能な判定方式の一つは、制御システムに対する入力データと出力データとの相関により異常を検出する方式である。制御システムでは、複数の機器を連携させて一連の動作を実現するため、連携する機器間では、プログラマブルロジックコントローラが機器に与える制御データと、機器から取得する制御データとの間に相関がある場合が多い。上述したベルトコンベア４１による部品加工装置４では、プログラマブルロジックコントローラ１は、センサ４２によって部品４０の位置を検出したタイミングで、モータ４３のトルク制御値に特定の値を出力する。その際、位置検出されたことを示す信号と、出力するトルク制御値との間に相関関係がある。 One of the determination methods that can be set in the abnormality determination setting 16 is a method for detecting an abnormality based on the correlation between input data and output data for the control system. In a control system, a plurality of devices are linked to realize a series of operations. Therefore, between linked devices, there is a correlation between control data given to the device by the programmable logic controller and control data acquired from the device. There are many. In the component processing apparatus 4 using the belt conveyor 41 described above, the programmable logic controller 1 outputs a specific value to the torque control value of the motor 43 at the timing when the position of the component 40 is detected by the sensor 42. At this time, there is a correlation between the signal indicating that the position has been detected and the torque control value to be output.
　このため、実施の形態にかかるプログラマブルロジックコントローラは、相関関係にある入出力データを関連付けて管理することにより、異常判定部１７において、上記相関関係にある入出力データに対し一括で正常か異常かを判定する。判定結果は、表示制御部１８において、各入出力データのトレンドグラフとともに並列で表示することにより、対象システムにおいて、最初に異常が生じたデータがどのデータであるか分かるため、異常発生の根本的原因を効率的に調べることができる。 Therefore, the programmable logic controller according to the embodiment manages the correlated input / output data in association with each other, so that the abnormality determination unit 17 determines whether the correlated input / output data is normal or abnormal in a batch. Determine. The judgment result is displayed in parallel with the trend graph of each input / output data in the display control unit 18 so that it can be understood which data is the first data in which the abnormality has occurred in the target system. The cause can be investigated efficiently.
　このように、本実施の形態にかかるプログラマブルロジックコントローラ１は、一定期間内に制御対象システム３から入力された入力データ及び一定期間内に制御対象システム３に出力した出力データが、正常稼働時と異なるトレンドを示す場合に、異常判定部１７が自動的に異常検出を行うため、特定の時点のデータに基づいて正常か異常かの判定を行う場合と比較して、異常を容易かつ高精度に検出できる。また、制御対象システム３から入力された入力データだけでなく、制御対象システム３へ出力する出力データも監視し、プログラマブルロジックコントローラ１の制御出力が正常か異常かの判定に用いることができる。収集データが正常か異常かの判定方式は、複数の方式の中から対象システムに合わせて選択可能であるため、判定方法が一つの場合と比較して高精度に異常を検出できる。また、監視データの収集方法及び正常か異常かの判定における判定方式の設定は、プログラミングツール２から行うことができるため、システム立ち上げ時に設定を調整する際の作業工数を削減できる。 As described above, the programmable logic controller 1 according to the present embodiment is configured so that the input data input from the control target system 3 within a predetermined period and the output data output to the control target system 3 within a predetermined period are during normal operation. Since the abnormality determination unit 17 automatically detects an abnormality when showing a different trend, the abnormality can be detected easily and with high accuracy compared to the case of determining whether it is normal or abnormal based on data at a specific time point. It can be detected. Further, not only the input data input from the control target system 3 but also the output data output to the control target system 3 can be monitored and used to determine whether the control output of the programmable logic controller 1 is normal or abnormal. Since the determination method of whether the collected data is normal or abnormal can be selected from a plurality of methods according to the target system, an abnormality can be detected with higher accuracy than in the case of a single determination method. In addition, since the monitoring data collection method and the determination method for determining whether the monitoring data is normal or abnormal can be set from the programming tool 2, it is possible to reduce the number of work steps when adjusting the settings at the time of starting the system.
　また、表示制御部１８では、正常データのトレンドグラフ１８２と収集データのトレンドグラフ１８３とをプログラミングツール２に同一画面上で重畳表示させ、異常検出時には異常箇所及び正常データと収集データとの差分を強調表示させる。したがって、正常データと収集データとの差分及び異常箇所を視覚的かつ直感的に認識することができ、異常発生原因の早期究明と、正常状態への復旧とにつなげることができる。 In addition, the display control unit 18 displays a trend graph 182 of normal data and a trend graph 183 of collected data on the same screen on the same screen on the programming tool 2, and when an abnormality is detected, an abnormality location and a difference between normal data and collected data are displayed. Highlight it. Therefore, the difference between the normal data and the collected data and the abnormal part can be visually and intuitively recognized, which can lead to early investigation of the cause of the abnormality and recovery to the normal state.
　データ収集設定１３及び異常判定設定１６を、プログラミングツール２から受信することにより、設定操作を容易に行える。 The setting operation can be easily performed by receiving the data collection setting 13 and the abnormality determination setting 16 from the programming tool 2.
　以上の実施の形態に示した構成は、本発明の内容の一例を示すものであり、別の公知の技術と組み合わせることも可能であるし、本発明の要旨を逸脱しない範囲で、構成の一部を省略、変更することも可能である。 The configuration described in the above embodiment shows an example of the contents of the present invention, and can be combined with another known technique, and can be combined with other configurations without departing from the gist of the present invention. It is also possible to omit or change the part.
　１　プログラマブルロジックコントローラ、２　プログラミングツール、３　制御対象システム、４　部品加工装置、１１　収集データ記憶部、１２　正常データ記憶部、１３　データ収集設定、１４　データ収集部、１５　正常データ登録部、１６　異常判定設定、１７　異常判定部、１８　表示制御部、２１　演算装置、２２　記憶装置、２３　内部メモリ、２５　通信装置、２６　制御プログラム、４０　部品、４１　ベルトコンベア、４２　センサ、４３　モータ、１５１　正常データ登録画面、１５２　トレンドグラフ、１５３　開始時刻欄、１５４　開始時刻表示バー、１５５　終了時刻欄、１５６　終了時刻表示バー、１５７　登録ボタン、１６１　異常判定設定画面、１６２　正常データ指定欄、１６３　比較開始時刻指定欄、１６４　判定方式指定欄、１６５　時間間隔指定欄、１６６　閾値指定欄、１６７　設定ボタン、１８１　判定結果表示画面、１８２　正常データのトレンドグラフ、１８３　収集データのトレンドグラフ、１８４　変化量の計算期間、１８５　ポインタ、１８６　警告コメント欄。 1 programmable logic controller, 2 programming tool, 3 system to be controlled, 4 parts processing device, 11 collected data storage unit, 12 normal data storage unit, 13 data collection setting, 14 data collection unit, 15 normal data registration unit, 16 abnormality determination Setting, 17 abnormality determination unit, 18 display control unit, 21 arithmetic unit, 22 storage device, 23 internal memory, 25 communication device, 26 control program, 40 parts, 41 belt conveyor, 42 sensor, 43 motor, 151 normal data registration screen , 152 Trend graph, 153 Start time column, 154 Start time display bar, 155 End time column, 156 End time display bar, 157 Registration button, 161 Abnormality judgment setting screen, 162 Normal data specification column, 163 Comparison start time indicator Field, 164 judgment method designation field, 165 time interval designation field, 166 threshold value designation field, 167 setting button, 181 judgment result display screen, 182 normal data trend graph, 183 collected data trend graph, 184 change amount calculation period, 185 Pointer, 186 Warning comment field.

Claims (4)

  1. 　プログラミングツールから転送された制御プログラムを実行して制御対象システムを制御するプログラマブルロジックコントローラであって、
    　前記制御プログラムの実行中に、前記制御対象システムとの入出力データを収集するデータ収集部と、
    　前記データ収集部で収集した入出力データを保存する収集データ記憶部と、
    　前記収集データ記憶部に保存した入出力データのうちの指定された一部分を記憶して、正常時の入出力データとする正常データ記憶部と、
    　前記収集データ記憶部及び前記正常データ記憶部から入出力データを取得し、前記収集データ記憶部から取得した入出力データと、前記正常データ記憶部から取得した正常時の入出力データとを一定期間分比較して、前記制御対象システムの制御が正常に行われているか否かを判定する異常判定部と、
    　前記異常判定部による判定結果をグラフィカルに表示する判定結果表示画面をエンジニアリングツールに表示させる表示制御部とを備えることを特徴とするプログラマブルロジックコントローラ。     A programmable logic controller that executes a control program transferred from a programming tool to control a controlled system,
    A data collection unit for collecting input / output data with the control target system during execution of the control program;
    A collection data storage unit for storing input / output data collected by the data collection unit;
    A normal data storage unit that stores a specified portion of the input / output data stored in the collected data storage unit and serves as normal input / output data;
    Input / output data is acquired from the collected data storage unit and the normal data storage unit, and the input / output data acquired from the collected data storage unit and the input / output data at normal time acquired from the normal data storage unit for a certain period Comparing the minute, an abnormality determination unit for determining whether or not the control of the control target system is normally performed; and
    A programmable logic controller comprising: a display control unit that causes an engineering tool to display a determination result display screen for graphically displaying a determination result by the abnormality determination unit.
  2. 　前記表示制御部は、前記収集データ記憶部に記憶された入出力データ及び前記正常データ記憶部に記憶された正常時の入出力データをグラフ表示し、かつ、前記収集データ記憶部に記憶された入出力データと前記正常データ記憶部に記憶された正常時の入出力データとの差分を前記判定結果表示画面で強調表示することを特徴とする請求項１に記載のプログラマブルロジックコントローラ。 The display control unit displays the input / output data stored in the collected data storage unit and the normal input / output data stored in the normal data storage unit in a graph, and stored in the collected data storage unit The programmable logic controller according to claim 1, wherein a difference between the input / output data and the normal input / output data stored in the normal data storage unit is highlighted on the determination result display screen.
  3. 　前記データ収集部の入出力データを収集する動作の設定と、前記異常判定部の前記制御対象システムの制御が正常に行われているか否かを判定する動作の設定とを、前記プログラミングツール上で設定可能であることを特徴とする請求項１に記載のプログラマブルロジックコントローラ。 On the programming tool, an operation setting for collecting input / output data of the data collection unit and an operation setting for determining whether the control of the control target system of the abnormality determination unit is normally performed are performed on the programming tool. The programmable logic controller according to claim 1, wherein the programmable logic controller is settable.
  4. 　前記異常判定部は、前記収集データ記憶部から取得した入出力データと前記正常データ記憶部から取得した正常時の入出力データとを、複数の方式中から選択された方式で比較することを特徴とする請求項１から３のいずれか１項に記載のプログラマブルロジックコントローラ。 The abnormality determination unit compares the input / output data acquired from the collected data storage unit and the normal input / output data acquired from the normal data storage unit by a method selected from a plurality of methods. The programmable logic controller according to any one of claims 1 to 3.
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