WO2020246518A1 - Production monitoring device, production monitoring system, production monitoring method, and program - Google Patents

Production monitoring device, production monitoring system, production monitoring method, and program Download PDF

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Publication number
WO2020246518A1
WO2020246518A1 PCT/JP2020/022001 JP2020022001W WO2020246518A1 WO 2020246518 A1 WO2020246518 A1 WO 2020246518A1 JP 2020022001 W JP2020022001 W JP 2020022001W WO 2020246518 A1 WO2020246518 A1 WO 2020246518A1
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Prior art keywords
production
programmable logic
logic controller
data
abnormality
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PCT/JP2020/022001
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French (fr)
Japanese (ja)
Inventor
篤彦 高瀬
安部　新一
声喜 佐藤
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株式会社Kmc
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Publication of WO2020246518A1 publication Critical patent/WO2020246518A1/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
    • G05B19/418—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
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/04—Manufacturing
    • 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]
    • 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
    • Y02P90/30—Computing systems specially adapted for manufacturing

Definitions

  • the present invention relates to a production monitoring device, a production monitoring system, a production monitoring method and a program for monitoring production by production equipment such as a molding machine or a press machine.
  • each monitoring data of the processing machine is evaluated based on the respective threshold values of a plurality of types of monitoring data, and the processing machine is evaluated based on the evaluation result for each product.
  • a technique for sorting products processed by the above is disclosed.
  • Patent Document 2 referring to FIG. 28 and the like, while looking at the information on the accuracy of the parts from the mapping data, the mold maintenance time, the remanufacturing of the mold parts, the set values of the cooling water and the mold temperature, It is disclosed that the set values (holding pressure, nozzle temperature, etc.) of the molding machine are determined in real time and appropriately.
  • the production monitoring device proposed by the present inventors collectively monitors, for example, eight production lines.
  • One production line collects data from molding machines, press machines, processing machines, automatic machines, robots, sensors, as well as these devices as production equipment for continuous production of products.
  • PLC programmable logic controller
  • the production monitoring device collects data from the eight PLCs and monitors the entire eight production lines. Therefore, if an abnormality occurs somewhere, we want to distinguish the location and type of the abnormality as much as possible from the viewpoint of human response.
  • an object of the present invention is a production monitoring device, a production monitoring system, and a production monitoring method capable of easily distinguishing the location and type of abnormality occurrence in a production system having a large number of production facilities. And to provide the program.
  • the production monitoring device collects equipment data from one or more production facilities for continuously producing products and the production facilities, and the production facilities.
  • a production monitoring device that monitors a production system having one or more production lines having a programmable logic controller capable of detecting a communication abnormality with the programmable logic controller, and the equipment data and the detected communication from the programmable logic controller.
  • An abnormality in the production equipment based on a communication unit that receives data related to the abnormality, a detection unit that detects a communication abnormality between the programmable logic controller, a reception result by the communication unit, and a detection result by the detection unit. It is provided with a warning information output unit that outputs information for distinguishing and warning a communication abnormality between the production equipment and the programmable logic controller and a communication abnormality between the programmable logic controller.
  • the warning information output unit outputs information that separately warns of abnormalities in the production equipment, communication abnormalities between the production equipment and the programmable logic controller, and communication abnormalities between the programmable logic controller and the production monitoring device. Therefore, in a production system having a large number of production facilities, it is possible to distinguish the location and type of abnormality occurrence.
  • an abnormality of the production equipment based on the warning information output from the warning information output unit, an abnormality of the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and the programmable logic It has a patrol light (registered trademark) that emits light in different colors for communication abnormalities between the controller and the production monitoring device.
  • the type of abnormality is displayed. And the location can be easily grasped.
  • an abnormality of the production equipment based on the warning information output from the warning unit, an abnormality of the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and the programmable logic controller It has a patrol light (registered trademark) display data output unit that outputs display data that displays on the screen a patrol light (registered trademark) that emits light in different colors for communication abnormalities with the production monitoring device.
  • a patrol light registered trademark
  • the equipment data collected by the programmable logic controller includes data of set values for the production equipment and actual values for the production monitoring equipment, and equipment data received from the programmable logic controller. Based on the above, it has a set value / actual value display data output unit that outputs display data for displaying the set value for the production equipment and the actual value for the set value on the screen.
  • the detection unit confirms whether or not the data can be received from the programmable logic controller via the communication unit, and the communication unit cannot receive the data. Occasionally, the programmable logic controller is requested to retransmit, and if the data is still not received, an alert is output.
  • the production monitoring device has means for accumulating the equipment data received from the programmable logic controller and managing the tendency value of the value based on the equipment data.
  • the tendency value is a value indicating a state in which the equipment data changes over time, and managing the tendency value means, for example, when the value based on the equipment data exceeds or is about to exceed a predetermined value. When predicted, it means issuing an alarm urging the operation of production equipment to be stopped.
  • waveform data in one cycle or one shot which is a unit for producing one product in the production equipment, is obtained from the equipment data received from the programmable logic controller.
  • a means for managing the production equipment based on the waveform data Managing the production equipment means, for example, issuing an alarm urging the operation of the production equipment to be stopped when an abnormal value or a tendency of an abnormal value is found in the waveform data.
  • the production monitoring system collects equipment data from one or more production facilities for continuously producing products and the production facilities, and has a communication abnormality between the production facilities.
  • a production monitoring device that monitors a production system having one or more production lines having a programmable logic controller capable of detecting the above, and a production monitoring system having the programmable logic controller.
  • the production monitoring device is the programmable logic controller.
  • the communication unit that receives the equipment data and the data related to the detected communication abnormality, the detection unit that detects the communication abnormality between the programmable logic controller, the reception result by the communication unit, and the detection unit.
  • Warning information output that outputs information that separately warns of an abnormality in the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and a communication abnormality between the programmable logic controller based on the detection result. Has a part.
  • the programmable logic controller holds the collected equipment data in the external memory device and sends the equipment data held in the external memory device to the production monitoring device. It is configured in.
  • the production monitoring method collects equipment data from one or more production facilities for continuously producing products and the production facilities, and has an abnormality in communication between the production facilities. It is a production monitoring method for monitoring a production system having one or more production lines having a programmable logic controller capable of detecting the above, and receives the equipment data and the data related to the detected communication abnormality from the programmable logic controller. A communication abnormality with the programmable logic controller is detected, and based on the data reception result and the abnormality detection result, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the programmable Outputs information that distinguishes and warns of communication abnormalities between the logic controller and the production monitoring side.
  • the program collects equipment data from one or more production facilities for continuously producing products and the production facilities, and detects a communication abnormality between the production facilities.
  • a program that monitors a production system having one or more production lines having a possible programmable logic controller, the step of receiving the equipment data and the data related to the detected communication abnormality from the programmable logic controller, and the programmable. Based on the step of detecting a communication abnormality with the logic controller and the data reception result and the abnormality detection result, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the programmable The computer is made to perform a step of outputting information that distinguishes and warns of communication abnormalities between the logic controller and the production monitoring side.
  • the present invention in a production system having a large number of production facilities, it is possible to easily distinguish the location and type of abnormality occurrence.
  • FIG. 1 It is a figure which shows the structure of the production system which concerns on one Embodiment of this invention. It is a figure which shows the structure of the production monitoring system in the production system shown in FIG. It is a figure which shows the display example of the set value and the actual value which concerns on one Embodiment of this invention. It is a flowchart which shows the operation of the production monitoring apparatus which concerns on one Embodiment of this invention. It is a figure which shows an example of the structure of the communication data transmitted from the PLC side to the production monitoring apparatus side which concerns on one Embodiment of this invention. This is an example of waveform data in one shot of the mold temperature of the molding machine acquired by the production monitoring device according to the embodiment of the present invention.
  • FIG. 1 is a diagram showing a configuration of a production system according to an embodiment of the present invention.
  • the production system 1 collects equipment data from one or more production equipments 10, 11 ... And production equipments 10, 11 ... For continuously producing products, and ,
  • the PLC 20 capable of detecting a communication abnormality with the production facilities 10, 11, ..., And the production monitoring device 30.
  • the equipment data includes various measurement data and the like in addition to the operation data in the production equipment.
  • one production line is composed of production facilities 10, 11 ... And one PLC20, and eight production lines 1-1, 1-2, ... 1- Has 8.
  • the production monitoring device 30 monitors the production of these eight production lines 1-1, 1-2, ... 1-8.
  • the production equipment refers to, for example, a molding machine 10, a press machine 11, a processing machine 12, an automatic machine 13, a robot 14, a sensor 15, and the like.
  • peripheral facilities such as a temperature controller and a dryer.
  • the sensor 15 there are a mold temperature sensor, a surface temperature sensor, a mold pressure sensor and the like arranged inside the mold used in the molding machine 10, and further, a temperature sensor and a flow rate sensor arranged around the equipment and the like. There is an incidental sensor.
  • the PLC 20 collects equipment data from the molding machine 10, the press machine 11, the processing machine 12, the automatic machine 13, the robot 14, and the sensor 15 in the line.
  • the equipment data refers to the molding machine 10, the molding time, the shot number, the VP switching position, the cushion position, the cycle time, the plasticizing time, the primary injection time, the pressure for generations, the minimum cushion, and the mold opening. Time, mold closing time, etc.
  • the data measured by the sensor 15 is also included in the equipment data.
  • the data measured by the sensor 15 also includes analog data (waveform data) such as pressure and temperature in one cycle or one shot, which is a unit for producing one product in a production facility.
  • the production monitoring device 30 collects the above-mentioned various equipment data from the eight PLC20s and monitors the entire eight production lines 1-1, 1-2, ... 1-8.
  • a patrol light (registered trademark) 40 and a display device 50 are connected to the production monitoring device 30. Further, the production monitoring device 30 can remotely exchange data via a network (not shown).
  • FIG. 2 is a diagram showing a configuration of a production monitoring system in the production system 1 shown in FIG.
  • the production monitoring system 2 includes the above-mentioned eight PLCs 20, a production monitoring device 30, a patrol light (registered trademark) 40, and a display device 50.
  • the PLC 20 mainly has a communication unit 21, a control unit 22, and a storage unit 23.
  • the communication unit 21 acquires equipment data from the production equipment 10, 11, ..., And sends the acquired data to the production monitoring device 30.
  • the control unit 22 functions as a detection unit that detects a communication abnormality between the production facilities 10, 11 ... And the PLC 20 via the communication unit 21. For example, if the communication path 25 between the production facilities 10, 11 ... Is disconnected (indicated by "x" in the figure), data will not be received from the production facilities 10, 11 ... (No response). ), So it is detected as a communication error. When data is lost from one of the production facilities 10, 11, ..., It is detected as a communication abnormality of the communication path 25 with the one production facility. In addition, it may be regarded as an abnormality due to damage to the production equipment.
  • An external memory 24 such as an SD memory card or a USB memory can be connected to the PLC 20 according to the present embodiment.
  • Equipment data from the production equipments 10, 11 ... Received via the communication unit 21 is temporarily stored in the external memory 24, and the PLC 20 is transferred to the production monitoring device 30 in the external memory 24 via the communication unit 21.
  • the accumulated equipment data is transmitted.
  • analog data waveform data
  • the amount of data becomes enormous, so it is useful to use such an external memory 24 for capacity flexibility.
  • the equipment data may be stored in the storage unit 23 without using the external memory 24.
  • the production monitoring device 30 mainly has a communication unit 31, a control unit 32, and a storage unit 33.
  • the communication unit 31 receives the equipment data and the data related to the communication abnormality detected by the PLC 20 from the PLC 20.
  • the control unit 32 has a function as a detection unit for detecting a communication abnormality with the PLC 20. For example, if the communication path 34 with the PLC 20 is disconnected (indicated by "x" in the figure), data will not come from the PLC 20 (no response), so it will be detected as a communication abnormality with the PLC 20. ..
  • the control unit 32 Based on the reception result by the communication unit 31 and the detection result as the above-mentioned detection unit by the control unit 32, the control unit 32 causes an abnormality in the production facilities 10, 11 ..., The production facilities 10, 11 ... And the PLC 20. It functions as a warning information output unit that outputs information that separately warns the communication abnormality between the two and the communication abnormality between the PLC 20 and the production monitoring device 30. Further, based on the warning information output from the production monitoring device 30, the control unit 32 causes an abnormality in the production facilities 10, 11 ..., a communication abnormality between the production facilities 10, 11 ... And the PLC 20, and the PLC 20. It functions as a patrol light (registered trademark) display data output unit that outputs display data that displays on the screen a patrol light (registered trademark) that emits light in different colors for communication abnormalities with the production monitoring device 30.
  • a patrol light registered trademark
  • the storage unit 33 stores the equipment data of the production equipments 10, 11 ... Received via the PLC 20.
  • the control unit 32 monitors the production by the production equipment 10, 11, ... Based on the equipment data accumulated in the storage unit 33. For example, the control unit 32 manages the tendency value (aging value) of the value of the equipment data stored in the storage unit 33, and for example, when the value based on the equipment data exceeds or is about to exceed a predetermined value, it is in advance. When predicted, an alarm is issued from Patrite (registered trademark) 40 or the like to urge the operation of the production equipment to be stopped. The production facilities 10, 11 ... May be forcibly stopped.
  • the control unit 32 obtains waveform data in one cycle or one shot, which is a unit for producing one product in production equipment 10, 11 ..., From the equipment data received from the PLC 20, and produces based on the waveform data. It functions as a means for managing the equipment 10, 11, .... To manage production facilities 10, 11 ... For example, when an abnormal value or a tendency of an abnormal value is found in waveform data, Patrite (registered trademark) issues an alarm prompting the stop of operation of production facilities 10, 11 ... It means that it originates from 40 mag.
  • the control unit 32 has a detection / retransmission request function for confirming whether or not equipment data or the like can be received from the PLC 20 via the communication unit 31 and requesting the PLC 20 to retransmit when the equipment data or the like cannot be received. Then, the control unit 32 outputs an alert when the equipment data or the like cannot be received despite the retransmission request.
  • the alert may be a notification sound, a display device 50, or the like.
  • the Patrite (registered trademark) 40 has an abnormality in the production facilities 10, 11 ..., a communication abnormality between the production facilities 10, 11 ... And the PLC 20, and the PLC 20.
  • the communication abnormality between the device and the production monitoring device 30 is emitted in different colors.
  • Patrite® 40 emits four colors: blue, yellow, red, and white.
  • Blue is emitted.
  • a part of the production facilities 10, 11 ... Is stopped, it emits yellow light.
  • Patrite (registered trademark) 40 is stopped, both blue and yellow are emitted by Patrite (registered trademark) 40. To do. Further, when the production facilities 10, 11 ... Are abnormal, the patrol light (registered trademark) 40 emits white light, and the communication abnormality between the production facilities 10, 11 ... And the PLC 20 and the PLC 20 and the production monitoring device 30 are abnormal. In the event of communication abnormality with, Patrite (registered trademark) 40 emits red light. Such light emission of Patrite (registered trademark) 40 is an example, and light emission in various patterns can be considered.
  • the display device 50 Based on the display data output from the production monitoring device 30, the display device 50 displays on the screen the abnormalities of the production facilities 10, 11 ..., And the above-mentioned Patrite (registered trademark) 40.
  • the equipment data collected by the PLC 20 includes data of set values for production equipment 10, 11 ... And actual values for the set values.
  • the control unit 32 outputs the set value / actual value for displaying the set value for the production equipment 10, 11 ... And the actual value for it on the screen. It functions as a value display data output unit.
  • the display device 50 displays the set value and the actual value on the screen based on the display data.
  • FIG. 3 shows an example of the screen. In the actual production facilities 10, 11, ..., Even if they are the same production facilities, there are differences. The operator can know this machine difference by comparing the set value displayed on the screen with the actual value, and can take measures corresponding to the difference, for example.
  • the control unit 32 determines whether communication with the PLC20 side is interrupted (step 401).
  • control unit 32 executes a reconnection operation with the PLC20 side (step 402).
  • the control unit 32 reads the header information from the communication data transmitted from the PLC20 side when the communication with the PLC20 side is not interrupted or the communication with the PLC20 side is not interrupted due to reconnection (Ste 403), read the equipment data and the like included in the communication data based on the header information (step 404).
  • FIG. 5 shows an example of the configuration of communication data transmitted from the PLC 20 side to the production monitoring device 30 side, and the communication data distinguishes the serial number, the time such as a shot, and the mode (whether the molding is in the manual mode or the automatic mode, etc.). ), Alarm type (distinguishes whether the alarm is an equipment alarm or a PLC alarm), sensor (1) data, sensor (2) data, and the like.
  • the equipment alarm indicates, for example, an abnormality in the production equipments 10, 11 ...
  • the PLC alarm indicates, for example, a communication abnormality between the production equipments 10, 11 ... And the PLC 20.
  • the waveform data in one cycle or one shot which is a unit for producing one product in the production facilities 10, 11, ..., Is obtained, and the production facilities 10, 11, ... are managed based on the waveform data. The points to be done will be described in more detail.
  • FIG. 6 is an example of waveform data in one shot of the mold temperature of the molding machine 10 acquired by the production monitoring device 30.
  • the mold temperature of the molding machine 10 first rises from the start of injection in one shot, peaks at a predetermined point, and then falls.
  • the peak temperature (t max ) needs to be within a predetermined range (t 0 to t 1 ).
  • the time when the mold temperature of the molding machine 10 peaks that is, the time (T peak ) from the start of injection to the peak of the mold temperature of the molding machine 10 is also within a predetermined range (T 0 to T 1 ).
  • T peak time from the start of injection to the peak of the mold temperature of the molding machine 10 is also within a predetermined range (T 0 to T 1 ).
  • the control unit 32 determines whether or not the peak temperature (t max ) is within a predetermined range (t 0 to t 1 ) with respect to the waveform data of the mold temperature of the molding machine 10 within one shot. In addition, the time when the mold temperature of the molding machine 10 peaks, that is, the time (T peak ) from the start of injection to the peak of the mold temperature of the molding machine 10 also falls within a predetermined range (T 0 to T 1 ). Determine if there is.
  • the control unit 32 patrols the waveform data of the mold temperature of the molding machine 10 in one shot when the peak temperature (t max ) is not within a predetermined range (t 0 to t 1 ).
  • the (registered trademark) 40 is made to emit white light, the display device 50 is similarly displayed, and the display device 50 is further instructed to raise or lower the mold temperature.
  • the control unit 32 may control the mold temperature to be raised or lowered via the PLC 20.
  • the control unit 32 has a predetermined range (T 0 to T 1 ) of the time (T peak ) until the mold temperature of the molding machine 10 reaches its peak with respect to the waveform data in one shot of the mold temperature of the molding machine 10. ) Is not included, the patrol light (registered trademark) 40 is made to emit white light, the same display is displayed on the display device 50, and the display device 50 further displays instructions for mold maintenance and confirmation.
  • FIG. 7 is an example of waveform data within one cycle of the machining load of the end mill of the machining machine 12 acquired by the production monitoring device 30.
  • the machining load of the end mill of the machining machine 12 first rises from the start of machining, peaks at a predetermined point, and then decreases.
  • the peak magnitude (P max ) needs to be within a predetermined range (P 0 to P 1 ).
  • the time (T peak ) from the start of machining to the peak of the machining load of the end mill of the machining machine 12 at the time when the machining load of the end mill of the machining machine 12 peaks is also within a predetermined range (T 0 to T 1). ) Must be inside. -If the peak magnitude (P max ) is lower than the predetermined range (P 0 to P 1 ), it is presumed that there is some problem on the work side.
  • the peak magnitude (P max ) is higher than the predetermined range (P 0 to P 1 )
  • the sharpness of the end mill has deteriorated.
  • the time (T peak ) until the machining load of the end mill of the processing machine 12 reaches its peak is shorter than the predetermined range (T 0 to T 1 )
  • the mounting position of the end mill is in the Z direction from the predetermined position. It is estimated that it is down.
  • the time (T peak ) until the machining load of the end mill of the processing machine 12 reaches its peak is longer than the predetermined range (T 0 to T 1 )
  • the mounting position of the end mill is in the Z direction from the predetermined position. It is estimated that it is down.
  • the control unit 32 determines whether or not the peak magnitude (P max ) is within a predetermined range (P 0 to P 1 ) with respect to the waveform data in one cycle of the machining load of the end mill of the machining machine 12.
  • the time (T peak ) from the start of machining to the peak of the machining load of the end mill of the machining machine 12 is also within a predetermined range (T peak ) at the time when the machining load of the end mill of the machining machine 12 peaks. Judge whether it is within 0 to T 1 ).
  • the control unit 32 is in the case where the peak magnitude (P max ) is not within a predetermined range (P 0 to P 1 ) with respect to the waveform data in one cycle of the machining load of the end mill of the machining machine 12.
  • Lights the patrol light (registered trademark) 40 in white displays the same on the display device 50, and further displays the display device 50 to prompt the replacement of the end mill or the like.
  • the control unit 32 has a predetermined range (T peak ) of the time (T peak ) until the machining load of the end mill of the machining machine 12 reaches the peak with respect to the waveform data in one cycle of the machining load of the end mill of the machining machine 12. If it is not within 0 to T 1 ), the patrol light (registered trademark) 40 is made to emit white light, the same display is displayed on the display device 50, and the display device 50 further displays an instruction for confirming the mounting state of the end mill. ..
  • the production monitoring device 30 obtains waveform data within one cycle or one shot from the equipment data received from the PLC 20, and manages the production equipments 10, 11, ... Based on the waveform data. ..
  • the upper limit value and the lower limit value of the peak value of the waveform data in one cycle or one shot are set and the peak value exceeds the upper limit value or the peak value becomes smaller than the lower limit value, Give a predetermined alarm, etc.
  • the time when the waveform data in one cycle or one shot peaks that is, the range of time from the start of one cycle or one shot to the peak is set, and the time is less than a predetermined time or a predetermined time. When it exceeds, a predetermined alarm or the like is issued.
  • the upper limit value and the lower limit value set as described above, or the time range, that is, the threshold range may be appropriately set.
  • control unit 32 obtains the waveform data in one cycle or one shot and manages the production facilities 10, 11, ... Based on the waveform data, but the control unit 32 is the storage unit. Various management is possible based on the equipment data accumulated in 33.
  • the above peak value and other measured values may be displayed in time series and managed as time series data.
  • the threshold value of the measured value other than the above peak value may be managed. For example, when the measured value exceeds a predetermined upper threshold value, a foreign matter defect of the product may occur, and when it becomes less than a predetermined lower limit value, a dimensional defect of the product may occur. A predetermined warning may be issued.
  • waveform data in one cycle or one shot may be synchronized in time and displayed simultaneously on the same screen.
  • waveform data of the resin temperature in the mold, the pressure in the mold, the surface temperature of the mold, and the injection pressure of the molding machine in the molding machine may be displayed on the display device at the same time. As a result, the state of molding by the molding machine can be accurately grasped.
  • time series data multiple types of time series data may be synchronized in time and displayed simultaneously on the same screen (see FIG. 8). At that time, as shown in FIG. 8, by providing the same time comparison line on the screen, it becomes easy to compare the data at the same time between a plurality of types of time series data.
  • Multiple types of equipment data for one production equipment may be displayed as one group at the same time on the same screen.
  • the data of the temperature controller of the molding machine, the dryer, the temperature sensor in the mold, the hot runner, the flow rate sensor, the pressure sensor in the mold, and the surface temperature sensor of the mold may be displayed simultaneously on the same screen.
  • Equipment data may be displayed simultaneously on the same screen for each production line.
  • a molding machine 10 a press machine 11, a processing machine 12, an automatic machine 13, a robot 14, a sensor, which belong to any one of eight production lines 1-1, 1-2, ... 1-8.
  • Equipment data may be displayed simultaneously on the same screen from 5.
  • the production monitoring device issues a warning or the like or controls the set value of the production equipment when a product defect is predicted, but when a product defect is predicted.
  • the production monitoring device may control the robot to take out the product produced by the production facility or the product being produced as a defective product from the production line.

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Abstract

Disclosed is a production system including a plurality of production facilities, the production system being provided with: a production monitoring device, a product monitoring system, a product monitoring method, and a program which can easily distinguish, from each other, a place, a type, or the like of the occurrence of an abnormality.　The product monitoring device (30) monitors a production system having one or more production lines, each production line including: a production facility; and a PLC (20) which collects facility data from the production facility. The production monitoring device (30) includes a control unit (32) which detects a communication abnormality with the PLC (20), wherein the control unit (32) distinguishes, from each other, an abnormality in the production facility, a communication abnormality between the production facility and the PLC (20), and a communication abnormality between the PLC (20) and the production monitoring device (30), and outputs information warning of the abnormalities.

Description

生産監視装置、生産監視システム、生産監視方法及びプログラムProduction monitoring equipment, production monitoring system, production monitoring method and program
　本発明は、成形機やプレス機などの生産設備による生産を監視する生産監視装置、生産監視システム、生産監視方法及びプログラムに関する。 The present invention relates to a production monitoring device, a production monitoring system, a production monitoring method and a program for monitoring production by production equipment such as a molding machine or a press machine.
　生産ラインにおいては、生産される製品の品質特性に影響する生産時の温度、圧力などの計測データなどを生産プロセス中で収集し、これらの計測データを生産監視装置で集中的に管理することが行われている。 On the production line, it is possible to collect measurement data such as temperature and pressure during production that affect the quality characteristics of the products produced during the production process, and centrally manage these measurement data with a production monitoring device. It is done.
　特許文献１には、加工機が加工した一製品ごとに、複数種類の監視データのそれぞれのしきい値に基づき加工機のそれぞれの監視データを評価し、一製品ごとの評価結果に基づき加工機により加工された製品を分別する技術が開示されている。 In Patent Document 1, for each product processed by the processing machine, each monitoring data of the processing machine is evaluated based on the respective threshold values of a plurality of types of monitoring data, and the processing machine is evaluated based on the evaluation result for each product. A technique for sorting products processed by the above is disclosed.
　特許文献２には、その図２８などを参照すれば、マッピングデータから、部品精度の情報を見ながら、金型メンテナンス時期、或いは金型部品の再製作、冷却水や金型温度の設定値、成形機の設定値（保圧、ノズル温度等）等の判断をリアルタイムに、かつ、適切に行うことが開示されている。 In Patent Document 2, referring to FIG. 28 and the like, while looking at the information on the accuracy of the parts from the mapping data, the mold maintenance time, the remanufacturing of the mold parts, the set values of the cooling water and the mold temperature, It is disclosed that the set values (holding pressure, nozzle temperature, etc.) of the molding machine are determined in real time and appropriately.
特開２０１９－０４６２９３号公報Japanese Unexamined Patent Publication No. 2019-046293 特開２０１８－０７３３２９号公報Japanese Unexamined Patent Publication No. 2018-073329
　本発明者らが提案している生産監視装置は、例えば８つの生産ラインを一括で監視する。一本の生産ラインは、製品を連続的に生産するための生産設備としての成形機、プレス機、加工機、自動機、ロボット、センサーのほか、当該ライン内ではこれらの機器からデータを収集するプログラマブルロジックコントローラ（以下、「ＰＬＣ」と呼ぶ。）を有する。従って、生産監視装置は、８台のＰＬＣからデータを収集して８つの生産ライン全体を監視することになる。そのため、どこかに異常が発生した場合に、人的な対応の面からしてもできるだけ異常発生の場所や種別等を区別したい。 The production monitoring device proposed by the present inventors collectively monitors, for example, eight production lines. One production line collects data from molding machines, press machines, processing machines, automatic machines, robots, sensors, as well as these devices as production equipment for continuous production of products. It has a programmable logic controller (hereinafter referred to as "PLC"). Therefore, the production monitoring device collects data from the eight PLCs and monitors the entire eight production lines. Therefore, if an abnormality occurs somewhere, we want to distinguish the location and type of the abnormality as much as possible from the viewpoint of human response.
　以上のような事情に鑑み、本発明の目的は、多数の生産設備をもつ生産システムにおいて、異常発生の場所や種別等を容易に区別することができる生産監視装置、生産監視システム、生産監視方法及びプログラムを提供することにある。 In view of the above circumstances, an object of the present invention is a production monitoring device, a production monitoring system, and a production monitoring method capable of easily distinguishing the location and type of abnormality occurrence in a production system having a large number of production facilities. And to provide the program.
　上記目的を達成するため、本発明の一形態に係る生産監視装置は、製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視する生産監視装置であって、前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信する通信部と、前記プログラマブルロジックコントローラとの間での通信異常を検出する検出部と、前記通信部による受信結果及び前記検出部による検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラとの間の通信異常を、それぞれ区別して警告する情報を出力する警告情報出力部とを具備する。 In order to achieve the above object, the production monitoring device according to one embodiment of the present invention collects equipment data from one or more production facilities for continuously producing products and the production facilities, and the production facilities. A production monitoring device that monitors a production system having one or more production lines having a programmable logic controller capable of detecting a communication abnormality with the programmable logic controller, and the equipment data and the detected communication from the programmable logic controller. An abnormality in the production equipment, based on a communication unit that receives data related to the abnormality, a detection unit that detects a communication abnormality between the programmable logic controller, a reception result by the communication unit, and a detection result by the detection unit. It is provided with a warning information output unit that outputs information for distinguishing and warning a communication abnormality between the production equipment and the programmable logic controller and a communication abnormality between the programmable logic controller.
　本発明では、警告情報出力部が生産設備の異常、生産設備とプログラマブルロジックコントローラとの間の通信異常及びプログラマブルロジックコントローラと生産監視装置との間の通信異常を、それぞれ区別して警告する情報を出力するので、多数の生産設備をもつ生産システムにおいて、異常発生の場所や種別等を区別することができる。 In the present invention, the warning information output unit outputs information that separately warns of abnormalities in the production equipment, communication abnormalities between the production equipment and the programmable logic controller, and communication abnormalities between the programmable logic controller and the production monitoring device. Therefore, in a production system having a large number of production facilities, it is possible to distinguish the location and type of abnormality occurrence.
　本発明の一形態に係る生産監視装置では、前記警告情報出力部から出力された警告情報に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視装置との間の通信異常を、それぞれ異なる色で発光するパトライト（登録商標）を有する。 In the production monitoring device according to one embodiment of the present invention, based on the warning information output from the warning information output unit, an abnormality of the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and the programmable logic It has a patrol light (registered trademark) that emits light in different colors for communication abnormalities between the controller and the production monitoring device.
　パトライト（登録商標）によって生産設備の異常、生産設備とプログラマブルロジックコントローラとの間の通信異常及びプログラマブルロジックコントローラと生産監視装置との間の通信異常を、それぞれ区別して表示することで、異常の種別や場所を容易に把握することができる。 By displaying the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the communication abnormality between the programmable logic controller and the production monitoring device separately by Patrite (registered trademark), the type of abnormality is displayed. And the location can be easily grasped.
　本発明の一形態に係る生産監視装置では、前記警告部から出力された警告情報に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視装置との間の通信異常を、それぞれ異なる色で発光するパトライト（登録商標）を画面上に表示する表示データを出力するパトライト（登録商標）表示データ出力部を有する。 In the production monitoring device according to one embodiment of the present invention, based on the warning information output from the warning unit, an abnormality of the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and the programmable logic controller It has a patrol light (registered trademark) display data output unit that outputs display data that displays on the screen a patrol light (registered trademark) that emits light in different colors for communication abnormalities with the production monitoring device.
　本発明の一形態に係る生産監視装置では、前記プログラマブルロジックコントローラが収集する設備データには、前記生産設備に対する設定値及びそれに対する実績値のデータが含まれ、前記プログラマブルロジックコントローラより受信した設備データに基づき、前記生産設備に対する設定値及びそれに対する実績値を画面上に表示する表示データを出力する設定値・実績値表示データ出力部を有する。 In the production monitoring device according to one embodiment of the present invention, the equipment data collected by the programmable logic controller includes data of set values for the production equipment and actual values for the production monitoring equipment, and equipment data received from the programmable logic controller. Based on the above, it has a set value / actual value display data output unit that outputs display data for displaying the set value for the production equipment and the actual value for the set value on the screen.
　これにより、各生産設備に対する設定値及びそれに対する実績値を生産監視装置側で集中的に把握することができる。 As a result, the set value for each production facility and the actual value for it can be centrally grasped on the production monitoring device side.
　本発明の一形態に係る生産監視装置では、前記検出部は、前記通信部を介して前記プログラマブルロジックコントローラより、前記データが受信できたかどうかを確認し、前記通信部は、前記データを受信できないときには前記プログラマブルロジックコントローラに再送信を要求し、それでも前記データが受信できないときには、アラートを出力する。 In the production monitoring device according to one embodiment of the present invention, the detection unit confirms whether or not the data can be received from the programmable logic controller via the communication unit, and the communication unit cannot receive the data. Occasionally, the programmable logic controller is requested to retransmit, and if the data is still not received, an alert is output.
　これにより、生産監視装置とプログラマブルロジックコントローラとの間での通信をより確実に行うことができる。 As a result, communication between the production monitoring device and the programmable logic controller can be performed more reliably.
　本発明の一形態に係る生産監視装置では、前記プログラマブルロジックコントローラより受信した前記設備データを蓄積し、前記設備データに基づく値の傾向値を管理する手段を有する。傾向値とは、経年による設備データの変化していく状態を示した値であり、傾向値を管理するとは、例えば設備データに基づく値が所定値を超えたとき、或いは超えそうになると事前に予測されるとき、生産設備の運転の停止等を促す警報を発することをいう。 The production monitoring device according to one embodiment of the present invention has means for accumulating the equipment data received from the programmable logic controller and managing the tendency value of the value based on the equipment data. The tendency value is a value indicating a state in which the equipment data changes over time, and managing the tendency value means, for example, when the value based on the equipment data exceeds or is about to exceed a predetermined value. When predicted, it means issuing an alarm urging the operation of production equipment to be stopped.
　本発明の一形態に係る生産監視装置では、前記プログラマブルロジックコントローラより受信した前記設備データから前記生産設備で１つの前記製品を生産する単位である１サイクル又は１ショット内での波形データを得て、前記波形データに基づき、前記生産設備を管理する手段を有する。生産設備を管理するとは、例えば波形データに異常値乃至異常値傾向が見られるとき、生産設備の運転の停止等を促す警報を発することをいう。 In the production monitoring device according to one embodiment of the present invention, waveform data in one cycle or one shot, which is a unit for producing one product in the production equipment, is obtained from the equipment data received from the programmable logic controller. , A means for managing the production equipment based on the waveform data. Managing the production equipment means, for example, issuing an alarm urging the operation of the production equipment to be stopped when an abnormal value or a tendency of an abnormal value is found in the waveform data.
　本発明の一形態に係る生産監視システムは、製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視する生産監視装置と、前記プログラマブルロジックコントローラとを有する生産監視システムであって、前記生産監視装置は、前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信する通信部と、前記プログラマブルロジックコントローラとの間での通信異常を検出する検出部と、前記通信部による受信結果及び前記検出部による検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラとの間の通信異常を、それぞれ区別して警告する情報を出力する警告情報出力部とを有する。 The production monitoring system according to one embodiment of the present invention collects equipment data from one or more production facilities for continuously producing products and the production facilities, and has a communication abnormality between the production facilities. A production monitoring device that monitors a production system having one or more production lines having a programmable logic controller capable of detecting the above, and a production monitoring system having the programmable logic controller. The production monitoring device is the programmable logic controller. The communication unit that receives the equipment data and the data related to the detected communication abnormality, the detection unit that detects the communication abnormality between the programmable logic controller, the reception result by the communication unit, and the detection unit. Warning information output that outputs information that separately warns of an abnormality in the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and a communication abnormality between the programmable logic controller based on the detection result. Has a part.
　本発明の一形態に係る生産監視システムでは、前記プログラマブルロジックコントローラは、前記収集した設備データを前記外部メモリ装置に保持し、前記外部メモリ装置に保持された設備データを前記生産監視装置に送るように構成されている。 In the production monitoring system according to one embodiment of the present invention, the programmable logic controller holds the collected equipment data in the external memory device and sends the equipment data held in the external memory device to the production monitoring device. It is configured in.
　本発明の一形態に係る生産監視方法は、製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視する生産監視方法であって、前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信し、前記プログラマブルロジックコントローラとの間での通信異常を検出し、前記データ受信結果及び前記異常検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視側の間の通信異常を、それぞれ区別して警告する情報を出力する。 The production monitoring method according to one embodiment of the present invention collects equipment data from one or more production facilities for continuously producing products and the production facilities, and has an abnormality in communication between the production facilities. It is a production monitoring method for monitoring a production system having one or more production lines having a programmable logic controller capable of detecting the above, and receives the equipment data and the data related to the detected communication abnormality from the programmable logic controller. A communication abnormality with the programmable logic controller is detected, and based on the data reception result and the abnormality detection result, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the programmable Outputs information that distinguishes and warns of communication abnormalities between the logic controller and the production monitoring side.
　本発明の一形態に係るプログラムは、製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視するプログラムであって、前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信するステップと、前記プログラマブルロジックコントローラとの間での通信異常を検出するステップと、前記データ受信結果及び前記異常検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視側の間の通信異常を、それぞれ区別して警告する情報を出力するステップとをコンピュータに実行させるものである。 The program according to one embodiment of the present invention collects equipment data from one or more production facilities for continuously producing products and the production facilities, and detects a communication abnormality between the production facilities. A program that monitors a production system having one or more production lines having a possible programmable logic controller, the step of receiving the equipment data and the data related to the detected communication abnormality from the programmable logic controller, and the programmable. Based on the step of detecting a communication abnormality with the logic controller and the data reception result and the abnormality detection result, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the programmable The computer is made to perform a step of outputting information that distinguishes and warns of communication abnormalities between the logic controller and the production monitoring side.
　本発明によれば、多数の生産設備をもつ生産システムにおいて、異常発生の場所や種別等を容易に区別することができる。 According to the present invention, in a production system having a large number of production facilities, it is possible to easily distinguish the location and type of abnormality occurrence.
本発明の一実施形態に係る生産システムの構成を示す図である。It is a figure which shows the structure of the production system which concerns on one Embodiment of this invention. 図１に示した生産システムにおける生産監視システムの構成を示す図である。It is a figure which shows the structure of the production monitoring system in the production system shown in FIG. 本発明の一実施形態に係る設定値と実績値の表示例を示す図である。It is a figure which shows the display example of the set value and the actual value which concerns on one Embodiment of this invention. 本発明の一実施形態に係る生産監視装置の動作を示すフローチャートである。It is a flowchart which shows the operation of the production monitoring apparatus which concerns on one Embodiment of this invention. 本発明の一実施形態に係るＰＬＣ側から生産監視装置側に送信される通信データの構成の一例を示す図である。It is a figure which shows an example of the structure of the communication data transmitted from the PLC side to the production monitoring apparatus side which concerns on one Embodiment of this invention. 本発明の一実施形態に係る生産監視装置において取得した、成形機の型温度の１ショット内での波形データの一例である。This is an example of waveform data in one shot of the mold temperature of the molding machine acquired by the production monitoring device according to the embodiment of the present invention. 本発明の一実施形態に係る生産監視装置において取得した、加工機のエンドミルの加工負荷の１サイクル内での波形データの一例である。This is an example of waveform data within one cycle of the machining load of the end mill of the machining machine acquired in the production monitoring device according to the embodiment of the present invention. 複数種類の時系列データを時間的に同期させて同一画面上に同時に表示した例を示す図である。It is a figure which shows the example which synchronized the time series data of a plurality of types in time, and displayed them simultaneously on the same screen.
　以下、図面を参照しながら、本発明の実施形態を説明する。　
　図１は、本発明の一実施形態に係る生産システムの構成を示す図である。　
　図１に示すように、生産システム１は、製品を連続的に生産するための１以上の生産設備１０、１１・・・と、生産設備１０、１１・・・から設備データを収集し、且つ、生産設備１０、１１・・・との間での通信異常を検出可能なＰＬＣ２０と、生産監視装置３０とを有する。設備データには、生産設備における稼働データの他、様々な計測データ等が含まれる。 Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a diagram showing a configuration of a production system according to an embodiment of the present invention.
As shown in FIG. 1, the production system 1 collects equipment data from one or more production equipments 10, 11 ... And production equipments 10, 11 ... For continuously producing products, and , The PLC 20 capable of detecting a communication abnormality with the production facilities 10, 11, ..., And the production monitoring device 30. The equipment data includes various measurement data and the like in addition to the operation data in the production equipment.
　本実施形態に係る生産システム１は、生産設備１０、１１・・・と１台のＰＬＣ２０とで１つの生産ラインを構成し、８つの生産ライン１－１、１－２、・・・１－８を有する。 In the production system 1 according to the present embodiment, one production line is composed of production facilities 10, 11 ... And one PLC20, and eight production lines 1-1, 1-2, ... 1- Has 8.
　生産監視装置３０は、これらの８つの生産ライン１－１、１－２、・・・１－８の生産を監視する。 The production monitoring device 30 monitors the production of these eight production lines 1-1, 1-2, ... 1-8.
　生産設備は、例えば成形機１０、プレス機１１、加工機１２、自動機１３、ロボット１４、センサー１５等のそれぞれをいう。生産設備としては、その他に様々のものがあり、例えば温調器や乾燥機などの周辺設備なども含まれる。また、センサー１５としては、成形機１０で用いられる型の内部に配置される型温センサー、表面温度センサー、型の圧力センサーなどがあり、更に設備の周辺に配置される温度センサーや流量センサーなどの付帯センサーがある。 The production equipment refers to, for example, a molding machine 10, a press machine 11, a processing machine 12, an automatic machine 13, a robot 14, a sensor 15, and the like. There are various other production facilities, including peripheral facilities such as a temperature controller and a dryer. Further, as the sensor 15, there are a mold temperature sensor, a surface temperature sensor, a mold pressure sensor and the like arranged inside the mold used in the molding machine 10, and further, a temperature sensor and a flow rate sensor arranged around the equipment and the like. There is an incidental sensor.
　ＰＬＣ２０は、当該ライン内の成形機１０、プレス機１１、加工機１２、自動機１３、ロボット１４、センサー１５から設備データを収集する。ここで、設備データとは、成形機１０でいうと、成形時刻、ショットＮｏ、Ｖ－Ｐ切換位置、クッション位置、サイクル時間、可塑化時間、１次射出時間、代々圧力、最小クッション、型開時間、型閉時間などである。上記のセンサー１５により計測されたデータも設備データに含まれる。また、センサー１５により計測されたデータには、生産設備で１つの製品を生産する単位である１サイクル又は１ショット内での圧力や温度などのアナログデータ（波形データ）も含まれる。 The PLC 20 collects equipment data from the molding machine 10, the press machine 11, the processing machine 12, the automatic machine 13, the robot 14, and the sensor 15 in the line. Here, the equipment data refers to the molding machine 10, the molding time, the shot number, the VP switching position, the cushion position, the cycle time, the plasticizing time, the primary injection time, the pressure for generations, the minimum cushion, and the mold opening. Time, mold closing time, etc. The data measured by the sensor 15 is also included in the equipment data. The data measured by the sensor 15 also includes analog data (waveform data) such as pressure and temperature in one cycle or one shot, which is a unit for producing one product in a production facility.
　生産監視装置３０は、８台のＰＬＣ２０から上記の様々設備データを収集して８つの生産ライン１－１、１－２、・・・１－８全体を監視する。生産監視装置３０には、パトライト（登録商標）４０と、表示装置５０とが接続されている。また、生産監視装置３０は、ネットワーク（図示を省略）を介して遠隔よりデータのやり取りを行うことも可能である。 The production monitoring device 30 collects the above-mentioned various equipment data from the eight PLC20s and monitors the entire eight production lines 1-1, 1-2, ... 1-8. A patrol light (registered trademark) 40 and a display device 50 are connected to the production monitoring device 30. Further, the production monitoring device 30 can remotely exchange data via a network (not shown).
　図２は、図１に示した生産システム１における生産監視システムの構成を示す図である。　
　図２に示すように、生産監視システム２は、上記の、８台のＰＬＣ２０と、生産監視装置３０と、パトライト（登録商標）４０と、表示装置５０とにより構成される。 FIG. 2 is a diagram showing a configuration of a production monitoring system in the production system 1 shown in FIG.
As shown in FIG. 2, the production monitoring system 2 includes the above-mentioned eight PLCs 20, a production monitoring device 30, a patrol light (registered trademark) 40, and a display device 50.
　ＰＬＣ２０は、主に通信部２１と、制御部２２と、記憶部２３とを有する。 The PLC 20 mainly has a communication unit 21, a control unit 22, and a storage unit 23.
　通信部２１は、生産設備１０、１１・・・より設備データを取得し、その取得したデータを生産監視装置３０に送る。 The communication unit 21 acquires equipment data from the production equipment 10, 11, ..., And sends the acquired data to the production monitoring device 30.
　制御部２２と、ＰＬＣ２０全体を包括的に制御する。例えば、制御部２２は、通信部２１を介して生産設備１０、１１・・・とこのＰＬＣ２０との間の通信異常を検出する検出部として機能する。例えば、生産設備１０、１１・・・との間の通信路２５が断線（図中「×」で示す。）があれば、生産設備１０、１１・・・からデータがこなくなる（応答しなくなる）ので、通信異常として検出する。なお、生産設備１０、１１・・・のうち１つの生産設備からデータがこなくなった場合には、当該１つの生産設備との間の通信路２５の通信異常として検出する。なお、当該生産設備の破損等による異常とみなしてもよい。 Comprehensively controls the control unit 22 and the entire PLC 20. For example, the control unit 22 functions as a detection unit that detects a communication abnormality between the production facilities 10, 11 ... And the PLC 20 via the communication unit 21. For example, if the communication path 25 between the production facilities 10, 11 ... Is disconnected (indicated by "x" in the figure), data will not be received from the production facilities 10, 11 ... (No response). ), So it is detected as a communication error. When data is lost from one of the production facilities 10, 11, ..., It is detected as a communication abnormality of the communication path 25 with the one production facility. In addition, it may be regarded as an abnormality due to damage to the production equipment.
　本実施形態に係るＰＬＣ２０には、ＳＤメモリカードやＵＳＢメモリなどの外部メモリ２４が接続可能とされている。外部メモリ２４には、通信部２１を介して受信した生産設備１０、１１・・・からの設備データが一旦蓄積され、ＰＬＣ２０から生産監視装置３０へは、通信部２１を介して外部メモリ２４に蓄積された設備データが送信される。これにより、内部メモリとしての記憶部２３のメモリ容量不足に柔軟に対応できる。特に、上記のようにアナログデータ（波形データ）を設備データとして扱うような場合には、データ量が膨大になるために、このような外部メモリ２４を用いて容量の柔軟性を図ることは有用である。なお、外部メモリ２４を用いずに記憶部２３に設備データを保持するようにしても勿論構わない。 An external memory 24 such as an SD memory card or a USB memory can be connected to the PLC 20 according to the present embodiment. Equipment data from the production equipments 10, 11 ... Received via the communication unit 21 is temporarily stored in the external memory 24, and the PLC 20 is transferred to the production monitoring device 30 in the external memory 24 via the communication unit 21. The accumulated equipment data is transmitted. As a result, it is possible to flexibly cope with the shortage of the memory capacity of the storage unit 23 as the internal memory. In particular, when analog data (waveform data) is treated as equipment data as described above, the amount of data becomes enormous, so it is useful to use such an external memory 24 for capacity flexibility. Is. Of course, the equipment data may be stored in the storage unit 23 without using the external memory 24.
　生産監視装置３０は、主に、通信部３１と、制御部３２と、記憶部３３とを有する。 The production monitoring device 30 mainly has a communication unit 31, a control unit 32, and a storage unit 33.
　通信部３１は、ＰＬＣ２０より、設備データ及びＰＬＣ２０で検出された通信異常に関するデータを受信する。 The communication unit 31 receives the equipment data and the data related to the communication abnormality detected by the PLC 20 from the PLC 20.
　制御部３２は、ＰＬＣ２０との間での通信異常を検出する検出部としての機能を有する。例えば、ＰＬＣ２０との間の通信路３４が断線（図中「×」で示す。）があれば、ＰＬＣ２０からデータがこなくなる（応答しなくなる）ので、当該ＰＬＣ２０との間の通信異常として検出する。 The control unit 32 has a function as a detection unit for detecting a communication abnormality with the PLC 20. For example, if the communication path 34 with the PLC 20 is disconnected (indicated by "x" in the figure), data will not come from the PLC 20 (no response), so it will be detected as a communication abnormality with the PLC 20. ..
　制御部３２は、通信部３１による受信結果及び制御部３２による上記の検出部としての検出結果に基づき、生産設備１０、１１・・・の異常、生産設備１０、１１・・・とＰＬＣ２０との間の通信異常及びＰＬＣ２０と当該生産監視装置３０の間の通信異常を、それぞれ区別して警告する情報を出力する警告情報出力部として機能する。また、制御部３２は、生産監視装置３０から出力された警告情報に基づき、生産設備１０、１１・・・の異常、生産設備１０、１１・・・とＰＬＣ２０との間の通信異常及びＰＬＣ２０と生産監視装置３０との間の通信異常を、それぞれ異なる色で発光するパトライト（登録商標）を画面上に表示する表示データを出力するパトライト（登録商標）表示データ出力部として機能する。 Based on the reception result by the communication unit 31 and the detection result as the above-mentioned detection unit by the control unit 32, the control unit 32 causes an abnormality in the production facilities 10, 11 ..., The production facilities 10, 11 ... And the PLC 20. It functions as a warning information output unit that outputs information that separately warns the communication abnormality between the two and the communication abnormality between the PLC 20 and the production monitoring device 30. Further, based on the warning information output from the production monitoring device 30, the control unit 32 causes an abnormality in the production facilities 10, 11 ..., a communication abnormality between the production facilities 10, 11 ... And the PLC 20, and the PLC 20. It functions as a patrol light (registered trademark) display data output unit that outputs display data that displays on the screen a patrol light (registered trademark) that emits light in different colors for communication abnormalities with the production monitoring device 30.
　記憶部３３は、ＰＬＣ２０を介して受け取った生産設備１０、１１・・・の設備データを蓄積する。 The storage unit 33 stores the equipment data of the production equipments 10, 11 ... Received via the PLC 20.
　制御部３２は、記憶部３３に蓄積された設備データに基づき、生産設備１０、１１・・・による生産を監視する。例えば、制御部３２は、記憶部３３に蓄積された設備データの値の傾向値（経年変化値）を管理し、例えば設備データに基づく値が所定値を超えたとき、或いは超えそうになると事前に予測されるとき、生産設備の運転の停止等を促す警報をパトライト（登録商標）４０等から発する。なお、生産設備１０、１１・・・を強制的に停止させてもよい。 The control unit 32 monitors the production by the production equipment 10, 11, ... Based on the equipment data accumulated in the storage unit 33. For example, the control unit 32 manages the tendency value (aging value) of the value of the equipment data stored in the storage unit 33, and for example, when the value based on the equipment data exceeds or is about to exceed a predetermined value, it is in advance. When predicted, an alarm is issued from Patrite (registered trademark) 40 or the like to urge the operation of the production equipment to be stopped. The production facilities 10, 11 ... May be forcibly stopped.
　制御部３２は、ＰＬＣ２０より受信した設備データから生産設備１０、１１・・・で１つの製品を生産する単位である１サイクル又は１ショット内での波形データを得て、波形データに基づき、生産設備１０、１１・・・を管理する手段として機能する。生産設備１０、１１・・・を管理するとは、例えば波形データに異常値乃至異常値傾向が見られるとき、生産設備１０、１１・・・の運転の停止等を促す警報をパトライト（登録商標）４０等から発することをいう。 The control unit 32 obtains waveform data in one cycle or one shot, which is a unit for producing one product in production equipment 10, 11 ..., From the equipment data received from the PLC 20, and produces based on the waveform data. It functions as a means for managing the equipment 10, 11, .... To manage production facilities 10, 11 ... For example, when an abnormal value or a tendency of an abnormal value is found in waveform data, Patrite (registered trademark) issues an alarm prompting the stop of operation of production facilities 10, 11 ... It means that it originates from 40 mag.
　制御部３２は、通信部３１を介してＰＬＣ２０より、設備データ等が受信できたかどうかを確認し、設備データ等を受信できないときにはＰＬＣ２０に再送信を要求する検出・再送要求機能を有する。そして、制御部３２は、再送要求にもかかわらず設備データ等が受信できないときには、アラートを出力する。アラートは、報知音でもよいし、表示装置５０に表示するものなどであってもよい。 The control unit 32 has a detection / retransmission request function for confirming whether or not equipment data or the like can be received from the PLC 20 via the communication unit 31 and requesting the PLC 20 to retransmit when the equipment data or the like cannot be received. Then, the control unit 32 outputs an alert when the equipment data or the like cannot be received despite the retransmission request. The alert may be a notification sound, a display device 50, or the like.
　パトライト（登録商標）４０は、生産監視装置３０から出力された警告情報に基づき、生産設備１０、１１・・・の異常、生産設備１０、１１・・・とＰＬＣ２０との間の通信異常及びＰＬＣ２０と生産監視装置３０との間の通信異常を、それぞれ異なる色で発光する。例えば、パトライト（登録商標）４０は、青、黄色、赤、白の４色を発光する。生産設備１０、１１・・・に異常がないときには、青を発光する。生産設備１０、１１・・・の一部が停止しているとき、黄色を発光する。したが手、生産設備１０、１１・・・に異常がないが、生産設備１０、１１・・・の一部が停止しているときには、パトライト（登録商標）４０では青と黄色の両方が発光する。また、生産設備１０、１１・・・が異常のときには、パトライト（登録商標）４０は白を発光し、生産設備１０、１１・・・とＰＬＣ２０との間の通信異常及びＰＬＣ２０と生産監視装置３０との間の通信異常のときには、パトライト（登録商標）４０は赤を発光する。このようなパトライト（登録商標）４０の発光は一例であり、様々なパターンでの発光が考えられる。 Based on the warning information output from the production monitoring device 30, the Patrite (registered trademark) 40 has an abnormality in the production facilities 10, 11 ..., a communication abnormality between the production facilities 10, 11 ... And the PLC 20, and the PLC 20. The communication abnormality between the device and the production monitoring device 30 is emitted in different colors. For example, Patrite® 40 emits four colors: blue, yellow, red, and white. When there is no abnormality in the production facilities 10, 11, ..., Blue is emitted. When a part of the production facilities 10, 11 ... Is stopped, it emits yellow light. However, there is no abnormality in the hands, production equipment 10, 11 ..., but when a part of production equipment 10, 11 ... is stopped, both blue and yellow are emitted by Patrite (registered trademark) 40. To do. Further, when the production facilities 10, 11 ... Are abnormal, the patrol light (registered trademark) 40 emits white light, and the communication abnormality between the production facilities 10, 11 ... And the PLC 20 and the PLC 20 and the production monitoring device 30 are abnormal. In the event of communication abnormality with, Patrite (registered trademark) 40 emits red light. Such light emission of Patrite (registered trademark) 40 is an example, and light emission in various patterns can be considered.
　表示装置５０は、生産監視装置３０から出力された表示データに基づき、生産設備１０、１１・・・の異常、上記のパトライト（登録商標）４０を画面上に表示する。ここで、ＰＬＣ２０が収集する設備データには、生産設備１０、１１・・・に対する設定値及びそれに対する実績値のデータが含まれている。生産監視装置３０では、制御部３２がＰＬＣ２０より受信した設備データに基づき、生産設備１０、１１・・・に対する設定値及びそれに対する実績値を画面上に表示する表示データを出力する設定値・実績値表示データ出力部として機能する。表示装置５０は、この表示データに基づき、設定値と実績値を画面上に表示する。図３にその画面の一例を示す。実際の生産設備１０、１１・・では、同一の生産設備であっても機差を有している。作業者は、画面上に表示された設定値と実績値とを比較することで、この機差を知ることができ、例えばそれに応じた対応をとることが可能となる。 Based on the display data output from the production monitoring device 30, the display device 50 displays on the screen the abnormalities of the production facilities 10, 11 ..., And the above-mentioned Patrite (registered trademark) 40. Here, the equipment data collected by the PLC 20 includes data of set values for production equipment 10, 11 ... And actual values for the set values. In the production monitoring device 30, based on the equipment data received from the PLC 20, the control unit 32 outputs the set value / actual value for displaying the set value for the production equipment 10, 11 ... And the actual value for it on the screen. It functions as a value display data output unit. The display device 50 displays the set value and the actual value on the screen based on the display data. FIG. 3 shows an example of the screen. In the actual production facilities 10, 11, ..., Even if they are the same production facilities, there are differences. The operator can know this machine difference by comparing the set value displayed on the screen with the actual value, and can take measures corresponding to the difference, for example.
　次に、生産監視装置３０の動作を図４に示すフローチャートを参照しながら説明する。 Next, the operation of the production monitoring device 30 will be described with reference to the flowchart shown in FIG.
　制御部３２は、ＰＬＣ２０側との間で通信が断となっていないか判断する（ステップ４０１）。 The control unit 32 determines whether communication with the PLC20 side is interrupted (step 401).
　制御部３２は、通信がＰＬＣ２０側との間で通信が断となっている場合には、ＰＬＣ２０側との間で再接続の動作を実行する（ステップ４０２）。 When communication is interrupted with the PLC20 side, the control unit 32 executes a reconnection operation with the PLC20 side (step 402).
　制御部３２は、ＰＬＣ２０側との間で通信が断ではなく、或いは再接続によりＰＬＣ２０側との間で通信が断ではなくなったとき、ＰＬＣ２０側から送信される通信データからヘッダの情報を読み取り（ステップ４０３）、ヘッダ情報に基づき通信データに含まれる設備データ等を読み取る（ステップ４０４）。 The control unit 32 reads the header information from the communication data transmitted from the PLC20 side when the communication with the PLC20 side is not interrupted or the communication with the PLC20 side is not interrupted due to reconnection ( Step 403), read the equipment data and the like included in the communication data based on the header information (step 404).
　図５に、ＰＬＣ２０側から生産監視装置３０側に送信される通信データの構成の一例を示し、通信データは、シリアルナンバー、ショット等の時刻、モード（成形が手動モードか自動モードかなどを区別する。）、アラーム種別（アラームが設備アラームかＰＬＣアラームかを区別する。）、センサー（１）のデータ、センサー（２）のデータ、・・・等を含む。設備アラームは、例えば生産設備１０、１１・・・が異常、ＰＬＣアラームは、例えば生産設備１０、１１・・・とＰＬＣ２０との間の通信異常を示す。 FIG. 5 shows an example of the configuration of communication data transmitted from the PLC 20 side to the production monitoring device 30 side, and the communication data distinguishes the serial number, the time such as a shot, and the mode (whether the molding is in the manual mode or the automatic mode, etc.). ), Alarm type (distinguishes whether the alarm is an equipment alarm or a PLC alarm), sensor (1) data, sensor (2) data, and the like. The equipment alarm indicates, for example, an abnormality in the production equipments 10, 11 ..., And the PLC alarm indicates, for example, a communication abnormality between the production equipments 10, 11 ... And the PLC 20.
　次に、生産設備１０、１１・・・で１つの製品を生産する単位である１サイクル又は１ショット内での波形データを得て、波形データに基づき、生産設備１０、１１・・・を管理する点について更に詳しく説明する。 Next, the waveform data in one cycle or one shot, which is a unit for producing one product in the production facilities 10, 11, ..., Is obtained, and the production facilities 10, 11, ... Are managed based on the waveform data. The points to be done will be described in more detail.
　図６は、生産監視装置３０において取得した、成形機１０の型温度の１ショット内での波形データの一例である。 FIG. 6 is an example of waveform data in one shot of the mold temperature of the molding machine 10 acquired by the production monitoring device 30.
　成形機１０の型温度は、１ショット内ではまず射出開始より上昇し、所定の時点でピークになり、その後低下する。ピーク時の温度（ｔｍａｘ）は所定の範囲（ｔ０～ｔ１）内にある必要がある。加えて、成形機１０の型温度がピークとなる時点、つまり射出開始より成形機１０の型温度がピークとなるまでの時間（Ｔｐｅａｋ）も所定の範囲（Ｔ０～Ｔ１）内にある必要がある。
・ピーク時の温度（ｔｍａｘ）が所定の範囲（ｔ０～ｔ１）より低いと、材料が型内に流れ込み難くなり、成形不良が発生する。
・ピーク時の温度（ｔｍａｘ）が所定の範囲（ｔ０～ｔ１）より高いと、材料が型内での流れが速くなり、対岸到着時間が早くなり、バリが発生してしまう。
・成形機１０の型温度がピークとなるまでの時間（Ｔｐｅａｋ）が所定の範囲（Ｔ０～Ｔ１）よりも短い場合は、型の注入口が経年変化で広がったと推定され、型のメンテナンスを行うべき時期として検出される。
・成形機１０の型温度がピークとなるまでの時間（Ｔｐｅａｋ）が所定の範囲（Ｔ０～Ｔ１）よりも長い場合は、型の注入口にゴミなどが詰まっていると推定され、型の確認を行うべきタイミングとして検出される。 The mold temperature of the molding machine 10 first rises from the start of injection in one shot, peaks at a predetermined point, and then falls. The peak temperature (t max ) needs to be within a predetermined range (t 0 to t 1 ). In addition, the time when the mold temperature of the molding machine 10 peaks, that is, the time (T peak ) from the start of injection to the peak of the mold temperature of the molding machine 10 is also within a predetermined range (T 0 to T 1 ). There is a need.
-If the peak temperature (t max ) is lower than the predetermined range (t 0 to t 1 ), it becomes difficult for the material to flow into the mold, and molding defects occur.
-If the peak temperature (t max ) is higher than the predetermined range (t 0 to t 1 ), the material flows faster in the mold, the arrival time at the opposite bank becomes faster, and burrs occur.
-If the time (T peak ) until the mold temperature of the molding machine 10 reaches its peak is shorter than the predetermined range (T 0 to T 1 ), it is estimated that the injection port of the mold has expanded due to aging, and the mold Detected as the time for maintenance.
-If the time (T peak ) until the mold temperature of the molding machine 10 reaches its peak is longer than the predetermined range (T 0 to T 1 ), it is estimated that the mold injection port is clogged with dust or the like. It is detected as the timing to confirm the type.
　制御部３２は、成形機１０の型温度の１ショット内での波形データに対して、ピーク時の温度（ｔｍａｘ）が所定の範囲（ｔ０～ｔ１）内にあるかどうかを判断し、加えて、成形機１０の型温度がピークとなる時点、つまり射出開始より成形機１０の型温度がピークとなるまでの時間（Ｔｐｅａｋ）も所定の範囲（Ｔ０～Ｔ１）内にあるかどうかを判断する。 The control unit 32 determines whether or not the peak temperature (t max ) is within a predetermined range (t 0 to t 1 ) with respect to the waveform data of the mold temperature of the molding machine 10 within one shot. In addition, the time when the mold temperature of the molding machine 10 peaks, that is, the time (T peak ) from the start of injection to the peak of the mold temperature of the molding machine 10 also falls within a predetermined range (T 0 to T 1 ). Determine if there is.
　制御部３２は、成形機１０の型温度の１ショット内での波形データに対して、ピーク時の温度（ｔｍａｘ）が所定の範囲（ｔ０～ｔ１）内にない場合には、パトライト（登録商標）４０を白に発光させ、表示装置５０に同様の表示を行い、更に表示装置５０に型温を上げる、或いは下げるように指示を表示する。或いは、制御部３２よりＰＬＣ２０を経由して型温を上げるように、或いは下げるようにコントロールしてもよい。 The control unit 32 patrols the waveform data of the mold temperature of the molding machine 10 in one shot when the peak temperature (t max ) is not within a predetermined range (t 0 to t 1 ). The (registered trademark) 40 is made to emit white light, the display device 50 is similarly displayed, and the display device 50 is further instructed to raise or lower the mold temperature. Alternatively, the control unit 32 may control the mold temperature to be raised or lowered via the PLC 20.
　制御部３２は、成形機１０の型温度の１ショット内での波形データに対して、成形機１０の型温度がピークとなるまでの時間（Ｔｐｅａｋ）が所定の範囲（Ｔ０～Ｔ１）内にない場合には、パトライト（登録商標）４０を白に発光させ、表示装置５０に同様の表示を行い、更に表示装置５０に型のメンテナンスや確認の指示を表示する。 The control unit 32 has a predetermined range (T 0 to T 1 ) of the time (T peak ) until the mold temperature of the molding machine 10 reaches its peak with respect to the waveform data in one shot of the mold temperature of the molding machine 10. ) Is not included, the patrol light (registered trademark) 40 is made to emit white light, the same display is displayed on the display device 50, and the display device 50 further displays instructions for mold maintenance and confirmation.
　図７は、生産監視装置３０において取得した、加工機１２のエンドミルの加工負荷の１サイクル内での波形データの一例である。 FIG. 7 is an example of waveform data within one cycle of the machining load of the end mill of the machining machine 12 acquired by the production monitoring device 30.
　加工機１２のエンドミルの加工負荷は、１サイクル内ではまず加工開始より上昇し、所定の時点でピークになり、その後低下する。ピーク時の大きさ（Ｐｍａｘ）は所定の範囲（Ｐ０～Ｐ１）内にある必要がある。加えて、加工機１２のエンドミルの加工負荷がピークとなる時点、つまり加工開始より加工機１２のエンドミルの加工負荷がピークとなるまでの時間（Ｔｐｅａｋ）も所定の範囲（Ｔ０～Ｔ１）内にある必要がある。
・ピーク時の大きさ（Ｐｍａｘ）が所定の範囲（Ｐ０～Ｐ１）より低いと、被加工側に何らかの問題があると推定される。
・ピーク時の大きさ（Ｐｍａｘ）が所定の範囲（Ｐ０～Ｐ１）より高いと、エンドミルの切れ味が悪くなったと推定される。
・加工機１２のエンドミルの加工負荷がピークとなるまでの時間（Ｔｐｅａｋ）が所定の範囲（Ｔ０～Ｔ１）よりも短い場合は、エンドミルの取り付け位置が所定の位置よりもＺ方向に下がっていると推定される。
・加工機１２のエンドミルの加工負荷がピークとなるまでの時間（Ｔｐｅａｋ）が所定の範囲（Ｔ０～Ｔ１）よりも長い場合は、エンドミルの取り付け位置が所定の位置よりもＺ方向に下がっていると推定される。 Within one cycle, the machining load of the end mill of the machining machine 12 first rises from the start of machining, peaks at a predetermined point, and then decreases. The peak magnitude (P max ) needs to be within a predetermined range (P 0 to P 1 ). In addition, the time (T peak ) from the start of machining to the peak of the machining load of the end mill of the machining machine 12 at the time when the machining load of the end mill of the machining machine 12 peaks is also within a predetermined range (T 0 to T 1). ) Must be inside.
-If the peak magnitude (P max ) is lower than the predetermined range (P 0 to P 1 ), it is presumed that there is some problem on the work side.
-If the peak magnitude (P max ) is higher than the predetermined range (P 0 to P 1 ), it is presumed that the sharpness of the end mill has deteriorated.
-If the time (T peak ) until the machining load of the end mill of the processing machine 12 reaches its peak is shorter than the predetermined range (T 0 to T 1 ), the mounting position of the end mill is in the Z direction from the predetermined position. It is estimated that it is down.
-If the time (T peak ) until the machining load of the end mill of the processing machine 12 reaches its peak is longer than the predetermined range (T 0 to T 1 ), the mounting position of the end mill is in the Z direction from the predetermined position. It is estimated that it is down.
　制御部３２は、加工機１２のエンドミルの加工負荷の１サイクル内での波形データに対して、ピーク時の大きさ（Ｐｍａｘ）が所定の範囲（Ｐ０～Ｐ１）内にあるかどうかを判断し、加えて、加工機１２のエンドミルの加工負荷がピークとなる時点、つまり加工開始より加工機１２のエンドミルの加工負荷がピークとなるまでの時間（Ｔｐｅａｋ）も所定の範囲（Ｔ０～Ｔ１）内にあるかどうかを判断する。 The control unit 32 determines whether or not the peak magnitude (P max ) is within a predetermined range (P 0 to P 1 ) with respect to the waveform data in one cycle of the machining load of the end mill of the machining machine 12. In addition, the time (T peak ) from the start of machining to the peak of the machining load of the end mill of the machining machine 12 is also within a predetermined range (T peak ) at the time when the machining load of the end mill of the machining machine 12 peaks. Judge whether it is within 0 to T 1 ).
　制御部３２は、加工機１２のエンドミルの加工負荷の１サイクル内での波形データに対して、ピーク時の大きさ（Ｐｍａｘ）が所定の範囲（Ｐ０～Ｐ１）内にない場合には、パトライト（登録商標）４０を白に発光させ、表示装置５０に同様の表示を行い、更に表示装置５０にエンドミルの交換等を促すように表示する。 The control unit 32 is in the case where the peak magnitude (P max ) is not within a predetermined range (P 0 to P 1 ) with respect to the waveform data in one cycle of the machining load of the end mill of the machining machine 12. Lights the patrol light (registered trademark) 40 in white, displays the same on the display device 50, and further displays the display device 50 to prompt the replacement of the end mill or the like.
　制御部３２は、加工機１２のエンドミルの加工負荷の１サイクル内での波形データに対して、加工機１２のエンドミルの加工負荷がピークとなるまでの時間（Ｔｐｅａｋ）が所定の範囲（Ｔ０～Ｔ１）内にない場合には、パトライト（登録商標）４０を白に発光させ、表示装置５０に同様の表示を行い、更に表示装置５０にエンドミルの取り付け状態の確認の指示を表示する。 The control unit 32 has a predetermined range (T peak ) of the time (T peak ) until the machining load of the end mill of the machining machine 12 reaches the peak with respect to the waveform data in one cycle of the machining load of the end mill of the machining machine 12. If it is not within 0 to T 1 ), the patrol light (registered trademark) 40 is made to emit white light, the same display is displayed on the display device 50, and the display device 50 further displays an instruction for confirming the mounting state of the end mill. ..
　本実施形態に係る生産監視装置３０では、ＰＬＣ２０より受信した設備データから１サイクル又は１ショット内での波形データを得て、波形データに基づき、生産設備１０、１１・・・を管理している。典型的には、１サイクル又は１ショット内での波形データのピーク値の上限値及び下限値を設定し、ピーク値が上限値を超えたとき、又はピーク値が下限値より小さくなったとき、所定の警報等を行う。また、１サイクル又は１ショット内での波形データがピークとなる時点、つまり１サイクル又は１ショットの開始よりピークとなるまでの時間の範囲を設定し、その時間が所定時間未満、又は所定時間を超えるときには、所定の警報等を行う。これにより、生産設備１０、１１・・・の異常をより的確に把握することができる。なお、上記のように設定される上限値及び下限値、或いは時間の範囲、つまり閾値の範囲は、適宜設定することができるようにしてもよい。 The production monitoring device 30 according to the present embodiment obtains waveform data within one cycle or one shot from the equipment data received from the PLC 20, and manages the production equipments 10, 11, ... Based on the waveform data. .. Typically, when the upper limit value and the lower limit value of the peak value of the waveform data in one cycle or one shot are set and the peak value exceeds the upper limit value or the peak value becomes smaller than the lower limit value, Give a predetermined alarm, etc. In addition, the time when the waveform data in one cycle or one shot peaks, that is, the range of time from the start of one cycle or one shot to the peak is set, and the time is less than a predetermined time or a predetermined time. When it exceeds, a predetermined alarm or the like is issued. As a result, it is possible to more accurately grasp the abnormality of the production facilities 10, 11 ... The upper limit value and the lower limit value set as described above, or the time range, that is, the threshold range may be appropriately set.
　以上の実施形態では、制御部３２が１サイクル又は１ショット内での波形データを得て、波形データに基づき、生産設備１０、１１・・・を管理していたが、制御部３２は記憶部３３に蓄積された設備データに基づき、様々な管理が可能である。 In the above embodiment, the control unit 32 obtains the waveform data in one cycle or one shot and manages the production facilities 10, 11, ... Based on the waveform data, but the control unit 32 is the storage unit. Various management is possible based on the equipment data accumulated in 33.
　例えば、上記のピーク値やその他の計測値などを時系列に表示して時系列データとして管理してもよい。 For example, the above peak value and other measured values may be displayed in time series and managed as time series data.
　上記のピーク値以外の計測値の閾値を管理してもよい。例えば、計測値が所定の上限閾値以上となったときには製品の異物不良が発生する可能性があるとし、所定の下限値以下となったときには製品の寸法不良が発生する可能性があるとし、それぞれ所定の警告を発してもよい。 The threshold value of the measured value other than the above peak value may be managed. For example, when the measured value exceeds a predetermined upper threshold value, a foreign matter defect of the product may occur, and when it becomes less than a predetermined lower limit value, a dimensional defect of the product may occur. A predetermined warning may be issued.
　設備データの値の傾向値（経年変化値）を管理し、例えば設備データに基づく値が所定値を超えたとき、或いは超えそうになると事前に予測されるとき、それぞれ所定の警告を発してもよい。 Even if you manage the tendency value (aging value) of the value of the equipment data, for example, when the value based on the equipment data exceeds the predetermined value or is predicted to exceed the predetermined value in advance, you can issue a predetermined warning respectively. Good.
　１サイクル又は１ショット内での複数種類の波形データを時間的に同期させて同一画面上に同時に表示してもよい。例えば、成形機における型の型内樹脂温度、型内圧力、型表面温度、成形機射出圧力の波形データを同時に表示装置に表示してもよい。これにより、成形機による成形の状況を正確に把握することができる。 Multiple types of waveform data in one cycle or one shot may be synchronized in time and displayed simultaneously on the same screen. For example, waveform data of the resin temperature in the mold, the pressure in the mold, the surface temperature of the mold, and the injection pressure of the molding machine in the molding machine may be displayed on the display device at the same time. As a result, the state of molding by the molding machine can be accurately grasped.
　時系列データに関しても複数種類の時系列データを時間的に同期させて同一画面上に同時に表示してもよい（図８参照）。その際に、図８に示すように、画面上に同時刻比較ラインを設けることで、複数種類の時系列データ間での同時刻におけるデータの比較がし易くなる。 Regarding time series data, multiple types of time series data may be synchronized in time and displayed simultaneously on the same screen (see FIG. 8). At that time, as shown in FIG. 8, by providing the same time comparison line on the screen, it becomes easy to compare the data at the same time between a plurality of types of time series data.
　１つの生産設備についての複数種類の設備データを同一の画面上に同時に１グループとして表示するようにしてもよい。例えば、成形機の温調機、乾燥機、型内温度センサー、ホットランナー、流量センサー、型内圧力センサー、型表面温度センサーのデータを同一の画面上に同時に表示してもよい。 Multiple types of equipment data for one production equipment may be displayed as one group at the same time on the same screen. For example, the data of the temperature controller of the molding machine, the dryer, the temperature sensor in the mold, the hot runner, the flow rate sensor, the pressure sensor in the mold, and the surface temperature sensor of the mold may be displayed simultaneously on the same screen.
　生産ライン単位で設備データを同一の画面上に同時に表示するようにしてもよい。例えば、８つの生産ライン１－１、１－２、・・・１－８のうち任意の１つの生産ラインに属する成形機１０、プレス機１１、加工機１２、自動機１３、ロボット１４、センサー（１）５から設備データを同一の画面上に同時に表示するようにしてもよい。 Equipment data may be displayed simultaneously on the same screen for each production line. For example, a molding machine 10, a press machine 11, a processing machine 12, an automatic machine 13, a robot 14, a sensor, which belong to any one of eight production lines 1-1, 1-2, ... 1-8. (1) Equipment data may be displayed simultaneously on the same screen from 5.
　本実施形態では、製品不良が予測されるようなときに、生産監視装置が警告等を発したり、生産設備の設定値をコントロールするものであったが、製品不良が予測されるようなときに、ロボットが生産設備によって生産された製品又は生産中の製品を不良品として生産ラインから取り出すように生産監視装置が管理してもよい。 In the present embodiment, the production monitoring device issues a warning or the like or controls the set value of the production equipment when a product defect is predicted, but when a product defect is predicted. The production monitoring device may control the robot to take out the product produced by the production facility or the product being produced as a defective product from the production line.
　本発明は、上記の実施形態に限定されず、様々な応用や変形が可能であり、そのような応用や変形の範囲も本発明の技術的範囲に属するものである。 The present invention is not limited to the above embodiment, and various applications and modifications are possible, and the range of such applications and modifications also belongs to the technical scope of the present invention.
１　　　：生産システム
１－１、・・・　：生産ライン
２　　　：生産監視システム
１０、１１・・・：生産設備
１０　　：成形機
１１　　：プレス機
１２　　：加工機
１３　　：自動機
１４　　：ロボット
１５　　：センサー
２０　　：ＰＬＣ（プログラマブルロジックコントローラ）
２１　　：通信部
２２　　：制御部
２３　　：記憶部
２４　　：外部メモリ
２５　　：通信路
３０　　：生産監視装置
３１　　：通信部
３２　　：制御部
３３　　：記憶部
３４　　：通信路
４０　　：パトライト（登録商標）
５０　　：表示装置 1: Production system 1-1, ...: Production line 2: Production monitoring system 10, 11 ...: Production equipment 10: Molding machine 11: Press machine 12: Processing machine 13: Automatic machine 14: Robot 15: Sensor 20: PLC (Programmable Logic Controller)
21: Communication unit 22: Control unit 23: Storage unit 24: External memory 25: Communication path 30: Production monitoring device 31: Communication unit 32: Control unit 33: Storage unit 34: Communication path 40: Patrite (registered trademark)
50: Display device

Claims (9)

  1. 　製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視する生産監視装置であって、
    　前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信する通信部と、
    　前記プログラマブルロジックコントローラとの間での通信異常を検出する検出部と、
    　前記通信部による受信結果及び前記検出部による検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラとの間の通信異常を、それぞれ区別して警告する情報を出力する警告情報出力部と
    　を具備する生産監視装置。     A production line having one or more production facilities for continuously producing products and a programmable logic controller capable of collecting equipment data from the production facilities and detecting an abnormality in communication with the production facilities. It is a production monitoring device that monitors a production system having one or more.
    A communication unit that receives the equipment data and data related to the detected communication abnormality from the programmable logic controller.
    A detection unit that detects a communication abnormality with the programmable logic controller,
    Based on the reception result by the communication unit and the detection result by the detection unit, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the communication abnormality between the programmable logic controller are detected. A production monitoring device including a warning information output unit that outputs information for distinguishing and warning.
  2. 　請求項１に記載の生産監視装置であって、
    　前記警告情報出力部から出力された警告情報に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視装置との間の通信異常を、それぞれ異なる色で発光するパトライト（登録商標）
    　を有する生産監視装置。     The production monitoring device according to claim 1.
    Based on the warning information output from the warning information output unit, an abnormality in the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and a communication abnormality between the programmable logic controller and the production monitoring device are detected. , Patrite (registered trademark) that emits light in different colors
    Production monitoring equipment with.
  3. 　請求項１又は２に記載の生産監視装置であって、
    　前記警告部から出力された警告情報に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視装置との間の通信異常を、それぞれ異なる色で発光するパトライト（登録商標）を画面上に表示する表示データを出力するパトライト（登録商標）表示データ出力部
    　を有する生産監視装置。     The production monitoring device according to claim 1 or 2.
    Based on the warning information output from the warning unit, an abnormality in the production equipment, a communication abnormality between the production equipment and the programmable logic controller, and a communication abnormality between the programmable logic controller and the production monitoring device are detected. A production monitoring device having a patrol light (registered trademark) display data output unit that outputs display data that displays a patrol light (registered trademark) that emits light in different colors on the screen.
  4. 　請求項１～３のうちいずれか１項に記載の生産監視装置であって、
    　前記プログラマブルロジックコントローラが収集する設備データには、前記生産設備に対する設定値及びそれに対する実績値のデータが含まれ、
    　前記プログラマブルロジックコントローラより受信した設備データに基づき、前記生産設備に対する設定値及びそれに対する実績値を画面上に表示する表示データを出力する設定値・実績値表示データ出力部
    　を有する生産監視装置。     The production monitoring device according to any one of claims 1 to 3.
    The equipment data collected by the programmable logic controller includes data of set values for the production equipment and actual values for the production equipment.
    A production monitoring device having a set value / actual value display data output unit that outputs display data for displaying the set value for the production equipment and the actual value for the set value on the screen based on the equipment data received from the programmable logic controller.
  5. 　請求項１～４のうちいずれか１項に記載の生産監視装置であって、
    　前記検出部は、前記通信部を介して前記プログラマブルロジックコントローラより、前記データが受信できたかどうかを確認し、
    　前記通信部は、前記データを受信できないときには前記プログラマブルロジックコントローラに再送信を要求し、それでも前記データが受信できないときには、アラートを出力する
    　生産監視装置。     The production monitoring device according to any one of claims 1 to 4.
    The detection unit confirms whether or not the data can be received from the programmable logic controller via the communication unit.
    A production monitoring device that requests retransmission from the programmable logic controller when the data cannot be received, and outputs an alert when the data cannot be received.
  6. 　製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視する生産監視装置と、
    　前記プログラマブルロジックコントローラと
    　を有する生産監視システムであって、
    　前記生産監視装置は、前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信する通信部と、
    　前記プログラマブルロジックコントローラとの間での通信異常を検出する検出部と、
    　前記通信部による受信結果及び前記検出部による検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラとの間の通信異常を、それぞれ区別して警告する情報を出力する警告情報出力部と
    　を有する
    　生産監視システム。     A production line having one or more production facilities for continuously producing products and a programmable logic controller capable of collecting equipment data from the production facilities and detecting an abnormality in communication with the production facilities. A production monitoring device that monitors a production system that has one or more
    A production monitoring system having the programmable logic controller.
    The production monitoring device includes a communication unit that receives the equipment data and data related to the detected communication abnormality from the programmable logic controller.
    A detection unit that detects a communication abnormality with the programmable logic controller,
    Based on the reception result by the communication unit and the detection result by the detection unit, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the communication abnormality between the programmable logic controller are detected. A production monitoring system that has a warning information output unit that outputs information that warns separately.
  7. 　請求項６に記載の生産監視システムであって、
    　前記プログラマブルロジックコントローラは、前記収集した設備データを前記外部メモリ装置に保持し、前記外部メモリ装置に保持された設備データを前記生産監視装置に送るように構成された
    　生産監視システム。     The production monitoring system according to claim 6.
    The programmable logic controller is a production monitoring system configured to hold the collected equipment data in the external memory device and send the equipment data held in the external memory device to the production monitoring device.
  8. 　製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視する生産監視方法であって、
    　前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信し、
    　前記プログラマブルロジックコントローラとの間での通信異常を検出し、
    　前記データ受信結果及び前記異常検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視側の間の通信異常を、それぞれ区別して警告する情報を出力する
    　を具備する生産監視方法。     A production line having one or more production facilities for continuously producing products and a programmable logic controller capable of collecting equipment data from the production facilities and detecting an abnormality in communication with the production facilities. It is a production monitoring method that monitors a production system having one or more.
    The equipment data and the data related to the detected communication abnormality are received from the programmable logic controller, and the data is received.
    Detecting a communication error with the programmable logic controller,
    Based on the data reception result and the abnormality detection result, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the communication abnormality between the programmable logic controller and the production monitoring side are classified. A production monitoring method that comprises outputting information that warns separately.
  9. 　製品を連続的に生産するための１以上の生産設備と、前記生産設備から設備データを収集し、且つ、前記生産設備との間での通信異常を検出可能なプログラマブルロジックコントローラとを有する生産ラインを１以上有する生産システムを監視するプログラムであって、
    　前記プログラマブルロジックコントローラより、前記設備データ及び前記検出された通信異常に関するデータを受信するステップと、
    　前記プログラマブルロジックコントローラとの間での通信異常を検出するステップと、
    　前記データ受信結果及び前記異常検出結果に基づき、前記生産設備の異常、前記生産設備と前記プログラマブルロジックコントローラとの間の通信異常及び前記プログラマブルロジックコントローラと生産監視側の間の通信異常を、それぞれ区別して警告する情報を出力するステップと
    　をコンピュータに実行させるプログラム。     A production line having one or more production facilities for continuously producing products and a programmable logic controller capable of collecting equipment data from the production facilities and detecting an abnormality in communication with the production facilities. A program that monitors a production system that has one or more
    A step of receiving the equipment data and data related to the detected communication abnormality from the programmable logic controller, and
    The step of detecting a communication abnormality with the programmable logic controller and
    Based on the data reception result and the abnormality detection result, the abnormality of the production equipment, the communication abnormality between the production equipment and the programmable logic controller, and the communication abnormality between the programmable logic controller and the production monitoring side are classified. A program that causes a computer to perform steps that output warning information separately.
PCT/JP2020/022001 2019-06-03 2020-06-03 Production monitoring device, production monitoring system, production monitoring method, and program WO2020246518A1 (en)

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