WO2022239171A1 - プログラマブルコントローラ、プログラマブルコントローラシステム、データ保存方法及びプログラム - Google Patents
プログラマブルコントローラ、プログラマブルコントローラシステム、データ保存方法及びプログラム Download PDFInfo
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Definitions
- the present disclosure relates to programmable controllers, programmable controller systems, data storage methods, and programs.
- control devices control various devices to realize production lines, processing lines, and inspection lines.
- data indicating the control history is analyzed in order to investigate the cause of the trouble. Therefore, techniques for saving data used for control have been proposed (see Patent Document 1, for example).
- Patent Document 1 when a first condition for a recording trigger is met, time-series device values are recorded as log data in a temporary recording unit, and when a second condition for a save trigger is met, a temporary recording unit is stored. describes a technique for saving log data held in a ring buffer in a storage memory. According to this technology, by inputting a save trigger when a trouble occurs, log data can be used to investigate the cause of the trouble.
- a programmable controller of the present disclosure is a programmable controller for controlling equipment, comprising: data collection means for repeatedly collecting data that changes when controlling the equipment from a memory; When the trigger condition is satisfied, a storing means for storing data collected by the data collecting means at a timing corresponding to the satisfaction of the first trigger condition in the storage means, and a second trigger condition different from the first trigger condition is satisfied.
- the storage means stores the data collected by the data collection means in the storage means when the first trigger condition is satisfied. This makes it possible to avoid the occurrence of a limitation due to the capacity of the temporary recording section other than the storage means in which the data is finally saved.
- the adding means adds additional information to at least one of the first data and the second data when the second trigger condition is satisfied, and the erasing means stores the first data in the storage means based on the additional information. Erasing the second data from the storage means while preserving it. Therefore, by saving necessary data in the storage means and securing an area for storing new data in the storage means, it is possible to leave a large number of histories of data related to control. Therefore, it is possible to make it easier to investigate the cause of the trouble.
- FIG. 1 is a diagram showing the configuration of a PLC system according to Embodiment 1
- FIG. 1 shows a hardware configuration of a PLC according to Embodiment 1
- FIG. 2 shows a functional configuration of the PLC according to Embodiment 1
- FIG. 4 is a diagram for explaining file erasure by an erasing unit according to the first embodiment
- Flowchart showing collection processing according to the first embodiment 4 is a flowchart showing storage processing according to the first embodiment
- FIG. 4 is a diagram for explaining saving and erasing of files according to Embodiment 1
- Flowchart showing additional processing according to the first embodiment A diagram for explaining the timing at which the first trigger condition and the second trigger condition are satisfied according to the first embodiment.
- FIG. 4 shows a functional configuration of a PLC according to Embodiment 2; Diagram for explaining addition of additional information according to Embodiment 3
- FIG. 11 shows a functional configuration of a display data generation device according to a fifth embodiment;
- FIG. 10 is a diagram for explaining the relationship between the timing at which data is collected and the data to which the trigger ID is assigned according to the modified example;
- FIG. 1 shows the configuration of a PLC (Programmable Logic Controller) system 1000 having a programmable controller according to this embodiment.
- the PLC system 1000 is a control system corresponding to a part of a manufacturing system, an inspection system, and other processing systems constructed in facilities represented by factories.
- a PLC 100 as a programmable controller operates a line by controlling a mechanical device 200 as controlled equipment connected via a communication line.
- the PLC 100 has a device memory 110 for controlling the mechanical device 200 and a buffer 120 and a storage unit 130 for recording logs of the device data 111 stored in the device memory 110 .
- the device data 111 stored in the device memory 110 includes data that is synchronized with data stored in the mechanical device 200 .
- the PLC 100 determines the state of the mechanical device 200 by reading the device data 111 and changes the operating mode of the mechanical device 200 by rewriting the device data 111 .
- the device data 111 includes intermediate data used in the calculation process for the PLC 100 to control the mechanical device 200 or statistical data for managing the mechanical device 200 . It may contain other internal data.
- the mechanical device 200 is, for example, a sensor device, an actuator, a robot, or other FA equipment installed in a line.
- the PLC 100 saves the log of the device data 111 in the storage unit 130 after passing through the buffer 120 .
- the buffer 120 is provided to absorb the difference in read/write speed between the device memory 110 and the storage unit 130 .
- the log stored in storage unit 130 is read by display data generation device 300 connected to PLC 100 via a communication line, and display data for investigating the cause of the trouble is generated from the log.
- a display screen is displayed to the user by the display device 301 according to the generated display data. On this display screen, images showing a plurality of data are displayed in a format that allows the user to compare the data.
- the display data generation device 300 and the display device 301 may be an industrial PC (Personal Computer) and attached LCD (Liquid Crystal Display) connected to the PLC 100, or may be an integrally formed tablet terminal. good too. Moreover, although the display data generating device 300 is arranged outside the PLC 100 in FIG.
- FIG. 2 schematically shows the hardware configuration of the PLC 100.
- PLC 100 has processor 101 , main memory section 102 , auxiliary memory section 103 , input section 104 , output section 105 and communication section 106 .
- Main storage unit 102 , auxiliary storage unit 103 , input unit 104 , output unit 105 and communication unit 106 are all connected to processor 101 via internal bus 107 .
- the processor 101 includes a CPU (Central Processing Unit) or MPU (Micro Processing Unit). By executing the program P1 stored in the auxiliary storage unit 103, the processor 101 realizes various functions and executes the processes described later.
- the processor 101 also controls the mechanical device 200 by executing the control program P2 stored in the auxiliary storage unit 103 .
- the control program P2 may be, for example, a ladder program or an executable binary file generated from source code written in a high-level language such as C language.
- the main storage unit 102 includes a RAM (Random Access Memory).
- the program P1 and the control program P2 are loaded from the auxiliary storage unit 103 into the main storage unit 102 .
- the main storage unit 102 is used as a work area for the processor 101 .
- the auxiliary storage unit 103 includes non-volatile memory represented by EEPROM (Electrically Erasable Programmable Read-Only Memory) and HDD (Hard Disk Drive).
- the auxiliary storage unit 103 stores various data used for the processing of the processor 101 in addition to the program P1 and the control program P2.
- Auxiliary storage unit 103 supplies data used by processor 101 to processor 101 in accordance with instructions from processor 101 .
- the auxiliary storage unit 103 stores data supplied from the processor 101 .
- the input unit 104 includes input devices typified by hardware switches, input keys, and pointing devices.
- the input unit 104 acquires information input by the user and notifies the processor 101 of the acquired information.
- the output unit 105 includes output devices typified by LEDs (Light Emitting Diodes), LCDs (Liquid Crystal Displays), and speakers.
- the output unit 105 presents various information to the user according to instructions from the processor 101 .
- the communication unit 106 includes a network interface circuit for communicating with external devices. Communication unit 106 receives a signal from the outside and outputs data indicated by this signal to processor 101 . Communication unit 106 also transmits a signal indicating data output from processor 101 to an external device.
- each unit constituting the PLC 100 has a part or all of the hardware configuration shown in FIG. 2 and is connected to each other via a system bus. good too.
- the PLC 100 exhibits the function of logging device data.
- the PLC 100 has, as its functions, a program execution unit 141 that executes the control program P2, a device memory 110 that stores data that changes under the control of the mechanical device 200, a device memory 110, a trigger determination unit 143 that determines whether there is a trigger for saving data, a buffering unit 144 that stores the collected data in the buffer 120, a data a buffer 120 that temporarily stores the data, a storage unit 145 that reads data from the buffer and stores it in the storage unit 130, a storage unit 130 that stores the data, and additional information described later in the data stored in the storage unit 130.
- It has an adding unit 146 for adding, an erasing unit 147 for erasing data to which additional information is not added after a certain storage period has passed, and a setting unit 148 for setting various parameters.
- the program execution unit 141 is mainly realized by the processor 101.
- the program execution unit 141 controls the mechanical device 200 using the data in the device memory 110 by repeatedly executing the procedure defined in the control program P2.
- the device memory 110 is mainly realized by the main storage unit 102.
- the data in the device memory 110 changes as the program execution unit 141 executes the control program P2.
- the control program P2 data indicating values as sensing results of the mechanical device 200, which is a sensor device, is periodically acquired and updated.
- the data indicating the rotation angle of the stepping motor that constitutes the mechanical device 200, which is an actuator, is updated at the timing at which the mechanical device 200 should be instructed to operate.
- FIG. 3 shows that data D[T100] is stored in the device memory 110.
- T100 corresponds to time
- D[T100] means the value of data at time T100.
- the data collection unit 142 is mainly realized by the processor 101.
- the data collection unit 142 repeatedly reads data stored in a preset address area of the device memory 110 at a preset cycle, and outputs the read data to the trigger determination unit 143 .
- the preset cycle is, for example, a scan time corresponding to one execution of the control program P2 by the program execution unit 141 .
- the data collection unit 142 corresponds to an example of data collection means for repeatedly collecting data that changes when controlling the device from the device memory 110 as a memory.
- the trigger determination unit 143 is mainly implemented by the processor 101 . Trigger determination unit 143 determines whether or not a first trigger condition for storing data in storage unit 130 is satisfied, and determines a second trigger condition for extending the storage period of data stored in storage unit 130. is established.
- the first trigger condition and the second trigger condition are preset by the setting unit 148 .
- the first trigger condition and the second trigger condition are different conditions. Detecting that a threshold value has been exceeded, detecting that a plurality of bit values have turned ON in a specified order, judging whether a condition related to a numerical value indicated by device data is satisfied from non-satisfaction, or being satisfied by a combination of these do.
- the first trigger condition and the second trigger condition are not limited to this, and may be other conditions.
- the first trigger condition and the second trigger condition may each be a condition whose success or failure is determined by determination regarding data to be collected or data not to be collected among device data, or may be satisfied regardless of device data. It may be a condition to For example, the first trigger condition and the second trigger condition may be conditions met by receiving a trigger signal from the outside of the PLC 100 .
- the trigger determination section 143 outputs the data collected by the data collection section 142 to the buffering section 144 .
- the trigger determination unit 143 determines that the first trigger condition is satisfied, the trigger determination unit 143 outputs data to the buffering unit 144 together with a trigger ID indicating that the first trigger condition is satisfied.
- the trigger determination unit 143 determines that the second trigger condition is satisfied, it notifies the addition unit 146 of the trigger ID.
- the second trigger condition is the length of the storage period for the data determined to be stored in the storage unit 130 when the first trigger condition is satisfied, and the length when the second trigger condition is not satisfied. is a condition for extending from When the second trigger condition is met, the trigger ID is used as information for identifying data whose storage period is to be extended.
- the buffering unit 144 is mainly realized by the processor 101.
- the buffering unit 144 sequentially stores the data output from the trigger determination unit 143 in the buffer 120, and when a trigger ID is output due to the establishment of the first trigger condition, the trigger ID is stored in the buffer 120 together with the corresponding data. store in
- the buffer 120 is a ring buffer realized mainly by the main storage unit 102.
- the buffer 120 stores D[T89], D[T90], D[T91], . [T90] is given.
- This trigger ID of TR[T90] indicates that the first trigger condition for storing data D[T90] in storage unit 130 has been met.
- the buffer 120 corresponds to an example of a buffer that sequentially stores data collected by the data collection means in the PLC 100 .
- the storage unit 145 is mainly implemented by the processor 101 .
- the storage unit 145 checks the presence or absence of data to which a trigger ID is assigned in the buffer 120 at predetermined time intervals. When new data with a trigger ID is found, the storage unit 145 reads a series of data including the new data from the buffer 120 together with the trigger ID.
- the series of data ranges from data collected by a preset number before the data to which the trigger ID is assigned to data collected by a preset number after the data to which the trigger ID is assigned. , are data collected continuously. Then, the storage unit 145 stores the file containing the read series of data in the storage unit 130 in association with the read trigger ID. In the example of FIG.
- the storage unit 145 confirms the data D[T90] to which the trigger ID TR[T90] is assigned, and stores data D[T86] to D[T95] in a file D[T86- T95] is stored in the storage unit 130.
- FIG. The storage unit 145 is an example of a storage unit that stores data collected by the data collection unit at a timing corresponding to the establishment of the first trigger condition in the PLC 100 when a predetermined first trigger condition is established. corresponds to
- the storage unit 130 is mainly implemented by the auxiliary storage unit 103 or a removable memory card.
- the adding unit 146 is mainly realized by the processor 101.
- the addition unit 146 searches the storage unit 130 for a file to which the trigger ID is assigned. Then, the adding unit 146 adds additional information to the file found as a result of the search.
- the additional information corresponds to a mark for making the storage period of a file to which the additional information is added longer than the storage period of the file to which the additional information is not added.
- the addition of additional information may be, for example, the insertion of a mark at the end of the file, the addition of a specific character string to the file name, or the addition of a folder attribute indicating the folder in which the file is stored. may be given. In the example of FIG.
- the addition unit 146 corresponds to an example of addition means for adding additional information to the data stored in the storage means by the storage means when the second trigger condition is satisfied.
- the erasing unit 147 is mainly implemented by the processor 101 .
- the erasing unit 147 scans the files stored in the storage unit 130 by the storage unit 145 at predetermined time intervals, and removes files whose retention period has passed among files to which additional information is not added. is erased from the storage unit 130 together with the trigger ID associated with the file. Erasure of a file by the storage unit 130 may be creation of a free area by deleting or moving data, or may be overwriting of another file.
- the length of the retention period of files to which additional information is not added is, for example, one day or one week.
- FIG. 4 shows that a free area is generated by erasing a file to which additional information is not added by the erasing section 147 .
- the deletion unit 147 may delete from the storage unit 130 a file whose retention period has elapsed among the files to which additional information is added, along with the trigger ID and additional information associated with the file.
- the retention period of files with additional information is longer than the retention period of files without additional information, for example, one month or one year.
- the erasing unit 147 corresponds to an example of erasing means for erasing data from the storage means in the PLC 100 .
- the setting unit 148 is realized mainly by the cooperation of the processor 101 and the input unit 104.
- the setting unit 148 acquires parameters input by the user and sets the acquired parameters in the data collection unit 142 , the trigger determination unit 143 , the storage unit 145 and the deletion unit 147 .
- the parameters set by the setting unit 148 include the address of the data to be collected in the device memory 110, the cycle of collecting data, the contents of the first trigger condition and the second trigger condition, information for generating the trigger ID, the storage unit 145 confirms the buffer 120, the number of data from the file start point data to the data to which the trigger ID is assigned, the number of data from the file end point data to the data to which the trigger ID is assigned, the deletion unit 147 scans the files in the storage unit 130, the length of storage periods for files with and without additional information added, and file operation details when deleting files.
- Information for generating a trigger ID may be, for example, an address of device data in which a value to be treated as a trigger ID is stored, or an instruction to treat time as a trigger ID.
- the file operation content is, for example, information indicating the selection of deletion or movement of the file and the location of the destination of the file movement.
- FIG. 5 shows the procedure of collection processing in which the PLC 100 collects data in the device memory 110.
- This collection process may be started simultaneously with execution of a specific application by the user's operation, or may be started simultaneously with execution of the control program P2.
- the data collection unit 142 determines whether or not the current time is the data collection timing (step S11). Specifically, the data collection unit 142 determines whether or not the time corresponding to the collection cycle set by the setting unit 148 has elapsed since the previous timing of data collection.
- the collection period is, for example, 1 millisecond or 1 second.
- the determination in step S11 may be affirmative regardless of the presence or absence of previous collection, or the determination in step S11 may be omitted. good too.
- step S11 If it is determined that the current time is not yet the data collection timing (step S11; No), the determination in step S11 is repeated, and the PLC 100 waits until the data collection timing. On the other hand, if it is determined that the current time is the data collection timing (step S11; Yes), the data collection unit 142 reads the data stored at the address set by the setting unit 148 from the device memory 110. Collect (step S12).
- the trigger determination unit 143 determines whether or not the first trigger condition is satisfied (step S13). For example, when the first trigger condition is satisfied by acquisition of a sensing result indicating that a single product has passed through the belt conveyor in the final stage of the manufacturing process, the trigger determination unit 143 determines that one product in the manufacturing process It is determined whether or not the manufacturing of the has been completed.
- step S13 If it is determined that the first trigger condition is satisfied (step S13; Yes), the trigger determination unit 143 assigns a trigger ID to the data collected in step S12 and outputs the data to the buffering unit 144 (step S14).
- the trigger ID is, for example, a value in one-to-one correspondence with the serial number of the manufactured product.
- step S13; No when it is determined that the first trigger condition is not satisfied (step S13; No), the trigger determination unit 143 directly transfers the collected data to the buffering unit 144 without adding a trigger ID to the collected data. After outputting, the process proceeds to step S15.
- the buffering unit 144 buffers the data (step S15). Specifically, the buffering unit 144 stores the data output from the trigger determination unit 143 in the buffer 120 together with the trigger ID if the trigger ID is assigned.
- step S11 the processes after step S11 are repeatedly executed.
- each time data to be collected is read from the device memory 110, the data is stored in the buffer 120.
- FIG. Also, when the first trigger condition is satisfied, a trigger ID is assigned to the data.
- the storage unit 145 determines whether the current time is the file storage timing (step S21). Specifically, the storage unit 145 determines whether or not the time interval set by the setting unit 148 has elapsed since the last time the file was stored in the storage unit 130 . This time interval is, for example, 10 milliseconds or 10 seconds. However, when the storage process is started and the determination of step S21 is executed for the first time, the determination of step S21 may be affirmative regardless of whether or not the previous storage was performed, or the determination of step S21 may be omitted. good too.
- step S21 If it is determined that the current time is not yet the file storage timing (step S21; No), the determination in step S21 is repeated, and the PLC 100 waits until the file storage timing. On the other hand, if it is determined that the current time is the file storage timing (step S21; Yes), the storage unit 145 determines whether or not new data satisfying the first trigger condition is stored in the buffer 120. (step S22). Specifically, the storage unit 145 scans the buffer 120 to search for unconfirmed data to which a trigger ID has been assigned.
- step S22 When it is determined that new data is not stored in the buffer 120 (step S22; No), the storage unit 145 repeats the processing from step S21 onwards. On the other hand, if it is determined that new data is stored in the buffer 120 (step S22; Yes), the storage unit 145 reads out from the buffer 120 a series of data groups including the data satisfying the first trigger condition, It is stored in the storage unit 130 as a file (step S23). Specifically, the storage unit 145 stores the new data to which the trigger ID found in step S22 is assigned, and one or a plurality of consecutive data of the number set by the setting unit 148 before and after the new data. , and the file is stored in the storage unit 130 in association with the trigger ID.
- the storage unit 145 repeats the processes after step S21.
- the time-series data before and after the data stored together with the trigger ID in the buffer 120 are repeatedly read, and a file showing the time-series data is stored in the storage unit 130 .
- FIG. 7 schematically shows storage of files in the storage unit 130 by execution of collection processing and storage processing.
- the "first trigger” arrows shown on the left side of FIG. 7 respectively indicate data for which the first trigger condition is satisfied. It also shows that files F1 to F5 are generated from a plurality of data including data satisfying the first trigger condition and stored in storage unit 130.
- the trigger determination unit 143 determines whether or not the second trigger condition is satisfied (step S31). For example, when the second trigger condition is established by detecting a nonconforming product in the inspection process after the manufacturing process, the trigger determination unit 143 determines whether there is an abnormality in the product manufactured in the manufacturing process. .
- step S31; No When it is determined that the second trigger condition is not satisfied (step S31; No), the trigger determination unit 143 repeats the determination of step S31. On the other hand, if it is determined that the second trigger condition is met (step S31; Yes), the adding unit 146 adds additional information to the file corresponding to the second trigger condition being met in step S31 (step S32). Specifically, the adding unit 146 adds additional information to the file having the trigger ID notified from the trigger determining unit 143 .
- step S31 onward After that, the processes from step S31 onward are repeated. As a result, the additional information is added to each file that satisfies the second trigger condition.
- the arrows of "second trigger" each indicate the establishment of the second trigger condition, and additional information is added to files F2 and F3.
- the file to which the additional information is added when the second trigger condition is satisfied is not limited to the file stored in the storage unit 130 immediately before the second trigger condition is satisfied. Additional information may be added to a plurality of files after the condition is met. For example, as shown in FIG. 9, in the manufacturing process, products are manufactured one by one, and whether or not the first trigger condition is met is determined based on the output of the manufacturing completion sensor 201. In the subsequent inspection process, three products are manufactured. are collectively inspected by the inspection sensor 202 to determine whether the second trigger condition is met. In this case, the cycle in which the success or failure of the first trigger condition is determined is different from the cycle in which the success or failure of the second trigger condition is determined.
- the product for which the second trigger condition is satisfied among the three products is the product for which the first trigger condition is satisfied immediately before, and when the product for which the first trigger condition is satisfied two times before, It is possible that the product is the product for which the first trigger condition was satisfied three times before.
- the deletion unit 147 determines whether or not the current time is the file deletion timing (step S41). Specifically, the erasing unit 147 determines whether or not the time interval set by the setting unit 148 has elapsed since the previous erasing timing. This time interval is, for example, one minute or one hour. However, when the erasing process is started and the determination of step S41 is executed for the first time, the determination of step S41 may be affirmative regardless of the presence or absence of the previous erasing timing, or the determination of step S41 may be omitted. may
- step S41 If it is determined that the current time is not yet the file erasing timing (step S41; No), the determination in step S41 is repeated, and the erasing unit 147 waits until the file erasing timing. On the other hand, when it is determined that the current time is the file erasing timing (step S41; Yes), the erasing unit 147 erases the file from the storage unit 130 based on the additional information (step S42). Specifically, the erasing unit 147 scans the files stored in the storage unit 130, and the corresponding retention periods for files with additional information added and files without additional information added are: Delete the file if it has passed.
- step S41 onward the processes from step S41 onward are repeated.
- This specific timing may be, for example, when a predetermined length of time or more has elapsed since the file was stored in the storage unit 130, or when the first trigger condition or the second trigger condition for the file has passed. It may be the point in time at which a predetermined length of time or more has elapsed from the time when is established.
- a file to which additional information is added is stored in the storage unit 130 for a long period of at least one year after the file is stored in the storage unit 130, while a free area is secured for a file to which additional information is not added.
- it may be deleted when one day or more has elapsed since the first trigger condition was satisfied.
- the above specific timing may be a point in time when the number of data or the amount of data stored in the storage unit 130 exceeds a threshold.
- files to which additional information is added are deleted from the oldest file when the usage of the storage unit 130 exceeds 90%, while files to which additional information is not added are deleted from the last 10 files.
- the file may be sufficient, and when the number of files stored in the storage unit 130 exceeds 10, the oldest files may be deleted.
- the storage unit 145 stores the data collected by the data collection unit 142 in the storage unit 130 when the first trigger condition is satisfied. As a result, it is possible to avoid the occurrence of a limitation due to the capacity of the buffer 120 other than the storage unit 130 in which data is finally stored. Further, when the second trigger condition is satisfied, the addition unit 146 adds additional information to the file specified by the trigger ID, and the deletion unit 147 saves the file to which the additional information is added in the storage unit 130. The file excluded from the target of addition of additional information by the addition unit 146 is erased from the storage unit 130 .
- the specific timing at which the file to which additional information is not added is deleted by the deletion unit 147 is the time when a predetermined length of time or more has elapsed since the file was stored in the storage unit 130, A point in time when a predetermined length of time or more has elapsed since the first trigger condition was satisfied for the file, or a point in time when the number of data or the amount of data stored in the storage unit 130 exceeds a threshold. . Therefore, the file to which the additional information is not added can be deleted after being stored in the storage unit 130 for the period requested by the user of the PLC 100 .
- Embodiment 2 Next, the second embodiment will be described, focusing on differences from the first embodiment described above. Equivalent reference numerals are used for configurations that are the same as or equivalent to those in the first embodiment.
- the present embodiment differs from the first embodiment in that the adding unit 146 adds additional information to the data in the buffer.
- the addition unit 146 searches the storage unit 130 for a file having the trigger ID notified from the trigger determination unit 143 .
- the file having the trigger ID notified by the adding unit 146 is not yet stored in the storage unit 130 because the data writing speed to the storage unit 130 is low.
- the addition unit 146 also searches for the trigger ID in the data stored in the buffer 120, as indicated by the thick arrow in FIG. Add additional information to data.
- the storage unit 145 stores the file containing the data assigned the trigger ID in the storage unit 130 with additional information added.
- a file to which additional information is added is more important than a file to which additional information is not added, and can be saved in storage unit 130 before being lost due to updating of data in buffer 120, which is a ring buffer. desirable. Therefore, the storage unit 145 stores the file containing the data to which the additional information is added in the buffer 120 in the storage unit 130 with priority over the file containing the data to which the additional information is not added.
- the storage unit 145 stores data D[T70] to which a trigger ID is assigned but not to which a trigger ID is assigned, and data to which both a trigger ID and additional information are assigned, as shown in FIG. Data D[T90] of D[T90] is read out before data D[T70]. Then, storage unit 145 stores the file including data D[T90] in storage unit 130 before storing the file including data D[T70].
- the storage unit 145 sequentially reads the data to which the trigger ID is assigned from the buffer 120 and stores the file in the storage unit 130
- the data to which the additional information is added is read ahead of the data. is read out from the buffer 120 with priority over other data collected in the above but to which additional information is not added, and the file containing the data is stored in the storage unit 130 .
- Adding unit 146 according to the present embodiment when the second trigger condition is satisfied, selects the third data collected before the first data and the first data stored in the buffer as It corresponds to an example of adding means for adding additional information to the first data.
- Embodiment 3 Next, the third embodiment will be described, focusing on differences from the first embodiment described above. Equivalent reference numerals are used for configurations that are the same as or equivalent to those in the first embodiment.
- the present embodiment is different from the first embodiment in that adding section 146 adds additional information to files stored in storage section 130 before and after the file in addition to the file that satisfies the second trigger condition. different from
- a file with additional information indicates the transition of device data. If the satisfaction of the first trigger condition corresponds to the completion of manufacturing of one product, and the satisfaction of the second trigger condition corresponds to the detection of an abnormality in the product, the products manufactured before and after the product in which the abnormality was detected There is also a desire to check the transition of device data.
- the addition unit 146 adds the file F3 having the trigger ID notified by the trigger determination unit 143 when the second trigger condition is satisfied. Then, the additional information is also added to the file F2 stored in the storage unit 130 immediately before the file F3 and the file F4 stored in the storage unit 130 immediately after the file F3.
- the addition unit 146 stores in the storage unit 130 the first data and the first trigger condition corresponding to the first data, and at least one of the previous and next satisfaction of the first trigger condition. It corresponds to an example of adding means for adding additional information to the fourth data.
- the file to which the addition unit 146 adds additional information is not limited to the example shown in FIG.
- the adding unit 146 may add additional information to the file F1, or may add additional information to the file F5.
- the addition unit 146 does not add additional information to the files F4 and F5, and stores one or more files set by the setting unit 148 in the storage unit 130 before the file F3 having the notified trigger ID. Additional information may be added to a plurality of consecutive files.
- the adding unit 146 does not add additional information to the files F1 and F2, and stores one or more information set by the setting unit 148 in the storage unit 130 after the file F3 having the notified trigger ID. Additional information may be added to consecutive files.
- the addition unit 146 adds the file to which the trigger ID has been notified and the data stored in the storage unit 130 when the first trigger condition corresponding to the file is satisfied at least one of the previous time and the next time the first trigger condition is satisfied. Additional information may be added. Further, although the description has focused on the differences from the first embodiment, in the configuration of the second embodiment, additional information may be added to files before and after the file specified by the trigger ID.
- Embodiment 4 Next, the fourth embodiment will be described, focusing on differences from the first embodiment described above. Equivalent reference numerals are used for configurations that are the same as or equivalent to those in the first embodiment.
- the present embodiment differs from Embodiment 1 in that adding section 146 adds one type of additional information among a plurality of types of additional information.
- FIG. 13 shows a functional configuration of PLC 100 according to this embodiment.
- the setting unit 148 presets a plurality of types of second trigger conditions in the trigger determination unit 143 .
- the plurality of types of second trigger conditions are, for example, a first type of second trigger condition for determining that the product is normal and a second type of second trigger condition for determining that the product is abnormal.
- the second trigger condition of the second type may be a condition that is satisfied when the second trigger condition of the first type is not satisfied, or a condition that is satisfied regardless of whether the second trigger condition of the first type is satisfied. It may be a condition to be established. For example, if the dimensional error of the product exceeds the allowable value, an abnormality may be detected, and if the dimensional error is within a range smaller than the allowable value, the product may be determined to be normal.
- the setting unit 148 sets all products as targets for determining whether or not the second trigger condition of the second type is met in order to detect the presence or absence of an abnormality, while setting unit 148 to determine whether or not the second trigger condition is normal.
- the trigger determination unit 143 may be set to periodically determine one of the plurality of products.
- the trigger determination unit 143 determines whether or not a plurality of types of second trigger conditions are met according to the settings of the setting unit 148 . Then, when it is determined that the second trigger condition is satisfied, the addition unit 146 is notified of the type of the second trigger condition and the trigger ID. In the example of FIG. 13, the trigger determination unit 143 notifies the trigger ID TR[T30] together with information indicating normality, and notifies the trigger ID TR[T50] together with information indicating abnormality.
- the addition unit 146 Based on the notification from the trigger determination unit 143, the addition unit 146 adds additional information corresponding to the notified type to the file having the notified trigger ID. For example, in the example of FIG. 13, the addition unit 146 adds additional information of OK[T30] indicating normality to file D[T26-T35] having a trigger ID of TR[T30]. Additional information of NG [T50] indicating an abnormality is added to the file D [T46-T55] having the trigger ID of T50]. The additional information may be added by inserting a character string "OK" indicating normality or a character string "NG” indicating abnormality at the end of the file or in the file name. It is also possible to assign a folder attribute.
- the deletion unit 147 deletes files from the storage unit 130 for which a period of time corresponding to the type of additional information has elapsed. For example, when the remaining capacity of the storage unit 130 falls below 10%, the deletion unit 147 deletes the files in order of oldest to which additional information is not added so that the remaining capacity becomes 10% or more. good too. In addition, the deletion unit 147 may delete files to which additional information indicating that there is an abnormality are added, in order from the files whose retention period is one year. Also, files to which additional information indicating that they are normal may be deleted in order from the oldest when the number of files stored in the storage unit 130 exceeds 100.
- the erasing unit 147 saves the data to which the additional information corresponding to the type of the second trigger condition is added in the storage means for a period of time corresponding to the one type, and then removes the data from the storage means. It corresponds to an example of erasing means for erasing.
- the adding unit 146 adds additional information corresponding to the one type to the file, and the erasing unit 147 deletes the file to which the additional information is added from the storage unit 130 after storing it in the storage unit 130 for a period of time corresponding to the one type.
- different storage periods can be set according to the types of files to be stored.
- the number of types of second trigger conditions is not limited to two, and may be three or more.
- different types of additional information may be added to the file for dimensional error anomalies, weight error anomalies, and impurity contamination anomalies.
- the additional information in the second and third embodiments may be provided with a plurality of types. If a plurality of types of additional information are provided in the third embodiment, the additional information of the same type as that of the file specified by the trigger ID may be added to the files before and after the file.
- Embodiment 5 Next, the fifth embodiment will be described, focusing on differences from the above-described fourth embodiment. Equivalent reference numerals are used for configurations that are the same as or equivalent to those in the fourth embodiment.
- the present embodiment differs from the fourth embodiment in that display data generation device 300 generates display data for generating a screen based on a plurality of types of additional information.
- FIG. 14 shows the functional configuration of the display data generating device 300 according to this embodiment.
- the display data generation device 300 has a hardware configuration similar to that of the PLC 100 shown in FIG. 2, and exhibits various functions through the cooperation of the hardware components.
- the display data generation device 300 includes a UI (User Interface) unit 310 that receives parameters set by the setting unit 148 of the PLC 100 from the user and outputs them to the setting unit 148, and a file from the storage unit 130.
- a waveform display data generation unit 330 for displaying waveforms showing changes in values of device data contained in the file; and a program display data generation unit 340 of.
- the acquisition unit 320 is mainly realized by the communication unit 106 of the display data generation device 300. Acquisition unit 320 acquires a list of files from storage unit 130 . Then, the acquiring unit 320 causes the display device 301 to display a screen as shown in FIG. 15 to prompt the user to select one of the files. The screen of FIG. 15 displays a list of file names including a character string "OK" indicating normality and file names including a character string "NG” indicating abnormality.
- acquisition unit 320 selects a file to which additional information indicating abnormality is added and a file to which additional information indicating normality is added for comparison with the selected file. Identify and display on this screen. Specifically, the acquisition unit 320 identifies the file stored in the storage unit 130 immediately before the file selected by the user, among the files to which the additional information indicating normality and abnormality is added, and obtains the file shown in FIG. Highlight as if hatched. Note that the acquisition unit 320 may specify a file stored in the storage unit 130 next to the file selected by the user, among the files to which additional information indicating normality and abnormality is added. Also, the file to be compared may be selected again by the user.
- Acquisition unit 320 corresponds to an example of a reception unit in display data generation device 300 that receives a user's selection of one of a plurality of first data stored in the programmable controller. Acquisition unit 320 outputs the determined three files to waveform display data generation unit 330 .
- the waveform display data generation unit 330 causes the display device 301 to display the changes in the values of the device data contained in the three files as waveforms in a comparable format. More specifically, as shown in FIG. 16, the waveform display data generating section 330 aligns the data to which the trigger ID corresponding to when the first trigger condition is satisfied is aligned with the position of the guide G1, and the data selected by the user. A waveform W1 corresponding to the file and waveforms W2 and W3 to be compared are displayed. As a result, the three waveforms are displayed side by side in the vertical direction, and the user can easily compare the three waveforms.
- the waveform display data generation unit 330 may display the sampling values of each waveform overlapping the guide G1, or the user may move the guide G1 in the horizontal direction.
- the waveform display data generation unit 330 generates, in the display data generation device 300, the one first data selected by the user and immediately before or after the one first data, the same as or different from the one first data.
- the waveform display data generation unit 330 outputs information about the file selected by the user to the program display data generation unit 340.
- the program display data generator 340 causes the display device 301 to display a sub-window A1 displaying information about the control program P2.
- a control program P2 which is a ladder program, is displayed in this subwindow A1, and when the user moves the guide G1, the image in the subwindow A1 is updated to display the state of the ladder program at that time.
- device data values corresponding to sampled values of the waveform overlapping the guide G1 are displayed in the ladder program.
- the display data generation device 300 generates display data for displaying information about data corresponding to the establishment of the second trigger condition of a single type. You may For example, the display data generation device 300 may cause the display device 301 to display waveforms indicated by a plurality of files selected by the user.
- Embodiment 6 Next, the sixth embodiment will be described, focusing on differences from the first embodiment described above. Equivalent reference numerals are used for configurations that are the same as or equivalent to those in the first embodiment. This embodiment differs from the first embodiment in that the PLC 100 includes a transfer unit 149 that transfers data to the outside, as shown in FIG.
- the transfer unit 149 monitors the information stored in the storage unit 130, and when the information is updated, transfers the information before or after the update to the external server 40 for backup. Specifically, the transfer unit 149 transfers the file to the external server 40 when the storage unit 145 stores the file. Further, the transfer unit 149 transfers the additional information and the file to which the additional information is added to the external server 40 when the additional information is added to the file by the adding unit 146 . Further, the transfer unit 149 transfers to the external server 40 files that are to be deleted when the files are deleted by the deletion unit 147 . Note that the transfer unit 149 may omit part of the transfer without executing all of these transfers.
- the transfer unit 149 corresponds to an example of transfer means for transferring information to the server in the PLC 100 . It should be noted that the description has focused on the differences from the first embodiment, but the transfer unit 149 according to the present embodiment may be added to the configurations of the second to fifth embodiments.
- the storage unit 145 stores a series of data including data assigned with a trigger ID as a file in the storage unit 130, but the present invention is not limited to this.
- the storage unit 145 may store the data read from the buffer 120 in the storage unit 130 as it is without converting it into a file format.
- storage unit 145 may store single data to which a trigger ID is assigned as is, or a file containing this single data in storage unit 130. good.
- adding additional information to a file is not limited to creating a single data set that includes both additional information and a file.
- the additional information may be added by associating it with the file using management information that associates the additional information and the file stored in different areas.
- management information it is preferable to secure a reserved area in preparation for updating the management information.
- Additional information may be added to files excluded from extension of the storage period, and the files with the additional information may be deleted in a shorter period of time than the files without the additional information.
- adding unit 146 adds the Additional information may be added.
- the erasing unit 147 saves the first data in the storage unit 130 and removes the second data from the storage unit 130 based on the additional information. It should be deleted.
- the trigger determination unit 143 determines whether the first trigger condition for the data is met. That is, an example has been described in which the timing at which data is collected and the timing at which it is determined whether the first trigger condition is met are substantially the same. However, these timings are not limited to matching examples.
- FIG. 18 shows an example in which the data collection unit 142 collects data D[T1], D[T2], D[T3], D[T4], and D[T5] in order.
- the data D[T3] is output to the trigger determination unit 143, it is determined that the first trigger condition is satisfied. It may be D[T1]. That is, where n is an integer, a trigger ID is assigned to data D[T(n ⁇ 2)] when it is determined that the first trigger condition is met at the time when data D[Tn] is output to trigger determination unit 143. may be Furthermore, in contrast to the example of FIG.
- the data D[T(n+2)] contains the trigger ID may be given.
- the data stored in the storage unit 130 may be data collected by the data collecting unit 142 at the timing corresponding to the establishment of the first trigger condition each time the first trigger condition is established.
- the functions of the PLC 100 according to the above embodiment can be realized by dedicated hardware or by a normal computer system.
- the program P1 is stored and distributed on a computer-readable recording medium represented by a flexible disk, CD-ROM (Compact Disk Read-Only Memory), DVD (Digital Versatile Disk), MO (Magneto-Optical disk).
- a computer-readable recording medium represented by a flexible disk, CD-ROM (Compact Disk Read-Only Memory), DVD (Digital Versatile Disk), MO (Magneto-Optical disk).
- the program P1 may be stored in a disk device of a server device on a communication network typified by the Internet, superimposed on a carrier wave, and downloaded to a computer.
- the above processing can also be achieved by starting and executing the program P1 while transferring it via a network represented by the Internet.
- processing can also be achieved by causing all or part of the program P1 to be executed on a server device, and executing the program P1 while the computer transmits and receives information regarding the processing via a communication network. .
- the functions described above are to be shared by the OS (Operating System) or by cooperation between the OS and the application, only the parts other than the OS may be stored in a medium and distributed. , or you may download it to your computer.
- the means for realizing the functions of the PLC 100 is not limited to software, and part or all of it may be realized by dedicated hardware or circuits.
- the present disclosure is suitable for logging data used for control by PLC.
- 1000 PLC system 100 PLC, 101 processor, 102 main storage unit, 103 auxiliary storage unit, 104 input unit, 105 output unit, 106 communication unit, 107 internal bus, 110 device memory, 111 device data, 120 buffer, 130 storage unit , 141 program execution unit, 142 data collection unit, 143 trigger determination unit, 144 buffering unit, 145 storage unit, 146 addition unit, 147 deletion unit, 148 setting unit, 149 transfer unit, 200 mechanical device, 201 manufacturing completion sensor, 202 inspection sensor, 300 display data generation device, 301 display device, 310 UI unit, 320 acquisition unit, 330 waveform display data generation unit, 340 program display data generation unit, 40 external server, A1 sub-window, F1 to F5 files, G1 guide , P1 program, P2 control program, W1 to W3 waveforms.
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Abstract
Description
図1には、本実施の形態に係るプログラマブルコントローラを有するPLC(Programmable Logic Controller)システム1000の構成が示されている。PLCシステム1000は、工場に代表される施設に構築される製造システム、検査システム、その他の処理システムの一部に相当する制御システムである。PLCシステム1000では、プログラマブルコントローラとしてのPLC100が、通信線で接続された被制御機器としての機械装置200を制御することでラインを稼働させる。PLC100は、機械装置200を制御するためのデバイスメモリ110と、デバイスメモリ110に記憶されるデバイスデータ111のログを記録するためのバッファ120及び記憶部130と、を有する。
続いて、実施の形態2について、上述の実施の形態1との相違点を中心に説明する。なお、上記実施の形態1と同一又は同等の構成については、同等の符号を用いる。本実施の形態は、付加部146が、バッファ内のデータにも付加情報を付加する点で、実施の形態1とは異なる。
続いて、実施の形態3について、上述の実施の形態1との相違点を中心に説明する。なお、上記実施の形態1と同一又は同等の構成については、同等の符号を用いる。本実施の形態は、付加部146が、第2トリガ条件が成立するファイルに加えて、当該ファイルの前後に記憶部130に格納されたファイルにも付加情報を付加する点で、実施の形態1とは異なる。
続いて、実施の形態4について、上述の実施の形態1との相違点を中心に説明する。なお、上記実施の形態1と同一又は同等の構成については、同等の符号を用いる。本実施の形態は、付加部146が、複数の種別の付加情報のうちのいずれか1つの種別の付加情報を付加する点で、実施の形態1とは異なる。図13には、本実施の形態に係るPLC100の機能的な構成が示されている。
続いて、実施の形態5について、上述の実施の形態4との相違点を中心に説明する。なお、上記実施の形態4と同一又は同等の構成については、同等の符号を用いる。本実施の形態は、表示データ生成装置300が、複数の種別の付加情報に基づく画面を生成するための表示データを生成する点で、実施の形態4とは異なる。
続いて、実施の形態6について、上述の実施の形態1との相違点を中心に説明する。なお、上記実施の形態1と同一又は同等の構成については、同等の符号を用いる。本実施の形態は、図17に示されるように、PLC100が、データを外部に転送する転送部149を備える点で、実施の形態1とは異なる。
Claims (11)
- 機器を制御するプログラマブルコントローラであって、
前記機器を制御するときに変化するデータをメモリから繰り返し収集するデータ収集手段と、
予め定められた第1トリガ条件が成立すると、該第1トリガ条件の成立に対応するタイミングにおいて前記データ収集手段によって収集されたデータを記憶手段に格納する格納手段と、
前記第1トリガ条件とは異なる第2トリガ条件が成立する場合に、前記格納手段によって前記記憶手段に格納されたデータである、第1データと、該第1データより後に前記データ収集手段によって収集された第2データと、の少なくとも一方に付加情報を付加する付加手段と、
前記第1データ及び前記第2データが前記記憶手段に格納された後に、前記付加情報に基づいて、前記第1データを前記記憶手段に保存しつつ、前記第2データを前記記憶手段から消去する消去手段と、
を備えるプログラマブルコントローラ。 - 前記第2トリガ条件は、前記第1データが前記記憶手段に保存される期間の長さを、該第2トリガ条件が成立しない場合の長さから延長するための条件であって、
前記付加手段は、前記第1データに前記付加情報を付加し、
前記消去手段は、前記付加情報が付加された前記第1データを前記記憶手段に保存しつつ、前記付加手段による前記付加情報の付加の対象から除外された前記第2データを前記記憶手段から消去する、
請求項1に記載のプログラマブルコントローラ。 - 前記データ収集手段によって収集されたデータを順次記憶するバッファ、をさらに有し、
前記付加手段は、前記第2トリガ条件が成立する場合において、前記バッファに格納されている、前記第1データより前に収集された第3データと、前記第1データと、のうちの前記第1データに前記付加情報を付加し、
前記格納手段は、前記バッファのデータを順次読み出して前記記憶手段に格納する際に、前記付加情報が付加された前記第1データを前記第3データより優先して前記バッファから読み出して前記記憶手段に格納する、
請求項2に記載のプログラマブルコントローラ。 - 前記付加手段は、複数の種別のうちの一の種別の前記第2トリガ条件が成立する場合に、前記一の種別に対応する前記付加情報を前記第1データに付加し、
前記消去手段は、前記付加情報が付加された前記第1データを、前記一の種別に対応する長さの期間だけ前記記憶手段に保存した後に前記記憶手段から消去する、
請求項2又は3に記載のプログラマブルコントローラ。 - 前記付加手段は、前記第1データと、該第1データに対応する前記第1トリガ条件の成立の前回及び次回の少なくとも一方の前記第1トリガ条件の成立により前記記憶手段に格納された第4データと、に前記付加情報を付加する、
請求項2から4のいずれか一項に記載のプログラマブルコントローラ。 - 前記消去手段は、特定のタイミングで、前記第1データを前記記憶手段に保存しつつ前記第2データを前記記憶手段から消去し、
前記特定のタイミングは、前記第2データが前記記憶手段に格納されたときから予め定められた長さ以上の時間が経過した時点、前記第1トリガ条件が成立したときから予め定められた長さ以上の時間が経過した時点、又は、前記記憶手段に保存されているデータのデータ数若しくはデータ量が閾値を超えた時点である、
請求項1から5のいずれか一項に記載のプログラマブルコントローラ。 - 前記格納手段による前記第1データ及び前記第2データの格納の際における前記第1データ及び前記第2データの外部のサーバへの転送、前記付加手段による前記第1データ及び前記第2データの少なくとも一方への前記付加情報の付加の際における前記付加情報及び該付加情報が付加されるデータの前記サーバへの転送、及び、前記消去手段による前記第2データの消去の際における前記第2データの前記サーバへの転送、の少なくとも1つを実行する転送手段、をさらに備える、
請求項1から6のいずれか一項に記載のプログラマブルコントローラ。 - 請求項2から5のいずれか一項に記載のプログラマブルコントローラと、
前記プログラマブルコントローラに接続される表示データ生成装置と、
を備えるプログラマブルコントローラシステムであって、
前記表示データ生成装置は、前記付加情報が付加された複数の前記第1データを前記プログラマブルコントローラから読み出して、複数の前記第1データに関する情報を表示するための表示データを生成する、
プログラマブルコントローラシステム。 - 請求項4に記載のプログラマブルコントローラと、
前記プログラマブルコントローラに接続される表示データ生成装置と、
を備えるプログラマブルコントローラシステムであって、
前記表示データ生成装置は、
前記プログラマブルコントローラに記憶される複数の前記第1データからいずれか一の前記第1データのユーザによる選択を受け付ける受付手段と、
ユーザにより選択された一の前記第1データと、該一の前記第1データの直前又は次に、該一の前記第1データと同一の又は異なる種別の前記付加情報が付加された他の前記第1データと、を前記プログラマブルコントローラから読み出して、読み出した一の前記第1データ及び他の前記第1データに関する情報を表示するための表示データを生成する生成手段と、を有する、
プログラマブルコントローラシステム。 - プログラマブルコントローラによって実行されるデータ保存方法であって、
変化するデータをメモリから繰り返し収集し、
予め定められた第1トリガ条件が成立すると、該第1トリガ条件の成立に対応するタイミングにおいて収集したデータを記憶手段に格納し、
前記第1トリガ条件とは異なる第2トリガ条件が成立する場合に、前記記憶手段に格納されたデータである、第1データと、該第1データより後に収集した第2データと、の少なくとも一方に付加情報を付加し、
前記第1データ及び前記第2データが前記記憶手段に格納された後に、前記付加情報に基づいて、前記第1データを前記記憶手段に保存しつつ、前記第2データを前記記憶手段から消去する、
ことを含むデータ保存方法。 - プログラマブルコントローラに、
変化するデータをメモリから繰り返し収集し、
予め定められた第1トリガ条件が成立すると、該第1トリガ条件の成立に対応するタイミングにおいて収集したデータを記憶手段に格納し、
前記第1トリガ条件とは異なる第2トリガ条件が成立する場合に、前記記憶手段に格納されたデータである、第1データと、該第1データより後に収集した第2データと、の少なくとも一方に付加情報を付加し、
前記第1データ及び前記第2データが前記記憶手段に格納された後に、前記付加情報に基づいて、前記第1データを前記記憶手段に保存しつつ、前記第2データを前記記憶手段から消去する、
ことを実行させるためのプログラム。
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