JPH06149347A - Abnormality reproducing device for equipment - Google Patents

Abstract

PURPOSE:To exactly analyze abnormality, and to early restore a device by preparing a data reproduction file only at the time of periodically fetching device monitoring data, and detecting the abnormality. CONSTITUTION:Device monitoring raw data are periodically collected from a communicating means in a raw data buffer 30 in the fixed time by referring to a raw data buffer management table 28 with a data fetching means 26. At the time of the end of the collection, when the abnormality is detected by an abnormality judging means 34, the raw data buffer 30 is synthesized with the raw data buffer management table 28, and a data reproduction file 46 is prepared. Then, abnormality data are developed on a restoration data buffer management table 40 and a restoration data buffer 42 from the data reproduction file 46, the reproducing method of the abnormality data is instructed by a reproduction instructing part 44 by an input from a key 14 or the like, the destination of a data fetch is decided by a flag 48, the device monitoring data for abnormality generation are fetched, and displayed at a display device 12.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is connected to various devices constituting an automated facility by using communication means such as a network, monitors the operating condition of the facility, and analyzes the cause when an abnormality occurs in the facility. The present invention relates to an abnormality reproducing device for equipment.

[0002]

2. Description of the Related Art At present, automation is actively carried out in an article assembly line and the like, and the automation equipment is becoming more and more complicated year by year, the equipment constituting the equipment is diversified, and the number thereof is increasing. Therefore, when an abnormality occurs in the equipment,
It also takes time to analyze the cause, which is one of the factors that lower the operating rate of equipment. Therefore, various methods of analyzing the cause of trouble have been devised.

For example, a method of displaying various equipment monitoring screens as shown in FIGS. 2 to 6 on a display device using the monitor device having the configuration shown in FIG. is there. In the monitor device of FIG. 1, 10 is a central processing unit, 12 is a display device, 14 is a key input device, 16 is a mouse input device, 18 is an equipment network interface (I / F), 20 is a hard disk, and 22 is a main memory. It is a device. The main storage device 22 is composed of an operating system (OS) 22a, a data collection unit 22b, a screen display unit 22c, and a collection data storage area 22d. Based on these instructions, the display device 12 is for monitoring various facilities. The screen is displayed.

2 to 6 show various equipment monitoring screens, and FIG. 2 is a drawing showing a sequence ladder diagram of software operating in the sequencer,
The current ON / OFF state of the input / output contact can be determined. FIG. 3 is a screen for creating a time chart diagram of a plurality of designated input / output contacts, and it is possible to see the timing of signal changes. FIG. 4 is a screen for displaying the execution cycle in the facility, and shows where the cycle currently being executed is. FIG. 5 shows the equipment that constitutes the facility and indicates the presence / absence of abnormality by color, and the type of abnormality can also be determined. FIG. 6 is a screen on which the content of the data collected by the data collection unit can be viewed as it is.

Using these screens, it is possible to find out how far the driving is progressing and what the signal at that time is, and to find out a portion having a control inconvenience.

ON / OFF of any input / output contact using the screen
As an example of monitoring the ON / OFF state, Japanese Patent Laid-Open No. 61-195
No. 408 describes a method of stopping a sequence ladder diagram by using a change of an arbitrary input / output contact as a trigger.

[0007]

The conventional method of displaying various screens on a CRT and referring to the screens when an abnormality occurs is the most commonly used method. However, there was a problem that the abnormality could not be completely analyzed.

That is, the abnormality can be roughly classified into the time when the abnormality of the equipment in the equipment is detected and the time when the control sequence is reversed and the signal waits.

When an abnormality is detected in the equipment, the equipment is usually interlocked with a logic to stop it.
In this state, the maintenance person can perform abnormality analysis using the screen. However, no abnormality can be detected in the signal waiting state, and it is general that a logic for resetting the equipment is incorporated due to timeout. In this case, the signal returns to the initial state, and even if all the signals at that time point are saved by using the time-out signal as a trigger, the signal when the control sequence reverses is long before the time-out occurs. Therefore, the cause analysis becomes very difficult even if the above screen is used.

In addition, when the maintenance person does not finish the cause analysis in a short time after an abnormality occurs, or when the maintenance person is not present at the site, the equipment operator initializes the equipment and starts operation. In many cases, it starts, and there is a problem that analysis of anomalies becomes impossible after that.

The present invention has been made to solve the above-mentioned conventional problems. When an abnormality occurs in the automated equipment, the equipment in which the abnormality occurs is initialized, and the situation in which the abnormality occurs cannot be saved as it is. Even in any case, the history of the occurrence of the abnormality can be completely reproduced, and the abnormality can be reliably analyzed.
It is an object of the present invention to provide an abnormality reproducing device for equipment, in which the equipment is restored at an early stage and the availability and reliability of the equipment are improved.

[0012]

SUMMARY OF THE INVENTION The present invention relates to an equipment abnormality reproducing apparatus, a communication means, and a communication means, which are connected to various devices constituting an automated equipment by using communication means and monitor equipment on a screen display. A means for periodically fetching equipment monitoring data by using it, a raw data buffer having a plurality of cases and periodically storing the equipment monitoring data, and a raw data buffer management table for managing it A memory means; a means for detecting an abnormality from the fetched equipment monitoring data and synthesizing the raw data buffer and the raw data buffer management table only when the abnormality occurs to create a data reproduction file; Memory composed of raw data buffer management table, restored data buffer of the same structure, and restored data buffer management table A step for expanding the data reproduction file on the restored data buffer and the restored data buffer management table to operate the restored data buffer management table; and means for instructing an operation of the restored data buffer management table. , Fetching equipment monitoring data from the raw data buffer or the restored data buffer using a flag indicating the destination of data fetching,
The above-mentioned object is achieved by comprising a means for displaying a screen.

[0013]

According to the present invention, the means for fetching the data from the communication means periodically collects the equipment monitoring raw data in the raw data buffer for a certain period of time by referring to the raw data buffer management table. When abnormality is detected from the data by the means for determining abnormality at the time when the data collection is completed, the raw data buffer and the raw data buffer management table are combined to create a data reproduction file.
The abnormal data is expanded from the data reproduction file on the restored data buffer management table and the restored data buffer,
By instructing the method of reproducing the abnormal data by inputting with the key or mouse, the data capture destination is determined by the flag, and from the raw data buffer or the restored data buffer, from a certain time before the abnormality occurs until the abnormality occurs. The equipment monitoring data is captured and displayed on the screen.

By analyzing using this reproduction screen, the cause of the abnormality can be surely investigated.

[0015]

Embodiments of the present invention will now be described in detail with reference to the drawings.

FIG. 7 is a block diagram showing a schematic structure of an equipment abnormality reproducing apparatus according to the present invention. In FIG.
Reference numeral 12 is a display device, 14 is a key input device, 16 is a mouse input device, 24 is an equipment network, 26 is an equipment monitoring data acquisition unit, 28 is a raw data buffer management table,
30 is a raw data buffer, 32 is a screen display unit, 34 is an abnormality determination unit, 36 is an abnormality determination formula file, 38 is an abnormality reproduction unit, 40 is a restored data buffer management table, 42 is a restored data buffer, and 44 is a reproduction instruction unit. , 46 is a data reproduction file, and 48 is an input changeover switch (flag).

When data is transmitted, or periodically, the equipment monitoring data fetching section 26 receives the data via the equipment network 24, and the received data is referred to the raw data buffer management table 28 to obtain the raw data. Buffer 30
To store.

The raw data buffer management table 28 and the raw data buffer 30 are both arranged on the main storage device to enable high speed access and have the structure shown in FIGS. 8 and 9. As shown in FIG. 9, the raw data buffer 30 has a plurality of cases, and when the data is full, the old data is overwritten in order from the oldest data. The raw data buffer management table 28 is shown in FIG.
As shown in FIG. 3, it has the latest write pointer for fetching the latest data from the raw data buffer 30 and the information of the fetch time.

The raw data buffer management table 28 is initialized when the apparatus starts up. At this time, the latest writing case No. and the number of fetched data are 0, and the maximum case No. is the number of cases (N) in the raw data buffer 30.
Is stored.

Each time data is fetched, the latest write case No. and the fetched data number are updated. The latest case No. starts from 1 and is used up to N. When N is exceeded, the value returns to 1 again, and this is repeated. The number of fetched data similarly increases to N, but N is maintained as it is even if N is exceeded.

The latest write date, month, day, hour, minute and second stores the year, month, day, hour, minute and second in which the data stored in the case indicated by the latest write case No. in the raw data buffer 30 is fetched. The oldest writing year, month, day, hour, minute, and second stores the year, month, day, hour, minute, and second in which the oldest data is taken in the raw data buffer 30. If the number of captured data is N or less, the 1st case, if the number of captured data exceeds N, the data of the latest writing case No. + 1 case (the first case if it exceeds N) is captured. Month day hour minute second.

If the number N of cases in the raw data buffer 30 is 60 and the number of data fetches exceeds one cycle, and the latest data is stored in the third case, the latest writing date and time in the raw data buffer 30 will be described. The minutes and seconds are the year, month, day, hour, minute, and second when the data of the third case was taken in. The oldest writing date, month, day, hour, minute, and second is the year, month, day, hour, minute, and second when the data of the fourth case was taken in, and the latest writing case No. is 3. Yes, the number of captured data and the maximum case No. are 60.

Number of cases in raw data buffer 30 (N)
Can be arbitrarily changed by the system. For example, if the number of cases N is 60, 60 cases are prepared, so if the data collection period is 1 second, it is possible to store data for 60 seconds before the occurrence of an abnormality.

The abnormality reproducing device normally monitors the operation of the equipment. The equipment monitoring data acquisition unit 26 activates the screen display unit 32 each time data collection is completed,
The screen display unit 32 uses the raw data buffer management table 28.
The screen is created using the data stored in the case of the raw data buffer 30 designated by the latest writing case No. The screens displayed at this time are those shown in FIGS. 2 to 6.

The abnormality judging section 34 is activated when the equipment monitoring data fetching section 26 has completed the data collection, and compares the latest raw data with the previous raw data according to the abnormality judgment formula file 36 to judge the occurrence of abnormality. . Since the abnormality judgment formula file 36 is a trigger for detecting an abnormality, it can be freely set by the system and can be freely changed even after the operation of the equipment. The abnormality judgment formula file 36 is created by using a text editor, and is read into the abnormality judgment unit 34 when the apparatus starts up.

FIG. 10 shows an example of an abnormality determination formula when a change in the contact state is used as a trigger for abnormality detection. A contact address and a bit position for identifying an abnormality and a direction of a contact state change are registered, and a plurality of expressions can be registered at the same time. In the example of FIG. 10, when the contact state of the 5th bit of the 10th byte changes from OFF to ON (0 to 1),
Or, it is judged as abnormal when either the contact state of the 5th bit of the 15th byte changes from ON to OFF, or the contact state of the 3rd bit of the 20th byte changes from OFF to ON. It

When the abnormality determination unit 34 determines that an abnormality has occurred, a file containing the raw data buffer management table 38, the raw data buffer 30, and the abnormality identification code is created in the hard disk. File names at this time are given different names depending on the time of occurrence of an abnormality, and a plurality of files can be stored at the same time. For example, the name of the abnormal file generated at 16:10:35 on September 24, 1992 is ERR.
OR. 92.09.24.16.10.35.

The abnormality reproducing unit 38 first expands the instructed abnormal data on the restored data buffer management table 40 and the restored data buffer 42. 11 and 12
Shows the structure of the restored data buffer management table 40 and the restored data buffer 42, and has the same structure and the same size as the raw data buffer management table 28 and the raw data buffer 30 shown in FIGS. 8 and 9.

Thereafter, the latest write pointer in the restored data buffer management table 40 is operated according to the instruction of the reproduction instruction section 44. Reproduction can be performed by changing the pointer at an interval corresponding to the real time, changing the pointer several times faster than the real time, and changing the pointer by only one count.

The reproduction instruction section 44 is a section in charge of the man-machine interface, and instructs the abnormality reproduction section 38 on the data reproduction file 46 selected using the key input device 14 or the mouse input device 16 and the reproduction method. To do.

In FIG. 13, the reproduction instructing section 44 is provided on the display device 12.
It is the operation menu of the data restoration displayed above. Reference numeral 101 in FIG. 13 indicates the year, month, day, hour, minute, and second at which the data reproduction file 46 expanded currently on the restored data buffer management table 40 and the restored data buffer 42 is created. 102a and 102b are the start time and end time of the collection of the restored data. 103a and 103b
Indicates the current mode of the input selector switch 48, and either the actual mode or the restoration mode can be selected. 104
Is the time at which the data pointed to by the latest write case No. in the restoration management table was fetched. 105a gives 10 instructions to reverse the latest writing case No. at high speed.
5b is an instruction to reverse the latest write case No. in real time, 105c is an instruction to end the operation of the latest write case No. currently being executed, and 105d is a real time to update the latest write case No. 105e
Indicates an instruction to rotate the latest writing case No. at a high speed at a high speed, and 106a indicates the latest writing case No. for only one case.
106b can send an instruction to reverse the latest writing case No. 1 for only one case to the abnormality reproducing unit 38 by selecting it with the mouse input device 16.

The screen display section 32 can determine the data capture destination by way of the mode changeover switch 48. The mode changeover switch 48 is the reproduction instruction unit 4
The abnormality reproducing unit 38 is operated via 4. The mode changeover switch 48 is a flag, which is 0 in the real mode and 1 in the reproduction mode.

By the above method, it is possible to reproduce the past abnormality that has occurred on this apparatus.

[0034]

As described above, according to the present invention, it is possible to easily reproduce an abnormality even in a facility which is operated while leaving a defect because sufficient cause analysis cannot be performed due to conventional operational restrictions. It has an excellent effect that the analysis can be performed at any time, the malfunction of the equipment can be surely dealt with early, and the operation rate and reliability of the equipment can be improved.

[Brief description of drawings]

FIG. 1 is a block diagram showing a configuration of a conventional monitor device that monitors equipment.

FIG. 2 is a ladder diagram of an example of an analysis screen displayed on the display device.

[FIG. 3] Similarly, a time chart diagram

[Figure 4] Similarly cycle diagram

[Figure 5] Similarly system diagram

[Figure 6] Similarly, a dump diagram

FIG. 7 is a block diagram showing an outline of an embodiment of an abnormality reproducing apparatus according to the present invention.

FIG. 8 is a structural diagram of a raw data buffer management table according to this embodiment.

FIG. 9 is a structural diagram of the raw data buffer.

FIG. 10 is an explanatory diagram showing an example of internal data of an abnormality definition formula file according to the present embodiment.

FIG. 11 is a structural diagram of a restored data buffer management table according to this embodiment.

FIG. 12 is a structural diagram of the restored data buffer.

FIG. 13 is an explanatory diagram showing a screen of an operation menu for data restoration displayed on the display device according to the present embodiment.

[Explanation of symbols]

 10 ... Central processing unit 12 ... Display device 14 ... Key input device 16 ... Mouse input device 18 ... Equipment network interface 20 ... Hard disk 22 ... Main storage device 24 ... Equipment network 26 ... Equipment monitoring data acquisition unit 28 ... Raw data buffer management table 30 ... Raw data buffer 32 ... Screen display unit 34 ... Abnormality judgment unit 36 ... Abnormality judgment formula file 38 ... Abnormality reproduction unit 40 ... Restoration data buffer management table 42 ... Restoration data buffer 44 ... Reproduction instruction unit 46 ... Data reproduction file 48 ... Input selector switch (flag)

Claims (1)

[Claims] 1. A device which is connected to various types of equipment constituting an automated facility by means of communication means and monitors equipment on a screen, and means for periodically fetching equipment monitoring data by means of the communication means. A raw data buffer having a case in which the equipment monitoring data is periodically stored, and a memory means configured by a raw data buffer management table for managing the raw data buffer; and an abnormality is detected from the taken equipment monitoring data. do it,
Means for synthesizing the raw data buffer and the raw data buffer management table only when an abnormality occurs to create a data reproduction file; the raw data buffer and the raw data buffer management table; and a restored data buffer and a restored data buffer having the same structure, respectively. A memory unit configured by a management table; a unit for expanding the data reproduction file into the restored data buffer and the restored data buffer management table to operate the restored data buffer management table; A means for instructing an operation and a means for displaying the screen by loading the facility monitoring data from the raw data buffer or the restored data buffer using a flag designating the destination of the data. An equipment abnormality reproduction device.