CN105122163B - Error processing system - Google Patents

Abstract

Its purpose is to smoothly transfer the management of error codes to unified management by a server or the like when managing error codes individually in each GOT, taking into consideration the unique situation of the FA system. When the GOT (30) acquires the error code of the error that occurred in the production facility, it searches the error database (40) using the error code as a key. When the message cannot be acquired, the GOT (30) searches the internal memory using the error code as a key. GOT (30) displays the acquired message.

Description

error handling system

technical field

The present invention relates to a technology for handling errors occurring in production equipment constituting a factory automation system (hereinafter, FA system).

Background technique

In the FA system, for each production equipment such as a processing machine and an inspection machine, a programmable logic controller (hereinafter, PLC) that controls the production equipment, and a graphic of the HMI (Human Machine Interface: Human Machine Interface) that is the PLC are set. Operation terminal (hereinafter, GOT).

In production equipment, various errors occur. When the PLC detects an error that has occurred in the production facility, the GOT acquires an error code indicating the error that occurred from the PLC. The GOT acquires and displays an error message corresponding to the error code from the internal memory. The operator confirms the error message displayed on the GOT, and specifies and handles the cause of the error.

Production equipment and PLC are being repeatedly improved day by day. If changes are made to production equipment or PLCs, error codes may increase or be changed. In this case, the error codes and corresponding error messages stored in the internal memory of the GOT are also maintained.

Since the GOT is installed corresponding to the production equipment and the PLC, it is necessary to maintain the corresponding error code and error message of the GOT for each of the production equipment and the PLC that have been changed.

When there are a plurality of the same production facilities, generally, the same changes are applied to each of the same production facilities. In this case, it is necessary to maintain the error codes and error messages of all the GOTs respectively corresponding to the production equipment.

Patent Document 1: Japanese Patent Laid-Open No. 2009-119616

Contents of the invention

The FA system may initially operate with a small number of production facilities, but the number of production facilities may gradually increase as demand increases. When the number of production facilities is small, maintenance of error codes and error messages for each GOT does not take so much effort. However, as the number of production facilities increases, it becomes more and more labor-intensive.

Therefore, it is desirable to install a server or the like for centralized management of error codes and error messages, and to reduce the maintenance effort of error codes and error messages accompanying changes in production equipment and PLCs.

However, in the FA system, it is not known whether the number of production equipment will increase in the future before operation, so it is often impossible to spend costs from the initial installation of servers and the like. Therefore, initially, error codes and error messages are managed in each GOT in advance, and when the number of production equipment increases to some extent, it may be necessary to perform unified management by switching to installing a server or the like.

In addition, in the FA system, since the purpose is to produce products, the communication among production-related devices is limited to give priority, and the traffic of other communication is often suppressed to a predetermined value or less. Therefore, when a server or the like for managing error codes and error messages is added later, it may be necessary to suppress the traffic generated by the server or the like added later to a predetermined value or less.

The present invention has been made in view of the above-mentioned circumstances peculiar to the FA system. An object of the present invention is to smoothly transfer the management of error codes and error messages to unified management by a server or the like when individual GOTs manage error codes and error messages in the FA system.

The present invention provides an error processing system that performs processing related to errors that have occurred in production equipment in a factory automation system that includes production equipment and controls the production equipment, and that includes an error database and an interface device. The PLC (programmable logic controller), and the interface device as the HMI (human-machine interface) of the PLC, is characterized in that,

The error database includes an error information storage unit that stores a message indicating the content of the error for each error code,

The interface device has:

a message storage unit that stores a message indicating the content of the error for each error code;

an error code acquisition unit that acquires an error code of an error that occurred in the production facility;

a database search unit for searching the error information storage unit by using the error code acquired by the error code acquisition unit as a key to obtain a message;

An internal search unit configured to search the message storage unit using the error code acquired by the error code acquisition unit as a key to acquire a message when the database search unit cannot acquire the message; and

A display unit that displays the messages acquired by the database search unit and the internal search unit.

It is characterized in that the error information storage unit stores a message and action information indicating an error handling method for each error code,

The database retrieval unit acquires the message and acquires the handling information,

The display unit may also display the action information when displaying the message acquired by the database search unit.

The error database is characterized in that the error database further includes a history storage unit that stores error codes used as keys by the database search unit as a history,

The error database includes a history output unit that outputs error codes stored in the history storage unit.

It is characterized in that the history output unit outputs only error codes not stored in the error information storage unit among the error codes stored in the history storage unit.

It is characterized in that the interface device further includes a recovery time measuring unit that measures a recovery time from occurrence of the error to elimination of the error,

the history storage unit stores the recovery time measured by the recovery time measuring unit together with an error code,

The history output unit outputs the error code and the recovery time.

The interface device further includes a message storage unit that combines the error code acquired by the error code acquisition unit with the error code retrieved by the internal search unit when the database search unit cannot obtain a message. The corresponding messages are stored in the error information storage unit.

In the error processing system of the present invention, the error message obtained from the error database is output for the error code stored in the error database, and the error message not stored in the error database is output to the interface device (for example, GOT). The error message stored in . Therefore, it is possible to gradually shift the management of error messages to unified management based on the error database while utilizing the error messages stored in the interface device.

In addition, when transferring the management of error messages to unified management by the error database, it is not necessary to extract all the error messages stored in the interface device and register them in the error database. Therefore, no large traffic will occur in the error database when moving to monadic management.

Description of drawings

FIG. 1 is a block diagram of an error handling system 100 according to Embodiment 1. As shown in FIG.

FIG. 2 is a functional configuration diagram of GOT 30 and error database 40 according to the first embodiment.

FIG. 3 is a diagram showing information stored in the message storage unit 31 according to the first embodiment.

FIG. 4 is a diagram showing information stored in the error information storage unit 41 according to the first embodiment.

FIG. 5 is a flowchart showing the processing of the error handling system 100 according to the first embodiment.

FIG. 6 is a diagram showing an example of a screen displayed on the display unit 35 .

FIG. 7 is a diagram showing an example of a maintenance screen of the error information storage unit 41 .

FIG. 8 is a functional configuration diagram of GOT 30 and error database 40 according to the second embodiment.

FIG. 9 is a diagram showing information stored in the history storage unit 42 according to the second embodiment.

FIG. 10 is a flowchart showing the processing of the error handling system 100 according to the second embodiment.

FIG. 11 is a functional configuration diagram of GOT 30 and error database 40 according to the third embodiment.

FIG. 12 is a flowchart showing the processing of the error handling system 100 according to the third embodiment.

Fig. 13 is a diagram showing an example of the hardware configuration of GOT 30, error database 40, and AP server 50 shown in Embodiments 1 and 2.

Symbol Description

10: Production equipment; 20: PLC; 30: GOT; 31: Message storage unit; 32: Error code acquisition unit; 33: Database search unit; 34: Internal search unit; 35: Display unit; 40: Error database; 41: Error information storage unit; 42: history storage unit; 43: history output unit; 50: AP server; 100: error handling system.

detailed description

Implementation mode 1.

FIG. 1 is a block diagram of an error handling system 100 according to Embodiment 1. As shown in FIG.

The error processing system 100 is a system that performs processing related to errors occurring in the production equipment 10 constituting the FA system. The error processing system 100 is provided with the production facility 10, PLC20, GOT30 (an example of an interface device), the error database 40, and the AP server 50 (application server).

There are a plurality of production facilities 10 , and PLC 20 and GOT 30 are provided for each production facility 10 . Between the production equipment 10 and the corresponding PLC20, between the PLC20 and the corresponding GOT30, between each GOT30 and the error database 40, and between the error database 40 and the AP server 50 are respectively connected via a network. The communication traffic between each GOT30 and the error database 40, and the network between the error database 40 and the AP server 50 may be limited to a predetermined value or less.

FIG. 2 is a functional configuration diagram of GOT 30 and error database 40 according to the first embodiment.

GOT 30 includes a message storage unit 31 , an error code acquisition unit 32 , a database search unit 33 , an internal search unit 34 , and a display unit 35 .

The error database 40 includes an error information storage unit 41 .

FIG. 3 is a diagram showing information stored in the message storage unit 31 according to the first embodiment.

The message memory|storage part 31 is the memory|storage device which GOT30 has inside, and has memorize|stored an error message. The message storage unit 31 stores an error message for each error code. The error code is the identifier of the error that occurred. The error message is information that simply shows the content of an error that occurred.

FIG. 4 is a diagram showing information stored in the error information storage unit 41 according to the first embodiment.

The error information storage unit 41 is a storage device that stores error messages and the like. The error information storage unit 41 stores an error message and action information for each of the device ID, language, and error code. The facility ID is an identifier of the production facility 10 . language is the identifier of the description language of the error message. Error codes and error messages are as above. The action information is information that is used as a reference every time an error is dealt with, such as what kind of action is to be taken with respect to an error that has occurred.

FIG. 5 is a flowchart showing the processing of the error handling system 100 according to the first embodiment.

An error occurs in the production facility 10 (S101). PLC20 detects the error which occurred in the production facility 10 (S102). Since the PLC 20 is a device for controlling and monitoring the operation of the production facility 10 , if an error occurs in the production facility 10 , it can be easily detected.

Then, the error code acquisition part 32 of GOT30 acquires the error code corresponding to the error which occurred from PLC20 (S103). The error code acquisition part 32 monitors the internal memory of PLC20, and can detect that PLC20 detected an error. Moreover, the error code acquisition part 32 can acquire the error code which shows the error which PLC20 detected from PLC20.

When the error code acquisition unit 32 acquires the error code, the database search unit 33 searches the error information storage unit of the error database 40 using the equipment ID of the production equipment 10 connected via the PLC 20, the language for displaying the error message, and the error code as keywords. 41 (S104). Moreover, the language which displays an error message is set by the user etc. of GOT30.

As a result of the search, when there is a record corresponding to the keyword (Yes in S104), the database search unit 33 acquires an error message and action information from the record (S105). Then, the display unit 35 displays the error message and action information acquired by the database search unit 33 ( S107 ).

On the other hand, when there is no record corresponding to the keyword as a result of the search (none in S104), the internal search unit 34 searches the message storage unit 31 using the error code as a key and acquires an error message (S106). . Then, the display unit 35 displays the error message acquired by the internal search unit 34 (S107).

FIG. 6 is a diagram showing an example of a screen displayed on the display unit 35 .

The display unit 35 displays various measured values 351 related to the production facility 10 , switches 352 for operating the production facility 10 , and the like in normal times. In S107 , the display unit 35 displays an error message in the message display field 353 in addition to the information displayed at normal time.

In addition, the administrator of the error processing system 100 appropriately maintains the error information storage unit 41 of the error database 40 via the AP server 50 .

FIG. 7 is a diagram showing an example of a maintenance screen of the error information storage unit 41 .

On the maintenance screen, a list of information stored in the error information storage unit 41 is displayed. The manager updates the information by selecting the information to be maintained, correcting the information and pressing the update button. In addition, the manager presses the register button to display a column for adding a new error code, and to add information related to the new error code.

The communication traffic of the network between each GOT30 and the error database 40 may be restricted below predetermined|prescribed. In this case, each GOT 30 cannot extract all the data from each GOT 30 and register it in the error database 40 every time the data of the error code and the error message are managed in each GOT 30 to the unified management by the error database 40 . Therefore, it is difficult to transfer data to the error database 40 at one time.

In the error handling system 100 of Embodiment 1, regarding the error code stored in the error database 40, the GOT 30 outputs the error message acquired from the error database 40, and outputs the error message obtained in the error database 40 for the error code not stored in the error database 40 in the GOT 30. The error message stored in . Therefore, in the error processing system 100 according to the first embodiment, the data stored in the GOT 30 can be continuously utilized while the data can be gradually transferred to the error database 40 and transferred to centralized management.

Sometimes trainees and others come to the factory from overseas. In such a case, it is necessary to temporarily switch the display language of the error message.

In the error processing system 100 according to Embodiment 1, it is possible to switch the display language for the error messages registered in the error database 40 . Therefore, also in the error processing system 100 of Embodiment 1, it is possible to easily cope with switching of the display language of a temporary error message.

Usually, when maintaining GOT30, it is necessary to stop the production line including the production facility 10 in which GOT30 was installed. Therefore, the time during which maintenance of GOT30 can be performed is very limited.

After the error database 40 is imported, there is no need to maintain the message storage unit 31 of the GOT 30 in principle. Therefore, maintenance of error messages becomes easy. Also, there is no need to stop the production line in order to maintain error messages.

In addition, the input/output device of GOT30 is a normal touch panel, does not have the keyboard which is hardware, and has only the keyboard which is software. Therefore, in GOT30, the operation|work of inputting characters, such as an error message, imposes a heavy load on a worker.

After the error database 40 is imported, there is no need to maintain the message storage unit 31 of the GOT 30 in principle. Therefore, the load on the worker is also reduced at the same time.

In the error database 40, disposition information is also stored together with error messages. Then, when displaying the error message acquired from the error database 40, GOT30 also displays the handling information together. By displaying the action information, it is possible to shorten the time it takes for an operator to deal with an error that has occurred.

As described above, in Embodiment 1, the data can be gradually transferred to the error database 40 and transferred to unified management. Ability to flesh out error messages. In addition, if error messages requiring items (language, action information, etc.) not in the message storage unit 31 are preferentially registered, useful information can be provided with little effort.

Implementation mode 2.

In Embodiment 2, the method which can perform maintenance of an error message efficiently is demonstrated.

In Embodiment 2, the description will focus on parts different from Embodiment 1. FIG.

When shifting to unified management of data based on the error database 40 , it may be registered in the error database 40 sequentially while checking the data stored in each GOT 30 . However, in the FA system, production of products is prioritized, and operators are so busy that they hardly care about the fact that the processing related to error messages is true. Therefore, a configuration is required to preferentially register error messages that really need to be registered in the error database 40 in the error database 40 .

FIG. 8 is a functional configuration diagram of GOT 30 and error database 40 according to the second embodiment.

The functional structure of GOT30 is the same as GOT30 of Embodiment 1 shown in FIG. The error database 40 includes a history storage unit 42 and a history output unit 43 in addition to the functions of the error database 40 according to Embodiment 1 shown in FIG. 2 .

FIG. 9 is a diagram showing information stored in the history storage unit 42 according to the second embodiment.

The history storage unit 42 is a storage device that stores information on errors that have occurred as a history. The history storage unit 42 stores error codes, device IDs, occurrence dates, restoration dates, and operator IDs. Error codes and device IDs are as above. The occurrence date is information indicating the date and time when the error occurred. The restoration date is information indicating the date and time when the error was eliminated. The worker ID is an identifier of the worker who used GOT30 when an error occurred.

FIG. 10 is a flowchart showing the processing of the error handling system 100 according to the second embodiment.

The processing from S201 to S204 is the same as the processing from S101 to S104 shown in FIG. 5 .

If the search is performed in S204, the history storage unit 42 of the error database 40 uses the date and time of receiving the keyword as the date and time of occurrence, and associates the device ID and error code as the keyword with the operator ID of the GOT 30, and stores for history (S205). In addition, the operator ID is registered in GOT30 at the time of use of GOT30, and is sent together when sending a keyword to the error database 40. In addition, here, regardless of whether there is a record corresponding to the keyword as a result of the search in S204, the history of all error codes searched in S204 (that is, all error codes acquired in S203) is stored.

The processing from S206 to S208 is the same as the processing from S105 to S107 shown in FIG. 5 .

Referring to the error message or the like displayed in S208, the operator handles the error, and the error is eliminated. Then, the operator presses the recovery button etc. which GOT30 has and the input error was eliminated, and notifies PLC20 that an error was eliminated (S209). At this time, information that the reset button was pressed is also sent to the error database 40 . The history storage unit 42 of the error database 40 stores the date and time when the message that the reset button was pressed is received as the reset date and time in a record storing the corresponding device ID, error code, and occurrence date and time (S210).

The history output unit 43 outputs the history stored in the history storage unit 42 to the AP server 50 upon receiving an instruction from the administrator of the error processing system 100 via the AP server 50 . The administrator maintains the error information storage unit 41 via the AP server 50 referring to the output history.

For example, the history output unit 43 extracts an error code not stored in the error information storage unit 41 among error codes included in the history, and outputs it together with the device ID stored in the same record as the error code. Thereby, the administrator can know the error code indicating the error that actually occurred among the error codes not stored in the error information storage unit 41 . Regarding an error that actually occurred, it is considered that the probability of occurrence is higher than other errors, so the error code indicating the error should be maintained with priority, and an appropriate error message or action information should be registered, for example.

Also, for example, the history output unit 43 calculates the restoration time required for restoration based on the date of occurrence and the restoration date, and outputs the restoration time together with the device ID and the like. The prolongation of recovery time may be caused by the operator not knowing how to deal with it. Therefore, the error code indicating an error that takes a long time to recover is an error code that should be maintained with priority, and an appropriate error message or action information, for example, should be registered.

In addition, the history output unit 43 may arrange and output the history in order of restoration time. In addition, the history output unit 43 may output only the information that the restoration time is equal to or greater than the reference time.

As described above, in the error processing system 100 according to Embodiment 2, the history of errors that have occurred can be stored in advance, and error messages and the like can be maintained with reference to the history. Therefore, error messages that really need to be registered in the error database 40 can be preferentially registered in the error database 40 .

In the case of registering an error message in the error database 40 , a more appropriate error message is registered, and disposition information is also registered. Therefore, the recovery time can be shortened by referring to the error message registered in the error database 40 rather than referring to the error message registered in the GOT 30 . Therefore, by preferentially registering error messages that need to be registered in the error database 40, the recovery time can be shortened, and the work efficiency of the production line can be improved.

In addition, the worker ID of the worker who actually dealt with the error is included in the history. Therefore, when registering an error message such as an error code that takes a long time to restore, the administrator may also register the operator ID in the action information. As a result, when the same error occurs later, the operator who actually handled the error can be identified from the operator ID, so the operator who actually handled the error can learn how to deal with it.

In addition, the history storage unit 42 may further store "worker's action information" indicating the content of action taken by the operator.

For example, after the reset button is pressed in S209, the operator's action information may be selected from the menu in advance, and the selected result may be stored in the history storage unit 42 as the operator's action information. In addition, in the menu, “Others” may be selected, and when “Others” is selected, the operator's action information may be input from another AP server 50 .

When maintaining error messages and the like with reference to the history, more appropriate error messages and action information can be created by referring to action information of actual workers.

Implementation mode 3.

In Embodiment 3, a method of automatically registering an error message will be described.

In Embodiment 3, the description will focus on parts different from Embodiment 2. FIG.

As described in Embodiment 1, the network between each GOT 30 and the error database 40 may be limited in communication traffic. Therefore, it is difficult to extract all the error codes and error messages from each GOT 30 via the network and register them in the error database 40 . However, as described in Embodiment 2, in the FA system, production products are prioritized, and it is true that workers are so busy that they hardly care about processing related to error messages. Therefore, there is a need for a structure that automatically registers necessary error messages in the error database 40 while satisfying the limitation of communication traffic.

FIG. 11 is a functional configuration diagram of GOT 30 and error database 40 according to the third embodiment.

GOT30 is equipped with the message storage part 36 other than the function with which the GOT30 of Embodiment 2 shown in FIG. 8 has. The functional configuration of the error database 40 is the same as that of the error database 40 in Embodiment 2 shown in FIG. 8 .

FIG. 12 is a flowchart showing the processing of the error handling system 100 according to the third embodiment.

The processing of S301 to S307 and S309 to S311 is the same as the processing of S201 to S210 shown in FIG. 10 .

In S307, when the internal search unit 34 has acquired an error message, the message storage unit 36 stores the acquired error message in the error information storage unit 41 of the error database 40 (S308). At this time, the message storage unit 36 stores the error message in association with the error code or the like used as a key in S304.

As described above, in the error processing system 100 according to Embodiment 3, when the error code and error message of an error that actually occurred are not stored in the error database 40 , the error code and error message are stored in the error database 40 .

As described in Embodiment 2, it is considered that errors that actually occurred are more likely to occur than other errors. Therefore, it is effective to preferentially register error codes and the like of errors that actually occurred in the error database 40 .

In particular, in the error handling system 100 of Embodiment 3, when an error actually occurs, the error code and error message are stored in the error database 40 . Therefore, it is possible to avoid the temporary concentration of communication traffic and satisfy the limitation of communication traffic.

Fig. 13 is a diagram showing an example of the hardware configuration of GOT 30, error database 40, and AP server 50 shown in Embodiments 1 and 2.

Each device of GOT30, error database 40, and AP server 50 is a computer. Each element of each device can be realized by a program.

As a hardware configuration of each device, an arithmetic device 901 , an external storage device 902 , a main storage device 903 , a communication device 904 , and an input/output device 905 are connected to a bus.

The computing device 901 is a CPU (Central Processing Unit: Central Processing Unit) or the like that executes programs. The external storage device 902 is, for example, a ROM (Read Only Memory), a flash memory, a hard disk device, or the like. The main storage device 903 is, for example, RAM (Random Access Memory: Random Access Memory) or the like. The communication device 904 is, for example, a communication board or the like. The input/output device 905 is, for example, a mouse, a keyboard, a display device, and the like.

The program is usually stored in the external storage device 902 , loaded into the main storage device 903 , and sequentially read and executed by the computing device 901 .

The program is a program that realizes the functions described as the error code acquisition unit 32 , the database search unit 33 , the internal search unit 34 , the display unit 35 , and the history output unit 43 .

Furthermore, an operating system (OS) is also stored in the external storage device 902 , at least a part of the OS is loaded into the main storage device 903 , and the computing device 901 executes the above-mentioned program while executing the OS.

In addition, in the description of Embodiment 1, it was explained that the information stored in the message storage unit 31 , the error information storage unit 41 , and the history storage unit 42 is stored as a file in the main storage device 903 .

In addition, the structure of FIG. 13 is only an example of the hardware structure of each device, and the hardware structure of each device is not limited to the structure shown in FIG. 13, and other structures are also possible.

Claims (6)

1. An error handling system, equipped with production equipment, the PLC that controls the production equipment can be a programmable logic controller, the HMI as the PLC is the interface device of the human-machine interface, and an error database, and is carried out in the production process. The processing related to the error occurred in the device is characterized in that, The error database includes an error information storage unit that stores a message indicating the content of the error for each error code, The interface device has: a message storage unit that stores a message indicating the content of the error for each error code; an error code acquisition unit that acquires an error code of an error that occurred in the production facility; a database search unit for searching the error information storage unit by using the error code acquired by the error code acquisition unit as a key to obtain a message; An internal search unit configured to search the message storage unit using the error code acquired by the error code acquisition unit as a key to acquire a message when the database search unit cannot acquire the message; and A display unit that displays the messages acquired by the database search unit and the internal search unit. 2. The error handling system according to claim 1, wherein: The error information storage unit stores a message and action information indicating an error handling method for each error code, The database search unit acquires the message and the handling information, The display unit may also display the action information when displaying the message acquired by the database search unit. 3. The error handling system according to claim 1, wherein: The error database also has: a history storage section that stores, as a history, an error code used as a key by the database retrieval section; and A history output unit that outputs the error codes stored in the history storage unit. 4. The error handling system of claim 3, wherein: The history output unit outputs only error codes not stored in the error information storage unit among the error codes stored in the history storage unit. 5. The error handling system according to claim 3, wherein: The interface device further includes a recovery time measurement unit that measures a recovery time from occurrence of the error to elimination of the error, the history storage unit stores the recovery time measured by the recovery time measuring unit together with an error code, The history output unit outputs the error code and the recovery time. 6. The error handling system of claim 1, wherein: The interface device further includes a message storage unit for associating the error code acquired by the error code acquisition unit with the message retrieved by the internal search unit when the message cannot be acquired by the database search unit. Get up and store in the error information storage unit.