JPH07104838A - Operation managing system - Google Patents

Abstract

PURPOSE:To automatically and surely collect operation data by inhibiting the decision of transition between operating states excepting for the specified operating state for eliminating the error of operation management. CONSTITUTION:According to an operated result collection program, a processor 20 for operation management monitors facility operating conditions through transmission/reception interfaces 25 and 10A at all times for each scan of a sequencer 10. Namely, a sampling means for sampling the operating conditions of a facility 11 corresponding to the transition information of an operating state grasping means composed of the sequencer 10 is provided in the manner of a software, with this means, sampling for operation analysis is performed, and the operated results of the facility are collected. Next, the processor 20 for operation management decides the operating state by providing a transition deciding means for detecting the transition between the provided states in the manner of the software. However, a decision inhibiting means is provided in the manner of the software so as to inhibit the decision of transition between the operating states excepting for the specified operating state, and the inhibition is performed through the operating state under automatic operating without fail.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an operation management system for a production line such as an automobile assembly line.

[0002]

2. Description of the Related Art In recent years, in a production line such as an automobile assembly line, there is an increasing number of cases where a dedicated operation analysis system is introduced for each line to automatically perform operation analysis.

In such a case, as a failure diagnosis method related to sequence control, a reference operation mode for the constituent elements of the sequence control circuit unit has been set in advance, as in Japanese Patent Laid-Open No. 60-238906. There is a failure diagnosis method in which the operation mode of the components of the sequence control circuit unit during actual operation of the facility is compared with the reference mode, and abnormality of the facility is detected based on the comparison result.

Regarding the equipment in the production line,
When a failure occurs and the output actuating element does not operate, the actuating step relating to the actuating element causing the failure is specified, and further, the cause of failure of the actuating elements related to the specified actuating step. There is also proposed a production line failure analysis method for quickly and properly identifying the above (see Japanese Patent Laid-Open No. 4-111729).

[0005]

However, the equipment evaluation is usually done manually, and the number of man-hours required for operation analysis is increasing with the complexity of equipment control. For this reason, in existing equipment, it is necessary for a person to stick to the equipment for several days to monitor the operation status of the equipment (data collection) in order to grasp the operation status of the equipment, and a great number of man-hours are spent for collecting the operation data.

[0006] In addition, even in the case of new equipment, it is possible to deal with it by constructing a network and introducing an operation analysis system, but in addition to becoming a costly system,
Normally, after installing all the equipment, a network is constructed, so after all the equipment is started up, the operation data of the equipment is collected manually, and it takes a lot of time to start up the equipment. Is.

Further, although the equipment has many operating states,
If the transitions among all the operating states are set as the determination target, the operation management content may be unintended.

For example, when the equipment is stopped due to some abnormality, the worker may push the emergency button. However, in such a case, data that should have been stopped due to an abnormality should be collected, and collecting data that was stopped due to an emergency stop may prevent accurate operation analysis. , It makes automatic operation analysis impossible.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above problems and provide an operation management system capable of automatically carrying out operation analysis in all individual facilities regardless of existing facilities or new facilities.

[0010]

In order to achieve the above object, the present invention is an operation management system in which an operation management processing device is connected to equipment having a plurality of operation states, and the actual operation state transitions to the equipment side. While the operating state grasping means for detecting the state and detecting the state is provided, the operation management processing device side collects the operating state of the equipment in accordance with the transition information of the operating state grasping means, and the sampling means A transition determining unit that detects a transition between the operating states that have been set and a determination inhibiting unit that inhibits the transition determination between operating states other than the specific operating state in order to eliminate an error in operation management are provided. Claim 1).

In this case, the operating state includes at least each of the states of automatic operation, abnormal stop, and emergency stop, and the determination prohibiting means sets the automatic operation to a specific operating state and makes only transition determination through this. The configuration can be allowed (claim 2).

Further, the operation management processing device can be provided with a means for outputting the timing at which the maintenance operation status has changed and each operation status to a performance collection file (claim 3).

Further, the transition judging means can judge the operating state according to the equipment state judging matrix table (claim 4).

Further, the operation management processing device can be provided with means for analyzing detailed factors thereof when determining an abnormal stop (claim 5).

[0015]

According to the present invention, the operating state grasping means on the equipment side detects the transition of the actual operating state of the equipment and grasps the state, while the operation management processing device connected thereto detects the operating state. The operating status of the equipment is sampled in correspondence with the transition information of the means, and the transition between the operating statuses obtained by sampling is determined. At that time, the judgment prohibition means
In order to eliminate the error of operation management, the transition judgment between the operation states other than the specific operation state is prohibited. Therefore, it is possible to automatically collect reliable operation data. As a result, it is possible to perform general-purpose operation analysis on all facilities, whether existing or new.

In addition to being able to accurately collect the operating results of the equipment, it is also possible to collect the operating status on the time axis, which could not be collected by humans. Further, since it is possible to automatically perform the operation analysis of the equipment operation and non-operation in a short period, it is possible to significantly reduce the operation analysis time when the conventional equipment is started.

According to a second aspect of the present invention, the operating state includes at least the states of automatic operation, abnormal stop, and emergency stop. Among them, the automatic operation is set as a specific operation state, and transition through this state. Allow only judgment. Therefore,
For example, the transition from the abnormal stop state to the emergency stop state will not be established suddenly, and automatic and reliable operation data can be collected.

In the third aspect, the timing (for example, date and time data) when the maintenance operation state changes and each operation state are output to the result collection file. Therefore, the operation analysis processing can be performed by utilizing the data of the result collection file as any commercially available software data.

In the present invention, since the transition judging means applies the equipment condition judging matrix table to judge the operating condition, the judgment result can be easily obtained.

According to the present invention, in the case of the abnormal stop state, detailed factors thereof are analyzed, and for example, detailed abnormality contents are sampled and output to the result collection file, so that the operating state can be managed more accurately. .

[0021]

An embodiment of the present invention will be described in detail below with reference to the accompanying drawings. Figure 1 is an application example of the operation management system,
The operation management system 1 is a sequencer (sequence control unit PLC) installed in the factory for each production line.
The operation management processing device 20 composed of, for example, a laptop computer is switched to and connected to the computer 10 in a one-to-one manner, and information on five types of operating states representing the states of the sequencer 10 is collected according to the built-in operating result collection program 29. Is configured to.

As shown in FIG. 4, the information on the five types of operating states includes automatic operation (P), automatic stop (S), waiting for preceding and following steps (W), abnormal stop (A), and emergency stop. (E) The information on which of the five states is described.

As shown in FIGS. 1 and 2, for the operation management system 1, a tag table file 3 to be described later is created in an office or the like outside the factory, for example, by a desktop personal computer 2, and a floppy disk or the like is created. The recording medium 4 is brought into the factory and is input to the operation management processing device 20. In the factory, the operation management processing device 20 is used by switching to the sequencer 10 of the production line on a one-to-one basis. The operation information collected by the operation management processing device 20 is stored in the recording medium 5 such as a floppy and carried out,
Operation and failure analysis are performed by the desktop PC 2 at an office outside the factory.

(1) Basic Configuration of System FIG. 3 shows the configuration of the operation management system 1. 11 is
One of the many production line facilities installed in the factory
1 is representatively shown, and each production line facility 11 is composed of n devices D1 to Dn (usually 100 to 200 units).

The operation management processor 20 is the bus line 2
Central processing unit (CPU) 2 connected through 1
2, a memory 23, an input / output interface (I / O interface) 24, and a transmission / reception interface 25. Further, a hard disk device 26 as an auxiliary memory connected to the I / O interface 24, a display (CRT). A device 27 and a keyboard 28 for entering data and control codes are provided.

Currently, R of the transmission / reception interface (communication board) 25 of the operation management processing device 20
The S232C port is connected to a specific one transmission / reception interface (communication board) 10A of the sequencer (PLC) 10 via an RS232C serial line (RS232C communication cable) 12 to enable bidirectional communication. ing. Therefore, the above D1
The symbols Dn to Dn indicate individual devices that constitute one production line facility 11 to which the operation management processing device 20 is currently connected.

The sequencer 10 functions as a means for grasping the operating state of the production line facility 11, and as shown in FIG. 4 as a facility state determination matrix, the operating state of the facility that it is in charge of is automatically running (P), It is defined by five states of automatic stop (S), waiting before and after process (W), abnormal stop (A), and emergency stop (E), and these state changes are turned on and off (logic "1") of the corresponding address bit. "," 0 ") transition information.

Here, the automatic operation (P), the waiting for the preceding and following steps (W), and the abnormal stop (A) are the automatic operation states without human intervention, and the automatic operation (P) is literally the automatic operation state. Waiting for front and rear process (W) means a state in which the previous work does not flow, and abnormal stop (A) means a state in which the machine side automatically stops due to lack of parts, abnormality of solenoid, air down, etc. In addition, automatic stop (S) and emergency stop (E) are when a person intervenes, and automatic stop (S) is an emergency stop (E) when a person uses the automatic stop function to stop the machine during lunch breaks. ) Means when a person stops in an emergency.

On the other hand, the operation management processing unit 20 displays the above-mentioned equipment operation status (P / S / W / A / E) via the transmission / reception interfaces 25 and 10A according to the operation result collection program 29 (FIG. 1). Sequencer (PLC) 10
The data is constantly monitored (scanned) for each scan. That is, the software has a sampling means for sampling the operation status of the equipment 11 in correspondence with the transition information of the operation status grasping means composed of the sequencer 10, and by this, sampling for operation analysis is performed and the operation record of the equipment is obtained. Collect (step (d) in FIG. 2). Then, the timing (date and time data) at which the operating state has changed and the operating state are output to the performance collection file 6 (step (e) in FIG. 2). It should be noted that the operation management processing device 20 is equipped with a means for analyzing detailed factors thereof when it is determined to be an abnormal stop (A), and is in the abnormal stop (A) and emergency stop (E) states. , The detailed abnormality content is sampled and output to the performance collection file 6.

Next, the operation management processing device 20 has a transition judging means for detecting the transition between the obtained states by software, and judges the operating state. This equipment operation state determination follows the equipment state determination matrix table of FIG. However,
A determination prohibiting unit that prohibits transition determination between operating states other than the specific operating state is provided by software, and the operating state transition method follows the equipment operating state transition diagram of FIG.

That is, in FIG. 5, the transition arrow 31 indicates from automatic operation (P = 1, E = W = A = S = 0) to automatic stop (S = 1, P = E = W = A = 0). The transition arrow 32 indicates that the automatic stop (P = 1, E = W = A = S = 0) to an abnormal stop (A = 1, P = W = 0) or an emergency stop (E =
1, P = W = 0), the transition arrow 33 indicates from the automatic operation (P = 1, E = W = A = S = 0) to the waiting for the preceding and following processes (W = 1, E = A = 0) Represents the transition to. The transition arrow 41 indicates the transition from the automatic stop (S = 1, P = E = W = A = 0) to the automatic operation (P = 1, E = W = A = S = 0). Indicates an automatic stop (P = 1) from an abnormal stop (A = 1, P = W = 0) or an emergency stop (E = 1, P = W = 0)
= 1 and E = W = A = S = 0), the transition arrow 43 indicates from the waiting for the preceding and following steps (W = 1, E = A = 0) to the automatic operation (P = 1, E = W = A =). Represents a transition to S = 0).

Considering the transition states between the states simply from the matrix table of FIG. 4, the transition between the automatic stop (S) and the abnormal stop (A) or the emergency stop (E), the waiting for the preceding and following steps (W ) And the abnormal stop (A) or the emergency stop (E), and the automatic stop (S) and the waiting for the preceding and following steps (W). However, these transitions are prohibited in order to collect correct data on the operating status of the equipment.

As described above, the characteristic feature is that the transition from one transition state to another transition state is always performed with the transition state during the automatic operation (P) being interposed. In other words, the equipment operating state transition method is applied to the equipment operating state transition diagram, but as can be seen from the figure, the operating state transition is
You can only transition from the automatic driving (P) state,
As for the transition from other states, only the transition to the automatic driving (P) state is permitted.

For example, it means that the transition from the abnormal stop (A) state to the emergency stop (E) state is not suddenly established. This means that if the transition to all operating states is allowed, for example, if the equipment is stopped due to some abnormality, if the worker presses the emergency button, the state that was originally stopped due to abnormality is data. Although it should be collected, it may be stopped due to an emergency stop, and accurate operation analysis may not be possible.

As for the timing of performing the operation analysis (sampling), when the set time of the operation analysis conditions and the number of production are reached, the operation status (P / S / W / A / E) of the equipment is automatically monitored (sampling). It is supposed to start. Sampling is always performed for each scan of the sequencer (PLC) 10. Basically, the operating state and date and time data are output to the performance collection file 6 each time the operating state of the equipment changes. In particular,
Only five operating states (P / S / W / A / E) of the above equipment are constantly monitored, and detailed abnormality contents are sampled only when the representative abnormal stop (A) address is turned on. As a result, the sampling time can be shortened and an instantaneous change in the operating state of 0.5 Sec or more can be tracked. Then, this sampling ends when the end time set on the operating condition setting screen is reached or when the number of finished production units is reached. However, the sampling can be forcibly ended by pressing the forcible end key provided on the sampling screen.

FIG. 6 shows a concrete equipment operation analysis flow chart. First, by communicating with the sequencer 10, P / S /
The ON / OFF state of the W / A / E address is fetched as data (step (1)).

ON / OF of P / S / W / A / E address
According to the F state, it is determined whether or not it is the P state by the equipment state determination matrix, and if YES, the P state flag is set and the other state flags are reset (steps (2), (3)).
).

Next, it is determined whether the P state has changed to another S, W, A or E state. That is, P status flag = 1
Under the condition of (step (4)), when it is judged to be the S condition, the S condition flag is set (other condition flags are reset) (steps (5), (6)), and when it is judged to be the W condition. Is W
The status flag is set (other status flags are reset) (steps (7), (8)), and when it is determined to be the A status, the A status flag is set (other status flags are reset) (steps (9), (10)) If the E state is determined, the E state flag is set (other state flags are reset) (steps (11), (12)). Then, the program is terminated after waiting for a determination (step (13)) as to whether the operation analysis is to be terminated.

(2) Tag table file By the way, the operating status of the above equipment (P / S / W / A / E)
In monitoring the above, first, it is necessary to preset in advance which address of the PLC each operating state corresponds to. However, as a matter of course, the address of the sequencer (PLC) 10 indicating the operating state differs depending on the equipment. Therefore,
The PLC address which is different for each equipment is separately set in the data file (tag table file) 3, and the program 29 is configured to read and operate when necessary, thereby realizing the generalization of the system.

In the case of this embodiment, the tag table file 3
In addition to the address setting indicating the five operating states of the sequencer (PLC) 10, detailed abnormal addresses and their abnormal contents are individually set for the abnormal stop (A). As a result, the detailed abnormality content is sampled only when the representative abnormal stop (A) address is turned on. Also, on the equipment side, B
Regarding the abnormal address used in the contact, it is dealt with by making a B contact expression after the comment of the abnormality content.

Next, the procedure of the operation analysis considering this tag table will be described according to the procedures (a) to (f) shown in FIG.

(A) Tag table selection Since the tag table file 3 is created individually for each piece of equipment, it is necessary to select the tag table file of the piece of equipment to be actually analyzed from a plurality of tag table files. Therefore, as shown in step (a) in FIG. 2, the operation management processing device 20 is provided with a selection screen for a plurality of tag table files 3 so that the tag can be freely selected according to the equipment for which operation analysis is performed. ing.

(B) Tag table address check Further, in order to determine whether the address setting of the selected tag table file 3 is actually used on the equipment side (PLC), it is shown in step (b) in FIG. As described above, the address check function of the tag table is provided. Actually, the address set in the tag table is read from the file 3 and is confirmed by communicating with the PLC, thereby preventing the collection error of the operation result data in advance.

(C) Setting of operating analysis conditions On the setting screen of operating analysis conditions, it is possible to set the sampling start timing and the end timing of the operating state of the equipment so that the operating analysis can be performed only when necessary. There are two setting methods, one for setting the date and time and one for setting the number of production units. As a result, even if a person does not start the system, it can be automatically started, and it is possible to support nighttime operation analysis. In addition, the file name of the performance collection file 6 (FIG. 2) that outputs the operating status of the equipment can be set on this setting screen, which facilitates the management of the performance collection file 6.

(D) Operational analysis (sampling) This is based on the already described above.

(E) Actual result collection file When sampling is started, first of all, in the actual result collection file 6, the line name, equipment name, PLC set in the tag table file 3 as equipment information is set.
The name is written. Then, the sampling start date and the set value of the start time set on the operation analysis condition setting screen and the date and time when the sampling actually starts are output to the actual result collection file. After that, each time the operating state of the equipment changes, the operating state, date, and time are output. However, only when the operating state is abnormal stop (A) or emergency stop (E), detailed comment of the abnormal content is output in addition to the date and time data. When the sampling end timing comes, the end date, the end time, the date and time when the sampling actually ends, the set value and the actual value of the number of production units at the start and end of the sampling are output, and the file is closed. .

(F) Analysis file for commercial software As described above, the performance collection file 6 is a raw data file that only outputs the timing when the operating state of the equipment has changed, and this data will be used in the future. A new system for operation analysis processing can be freely developed. However, here, the analysis contents are not fixed, and in order to allow analysis freely according to the purpose at that time, commercially available application software, for example, Lotus (trade name) is used for the analysis. Actually, the Lot which calculated the stop time etc. so that the result collection file 6 could be easily analyzed.
The result of conversion into a us analysis file is shown in FIG. 2 as a commercial software analysis file 7.

The system configuration of the embodiment described above has the following features. (1) Operation analysis can be performed universally for all equipment, whether existing or new. (2) Also, a computer for operation analysis is a portable notebook computer, which is a sequencer 10 and an R.
Since the system can be constructed simply by connecting with the S232C cable, the operation results can be easily collected.
That is, the operation analysis can be performed by setting it in the equipment only when necessary, and when the operation analysis is not performed, it can be easily removed from the equipment and set in another equipment to perform the operation analysis statement. Therefore, it is not necessary to have a plurality of operation analysis systems in the factory, which leads to a reduction in investment. (3) In addition to being able to accurately collect equipment operation records,
It is also possible to collect operating conditions that could not be collected by humans. (4) Operation analysis of equipment operation and non-operation can be automatically performed in a short period, and the operation analysis time can be significantly shortened.

[0049]

In summary, according to the present invention, the following excellent effects can be obtained. (1) According to claim 1, the operation management processing device connected to the operation state grasping means on the equipment side samples the operation state of the equipment and determines the transition between the operation states. Moreover, in order to eliminate the error of the operation management, the transition judgment between the operation states other than the specific operation state is prohibited. Therefore, it is possible to automatically collect reliable operation data. As a result, whether existing or new,
Operation analysis can be performed universally in all facilities. Further, in addition to being able to accurately collect the operational results of the equipment, it is also possible to collect the operational status on the time axis, which could not be collected by humans. Further, since it is possible to automatically perform the operation analysis of the equipment operation and non-operation in a short period, it is possible to significantly reduce the operation analysis time when the conventional equipment is started.

(2) According to claim 2, the operating state includes at least each of the states of automatic operation, abnormal stop, and emergency stop. Of these, only transition determination through the automatic operation is permitted. To be done. Therefore, for example, the transition from the abnormal stop state to the emergency stop state is not established in data collection, and automatic and reliable operation data can be collected.

(3) According to claim 3, the timing at which the maintenance operation state changes and the respective operation states are output to the performance collection file, so this data can be utilized to perform the operation analysis processing. .

(4) According to the fourth aspect, since the transition judging means applies the equipment state judging matrix table to judge the operating state, the judgment result can be easily obtained.

(5) According to claim 5, in the case of an abnormal stop state, detailed factors are analyzed, and for example, detailed abnormality contents are sampled and output to a performance collection file, so a more accurate operating state Can be managed.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing an application example of an equipment operation management system of the present invention.

FIG. 2 is a conceptual diagram showing an equipment operation management system according to an embodiment of the present invention.

FIG. 3 is a configuration diagram showing an equipment operation management system according to an embodiment of the present invention.

FIG. 4 is a diagram showing a matrix of operating states of equipment.

FIG. 5 is a diagram showing a transition of operating states of equipment.

FIG. 6 is a diagram showing a flow of operation analysis of equipment.

[Explanation of symbols]

1 Operation Management System 2 Desktop Computer 3 Tag Table File 4, 5 Recording Medium such as Floppy 6 Achievement Collection File 7 Commercial Software Analysis File 10 Sequencer 10A Transmission / Reception Interface (Communication Board) 11 Production Line Equipment 12 Serial Line (RS232C Communication Cable) ) 20 operation management processing device (notebook personal computer) 21 bus line 22 central processing unit (CPU) 23 memory 24 I / O interface 25 transmission / reception interface 26 hard disk device 27 display (CRT) device 28 data and control code input Keyboard 29 Operation performance collection program 31 to 33, 41 to 43 Transition arrows D1 to Dn n devices that compose one production line facility

Claims (5)

[Claims] 1. In an operation management system in which an operation management processing device is connected to equipment having a plurality of operation states, the equipment is provided with operation state grasping means for detecting transitions of actual operation states and grasping the states, On the operation management processor side,
Sampling means for sampling the operating status of the equipment in association with the transition information of the operating status grasping means, transition judging means for detecting the transition between the operating statuses obtained by sampling, and identification for eliminating error in operation management The operation management system is provided with a judgment prohibition unit that prohibits a transition judgment between operating states other than the operating state. 2. The operating condition is at least during automatic operation,
2. The operation management system according to claim 1, wherein the operation prohibition means includes an abnormal stop state and an emergency stop state, and the determination prohibiting means allows only the transition determination through the automatic operation as a specific operation state. . 3. The operation management according to claim 1 or 2, wherein the operation management processing device comprises means for outputting the timing when the operation status of maintenance has changed and each operation status to a performance collection file. system. 4. The operation management system according to any one of claims 1 to 3, wherein the transition judging means judges an operating state according to an equipment state judging matrix table. 5. The operation management system according to claim 1, wherein the operation management processing device comprises means for analyzing detailed factors of the abnormal stop when it is determined.