Information processing apparatus, control method, production system, manufacturing method, and medium

Abstract

The present disclosure relates to an information processing apparatus, a control method, a production system, a manufacturing method, and a medium. An information processing apparatus for displaying information on a state of a machine facility including a plurality of devices is provided. An operation time of an operation of a predetermined device among the plurality of devices and a signal related to the operation are displayed on the display unit.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an information processing apparatus. BACKGROUND

[0002] In a production line including a plurality of machine facilities controlled by a control apparatus such as a sequence controller, it is desirable to quickly and appropriately grasp the operation state of the machine facilities in order to perform maintenance on the machine facilities. Thus, a function is proposed that detects an operation deviating from a normal operation state by monitoring the operation state of the machine facilities, and notifies the result to a user. For example, Japanese Patent Application No. 2008-97096 discusses a monitoring system that records the on / off state of a signal of a sensor, an actuator, or the like installed on a machine facility when the machine facility is operated a predetermined number of times, and monitors the operation state of the machine facility based on the on / off state of each signal.

[0003] In order to monitor the operation state of the machine facilities by using the period from the timing at which the machine facilities start operation to the timing at which the signal of each device is turned on or off as described in Japanese Patent Application No. 2008-97096, it is necessary to teach the monitoring system the operation start timing of the machine facilities as a measurement reference of each signal. Further, in typical technology, control signals are simply displayed in a list form on a screen displaying the operation state of the machine facilities. Thus, it is necessary to check whether each component of the machine facilities is abnormal one by one in order to locate the abnormal point. Thus, it takes a long time to specify where and when an abnormality occurs in the machine facilities. SUMMARY

[0004] An embodiment of the present disclosure is directed to an information processing apparatus that enables easy grasping of the operation state of a machine facility.

[0005] According to an embodiment of the present invention, there is provided an information processing apparatus for displaying a state of a machine facility including a plurality of devices on a display unit. An operation time of an operation of a predetermined device among the plurality of devices and a signal related to the operation are displayed on the display unit.

[0006] Other features of the present disclosure will become apparent from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figure 1 is a control block diagram of a production system according to an exemplary embodiment.

[0008] Figure 2 is a schematic view of a production line according to an exemplary embodiment.

[0009] Figures 3A-3C is an operation flowchart of each unit according to an exemplary embodiment.

[0010] consisting of Figures 4A-4C consisting of Figure 4 is a diagram illustrating a process number and a control signal according to an exemplary embodiment.

[0011] Figure 5 is a table illustrating a list of used signals according to an exemplary embodiment.

[0012] Figure 6 is a table illustrating a list of determination conditions of a control signal according to an exemplary embodiment.

[0013] Figure 7 is a table illustrating a list of determination conditions of a process according to an exemplary embodiment.

[0014] Figure 8 is a diagram illustrating a state of a control signal in a process of an input unit according to an exemplary embodiment.

[0015] consisting of Figure 9A and 9B consisting of Figure 9 is a diagram illustrating an average value and a standard deviation of a measurement result of a control signal at an on / off timing of a control signal of each unit, and a determination threshold value at the on / off timing according to an exemplary embodiment.

[0016] Figure 10 is a diagram illustrating an example of a screen displayed on a display device by a display unit according to an exemplary embodiment.

[0017] Figure 11 is a diagram illustrating another example of a screen displayed on a display device by a display unit according to an exemplary embodiment.

[0018] Figure 12 is a diagram illustrating another example of a screen displayed on a display device by a display unit according to an exemplary embodiment.

[0019] Figure 13 is a control flowchart of a display unit according to an exemplary embodiment.

[0020] Figure 14 is a diagram illustrating still another example of a screen displayed on a display device by a display unit according to an exemplary embodiment.

[0021] Figure 15 is a diagram illustrating still another example of a screen displayed on a display device by a display unit according to an exemplary embodiment. DETAILED DESCRIPTION

[0022] Exemplary embodiments of the present disclosure will be described below with reference to the accompanying drawings. The exemplary embodiments described below are merely illustrative and, for example, the details of the configuration can be appropriately changed by those skilled in the art without departing from the spirit of the present disclosure. Furthermore, the numerical values described in the present exemplary embodiments are reference values and are not intended to limit the present disclosure.

[0023] A first exemplary embodiment of the present disclosure will be described below. Figure 1 is a control block diagram illustrating a production system 1000 including a production line 100 and a monitoring device 120 according to the present exemplary embodiment. The production line 100 includes a plurality of machines 101-103 that can be operated independently of each other. Each of the machines 101-103 includes a plurality of sensors, pneumatic devices, and robots. The machines 101-103 are sequentially controlled by a programmable logic controller (PLC) 110.

[0024] The monitoring device 120 includes a programmed general-purpose computer and includes a central processing unit (CPU), a random access memory (RAM), and a read only memory (ROM). The monitoring device 120 also includes a large-capacity nonvolatile storage device such as a memory and a disk device. The monitoring device 120 also includes a display device 150 such as a display and an input device 140 such as a mouse and a keyboard. The program portion of the monitoring device 120 is mainly configured by the CPU functioning as a control unit, and the functions of the control blocks included in the program portion are executed by the CPU. As a result, the monitoring device 120 functions as an information processing device.

[0025] Next, the transmission of information from the PLC 110 to the monitoring device 120 in Figure 1 The monitoring device 120 includes a program portion and a database portion. The programs in the program portion are divided into a program for monitoring the machines and a program for creating conditions for monitoring the machines. Information such as the process number 111 and the control signal 112 stored in the transmission area memory within the PLC 110 is transmitted from the transmission unit 113 of the PLC 110 to the reception unit 121 of the monitoring device 120. The information as the process number 111 and the control signal 112 indicates the history of the control performed by the PLC 110.

[0026] The process number 111 indicates a number that identifies the minimum operation unit of each unit (each machine 101-103 is regarded as a unit). For example, the opening operation of the chuck of the robot arm of the machine 101 is defined by the PLC 110 with a numerical value, such as the process number (1).

[0027] The control signal 112 indicates a signal output from the PLC 110 to control the machines 101-103. For example, the control signal 112 is used to inform the PLC 110 that a sensor installed on the corresponding machine 101-103 has detected a workpiece, and for the PLC 110 to instruct the machine 101-103 to start operation. The state of each control signal 112 is represented by on (1) or off (0). The recording unit 122 of the monitoring device 120 organizes the process number 111 and the control signal 112 received by the receiving unit 121 so as to be subsequently retrieved, and records the result in a database. The definition of the process number 111 and the recording of the control signal 112 described above are based on, for example, the definition specification of the process number 111 and the recording specification of the control signal 112 described in the step program to be referred to by the PLC 110.

[0028] Next, the analysis unit 123 and the determination creation unit 124, which are programs for creating conditions for monitoring the machines described above, will be described.

[0029] The analysis unit 123 automatically determines which signal is being used in each process of each unit included in the production line 100, based on information about the process number 130 and the control signal 131 in the database of the monitoring device 120. In addition, the analysis unit 123 records the determination result as a used signal list 132 in the database. Figure 5 ) records the determination result as a used signal list 132 in the database.

[0030] The determination creation unit 124 measures the variation of the operation time of each process in each unit, and determines a threshold value for determining whether the machine is operating normally, based on, for example, the maximum value and the minimum value thereof. After the threshold value of the normal / abnormal determination condition is determined for all processes, the determination creation unit 124 stores the determination result as a determination condition list 133 in the database.

[0031] Next, the determination unit 125 and the display unit 126, which are programs for monitoring the machines described above, will be described.

[0032] When the determination condition list 133 is created, the processing of the determination unit 125 is automatically started. More specifically, when the process number 130 and / or the control signal 131 is newly recorded in the monitoring device 120, the determination unit 125 determines the normality / abnormality of each control signal of each process based on the determination condition list 133. In the case where an abnormal signal exceeding the threshold value range of the determination condition is detected, the time of the occurrence of the abnormality and the sign of the signal for which the abnormality is detected are recorded as an abnormality history 134 in the database.

[0033] The display unit 126 has a function of notifying a worker of the occurrence of an abnormality and / or displaying the occurrence of the abnormality. When the abnormality history 134 is updated, the display unit 126 edits the abnormality history 134, the process number 130, the control signal 131, and the determination condition list 133 into a chart (described below) in which visibility is high, and displays the chart on the display device 150.

[0034] Figure 2 is a diagram schematically illustrating units in the production line 100 according to the present exemplary embodiment. Figures 3A-3C are flowcharts illustrating minimum operations (processes) in each unit, respectively. Figure 2 The production line 100 inincludes an input unit 203, a conveyor 204, an adhesive applying unit 207, and a discharge unit 209, which are machine units controlled by one controller (PLC). Each of these units performs predetermined work on the workpiece 201, thereby manufacturing an article. Figure 2 The input unit 203, the adhesive applying unit 207, and the discharge unit 209 in correspond to Figure 1 the machine A (101), the machine B (102), and the machine C (103) in

[0035] Next, the operations performed by each unit will be described with reference to Figure 2 and Figures 3A-3C Figure 3A The operation process of the input unit 203 is illustrated in Figure 3B The operation process of the adhesive applying unit 207 is illustrated in Figure 3C The operation process of the discharge unit 209 is illustrated in For simplicity of explanation, the description of the control of the conveyor 204 in conjunction with the flowcharts is omitted.

[0036] Referring to Figure 3A When the input tray 202 is set, the input unit 203 picks up the workpiece 201 on the input tray 202 and carries the workpiece 201 to the conveyor 204. In Figure 3A Process 1, the chuck 1 of the input unit 203 is clamped to grip the workpiece 201 on the input tray 202. Thereafter, in Process 2, the X-axis of the robot 1 of the input unit 203 is rotated. In Process 3, the chuck 1 is opened, thereby placing the workpiece 201 on the conveyor 204.

[0037] After the workpiece 201 is placed on the conveyer 204, it is determined in Step 4 whether the sensor 205 detects the workpiece 201. If the sensor 205 detects the workpiece 201, the operation of Step 4 becomes an ON state. In Step 5, in order to pick up the workpiece 201 again, the X-axis of the robot 1 is controlled so that the chuck 1 is moved above the input tray 202. At this time, the conveyer 204 is operated until the sensor 206 detects the workpiece 201. If the sensor 205 does not detect the workpiece 201 and the OFF state of the operation of Step 4 continues for a predetermined time, an error is notified.

[0038] Next, in Step 1 of Figure 3B , if the sensor 206 detects the workpiece 201, the operation of Step 1 becomes an ON state, and the adhesive applying unit 207 starts the work of applying adhesive to the workpiece 201. In Figure 3B , the operation of Step 1 is repeated during the OFF state of Step 1 until the sensor 206 detects the workpiece 201. Figure 3B

[0039] If the operation of Step 1 is in the ON state, in Step 2, the X-axis for controlling the dispenser of the adhesive applying unit 207 is moved forward, the dispenser is opened, and a predetermined amount of adhesive is applied to the workpiece 201. Thereafter, in Step 3, the X-axis for controlling the dispenser is moved back.

[0040] In response to the operation of Step 1 of Figure 3B being changed to the ON state, the input unit 203 performs Steps 1-3 of Figure 3A to pick up the next workpiece 201 from the input tray 202 and place the workpiece 201 on the conveyer 204.

[0041] Thereafter, in Figure 3C , after the work of applying adhesive by the adhesive applying unit 207 and the work of placing the workpiece 201 by the input unit 203 are both completed, the conveyer 204 conveys the workpiece 201. At this time, the conveyer 204 is continuously operated until the sensor 208 detects the workpiece 201 processed by the adhesive applying unit 207.

[0042] If the sensor 208 detects the workpiece 201, the operation of Step 1 of Figure 3C becomes the ON state, and the discharge unit 209 starts the work of storing the workpiece 201 in the discharge tray 210. At the same time that the discharge unit 209 starts the operation, the input unit 203 and the adhesive applying unit 207 start their respective works on the subsequent workpiece 201.

[0043] In Figure 3C ​If the sensor 208 detects the workpiece 201, the ejection unit 209 picks up the workpiece 201 on the conveyer 204 and carries the workpiece 201 onto the ejection tray 210. In Figure 3C In Step 2 in FIG. 10, the chuck 2 of the ejection unit 209 is clamped to grasp the workpiece 201 on the conveyer 204. In Step 3, the X-axis of the robot 2 of the ejection unit 209 is turned. In Step 4, the chuck 2 is opened to place the workpiece 201 on the ejection tray 210. In Step 5, the X-axis of the robot 2 is turned to move the chuck 2 above the conveyer 204 to pick up the workpiece 201 again. Unless the sensor 208 detects the workpiece 201, the operation of Steps 1 to 5 is repeated in the closed state. Figure 3C The operation of Step 1 in FIG. 10.

[0044] The above operation is repeated until all the workpieces 201 are emptied from the input tray 202. Here, a period during which each unit performs a corresponding operation on a single workpiece 201 is called a cycle. When the production line 100 starts the operation in a state where no workpiece 201 is placed on the conveyer 204, only the input unit 203 operates in the first cycle, the input unit 203 and the adhesive applying unit 207 operate in the second cycle, and all the units operate in the third cycle. In the third cycle and thereafter, each unit operates until all the workpieces 201 are emptied from the input tray 202.

[0045] When all the workpieces 201 are emptied from the input tray 202, the input unit 203 shifts to the standby state. At the end of the next cycle, the adhesive applying unit 207 shifts to the standby state. Subsequently, at the end of the next cycle, all the units shift to the standby state. In the standby state of the input unit 203, the chuck 1 is positioned above the conveyer 204. In the standby state of the adhesive applying unit 207, the X-axis is retracted. In the standby state of the ejection unit 209, the chuck 2 is positioned above the conveyer 204.

[0046] When the initial number of the workpieces 201 on the input tray 202 is N, each unit performs the cycle operation N times until all the workpieces 201 are emptied from the input tray 202, and then each unit stops the operation.

[0047] Next, a method of determining a control signal used in each process in each unit to set a monitoring condition will be described. Figures 4A-4C Each of FIGS. 11 to 14 is a diagram illustrating an example of the control signal used in each process in each unit. Figure 2 FIG. 11 is a diagram illustrating an example of the control signal used in the process of picking up the workpiece 201 on the conveyer 204. Figures 3A-3CA time chart illustrating the timing of the control operation of the machines of the units of the production line 100 is illustrated in FIG. 1. The upper drawing illustrates the machine (unit) operation states, specifically, the operation state of the input unit 203 having machine number 1, the operation state of the adhesive applying unit 207 having machine number 2, and the operation state of the discharge unit 209 having machine number 3. Further, in the time chart in which the horizontal axis indicates time, the execution state of the operation process indicated by each process number 130 is illustrated.

[0048] The lower specifically illustrates each control signal 131 corresponding to the respective one operation process indicated by the corresponding process number 130 of the unit having machine number 1-3, respectively. In the lower, in the time chart in which the horizontal axis indicates time, the signal symbol indicating the respective control signal 131, the signal name indicating the control operation of the respective control signal 131, and the on / off state of the control signal 131 are illustrated, respectively.

[0049] First, the monitoring device 120 is communicatively connected to the PLC 110 controlling each unit of the production line 100, and causes the production line 100 to operate. The recording unit 122 of the monitoring device 120 organizes the information within 10 seconds from the PLC 110 regarding the control signal 112 and the process number 111 of each unit as one record of the database, and records the result as the process number 130 and the control signal 131 in the database.

[0050] The process number 130 indicates the process in which the corresponding unit is performed at a certain time among the processes illustrated in FIG. 1. Figures 3A-3C The analysis unit 123 determines which control signals are used in the corresponding process by using the characteristics of the work 201 subjected to the processes in the appropriate order from the process number 130 and the control signal 131 read out from the database. Figures 3A-3C The analysis unit 123 determines which control signals are used in the corresponding process by using the characteristics of the work 201 subjected to the processes in the appropriate order from the process number 130 and the control signal 131 read out from the database.

[0051] Next, the method of determining the control signal by the analysis unit 123 described above will be specifically explained. In a case where the used signal list 132 is not generated in Figure 5 In a case where the used signal list 132 is not generated in

[0052] Examples of the method by which the analysis unit 123 acquires the above-mentioned time period include acquiring the time period from the operation data about the production line 100 that has been accumulated in the past. The time period from when the process number 130 of each unit becomes 0 (i.e., the production line 100 becomes a state in which no units are performing a process) to when any one of the process numbers 130 of the units becomes a number other than 0 (i.e., any unit starts operating) is regarded as a time period during which the workpiece 201 is input. Furthermore, the time period from when any unit starts operating to when the process number 130 of each unit becomes 0 (i.e., all units stop operating) is regarded as a time period during which the finished product is discharged.

[0053] Figures 4A-4C The process number 130 and the control signal 131 in the time period from when each unit starts operating in a state in which no workpiece 201 is present in each unit, and each unit is stopped, to when each unit has at least completed one corresponding operation (one cycle of each flowchart in Figures 3A-3C

[0054] In Figures 4A-4C , the signal symbols Y1, X1, Y6, X6,... represent the symbols and addresses used by the PLC 110 to manage the control signal 131. Figures 4A-4C The column 400 in

[0055] For example, in the case of the time period 401 in the upper portion of Figure 4A , the analysis unit 123 determines that process 2 of the input unit 203 is being performed. Figure 4A The time period 402 and Figure 4B The region 431 in the lower portion each indicates an operation that is performed for the first time by the input unit 203 having machine number 1, the time period 403 indicates an operation that is performed for the second time by the input unit 203 having machine number 1, and the time period 404 indicates an operation that is performed for the third time by the input unit 203 having machine number 1. These indicate that the process of a certain unit is performed in stages in the time periods 402-404.

[0056] Similarly, the time period 411 and the region 432 each indicate an operation that is performed for the first time by the adhesive applying unit 207 having machine number 2, the time period 412 indicates an operation that is performed for the second time by the adhesive applying unit 207 having machine number 2, and the time period 421 and the region 433 each indicate an operation that is performed for the first time by the discharge unit 209 having machine number 3.

[0057] ​Based on this information, the analysis unit 123 identifies a signal that is always changing between on and off while any process of the same unit is being performed, as a signal that is being used by the unit. Further, the analysis unit 123 associates a process with a corresponding one of the control signals based on the premise that one signal is always used by only one unit. In the above example, the period 402 corresponds to the region 431, the period 411 corresponds to the region 432, and the period 421 corresponds to the region 433.

[0058] In a state where all units are operating, as in the periods 404, 412, and 421 in Figure 4A It is not easy to determine a signal that is being used in a corresponding process from on / off information about the control signals. However, using the characteristic that the units and processes are operated in a phased manner makes it possible to easily and accurately associate the control signals with the processes of the units.

[0059] For example, during the period 401 in Figure 4A During the period 401 in

[0060] Next, when focusing on the periods 411 and the region 432, the input unit 203 and the adhesive applying unit 207 are simultaneously operating during these periods. However, considering the difference between the period 402, in which only the input unit 203 is operating, and the period 411, it is possible to similarly specify the control signals that are used in the respective processes of the adhesive applying unit 207.

[0061] Similarly, the operation information of a period in which the input unit 203, the adhesive applying unit 207, and the discharge unit 209 are simultaneously operating is calculated from the difference between the operation information of a period in which only the input unit 203 and the adhesive applying unit 207 are operating. This makes it possible to determine the control signals that are used in the respective processes in the period 421 and the region 433 only for the discharge unit 209.

[0062] The above method specifies the control signal used in the corresponding process by using the characteristic that the units and processes operate in stages from the state in which no workpiece 201 is present in the corresponding unit to the state in which the corresponding unit performs the corresponding work on the corresponding workpiece 201. On the other hand, the number of processes in progress also decreases in stages during the period from the start of the operation of discharging the workpieces 201 from the state in which the corresponding unit performs the corresponding work on the corresponding workpiece 201 to the time when all the workpieces 201 are discharged. Thus, the control signal used in the corresponding process can also be similarly specified for the period thereafter.

[0063] Thus, the worker can specify the period from the state in which the input of the workpieces 201 is stopped in each machine (unit) of the production line 100 to the time when the workpieces 201 processed by the units are all discharged, and by using the process number 130 and the control signal 131 of the period, the used signal list 132 can be created.

[0064] Further, depending on the production line, a plurality of units can perform work on one workpiece at the same time. Examples of such cases include a case in which two adhesive applying units 207 are provided in the adhesive applying unit 207, and the two adhesive applying units 207 apply adhesive to a single workpiece 201 at the same time. Figure 2

[0065] In this case, although the above method of specifying the signal used by the first or second adhesive applying unit 207 can be used to specify a certain signal, it is not possible to specify which unit uses the certain signal.

[0066] In this case, the process that uses a certain signal is specified by using a slight deviation in the on / off timing of the signal that occurs in each unit. In terms of the deviation in the on / off timing of the control signal, the on / off timing is slightly different even between the same control signals due to various factors such as the response speed of each sensor, the transmission time of the control signal, and the sliding resistance of the unit.

[0067] In fact, the deviation in the timing at which the control signal used in the process of the unit is turned on and the deviation in the timing at which the process ends are often smaller than the deviation in the timing at which the process of the unit that does not use the control signal is started and the deviation in the timing at which the process ends. For example, assume that unit A and unit B that perform work on a workpiece at the same time are provided, and a control signal a is used in process 1 of unit A.

[0068] In this case, the deviation in the timing at which the signal a is turned on and the deviation in the timing at which process 1 ends are smaller than the deviation in the timing at which process 1 of unit B is started and the deviation in the timing at which process 1 ends.

[0069] ​As described above, in cases where multiple units operate on a single workpiece, the method described above reduces the number of steps that may require the specified control signals. Furthermore, measurements can be taken within multiple cycles, such as... Figure 4B The time period 434 in the diagram illustrates "the time period from when a certain signal is activated to the end of the process," and the process signal used during which the difference between the maximum and minimum values ​​of the time becomes minimal is determined. As a result, even when multiple units are operating simultaneously, the control signal being used in the corresponding process unit can be specified.

[0070] Figure 5 It is a table that illustrates the interconnectedness of each unit, each process, and each control signal used in each process, as determined by the above method. Figure 5 The table shown in the diagram is recorded in the database as a list 132 of the signals used.

[0071] Next, we will explain how to create monitoring conditions for a machine (unit). After creating... Figure 5 If the signal list 132 used in the process has not yet been created, but the decision creation unit 124 has not yet created the decision condition list 133, the decision creation unit 124 will automatically start processing.

[0072] The determination of creation unit 124 is based on reference. Figure 5 The diagram shows the list of signals used (132), which is used to create... Figure 6 and Figure 7 The diagram shows a list of decision criteria 133. This list is used to determine whether each process and each control signal is normal or abnormal. The list of signals used 132 is created by the analysis unit 123 and stored in the database. Figure 6 The diagram illustrates the list of judgment conditions for control signal 131. Figure 7 This diagram illustrates the decision condition list for process number 130. The process of exporting the decision condition list will be explained below.

[0073] In this example, multiple determination conditions can be set for one signal symbol in the signal list 132 used. Furthermore, the method for determining the normal / abnormal state of each control signal is predetermined, and in this exemplary embodiment, normal and abnormal states are determined by using the on / off timing of each control signal. The on / off timing is defined as the time when the control signal used in each step of each unit is turned on or off after the start of operation of that step.

[0074] Figure 8The diagram illustrates the state of the control signal in steps 1-5 of input unit 203 recorded multiple times (n times, where n = 1 to N), where t1, t2, and tn represent the on-time of control signal X1, and T1, T2, and Tn represent the off-time of control signal X1. Furthermore, the natural number immediately following t or T indicates the nth record of the on / off timing of control signal X1.

[0075] As mentioned above, due to various factors such as reaction speed, control signal transmission time, and machine sliding resistance, each sensor exhibits slight differences in on / off timing. Therefore, by utilizing this characteristic, the on / off timing of individual control signals is measured across multiple cycles, and the range from minimum to maximum value is defined as "the allowable range of variation in on / off timing under normal conditions."

[0076] Next, the process of measuring the on / off timing of each control signal in the corresponding process within multiple cycles will be explained.

[0077] First, the process number 130 of each unit and the signal symbol of each control signal 131 are obtained from the list 132 of used signals stored in the database. Then, based on the obtained information, the on / off timing of the control signals used in each process of each unit is measured n times (n = 1 to N).

[0078] Figure 9A and 9B The diagram illustrates the average and standard deviation of n measurements of the control signal (n = 1 to N) at the on / off timing of each unit's control signal, as well as the judgment threshold at the on / off timing. The upper and lower limits of the judgment threshold used for normal / abnormal determination are calculated based on the statistical values ​​of the measurement results. For example, the calculation can be performed using values ​​obtained by the average ± 6 × standard deviation, or using the maximum and minimum values.

[0079] For each control signal in the signal list 132 used, a decision threshold is calculated to generate... Figure 6 The diagram shows a list of decision criteria for control signal 131. Additionally, based on process number 130, the execution time of each process in each unit is calculated, and in a manner similar to the calculation of the decision threshold for the control signal, the upper and lower limits of the decision threshold are calculated based on the statistical values ​​(e.g., average and deviation) of n measurements (n = 1 to N). Afterwards, a... Figure 7 The diagram shows the list of decision criteria for the process corresponding to process number 130. Figure 6 and Figure 7 The list of decision conditions shown in the diagram is stored together in the database as decision condition list 133.

[0080] Next, the method of monitoring each unit and each process will be explained. When Figure 6 and Figure 7 The determination condition list 133 illustrated in FIG. 13 is stored in the database, and the monitoring device 120 starts monitoring the process number 130 and the control signal 131 transmitted from the PLC 110.

[0081] After that, the determination unit 125 performs normal / abnormal determination for each process and each control signal based on the determination condition list 133. In the present exemplary embodiment, the normal / abnormal determination for each process is performed at the timing when each process is turned off (at the timing when each process ends), and the normal / abnormal determination for each control signal is performed at the timing when each control signal is turned on.

[0082] This is because even in the on state, each control signal does not affect the corresponding process itself, so that the turn-off timing of each control signal is not suitable for determination. Further, since each process is turned on when the corresponding signal is turned on, so that the start timing of the process can be grasped only by checking whether the corresponding control signal is in the on state. Further, if the on timing is abnormal, then the off timing inevitably also becomes abnormal. Thus, the determination as to whether the timing when the process is turned off is accurate is more suitable for the normal / abnormal determination for each process.

[0083] In a case where one or both of the turn-off timing of the process and the turn-on timing of the corresponding control signal is outside the determination threshold in the determination condition list 133, the time, the machine number, the process number, the signal symbol, and the signal name at the time when one or both of the turn-off timing of the process and the turn-on timing of the control signal exceeds the determination threshold are recorded in the abnormal history 134.

[0084] Figure 10 An example of the screen displayed on the display device 150 by the display unit 126 is illustrated. In the present exemplary embodiment, as an example of the display device 150, a display used for a personal computer (PC) is described; however, the display device 150 can be a touch panel. In a case where the abnormal history 134 is updated, the display unit 126 displays the update result on the display device 150. In a case where an abnormality occurs, the display unit 126 notifies the worker of the occurrence of the abnormality.

[0085] Figure 10 The block 1001 in FIG. 10 illustrates the history period in the abnormal history 134. In the present exemplary embodiment, the abnormal history for the past 10 days from the last update date of the abnormal history 134 is first displayed. By operating the block 1001, the worker can change the display period.

[0086] Figure 10Table 1002 illustrates the total delay time and total number of delays for each process in each unit. When a cell in the column for total delay time in Table 1002 is selected, Table 1003 is displayed, which shows the delay occurrence time and delay time for the selected item. For example, when the cell with a total delay time of 2.45 is selected, the display format of the column containing the selected cell (horizontally on the paper) changes, such as color, and the delay time and delay occurrence timing for process 3 in input unit 203 are displayed in Table 1003.

[0087] Chart 1004 uses a bar chart to illustrate the total delay time for all processes in all units on each day during the display period shown in box 1001. For example, bar 1005 shows that on February 11, 2015, a total delay of 5 minutes occurred in production line 100.

[0088] Figure 11 The occurrence frequency of delays is used to illustrate the history of anomalies that occurred during the display period shown in box 1101. The display switching button 1006 allows switching the screen and display method. Figure 11 The diagram illustrates the screen and display method. Figure 11 Table 1102 illustrates the abnormal history 134 during the display period shown in box 1101.

[0089] Figure 11 Chart 1103 in the chart uses a bar chart to illustrate a compilation of the number of delays occurring in all processes across all units each day, based on the anomaly history 134. For example, Figure 11 Item 1104 indicates that on February 10, 2015, 60 delays occurred on production line 100. Staff inspected... Figure 10 and / or Figure 11 The abnormal history in the data is used to understand the state of anomalies.

[0090] In the example above, the display is switched using the display toggle button 1006. Alternatively, when a cell containing the total delay in table 1002 is selected, the screen can be switched to... Figure 11 The display screen.

[0091] In addition, staff from Figure 10 Table 1003 or Figure 11 In the anomaly history in Table 1102, select the anomalies you want to examine in detail. For example, when selecting... Figure 10 In the case of the first row of Table 1003 (occurrence time: 2015 / 2 / 1 14:30:55), the screen of display device 150 changes to Figure 12 The scene.

[0092] Figure 12 is a bar chart illustrating the operation state of the process and the control signal in each unit, in which the horizontal axis represents time. In Figure 12 , the frame 1201 is displayed in the table 1003 in Figure 10 . The period of 10 seconds in total, 5 seconds before and after the date and time of the occurrence of the selected abnormality in the table 1003 in Figure 12 , can be set by the worker. The worker can change the display period by operating the frame 1201.

[0093] Next, the control process for displaying the operation state of the process and the control signal in each unit in a bar chart, such as the bar chart illustrated in Figure 13 , will be described with reference to Figure 12 . Figure 13 is a flowchart of the control for displaying the operation state of the process and the control signal in each unit in a bar chart, such as the bar chart illustrated in Figure 12 . Figure 13 The process of the control in Figure 12 is executed by the CPU functioning as the display unit 126. Further, the frame described below is merely an example, , a similar frame in

[0094] has a function similar to the function described below. Figure 12 First, in step S101, the process number 130 and the control signal 131 within the display period 1201 in Figure 12 are acquired from the abnormality history 134. In step S102, the period in which each acquired process is operated is displayed as a rectangle (indicated by the frame 1203 in ) in order of the start time from the top. The portion without a bar (rectangle or frame) indicates that the corresponding process is in standby (0).

[0095] Figure 8 Next, in step S103, the determination upper limit value and the determination lower limit value (determination threshold value) for each process are acquired with reference to the determination condition list 133. In step S104, the determination upper limit value and the determination lower limit value are displayed as a dotted rectangle (frame 1205) on the rectangle (frame 1203) of the process in the operation state. The width of the dotted rectangle (frame 1205) indicates the range for determining whether the corresponding process is normally ended. Since each process is performed within a predetermined cycle as illustrated in

[0096] Next, in step S105, referring to the decision condition list 133, the control signals used in each process are obtained, along with the upper and lower decision limits (decision thresholds) for each signal. In step S106, in a manner similar to the process, the time periods during which the corresponding signal is activated are displayed as a rectangle (box 1204), and the boxes 1204 are arranged from top to bottom according to the control sequence in each process. The absence of bars (rectangles, boxes) indicates that the corresponding control signal is in standby (0).

[0097] In this exemplary embodiment, the display modes of the process block and the control signal block are different to facilitate understanding of the display; however, different display modes may be used.

[0098] Next, in step S107, the upper and lower limits of each control signal are displayed as dashed rectangles (box 1206) on the rectangle (box 1204) indicating the signal's on state. The width of the dashed rectangle indicates the range used to determine whether the timing is normal when the signal is on. Since each control signal... Figure 8 As shown, the process is generated within a predetermined loop, so each dashed rectangle is also displayed on the timeline to ensure it appears within the predetermined loop while maintaining the width of the decision threshold. The processing of the control flow diagram then concludes.

[0099] In this exemplary embodiment, an example is described in which the determination thresholds for both the process and the control signal are displayed as dashed rectangles; however, the display mode is not limited to this. For example, the block for each process may be displayed with a higher transmittance than the block for each control signal, or the display mode may be different from the display mode of the block for each control signal.

[0100] For example, in Figure 12 In boxes 1207 and 1208, the start of time T when the chuck 1 opening end signal (control signal X2) is in the open state does not fall within the normal range (box 1208). Therefore, the start timing of time t is delayed while process 3, which is related to control signal X2, is in progress, and the end of time t is outside the normal range (box 1207). This indicates that control signal X2 and process 3 are determined to be abnormal.

[0101] In selection Figure 11 In the case of the third row of Table 1102 (time: 2015 / 2 / 1 14:32:17), the screen of display device 150 changes to the same format as the image above. Figure 12 Similar to the picture Figure 14 The scene. Figure 14 This is a bar chart illustrating the operational status of processes and control signals within a unit, such as... Figure 12 Similar to the previous example, the horizontal axis represents time.

[0102] The explanation of the bar chart of the operation state of the process and the control signal is similar to that of the label of the unit and the display period. Figure 12 Figure 14 The block 1301 in FIG. 13 illustrates an example of a point at which the sensor for the opening instruction signal of the chuck 1 (control signal Y2) is not turned on and an abnormality occurs. By turning on the sensor for the opening instruction signal of the chuck 1 (control signal Y2) at the point at which the abnormality occurs, the abnormality can be eliminated. Figure 12 Figure 14 By any one of the block 1208 in FIG. 12 and the block 1301 in FIG. 13, the abnormal portion outside the normal range can be identified at a glance.

[0103] At this time, in order to further enhance the visibility, as shown in FIG. 14, the control signal of which the turning-on timing is outside the determination threshold and / or the control signal of which the turning-off timing is outside the determination threshold, and the determination threshold related thereto can be displayed in a different pattern from the above-described pattern. In FIG. 14, the display pattern of the process 3, the opening end signal of the chuck 1 (control signal X2), and each of the blocks 1207 and 1208 is changed. The use of a color or a display pattern different from that of the normal portion can facilitate the identification. Figure 15 Figure 15

[0104] In the above-described manner, the operation state in each unit is divided in units of processes, the control signal related to each process is specified, and the processes and the control signals are displayed in the time chart in the order of the control. This enables the worker to easily grasp the abnormality occurrence state.

[0105] Further, the display pattern of the process and the control signal having the abnormality is made different from the display pattern in the normal state, which makes it possible to narrow down the range to be checked when the abnormality occurs. Further, by following the control signal in the time series, the degree of deviation of the turning-on / off timing of the signal from the normal state and the timing at which the deviation occurs can be grasped at a glance. This makes it possible to greatly reduce the time required for specifying the abnormality. In addition, even in the case where the number of units, the number of processes, and the number of signals increase, the monitoring condition can be automatically set by simply operating the production line as usual. This makes it possible to easily construct the monitoring system.

[0106] In the above description, the control method in the exemplary embodiment is specifically executed by the CPU included in the program portion of the monitoring device 120. However, a software control program that can execute the above-described functions and a recording medium that holds the program can be installed in, for example, other information processing devices and implemented. Thus, the software control program that can execute the above-described functions, the recording medium that holds the program, the communication device, and the application constitute exemplary embodiments of the disclosure.

[0107] ​​​​The control program that realizes the exemplary embodiments of the present disclosure can be recorded in any computer-readable recording medium. Examples of the recording medium that supplies the control program include a hard disk drive (HDD), an external storage device, and a recording disk.

[0108] (Other Embodiments)

[0109] In each of the above-described exemplary embodiments, a case where each unit of the production line 100 uses a robot having a joint driven along a single axis is described; however, the number of joints is not limited thereto. In a robot arm having other types of joints, such as a vertical articulation joint and a parallel link joint, a configuration equivalent to the above-described configuration can be realized.

[0110] Further, each of the above-described exemplary embodiments is applicable to a machine that can automatically perform an extension, a stretching, a vertical movement, a lateral movement, a rotation operation, or a combined operation thereof, based on information stored in a storage device provided in a control device.

[0111] Note that the present disclosure is not limited to the above-described exemplary embodiments, and various modifications can be made within the scope of the technical idea of the present disclosure. Further, the effects described in the exemplary embodiments of the present disclosure are merely illustrative of the most preferable effects obtained by the present disclosure, and the effects of the present disclosure are not limited to those described in the exemplary embodiments of the present disclosure.

[0112] Other Embodiments

[0113] One or more embodiments of the present disclosure can also be realized by a computer of a system or apparatus reading out and executing computer executable instructions (e.g., one or more programs) recorded on a storage medium (which can also be referred to more fully as a 'non-transitory computer-readable storage medium') to perform the functions of one or more of the above-described embodiments and / or one or more circuits (e.g., application specific integrated circuit (ASIC)) for performing the functions of one or more of the above-described embodiments, and by a method performed by the computer of the system or apparatus, by, for example, the computer of the system or apparatus, reading out and executing the computer executable instructions. The computer can comprise one or more processors (e.g., central processing unit (CPU), micro processing unit (MPU)) and can include a network of separate computers or separate processing machines to read out and execute the computer executable instructions. The computer executable instructions can be provided to a computer, for example, from a network or the storage medium. The storage medium can include, for example, a hard disk, a random access memory (RAM), a read only memory (ROM), a storage of distributed computing systems, an optical disk (such as a compact disc (CD), digital versatile disc (DVD), or Blu-ray Disc (BD)®), a flash memory device, a memory card, and the like.TM one or more of a main memory such as a dynamic random access memory (DRAM), a flash memory, a memory card, and the like.

[0114] Embodiments of the present application can also be implemented by a method of providing, through a network or various storage media, software (program) that performs the functions of the above-described embodiments to a system or apparatus, which reads and executes the program by using a computer or a central processing unit (CPU), a micro processing unit (MPU).

[0115] According to the exemplary embodiments of the present disclosure, the operating state of the machine facility can be easily grasped.

[0116] Although the present disclosure includes exemplary embodiments, it is to be understood that the present disclosure is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

Claims

1. An information processing apparatus for displaying a state of a machine facility including a plurality of devices on a display unit and performing a plurality of operations using the plurality of devices based on an instruction from a control device, wherein a first signal output from the control device to the machine facility for instructing the machine facility to start an operation and a second signal output from the machine facility to the control device for notifying the control device of completion of the operation are set in each of the plurality of operations, wherein the information processing apparatus displays, on the display unit, in a time series, a first graphic for indicating a period in which the first signal is being output, a second graphic for indicating a period in which the second signal is being output, and a third graphic for indicating a period including a first timing at which the first signal has been output and a second timing at which the second signal has been output, and wherein the third graphic, the first graphic, and the second graphic are displayed in a manner arranged in an order of control for each of the plurality of operations.

2. The information processing apparatus according to claim 1, wherein the first graphic and the second graphic are displayed on the display unit in a manner arranged side by side below the third graphic.

3. The information processing apparatus according to claim 1, wherein the information processing apparatus displays, on the display unit, a first range indicating a range in which the first timing is to be included and a second range indicating a range in which the second timing is to be included.

4. The information processing apparatus according to claim 1, wherein the information processing apparatus displays, on the display unit, a name of the operation corresponding to the third graphic, a name of the first signal corresponding to the first graphic, and a name of the second signal corresponding to the second graphic.

5. The information processing apparatus according to claim 1, wherein the information processing apparatus displays, on the display unit, a plurality of the first graphics in a manner arranging the plurality of first graphics in a time series, a plurality of the second graphics in a manner arranging the plurality of second graphics in a time series, and a plurality of the third graphics in a manner arranging the plurality of third graphics in a time series.

6. The information processing apparatus according to claim 4, wherein the information processing apparatus displays, on the display unit, on the third graphic, a third range indicating a range in which a third timing at which the operation is to be completed is to be included.

7. The information processing apparatus according to claim 3, wherein the information processing apparatus displays, on the display unit, the first range on the first graphic and the second range on the second graphic.

8. The information processing apparatus according to claim 7, wherein the information processing apparatus displays, on the display unit, the first range in a display mode different from a display mode in which the first graphic is displayed, and displays, on the display unit, the second range in a display mode different from a display mode in which the second graphic is displayed.

9. The information processing apparatus according to claim 8, wherein the information processing apparatus displays, on the display unit, each of the first graphic and the second graphic as a rectangle, and displays each of the first range and the second range as a dotted rectangle.

10. The information processing apparatus according to claim 7, wherein the information processing apparatus displays a third graphic for which the third timing is not included in the third range and a third graphic for which the third timing is included in the third range in different display modes on the display unit.

11. The information processing apparatus according to claim 3, wherein the information processing apparatus displays a second graphic for which the second timing is not included in the second range and a second graphic for which the second timing is included in the second range in different display modes on the display unit.

12. The information processing apparatus according to claim 3, wherein the information processing apparatus records as an anomaly a first signal corresponding to the first graphic for which the first timing is not included in the first range, a second signal corresponding to the second graphic for which the second timing is not included in the second range, or an operation corresponding to the third graphic for which the third timing is not included in the third range.

13. The information processing apparatus according to claim 1, wherein the information processing apparatus is capable of setting a display period of the first graphic, the second graphic, and the third graphic.

14. The information processing apparatus according to claim 6, wherein the information processing apparatus displays the third range and the third graphic in different display modes on the display unit.

15. The information processing apparatus according to claim 3, wherein the information processing apparatus displays a first graphic for which the first timing is not included in the first range and a first graphic for which the first timing is included in the first range in different display modes on the display unit.

16. The information processing apparatus according to claim 1, wherein the machine facility performs the plurality of operations using the plurality of devices in a predetermined cycle.

17. The information processing apparatus according to claim 1, wherein the information processing apparatus displays information on a delay of an operation on the display unit.

18. The information processing apparatus according to claim 17, wherein the information on the delay includes at least one of a delay time, a number of occurrences of a delay, and a timing of occurrence of a delay.

19. The information processing apparatus according to claim 18, wherein the information processing apparatus displays at least one of the delay time, the number of occurrences of a delay, and the timing of occurrence of a delay in a table format on the display unit.

20. The information processing apparatus according to claim 17, wherein the information processing apparatus displays a total time of a delay time or a number of occurrences of a delay in a bar chart on the display unit.

21. The information processing apparatus according to claim 20, wherein a first screen on which the total time is displayed in a bar chart on the display unit and a second screen on which the number of occurrences of a delay is displayed in a bar chart on the display unit are switchable.

22. The information processing apparatus according to claim 1, wherein the display unit is a touch panel.

23. A production system comprising: the information processing apparatus according to any one of claims 1 to 22; and the machine facility.

24. A method of manufacturing an article by using the production system according to claim 23. ​ 25. A method of controlling an information processing apparatus to display a state of a machine facility including a plurality of devices on a display unit and perform a plurality of operations using the plurality of devices based on an instruction from a control device, wherein a first signal output from the control device to the machine facility for instructing the machine facility to start an operation and a second signal output from the machine facility to the control device for notifying the control device of completion of the operation are set in each of the plurality of operations, the method comprising: displaying, on the display unit, in a time series, a first graph for indicating a period in which the first signal is being output, a second graph for indicating a period in which the second signal is being output, and a third graph for indicating a period including a first timing at which the first signal has been output and a second timing at which the second signal has been output, wherein for each of the plurality of operations, the third graph, the first graph, and the second graph are displayed in a manner arranged in an order of control.

26. A non-transitory computer-readable recording medium storing a control program that enables the method according to claim 25 to be executed.

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