Industrial system, anomaly detection system, and anomaly detection method

Abstract

An industrial system includes a storage section that stores design data used when an industrial pipeline is constructed, a simulation execution section that executes simulation of operation of the industrial pipeline based on the design data, and a detection section that detects an abnormality of a constituent element of the industrial pipeline by comparing a result of the simulation with operation of the industrial pipeline when the industrial pipeline is put into operation. With this structure and operation, it is possible to effectively utilize in operation assistance of the pipeline and high-resolution abnormality detection.

Description

Technical Field

[0001] This invention relates to industrial systems, anomaly detection systems, and anomaly detection methods. Background Technology

[0002] Patent document 1 describes a manufacturing production line evaluation assistance method, characterized by including: a simulation result data input step, which collects simulation result data of various elements of the manufacturing production line constructed on a virtual design simulator and transmits it to the evaluation assistance device; a data processing step, which takes the collected simulation result data and processes it into the form of operating rate, production quantity, and evaluation indicators; and a problem point analysis step, which uses pre-stored evaluation rules consisting of evaluation items and evaluation benchmark values ​​relative to the result data of each manufacturing production line category and evaluation process to evaluate the simulation result data and extract problem points related to the constituent elements of the manufacturing production line.

[0003] Patent Document 2 discloses a method for constructing a manufacturing production line simulation model, characterized by comprising: a step of constructing a predictive formula for approximately predicting the lead time of each process based on the results of past simulations or production performance; a step of calculating the error between the predicted formula and the past simulations, or the error between the predicted formula and the production performance, for each process; a step of determining in which process a simplified simulation using the predicted formula is applied based on the calculated error information for each process; and a step of performing a manufacturing production line simulation in the process where the simplified simulation is applied, wherein the manufacturing production line simulation applies the process lead time obtained using the predicted formula.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2003-280730

[0007] Patent Document 2: Japanese Patent No. 5775803 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] Previous production line simulation models are difficult to use for purposes that require more detailed information, such as productivity evaluation or production line composition evaluation, and it is difficult to build models for these purposes.

[0010] Therefore, the purpose of this invention is to provide a system and method that can be flexibly applied to assist in the use of pipelines and to detect anomalies at high resolution by using a pipeline simulator for design verification.

[0011] Methods for solving problems

[0012] To achieve the above objectives, a representative industrial system of the present invention is characterized by comprising: a storage unit that stores design data used in constructing an industrial production line; a simulation execution unit that performs a simulation of the operation of the industrial production line based on the design data; and a detection unit that compares the simulation results with the operation of the industrial production line during its use to detect abnormalities in the constituent elements of the industrial production line.

[0013] Furthermore, a representative industrial system of the present invention is characterized by having: a sensor that acquires information about industrial equipment; and a computing unit that performs calculations based on the information acquired by the sensor, wherein, when the industrial equipment is in use, the sensor acquires information about the movable part, including position information, velocity information, and acceleration information of the movable part of the industrial equipment; and the computing unit performs a process of comparing the information about the movable part acquired by the sensor with information about a hypothetical movable part obtained through simulation of the industrial equipment, and outputs the result of the comparison process.

[0014] Furthermore, a representative industrial system of the present invention is characterized by comprising: a storage unit that stores design data used in constructing an industrial production line containing multiple processes; a simulation execution unit that performs a simulation of the operation of the industrial production line based on the design data; and a detection unit that detects anomalies in the industrial production line by comparing the hypothetical relationships between the multiple processes in the simulation results with the relationships between the multiple processes when the industrial production line is in operation.

[0015] Additionally, a representative industrial system of the present invention is characterized by including: a simulation execution step, which simulates the operation of the industrial assembly line based on design data used in constructing the industrial assembly line; an information acquisition step, which acquires information representing the operation of the industrial assembly line during use; and a detection step, which compares the simulation results with the operation of the industrial assembly line during use to detect anomalies in the constituent elements of the industrial assembly line.

[0016] Invention Effects

[0017] According to the present invention, it can be effectively utilized in production line applications and high-resolution anomaly detection. The issues, structures, and effects beyond those described above become clear through the following description of embodiments. Attached Figure Description

[0018] Figure 1 This is an explanatory diagram of the industrial system and anomaly detection of the present invention.

[0019] Figure 2 It is a structural diagram of an industrial system.

[0020] Figure 3 It is a flowchart that shows the processing order when performing a simulation.

[0021] Figure 4 It is a flowchart that shows the processing sequence when it is used.

[0022] Figure 5 It is a flowchart that shows the processing sequence based on the estimated fault factors.

[0023] Figure 6 This is an explanatory diagram of a specific example of sensor data.

[0024] Figure 7 This is an explanatory diagram about the simulation.

[0025] Figure 8 It is a variation of the structure of an industrial system.

[0026] Figure 9 This is an explanatory diagram of the structure that enables the control system to perform simulation and anomaly detection.

[0027] Figure 10 It is an explanatory diagram of the overall operation of an industrial system.

[0028] Figure 11 This is an explanatory diagram for anomaly detection. Detailed Implementation

[0029] The embodiments of the present invention will now be described with reference to the accompanying drawings. Furthermore, the embodiments described below do not limit the scope of the invention, and the elements and combinations thereof described in the embodiments are not limited to those necessary for the solution of the invention.

[0030] In the following description, identification numbers are used as identification information for various objects, but other types of identification information (e.g., identifiers containing letters or symbols) may also be used.

[0031] In addition, in the following descriptions, when describing the same type of element without distinguishing them, reference symbols (or common symbols among reference symbols) are sometimes used; when describing the same type of element, the element identification number (or reference symbol) is used.

[0032] Example

[0033] Figure 1 This is an explanatory diagram of the industrial system and anomaly detection of the present invention. Figure 1The assembly line shown is an industrial assembly line for manufacturing items and conveying items, such as material handling. Here, "industrial assembly line" refers to equipment that sequentially performs predetermined processes to manufacture objects and handle materials (including processing, assembly, painting, inspection, conveying, sorting, picking, palletizing, and storage). In other words, an assembly line that includes not only manufacturing lines and production lines but also lines for conveying items is called an industrial assembly line. Furthermore, in this embodiment, industrial equipment is included as a constituent element of the industrial assembly line. Industrial equipment includes, for example, movable parts such as robotic arms, and manufacturing and material handling are performed by controlling the movement of these movable parts. In addition, industrial equipment includes: a linkage mechanism with multiple actuators; a mechanism with a self-propelled unit and a holding unit, wherein the self-propelled unit has a chuck or clamp; a conveying unit such as a hoist, conveyor, or crane; a movable body whose position is controlled by a linear guide or ball screw; a rotating body whose angle or acceleration is controlled; and also includes an electric motor, inverter, compressor, etc.

[0034] When constructing an industrial production line, the production line manufacturer responsible for its construction performs design and other engineering work based on the requirements of the customer who commissioned the construction. Customer requirements 10 may include, for example, workpiece information, processing specifications, production capacity, and operational plans related to the target items. Engineering work 11 includes process information, functional design, control design, structural design, computer-aided design (CAD), computer-aided engineering (CAE), and bill of materials (BOM).

[0035] Following Project 11, actual machine manufacturing 12 is carried out on the industrial production line, followed by the application 13 of the industrial production line. Actual machine manufacturing 12 includes hardware fabrication, sensor configuration, and timing control. Application 13 includes the production of the target product and the maintenance of the production line.

[0036] Among them, Project 11 and Actual Machine Production 12 are referred to as the Production Line Construction Stage, and Application 13 is referred to as the Application Stage.

[0037] In Project 11 of the pipeline construction phase, a simulation model is built based on the design information, and simulation-based verification is performed. This pipeline simulation 21 can virtually determine the entire pipeline process, including the actions of industrial equipment such as robots and devices, and verify whether the desired actions can be achieved.

[0038] Previously, the simulation model used for design verification, through the generated pipeline SIer, was mainly used for motion verification during the pipeline construction phase. This invention advances this simulation to realize an application support system 23 applied during the operational phase.

[0039] Specifically, the auxiliary system 23 uses various design information used during the assembly line construction phase (assembly line construction phase) as design data. Based on the design data and operational information obtained during production and maintenance, it performs simulations during the operational phase, compares the simulation results with the actual operation of the assembly line during operation, and detects anomalies in the components of the assembly line. Here, anomalies include not only any actual abnormalities occurring in industrial equipment or industrial assembly lines, but also signs of anomalies. By changing the value used to determine or judge anomalies (described later), or a threshold representing the difference between predetermined actions between the actual machine and the simulation, signs of anomalies can be detected or determined.

[0040] In the simulation, the auxiliary system 23 uses the shape of the industrial equipment determined based on design data to calculate the position, velocity, and acceleration information of the movable parts of the industrial equipment, thereby obtaining information about the virtual movable parts. In the simulation, not only the determined shape of the industrial equipment can be referenced, but also data sheets provided by the industrial equipment manufacturer can be consulted.

[0041] On the other hand, the auxiliary system 23 uses the information output by the sensors installed on the production line and the industrial equipment to calculate the position information, speed information and acceleration information of the movable part of the industrial equipment during operation, thereby obtaining the actual information of the movable part.

[0042] As a result of comparing the information of the real movable part with the information of the virtual movable part, if a deviation exceeding a predetermined range occurs, the auxiliary system 23 detects an anomaly and outputs a warning. For example, if the time required for the real movable part to perform a predetermined action is longer than the time required for the simulated predetermined action, and the difference exceeds a threshold, an anomaly is detected.

[0043] As a sensor or output for obtaining information about the actual movable part, sensors or outputs designed for other purposes can be used. Sensors can also be added to detect the aforementioned anomalies. For example, a newly configured camera is preferred to photograph the movable part to determine its position, velocity, and acceleration. In this case, by identifying the area near the front end of the movable part, the state of the movable part can be detected with high precision. The area near the front end refers to the region from the front end to a predetermined position, or the region from the front end to a first predetermined position to a second predetermined position, excluding the front end. The front end itself is effective when it cannot be detected by a camera. Furthermore, if a structure is used to identify the marker by attaching a mark to the movable part, the state of the movable part can be easily identified. By attaching the mark, the distance from the mark to the actual front end position is stored in a storage unit, thereby allowing calculation to determine the front end position, which is difficult to detect by a camera, and obtaining more accurate information about the movable part. Direct detection of the area near the front end by the camera and detection of the mark can also be combined. This is effective when detecting movable bodies that hide the mark by rotating.

[0044] In system development 22, based on the pipeline simulation 21 used for pipeline construction, the entire system is constructed by configuring the inspection camera, the human detection algorithm, and cooperating with the production execution system, so as to obtain the information used in the actions of the auxiliary system 23.

[0045] Figure 2 This is a structural diagram of an industrial system. For example... Figure 2 As shown, the industrial system 30 includes a control system 50, an anomaly detection system 60, and a simulation system 70. The control system 50 obtains various information from the industrial production line and performs motion control of the industrial production line.

[0046] The simulation system 70 is, for example, a computer, and includes an input unit 71, a display unit 72, a communication unit 73, a control unit 74, and a storage unit 75.

[0047] Input unit 71 includes a keyboard, mouse, etc.

[0048] Display unit 72 is a liquid crystal display, etc.

[0049] The communication unit 73 is a communication interface for communicating with the anomaly detection system 60 and the like.

[0050] The control unit 74 performs various functions by executing predetermined programs using a computing device such as a CPU (Central Processing Unit). In particular, in this embodiment, the control unit 74 functions as an analog execution unit.

[0051] Storage section 75 contains magnetic storage devices, flash memory, etc., and stores pipeline design data, process planning data, simulation result data, etc.

[0052] The control unit 74 performs a simulation by using the production line design data and process plan data stored in the storage unit 75, thereby determining the virtual movements of the industrial production line 40 and generating simulation result data.

[0053] The control unit 74 stores the simulation result data in the storage unit 75 and sends it to the anomaly detection system 60.

[0054] Furthermore, if design changes are made to the industrial equipment on the industrial production line 40, the production line design data in the storage unit 75 is updated, and the control unit 74 performs a simulation again, updating the simulation result data of the storage unit 75 and the anomaly detection system 60. This updates the simulation result data in the storage unit 75 and sends it again to the anomaly detection system 60. Therefore, the simulation result data reflects the latest status of the industrial production line 40.

[0055] The anomaly detection system 60 is, for example, a computer, having an input unit 61, a display unit 62, a communication unit 63, a control unit 64, and a storage unit 65.

[0056] Input unit 61 includes a keyboard, mouse, etc.

[0057] The display unit 62 is a liquid crystal display or the like. The display unit 62, the input unit 61, and the communication unit 62 can be implemented as a single tablet terminal, enabling input / output and communication via a touch panel. In this case, the control unit 64 and the storage unit 65 are preferably separate units for computational processing.

[0058] The communication unit 63 is a communication interface for communicating with the analog system 70, the control system 50, etc.

[0059] The control unit 64 performs various functions by executing predetermined programs using a computing device such as a CPU (Central Processing Unit). In particular, in this embodiment, the control unit 64 functions as an anomaly detection unit and a fault estimation unit. That is, the control unit 64 corresponds to the computing unit within the protection range.

[0060] Storage unit 65 is a magnetic storage device or flash memory, etc., that stores simulation result data, comparison condition data, measurement data, process plan data, etc. The simulation result data in storage unit 65 is received from the simulation system 70. The measurement data in storage unit 65 is received from the control system 50, representing the outputs of various sensors in the industrial production line 40, etc.

[0061] The control unit 64 compares the information of the virtual movable part represented by the simulation result data with the information of the real movable part represented by the measurement data, and issues a warning if the deviation exceeds a predetermined range, thereby acting as an anomaly detection unit. The comparison condition data shows the conditions under which the simulation result data and the measurement data are compared.

[0062] In addition, when an anomaly is detected by the anomaly detection unit, the control unit 64 performs an operation to determine the main cause of the malfunction by detecting the operation of the constituent elements of the industrial production line that are the main cause of the malfunction.

[0063] Figure 3 This is a flowchart illustrating the processing sequence during simulation. Simulation system 70 first acquires production line design data and process plan data (step S101), and generates a simulation model (step S102). Then, simulation system 70 executes a simulation of the industrial production line, calculating position, time, and speed for predetermined actions and operations on the computer of the entire industrial production line or industrial equipment (step S103). That is, it calculates information about hypothetical movable parts and stores the calculation results in the storage unit. Control unit 74 stores the simulation result data in storage unit 75 (step S104) and ends the processing. Additionally, the stored simulation result data is sent to the anomaly detection system 60 at arbitrary time intervals. Alternatively, a simulation model can be pre-generated in the storage unit and read from the storage device in step S102.

[0064] Figure 4 This is a flowchart illustrating the processing sequence during operation. During operation, firstly, the control system 50 inputs production command data (step S201), causing the industrial production line 40 to start running, and then the anomaly detection system 60 begins anomaly detection.

[0065] While the industrial production line 40 is running, it inputs sensor data (step S202) and calculates position, time, and speed for predetermined actions and tasks (step S203). The calculation results of the industrial production line 40 are sent to the anomaly detection system 60 as measurement data representing information about the actual movable parts.

[0066] The anomaly detection system 60 reads the simulation result data (step S204) and compares the measurement data received from the industrial production line 40 with the simulation result data (step S205). If the deviation exceeds a threshold, the anomaly detection system 60 outputs an indication that an anomaly has occurred (step S206) and terminates the process. In other words, when a difference arises between the action of the hypothetical movable part (representing ideal motion) and the action of the actual movable part, it is considered that an anomaly or a sign of an anomaly has occurred in the actual machine, thus enabling notification to users or managers before a major malfunction occurs on the industrial production line.

[0067] Figure 5 This is a flowchart illustrating the processing sequence for estimating the primary cause of a fault. When an anomaly is detected by the anomaly detection unit of the anomaly detection system 60, the fault estimation unit of the anomaly detection system 60 performs the estimation of the primary cause of the fault. For example, this is used when estimating the primary cause in cases where an anomaly occurs throughout the industrial production line 40, such as a decrease in throughput.

[0068] Specifically, the anomaly detection system 60 receives measurement data from the industrial production line 40 (step S301) and statistically analyzes the position, time, and speed of predetermined actions and operations in multiple processes (step S302). The anomaly detection system 60 compares the calculated information of the actual movable parts with the simulation results for each process. Then, it outputs information related to processes with large deviations (step S303).

[0069] Based on the presumed cause of the failure, even if the deviation from the simulation results does not exceed a threshold, the process that is the main cause of the anomaly can be presumed by relatively comparing information from multiple processes. For example, when an anomaly is detected in a series of processes accompanied by actions A, B, and C, by comparing the simulation results of each action A, B, and C with the action times corresponding to each action calculated based on sensor detection values, the action with the largest peeling and the pattern with the largest peeling (the axis corresponding to the robot's motion axis and the actuator's rotation axis) can be identified and presumed.

[0070] Figure 6 This is an illustrative diagram illustrating specific examples of sensor data. For example... Figure 6 As shown, sensor data can include position data of the robot and workpiece identified by cameras, encoder output of the robot arm, torque sensor data, control sequence data from PLCs (Programmable Logic Controllers), IPCs (Industrial PCs), and IoT controllers. Regarding sequence data, ladder diagrams, ST (Structured Text), IL (Instruction List), and SFC (Sequential Function Chart) can be read.

[0071] Figure 7This is an explanatory diagram about the simulation. The components of the simulation utilize customer-required data, engineering data, and operational condition data. Customer-required data includes workpiece information, processing specifications, production capacity, and operational plans. Engineering data includes process information, functional design, control design, structural design, and CAD / CAE / BOM data. Operational condition data includes sensor setpoints, sequence, control parameters, and production command data.

[0072] Simulations using this data as constituent components can yield the duration of a predetermined action A, the coordinates of the arm tip of action A at a predetermined time (which could also be a marker or other part, or the position of the workpiece), and the moving speed of the arm (including the workpiece or other parts) at the predetermined coordinates. Furthermore, as a result of the simulation, the required time for, for example, process B which includes action A can also be obtained.

[0073] Figure 8 It is a variation of the structure of an industrial system. Figure 8 The industrial system shown has a network between the control system 50 and the anomaly detection system 60. Figure 2 The difference lies in the structure. In this structure, the anomaly detection system 60 and the simulation system 70 can be separated from the industrial production line 40 and can be implemented through cloud services.

[0074] exist Figure 8 The diagram shows a modified example where the network is located between the control system 50 and the anomaly detection system 60, but it is also possible to set a modified example where the network is located between the anomaly detection system 60 and the simulation system 70.

[0075] Figure 9 This is an explanatory diagram of the structure that enables the control system to perform simulation and anomaly detection. In Figure 9 In this system, industrial system 30a has control system 50a. Control system 50a obtains various information from industrial production line 40 and performs motion control of industrial production line.

[0076] The control system 50a is, for example, a computer, and includes an input unit 51, a display unit 52, a communication unit 53, a control unit 54, and a storage unit 55.

[0077] Input unit 51 includes a keyboard, mouse, etc.

[0078] Display unit 52 is a liquid crystal display, etc.

[0079] The communication unit 53 is a communication interface for communicating with other devices.

[0080] The control unit 54 performs various functions by executing predetermined programs using a computing device such as a CPU (Central Processing Unit). In particular, in this embodiment, the control unit 54 performs the functions of a simulation execution unit, a production execution unit, and an anomaly detection unit.

[0081] Storage unit 55 is a magnetic storage device or flash memory, etc., that stores pipeline design data, process planning data, simulation result data, measurement data, etc.

[0082] The control unit 54 performs simulations by using the production line design data and process plan data stored in the storage unit 55, thereby determining the virtual actions of the industrial production line 40 and generating simulation result data, which then acts as the simulation execution unit.

[0083] In addition, the control unit 54 obtains sensor outputs from the industrial production line 40 to generate measurement data and controls the operation of the industrial production line 40, thereby acting as a production execution unit.

[0084] Furthermore, the control unit 54 compares the information of the virtual movable part represented by the simulation result data with the information of the real movable part represented by the measurement data, and issues a warning if it deviates from the predetermined range, thereby acting as an anomaly detection unit.

[0085] Figure 10 It is an explanatory diagram illustrating the overall operation of an industrial system. For example... Figure 10 As shown, industrial system 30 (including Figure 1 Industrial system 30 and shown Figure 9 The industrial system 30a) shown cyclically executes C1 to C5. In C1, the industrial system 30 acquires operational information for each component. In C2, the industrial system 30 accumulates operational data and monitors trends. In C3, the industrial system 30 compares action times and issues a warning if the deviation exceeds a threshold. In C4, the industrial system 30 focuses on investigating the warning location to determine the cause of the anomaly. In C5, the industrial system 30 adjusts the machine to restore it to normal operation.

[0086] Figure 11 This is an explanatory diagram for anomaly detection. In Figure 11 In the diagram, the temporal changes of the arm's tip coordinates obtained through simulation are displayed as dashed lines. Conversely, the temporal changes of the arm's tip coordinates identified through camera capture are displayed as solid lines. For clarity, the arm's coordinates are shown in only one dimension. Furthermore, in... Figure 11 In this model, the deviation between the simulation results and the camera's recognition results is represented as a shaded area.

[0087] In this way, by overlaying the simulation results and the identification results on the same chart, the deviation can be clearly represented.

[0088] As a benchmark for anomaly detection recorded as comparative data, comparisons can be made based on the distances to the coordinates reached by predetermined parts of the arm during simulations and actual operations. Additionally, comparisons can be made based on the movement speed during the predetermined action. Furthermore, for example, regarding a series of steps from when robot arm A begins and completes a predetermined action on an item, then when robot arm B completes the predetermined action, comparisons can be made based on the position or arrival time of the item being processed or transported.

[0089] As described above, in this embodiment, the industrial system 30 includes: a storage unit 65 that stores design data used when constructing the industrial production line; a control unit 74 that functions as a simulation execution unit that performs simulations of the operation of the industrial production line based on the design data; and a control unit 64 that functions as a detection unit that compares the simulation results with the operation of the industrial production line during its use to detect abnormalities in the components of the industrial production line.

[0090] Through this structure and operation, the industrial system 30 can be effectively utilized for production line assistance and high-resolution anomaly detection.

[0091] Additionally, an industrial system 30 includes a sensor for acquiring information about industrial equipment and a computing unit for performing calculations based on the information acquired by the sensor. When the industrial equipment is in use, the sensor acquires information about the movable part, including position information, velocity information, and acceleration information of the movable part of the industrial equipment. The computing unit performs a process of comparing the information about the movable part acquired by the sensor with information about a hypothetical movable part obtained through simulation of the industrial equipment, and outputs the result of the comparison process.

[0092] In addition, in industrial system 30, the simulation is based on design data used in the design of the industrial equipment.

[0093] Through this structure and action, the industrial system 30 can effectively utilize the simulation during the construction of the production line to assist in operation and detect anomalies.

[0094] Furthermore, in the industrial system 30, if the result of comparing the information of the movable part obtained by the sensor with the information of the virtual movable part is a deviation from a predetermined range regarding the action time of the movable part, the computing unit outputs a warning.

[0095] In addition, the sensor identifies the vicinity of the front end of the movable part to obtain the information.

[0096] The sensor may be a camera unit that can identify the markings pasted on the movable part to obtain the information.

[0097] Through these structures and movements, information about the movable parts can be easily obtained. Furthermore, by comparing with simulations that have not been used before, abnormalities and signs of abnormality in the actual device can be detected.

[0098] Furthermore, the industrial equipment constitutes at least a part of the manufacturing production line, and the simulation is a simulation using computer-aided design data from the design of the manufacturing production line. Therefore, data used in the design of the production line can be directly utilized.

[0099] Furthermore, by updating the simulation results data in the event of design changes to industrial equipment, it is possible to adapt to the latest conditions and perform anomaly detection with high accuracy.

[0100] Furthermore, by using design data from the construction of an industrial assembly line containing multiple processes to simulate the operation of the industrial assembly line, and comparing the hypothetical relationships between the multiple processes in the simulation results with the relationships between the multiple processes when the industrial assembly line is in operation, anomalies in the industrial assembly line can be detected, thereby identifying the parts that are most likely to be the main cause of the anomalies.

[0101] Furthermore, the present invention is not limited to the embodiments described above, but includes various modifications. For example, the embodiments described above are examples given in detail for the purpose of readily understanding the present invention, and are not limited to having all the structures described. In addition, structural substitutions or additions are also possible, without being limited to the deletion of the structure.

[0102] Furthermore, regarding the aforementioned structures, functions, processing units, and processing modules, some or all of them can be implemented in hardware, for example, through integrated circuit design. Additionally, the present invention can also be implemented using software program code for implementing the functions of the embodiments. In this case, a storage medium storing program code is provided to a computer, and the computer's processor reads the program code stored in the storage medium. In this case, the program code read from the storage medium itself implements the functions of the aforementioned embodiments, and the program code itself and the storage medium storing the program code constitute the present invention. Examples of storage media for supplying such program code include floppy disks, CD-ROMs, DVD-ROMs, hard disks, SSDs (Solid State Drives), optical disks, optical discs, CD-Rs, magnetic tapes, non-volatile memory cards, and ROMs.

[0103] Furthermore, the program code used to implement the functions described in this embodiment can be installed using a wide range of program or scripting languages, such as assembler, C / C++, perl, shell, PHP, and Java (registered trademark).

[0104] In the above embodiments, control lines and information lines refer to the control lines and information lines deemed necessary for the description, but may not necessarily represent all control lines and information lines on the product. All structures can be interconnected.

[0105] Explanation of reference numerals in the attached figures

[0106] 30: Industrial system; 40: Industrial production line; 50: Control system; 60: Anomaly detection system; 61, 71: Input unit; 62, 72: Display unit; 63, 73: Communication unit; 64, 74: Control unit; 65, 75: Storage unit; 70: Analog system.

Claims

1. An industrial system, characterized in that, have: The storage department stores process planning data and design data for verifying the operation of industrial equipment during the construction of industrial production lines. The simulation execution unit generates a simulation model based on the process planning data and the design data, and performs simulations of the operation of the industrial production line through the simulation model; as well as The detection department compares the simulation results with the actual operation of the industrial production line to detect abnormalities in its components. The industrial production line includes multiple of the aforementioned industrial devices. The design data includes data that determines the shape of the industrial equipment. The simulation actuator uses the shape of the industrial equipment determined according to the design data to calculate at least one of the velocity and acceleration information of the movable parts of the industrial equipment, as well as the position information. The detection unit compares at least one of the velocity and acceleration information and the position information of the movable part of the industrial equipment calculated based on the measurement results of the sensors installed on the industrial production line with at least one of the velocity and acceleration information and the position information of the movable part calculated by the simulation execution unit, and outputs the comparison result.

2. The industrial system according to claim 1, characterized in that, The industrial system includes a fault cause estimation unit, which, based on the comparison results, detects the operation of the constituent elements of the industrial production line that are the primary cause of an anomaly when an anomaly is determined.

3. An industrial system having: Sensors that acquire information from industrial equipment; and The computing unit performs calculations based on the information obtained from the sensor. Its features are, When the industrial equipment is used, the sensor acquires at least one of the velocity and acceleration information of the movable parts of the industrial equipment, as well as the position information. The computing unit performs a comparison between at least one of the velocity and acceleration information and the position information of the movable part obtained by the sensor and at least one of the velocity and acceleration information and the position information of a virtual movable part obtained through simulation of the industrial equipment, and outputs the result of the comparison process. The simulation is a simulation of the operation of the industrial production line during its use, generated using a simulation model based on process planning data and design data for verifying the movement of industrial equipment during the construction of the industrial production line. The design data includes data that determines the shape of the industrial equipment. In the simulation, using the shape of the industrial equipment determined according to the design data, at least one of the velocity information and acceleration information of the movable parts of the industrial equipment, as well as the position information, are calculated.

4. The industrial system according to claim 3, characterized in that, The sensor identifies the vicinity of the front end of the movable part to obtain at least one of the velocity information and acceleration information of the movable part, as well as the position information. The vicinity of the front end of the movable part is the region from the front end of the movable part to a predetermined position.

5. The industrial system according to claim 3, characterized in that, The sensor is a camera unit that identifies a mark pasted on the movable part to obtain at least one of the velocity information and acceleration information of the movable part, as well as its position information.

6. The industrial system according to claim 3, characterized in that, The industrial equipment constitutes at least a part of the manufacturing production line.

7. The industrial system according to claim 3, characterized in that, The computing unit reads simulation result data representing at least one of the velocity and acceleration information of the virtual movable part, as well as the position information, from a predetermined storage unit to perform the comparison. If a design change is made to the industrial equipment or the operation of the industrial equipment, the simulation result data in the storage unit is updated.

8. The industrial system according to claim 3, characterized in that, Multiple of the aforementioned industrial devices are installed on the industrial production line. The computing unit performs a series of process simulations of multiple industrial devices, compares at least one of the velocity and acceleration information and the position information of the movable part based on the measurement results of sensors installed on the industrial production line with at least one of the velocity and acceleration information and the position information of the movable part based on the simulation results of the series of process simulations, and outputs the comparison result.

9. The industrial system according to claim 3, characterized in that, Multiple of the aforementioned industrial devices are installed on the industrial production line. Based on the results of the comparison process, the calculation unit detects the actions of the constituent elements of the industrial production line that are the main cause of an anomaly when an anomaly is determined.

10. An anomaly detection system, characterized in that, have: The storage department stores process planning data and design data for verifying the operation of industrial equipment when building industrial production lines that include multiple processes. The simulation execution unit generates a simulation model based on the process planning data and the design data, and performs simulations of the operation of the industrial production line through the simulation model; as well as The detection department compares the virtual relationships between multiple processes in the simulation results with the actual relationships between the multiple processes during the operation of the industrial production line to detect anomalies in the industrial production line. The industrial production line includes multiple of the aforementioned industrial devices. The design data includes data that determines the shape of the industrial equipment. The simulation actuator uses the shape of the industrial equipment determined based on the design data to calculate at least one of the velocity and acceleration information of the movable parts of the industrial equipment, as well as the position information. The detection unit compares at least one of the velocity and acceleration information and the position information of the movable part of the industrial equipment calculated based on the measurement results of the sensors installed on the industrial production line with at least one of the velocity and acceleration information and the position information of the movable part calculated by the simulation execution unit, and outputs the comparison result.

11. An anomaly detection method, characterized in that, Include: The simulation execution steps utilize a simulation model generated based on process planning data and design data for verifying the motion of industrial equipment during the construction of industrial production lines. This model simulates the motion of the industrial production line during operation. The simulation results yield at least one of the velocity and acceleration information of the movable parts of the industrial equipment, as well as its position information. The information acquisition step involves acquiring at least one of the speed information and acceleration information of the movable parts of the industrial equipment during the operation of the industrial production line, as well as the position information. The detection step involves comparing at least one of the velocity and acceleration information, and the position information, of the movable parts of the industrial equipment as a result of the simulation with at least one of the velocity and acceleration information, and the position information, of the movable parts of the industrial equipment during operation of the industrial production line, to detect abnormalities in the constituent elements of the industrial production line. The industrial production line includes multiple of the aforementioned industrial devices. The design data includes data that determines the shape of the industrial equipment. In the simulation execution step, using the shape of the industrial equipment determined according to the design data, at least one of the velocity information and acceleration information of the movable part of the industrial equipment, as well as the position information, are calculated.

12. An anomaly detection method, characterized in that, Include: The steps of generating a simulation model for verifying the motion of industrial equipment during the construction of an industrial production line based on process planning data and design data, wherein the design data represents the requirements for the industrial production line; The steps of simulating the actual actions of the industrial production line during its operation using the simulation model; The step of storing at least one of the velocity information and acceleration information of the movable part of the industrial equipment, representing the result of the simulation, and the position information; The step of obtaining information on at least one of the velocity and acceleration information of the movable parts of the industrial equipment used in an industrial production line constructed based on the simulation results, as well as the position information; and A detection step for detecting anomalies in the components of the industrial production line involves comparing at least one of the velocity and acceleration information and the position information of the movable parts of the industrial equipment, representing the results of the simulation, with the velocity and acceleration information and the position information of the movable parts of the industrial equipment during operation of the industrial production line. The industrial production line includes multiple of the aforementioned industrial devices. The design data includes data that determines the shape of the industrial equipment. In the simulation step, using the shape of the industrial equipment determined according to the design data, at least one of the velocity information and acceleration information of the movable part of the industrial equipment, as well as the position information, are calculated.

13. The anomaly detection method according to claim 12, characterized in that, The anomaly detection method further includes: The step of re-executing the simulation to update the simulation results data as the structure of the industrial production line changes; The step of detecting anomalies in the components of the industrial production line by comparing the updated result data with the operation of the industrial production line when the changes in its structure have been made.

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