Control device, control method, and control system

Abstract

The invention provides a control device, a control method and a control system, which can make a more suitable control system for a control object. The control device is provided with: a control object state ascertaining device (601) that acquires a predetermined state quantity of the control object (500) and detects an abnormality in the state quantity of the control object (500) on the basis of the operation performance of the control object (500); a control object analysis device (701) that estimates the correlation between the state quantities of the control object (500) and determines the input state quantity, the output state quantity, and the type of control system required to control the control object (500); and a control system design device (702) that sets a transfer function, which is the temporal response of the control object (500), and a control parameter of the control system.

Description

Technical Field

[0001] The present invention relates to a control device, a control method, and a control system, and in particular to a control device and the like to which various control systems can be applied. Background Art

[0002] In order to improve product quality and operational efficiency, industrial equipment and other control objects are controlled based on various control methods. A certain control method is not always optimal for all states of the industrial equipment that is the control object, but is almost always optimal under specific states. Since the state of industrial equipment is always changing, even for the same control purpose, it is necessary to prepare multiple control methods and change the control method according to the state of the industrial equipment. In addition, by developing and applying new control methods for improving control performance, it is possible to expect further improvements in product quality and operational efficiency.

[0003] Generally, the control of one control object in industrial equipment is undertaken by a single manufacturer, so when another manufacturer develops a new control method, it is difficult to apply the new control method. Therefore, the control in the industrial equipment is often not in the highest state at that moment.

[0004] As an industrial equipment, for example, a rolling mill for rolling a metal plate as a rolled material is known. The rolling mill uses a tension reel to deliver and coil the rolled material, and the rolled rolled material is rolled between a pair of rollers. In such a rolling mill, for example, plate thickness control for controlling the interval between the roller pairs and tension control for controlling the speed of the tension reel (actually, the current of the motor) have been used. However, under certain rolling conditions, the control effect of control systems such as plate thickness control for adjusting the speed of delivering the rolled material from the tension reel and tension control for controlling the interval between the roller pairs is higher, so it has been proposed to maximize the control effect by switching between the two (for example, refer to Patent Document 1).

[0005] Furthermore, it has been proposed to perform control of the thermal expansion of the rolls also using the rolling speed when rolling an extremely thin material such as foil (for example, refer to Patent Document 2).

[0006] Patent Document 1: Japanese Patent Application Publication No. 2014-113629

[0007] Patent Document 2: Japanese Patent Application Publication No. 2020-104165 Summary of the invention

[0008] The object of control is, for example, a device that can manufacture various products. The state of the object of control changes depending on the manufactured product and the operating conditions (mechanical conditions of the device such as the manufacturing speed and manufacturing temperature). When the state of the object of control changes, the control method needs to be changed accordingly. As the change method, there are control methods (proportional control, integral control, etc., a combination of a state quantity and a control operation end, etc.), and there are control gains in each control method.

[0009] By changing the control system according to the state of the controlled object, the value and manufacturing efficiency of the products manufactured by the controlled object equipment can be improved. Therefore, new control methods are being developed.

[0010] When developing a new control method, a control technician analyzes a problem point according to a requirement such as improving the product accuracy of the controlled object equipment, selects a detectable state quantity of the controlled object from a state quantity detection device according to the problem point, selects an operating end for operating the selected state quantity from an operating end working device, and designs the relationship between the state quantity and the operating end as a control system-i of the control device. When designing a control system, the dynamic characteristics (time response characteristics) between the operating end and the state quantity are considered, and the control system needs to be stabilized. In the past, this operation was performed by a control technician, but it was necessary to perform analysis of the actual performance data of the controlled object equipment and design of the control system, which was a heavy burden on the technician.

[0011] In addition, it is necessary to verify the effectiveness of the new control system, the adjustment of the optimal control gain, the range of state quantities of the control object that can be used, etc.

[0012] In addition, when applying a new control method, it is necessary to analyze the controlled object, design the control system based on the results, and apply the control method experimentally while observing the state of the controlled object according to the purpose of the control method (effective when the state of the controlled object exists, etc.), and adjust the control method while distinguishing the effect. At present, people perform these operations while confirming the state of the controlled object, which becomes manual work.

[0013] An object of the present invention is to provide a control device, a control method and a control system capable of making a more suitable control system for a controlled object.

[0014] In order to solve the above-mentioned problems, the present invention is a control device, comprising: an acquisition unit, which acquires a predetermined state quantity of a control object; a detection unit, which detects an abnormality in the state quantity of the control object based on the operating performance of the control object; a determination unit, which infers the correlation between the state quantities of the control object and determines the input state quantity, output state quantity and type of control system required for controlling the control object; and a setting unit, which sets the transfer function as the time response of the control object and the control parameters of the control system.

[0015] In addition, the present invention is a control method comprising the following steps: obtaining a predetermined state quantity of a control object; detecting an abnormality in the state quantity of the control object based on the operating performance of the control object; estimating the correlation between the state quantities of the control object, determining the input state quantity, output state quantity and type of control system required to control the control object; and setting a transfer function as a time response of the control object and control parameters of the control system.

[0016] Moreover, the present invention is a control system comprising: a predetermined control object; and a control device, which selects a control system applied to the control object, the control device comprising: an acquisition unit, which acquires the state quantity of the control object; a detection unit, which detects abnormalities in the state quantity of the control object based on the operating performance of the control object; a determination unit, which infers the correlation between the state quantities of the control object and determines the input state quantity, output state quantity and type of control system required for controlling the control object; and a setting unit, which sets the transfer function as the time response of the control object and the control parameters of the control system.

[0017] According to the present invention, a control device, a control method, and a control system can be provided, which can produce a control system more suitable for a control object compared to a case where the present structure is not adopted. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a conceptual diagram showing the overall configuration of the control system in the first embodiment.

[0019] Figure 2 It is a diagram showing an example of a control system for a control object.

[0020] Figure 3 (A) is a conceptual diagram showing the structure of a controlled object, and (B) is a diagram showing the definition of a transfer function.

[0021] Figure 4 This is a diagram showing the relationship between the control target, FF control, and FB control.

[0022] Figure 5It is a block diagram showing the functional structure of the control system according to the present embodiment.

[0023] Figure 6 This is a diagram showing an example of a transfer function of a controlled object.

[0024] Figure 7 It is a diagram showing an example of a control object influence DB.

[0025] Figure 8 This is a diagram showing an example of a control object characteristic DB and a control system template DB.

[0026] Fig. 9 This is a diagram showing the procedure for automatically designing a control system.

[0027] Fig.10 Yes means through Fig. 9 The diagram shows an example of a control system produced in the order shown.

[0028] Fig.11 Yes means through Fig. 9 The diagram shows an example of a control system produced in the order shown.

[0029] Fig.12 is a more detailed representation Figure 1 A conceptual diagram of the overall structure of the control system shown.

[0030] Fig.13 This is a diagram showing the contents of data registered in the registration control system DB.

[0031] Fig.14 This is a diagram showing the contents of data registered in the control system selection DB.

[0032] Fig.15 This is a diagram showing the operation flow of the control system when the control object is controlled using the general control system 6 and the registered control system.

[0033] Fig.16 This is a diagram showing an overview of processing performed by the registration control system execution device.

[0034] Fig.17 The diagrams respectively show input data and output data registered in the registration control system DB for each registration control system.

[0035] Fig.18 It is a schematic diagram showing a control system in the second embodiment.

[0036] Fig.19 This is a diagram showing input (disturbance), input (operation amount), and output (state amount) when the control object is replaced with a rolling mill.

[0037] Fig. 20 This is a diagram showing the change in shape of the rolled material caused by changing the bending machine.

[0038] Explanation of symbols

[0039] 500…Control object, 501…Control system, 511…Control device, 401, 601…Control object state grasping device, 402, 602…Control system switching device, 403, 603…Control system adjusting device, 701…Control object analyzing device, 702…Control system designing device, 703…Control system registration device, 711…Control object characteristic DB, 712…Control system template DB, 713…Control object influence DB, 801, 901…Input (interference), 802, 902…Input (operation quantity), 803, 903…Output (state quantity), 810…Control object device transfer function, 812…Operation end working device transfer function, 813…State quantity detection device transfer function, 814…Interference transfer transfer function, S…Control system. DETAILED DESCRIPTION

[0040] Hereinafter, embodiments of the present invention will be described in detail through first and second embodiments with reference to the drawings.

[0041] [First embodiment]

[0042] Here, first, a first embodiment of a control system S to which this embodiment is applied is described. In the first embodiment, the control system S uses a control target device 510, which is a general industrial device, as a control target 500. In addition, a case where a control device 511 included in the control system S selects a control system 501 to be applied to the control target device 510 from among a general control system 614 and registered control systems 615B to 615Z is described. In addition, below, when the registered control systems 615B to 615Z are not distinguished, they are sometimes simply referred to as the registered control system 615.

[0043] <Description of the overall structure of the control system S>

[0044] Figure 1 It is a conceptual diagram showing the overall configuration of the control system S in the first embodiment.

[0045] Generally, the device control is implemented by using the deviation between the state quantity of the control object 500 and the command value to perform control calculation by the control system 501 and provide the control command to the control object 500. The control object 500 has state quantities and control operation terminals composed of multiple types, and the control system 501 combines them to implement control.

[0046] Here, "state" means the state of the control object 500 itself and the state of the product manufactured by the control object 500. The state of the control object 500 itself is equivalent to, for example, the operating speed, operating temperature, etc. In addition, the state of the product manufactured by the control object 500 is, for example, the temperature, size, etc. of the product. In the case where the control object 500 is a rolling mill that manufactures rolled steel plates, the thickness of the rolled steel plates, etc. are equivalent to the state of the product. The "state quantity of the control object 500" is obtained by quantifying the state. The "control operation end of the control object 500" refers to the part of the control object 500 that receives control instructions.

[0047] The control object 500 is, for example, the control object device 510 described later, which is an industrial device capable of manufacturing various products. In the control object 500, the above-mentioned state changes according to the manufactured product and the operating conditions. "Operating conditions" are, for example, mechanical conditions of industrial equipment such as manufacturing speed and manufacturing temperature. In addition, when the state of the control object 500 changes, the control system 501 changes the control method accordingly. As a change in the control method, in addition to the change in the control method itself, there is also a change in the control gain. As a change in the control method itself, for example, it corresponds to a change in the combination of proportional control, integral control, differential control, etc., a combination of state quantity and control operation end, etc.

[0048] By changing the control method according to the state of the control object 500, it is possible to improve the value and manufacturing efficiency of the product manufactured by the control object 500. Therefore, the manufacturer develops the control system 501 that always uses a new control method.

[0049] Figure 2 1 is a diagram showing an example of a control system 501 for a control object 500 .

[0050] Regarding the controlled object 500, the output (state quantity) 803 of the controlled object 500 changes according to the input (disturbance) 801 and the input (operation quantity) 802. Here, the input (disturbance) 801 is a change in an external factor that affects the controlled object 500, and also includes a change that can be detected by the state quantity detection device 513 of the controlled object device 510. The input (operation quantity) 802 can artificially change the output (state quantity) 803 of the controlled object 500. The output (state quantity) 803 changes due to the input (disturbance) 801, but it can be eliminated by changing the input (operation quantity) 802. In addition, sometimes the input (operation quantity) 802 is changed in order to change the output (state quantity) 803 from a certain state to another state.

[0051] If the influence of input (disturbance) 801 on output (state quantity) 803 is known, the change of input (disturbance) 801 can be detected and the change of output (state quantity) 803 can be predicted. Moreover, by changing the input (operation quantity) 802, the output (state quantity) 803 can be kept constant. This control is performed by FF (feedforward) control 804. Since all input (disturbance) 801 cannot be detected, unpredictable changes occur in output (state quantity) 803. Therefore, FB (feedback) control 805 changes the input (operation quantity) 802 according to the change of output (state quantity) 803, and suppresses the change of output (state quantity) 803. As a control system, FF control or FB control is adopted, so that the control accuracy of the control object 500 is improved.

[0052] There are multiple types of input (disturbance) 801, input (operation amount) 802, and output (state amount) 803, and the influence of each is different.

[0053] For example, when the output (state quantity) 803 (a) changes greatly (has a large influence) due to the change of the input (disturbance) 801 (a), if it is known that the output (state quantity) 803 (a) changes greatly due to the input (operation quantity) 802 (b), the FF control 804 that takes the input (disturbance) 801 (a) as input and outputs to the input (operation quantity) 802 (b) is used. In this way, the influence of the input (disturbance) 801 (a) on the output (state quantity) 803 (a) can be suppressed.

[0054] In addition, when the output (state quantity) 803 (b) changes greatly due to the input (operation quantity) 802 (n), the FB control 805 that changes the input (operation quantity) 802 (n) according to the change of the output (state quantity) 803 (b) is used. In this way, the change of the output (state quantity) 803 (b) can be suppressed.

[0055] Figure 3 (A) is a conceptual diagram showing the structure of the control object 500.

[0056] like Figure 3 As shown in (A), the control object 500 is composed of a control object device 510, an operation end working device 512 for providing an input (operation amount) 802 to the control object device 510, a time response until the input (disturbance) 801 affects the control object device 510, that is, a disturbance transfer 514, and a state quantity detection device 513 for detecting the state quantity of the control object device 510. The operation end working device 512, the state quantity detection device 513, and the disturbance transfer 514 are determined by the mechanical structure of the control object 500, the electrical response of the mechanical device used, and the mechanical response, and the transfer function as the time response can be known in advance. Therefore, it can be considered that these transfer functions are fixed.

[0057] In this embodiment, if Figure 3 As shown in (B), the transfer functions as the time responses of the control object device 510, the operating end working device 512, the interference transfer 514, and the state quantity detection device 513 are respectively defined corresponding to each other. The control object device transfer function G(S) 810 is a transfer function representing the time response to the control object. The operating end working device transfer function A(S) 812 is a transfer function representing the time response to the operation quantity. The state quantity detection device transfer function M(S) 813 is a transfer function representing the time response to the state quantity detection device 513. The interference transfer transfer function D(S) 814 is a transfer function representing the time response to the interference. By setting such a transfer function to be consistent with the actual time response of the control object, the control accuracy of the control object 500 can be improved.

[0058] The control target device transfer function G(S)810 changes depending on the state of the control target device and the product produced, but the operating end working device transfer function A(S)812, the state quantity detection device transfer function M(S)813, and the disturbance transfer transfer function D(S)814 are functions inherent to the control target 500 and can be investigated in advance through experiments or the like. Therefore, it can be considered that these transfer functions are known. That is, the operating end working device transfer function A(S)812, the state quantity detection device transfer function M(S)813, and the disturbance transfer transfer function D(S)814 are predetermined by the characteristics of the control target 500. In this case, the setting of the transfer function becomes easier.

[0059] Therefore, if the controlled device transfer function G(S) 810 can be obtained, the transfer function of the controlled object 500 can be estimated.

[0060] Figure 4 80 is a diagram showing the relationship among the control object 500 , FF control 804 , and FB control 805 .

[0061] As described above, if the transfer function G(S) 810 can be estimated, each control can be designed. Here, design means determining the following control parameters for each control so that each control is stable in control theory. In this case, the control parameters include the gain of at least one of FF (feedforward) control and FB (feedback) control. Thus, when performing FF control and FB control, it is possible to make settings that make it easy to exert these functions.

[0062] FF control situation

[0063] Conversion gain C: Coefficient for converting input (interference) 801 to input (operation amount) 802

[0064] Control gain K FF : Coefficient for stable implementation of FF control 804

[0065] Useless time T FF : Coefficients of the correction disturbance transfer function 814

[0066] FB control situation

[0067] Conversion gain C: The coefficient control gain K that converts the output (state quantity) 803 into the input (operation quantity) 802 P : Coefficient for stable proportional control

[0068] Control gain K I : Coefficient for stable implementation of integral control

[0069] The design methods of the FF control 804 and the FB control 805 are described in various ways in known documents, and thus the description thereof is omitted.

[0070] In addition, here, the FF control 804 and the FB control 805 are described, but the FB control 805 may be set to proportional control or proportional integral derivative control, or the optimal control may be applied by presetting a template of the control system.

[0071] By predefining control templates such as the FF control 804 and the FB control 805 and the setting method of each of the above-mentioned control parameters corresponding to the transfer function of the control object 500, the design work can be automated.

[0072] <Description of the method for automating the design work of the control system>

[0073] Next, a method of automating the design work of the control system will be described below.

[0074] Figure 5 : is a block diagram showing the functional structure of the control system S according to the present embodiment.

[0075] The control system S of this embodiment includes a control object analyzing device 701 , a control system designing device 702 , a control system registering device 703 , a control object characteristic DB (database) 711 , a control system template DB 712 , and a control object influence DB 713 .

[0076] The controlled object analyzing device 701 estimates the transfer function 810 of the controlled object 500, in particular, the controlled object device 510. The state of the controlled object 500 changes according to the operating state (operating mode, operating speed, product type, etc.) of the controlled object 500, so it is necessary to estimate the controlled object device transfer function 810 according to the operating state.

[0077] After the analysis in the control object analysis device 701 is completed, the control system design device 702 implements the design work of the control system. The control system design device 702 extracts a combination with a larger relationship from the relationship between multiple inputs (disturbances) 801 and inputs (operation quantities) 802, and the relationship between multiple outputs (state quantities) 803 and inputs (operation quantities) 802, and selects a control system (FF control, FB control, etc.) as a template from the control system template DB712 for the combination. In addition, the control system design device 702 estimates the transfer function of the control object 500 based on the control object device transfer function 810 estimated by the control object analysis device 701 and the operating end working device transfer function A(S)812, state quantity detection device transfer function M(S)813 and disturbance transfer transfer function D(S)814 pre-registered in the control object characteristic DB711, and determines the control parameters required for the template of the selected control system.

[0078] The control system registration device 703 registers the new control system created by the control system design device 702 in the registered control system DB 605 and the registered control system 615 .

[0079] As an example of automatic design of a control system, the following matters are assumed regarding the control object 500 .

[0080] Each transfer function (can) be approximated by dead time + primary delay.

[0081] The control target device transfer function 810 is a physical phenomenon of the control target device 500, so the time constants of the dead time and the first-order delay are set to be smaller than the others. Therefore, the control target device transfer function 810 is considered to be a conversion gain G without time response. G In this case, the controlled device transfer function 810 can be expressed in a simpler expression while maintaining accuracy.

[0082] The disturbance transfer function 814 is considered to be a time delay from the disturbance generation source to the time when the input (disturbance) 801 reaches the control target device 510, and the primary delay time is considered to be negligible.

[0083] Figure 6 3 is a diagram showing an example of the transfer function of the control object 500 obtained based on the above assumptions.

[0084] Figure 6 The transfer function illustrated in FIG. 8 exists for each of a plurality of types of input (disturbance) 801 , input (operation amount) 802 , and output (state amount) 803 .

[0085] In the controlled object analysis device 701, the performance data of the controlled object 500 is used to obtain the correlation between various types of input (disturbance) 801 of the controlled object 500 and various types of output (state quantity) 803 of the controlled object 500, and the correlation between various types of input (operation quantity) 802 of the controlled object 500 and various types of output (state quantity) 803 of the controlled object 500. The correlation can be obtained by obtaining the similarity of movement in the time series using the time series performance data, or whether the output (state quantity) 803 changes when the input (operation quantity) 802 changes. This is accumulated in the controlled object influence DB 713 as the change ratio (influence degree) of the output (state quantity) 803 to the change of the input (operation quantity) 802 and the change ratio (influence degree) of the output (state quantity) 803 to the change of the input (disturbance) 801.

[0086] Figure 7 It is a diagram showing an example of the control object influence DB 713.

[0087] Figure 7 The control object influence DB 713 shown includes the state of the control object 500 with respect to the input (operation amount) 802 and the output (state amount) 803. In addition, the control object influence DB 713 includes the state of the control object 500 with respect to the input (disturbance) 801 and the output (state amount) 803. Then, the change ratio (degree of influence) is calculated based on these.

[0088] The control object influence DB 713 is classified according to the control object state determined by the control object state grasping device 601 described in detail later, and the influence degree is accumulated. The physical meaning of the signal varies according to the type of input and output, and it is difficult to compare them in general. Therefore, an allowable range is set so that there is no problem even if it changes according to the type of each signal, and the ratio of the output (state quantity) to the change in the allowable range when the input (operation amount, disturbance) changes within the allowable range is used as the influence degree.

[0089] In the control system design device 702, a new control system design operation is performed using the control object characteristic DB 711, the control system template DB 712, and the control object influence DB 713.

[0090] Figure 8 It is a diagram showing an example of the control object characteristic DB 711 and the control system template DB 712.

[0091] The control object characteristic DB 711 is a database in which the characteristics of the control object 500 are registered. The characteristics of the control object 500 can be determined based on electrical and mechanical characteristics, so the characteristics are measured in advance and registered in the control object characteristic DB 711. Here, as the characteristics of the control object 500, the operating end working device transfer function 812, the state quantity detection device transfer function 813, and the disturbance transfer transfer function 814 are registered.

[0092] The control system template DB 712 is a database in which control system templates are registered. The control system template DB 712 pre-registers the template of the control system to be automatically designed. Here, FF control and FB control are registered as control system templates. In addition, the control system stability margin is also registered in the control system template DB 712, which is used in actual design.

[0093] The controlled object state grasping device 601 monitors the state of the controlled object 500 and determines the quality of the product produced by the controlled object 500 by analyzing the performance data. Here, as a state where the output (state quantity) 803 (a) changes greatly and the product quality deteriorates, when the controlled object state is state B (refer to Figure 7 ), as a countermeasure, the following describes the situation of creating a new control system.

[0094] Fig. 9 This is a diagram showing the procedure for automatically designing a control system.

[0095] like Fig. 9 As shown, the automatic design of the control system is based on the analysis of the relationship between the input and output of the control object 500, and then the input and output of the control system are selected, the control system is selected, and finally the control system gain is set.

[0096] In the input-output relationship analysis, according to the control object impact DB713, when the control object state is in state B, the influence of the input (operation quantity) 802(a) on the output (state quantity) 803(a) is large, and the influence of the input (interference) 801(b) on the output (state quantity) 803(a) is large.

[0097] Therefore, in this case, FF control and FB control are selected as the control system. Regarding the input and output to the control system, as FF control, it is effective to use the input (disturbance) 804 (b) as the input and output the input (operation amount) 802 (a). As FB control, if the output (state amount) 803 (a) is used as the input and the input (operation amount) 802 (a) is used as the output, it can be judged that the control effect is large.

[0098] Fig. 9 The method shown can also be said to be making a control system according to the following steps.

[0099] First, the controlled object state grasping device 601 as an example of an acquisition unit acquires a predetermined state quantity of the controlled object 500. The state quantity corresponds to input (disturbance) 801, input (operation quantity) 802, and output (state quantity) 803. In this case, a more appropriate state quantity can be extracted.

[0100] Next, the controlled object state grasping device 601 as an example of a detection unit detects an abnormality in the state quantity of the controlled object 500 based on the operation performance of the controlled object 500. If the product quality deteriorates, an abnormality in the state quantity occurs.

[0101] Furthermore, the control object analysis device 701 as an example of a determination unit estimates the correlation between the state quantities of the control object 500, and determines the input state quantity, output state quantity and the type of control system required for controlling the control object 500. The above-mentioned input-output relationship analysis is equivalent to estimating the correlation. The input state quantity is equivalent to the input (disturbance) 801 and the input (operation quantity) 802. The output (state quantity) 803 is equivalent to the output state quantity. In the above-mentioned example, FF control and FB control are equivalent to the types of control systems.

[0102] In addition, at this time, the control object analysis device 701 obtains the input state quantity, output state quantity, and the relationship between the input state quantity and the output state quantity, and determines the input state quantity, output state quantity, and type of control system required for controlling the control object 500 based on the obtained relationship. In this way, the input state quantity, output state quantity, and type of control system with a large control effect can be determined. The correlation is as follows: Figure 7 As described in , the influence degree of the input state quantity on the past operation performance is obtained. Thus, the control effect can be judged based on the past operation performance.

[0103] Furthermore, the control system design device 702 as an example of setting means sets a transfer function as a time response of the control object 500 and a control parameter of the control system. In this case, the value of the product manufactured by the control object 500 and the improvement of manufacturing efficiency can be achieved.

[0104] Fig.10 and Fig.11 Yes means through Fig. 9 Figure 1 shows an example of a control system generated in sequence.

[0105] Here, the G of the transfer function of the operating end working device is A (a) T DA (a) T A (a) represents the input (a) operation end transfer function parameter (refer to Figure 8 ), the state quantity detection device transfer function and the interference transfer transfer function are also the same.

[0106] The control target device transfer function GG is a transfer function G from input (operation quantity) to output (state quantity). GA (a, a) and the transfer function G from input (disturbance) to output (state quantity) GD (b, a).

[0107] Through the above sequence, a new control system can be generated. Fig.10 The FB control 805 shown and Fig.11 The transfer function related to the FF control 804 is shown. Since each control parameter of the transfer function is determined numerically, each control parameter of the FF control 804 and the FB control 805 can be determined as the control system stability margin set in the control system template DB712.

[0108] The control parameters may be determined by performing a time response simulation while changing the control gain to determine the optimal value, or may be automatically determined by a computer by creating a Bode plot or a Nyquist plot to set the control parameters.

[0109] As described above, a control system that is considered to be effective in suppressing product accuracy abnormalities can be automatically designed according to the state of the control object 500. Here, as the control system template, FF control 804 and FB control 805 with 1 input and 1 output are used, but other control systems such as optimal control can also be set. In this case, the control parameters to be set in the design of the control system, the setting method of the control system stability margin, etc. are different, but it can be dealt with by changing the content of the control system template DB712, the setting method of the control parameters, etc.

[0110] In the control system registration device 703, the newly designed new control system is set as the registered control system 615, and is set as a valid control system when the control object 500 in the registered control system DB is in state B. Thus, the adjustment and confirmation of the new control system can be implemented as one of the following registered control systems 615.

[0111] <Description of a method of controlling the controlled object 500>

[0112] Next, a method of controlling the control object 500 using the prepared control system or the control system produced by the above-mentioned method will be described.

[0113] Fig.12 is a more detailed representation Figure 1 A conceptual diagram of the overall structure of the control system S shown.

[0114] As shown in the figure, the control system S includes: a control object device 510 as an example of a predetermined control object 500; a control device 511 for selecting and executing the control system 501; an operating end working device 512 for operating the control object device 510; and a state quantity detection device 513 for detecting the state quantity of the control object device 510.

[0115] In this case, the state quantity detection device 513 detects the state quantity of the control target device 510. In addition, the control system 501 of the control device 511 performs control calculations and outputs control instructions to the operation end working device 512. In addition, the operation end working device 512 sends control instructions to the control operation end of the control target device 510 to operate the control target device 510. In this control system S, there are n types of control systems 501, namely, control system-1 to control system-n. According to the detected state of the control target device 510, the control device 511 selects any one of the control systems 501 to execute.

[0116] Hereinafter, first, the operation of the conventional control system S will be described.

[0117] Usually, for a certain controlled device 510, a control device 511 uses a control device of one manufacturer. In addition, the state quantity and control command of the controlled device 510 required in the control system 501 are different depending on the control purpose. Therefore, there are cases where control devices of different manufacturers are used as the control device 511 according to multiple control purposes, but usually a control device of one manufacturer is used for the control device 511 corresponding to one control purpose. In addition, the control device 511 is delivered in the form of being assembled with the control system 501 when the controlled device 510 is delivered, and thereafter, the manufacturer of the control device 511 updates the control system 501, etc.

[0118] As described above, the control system 501 is always under development, and a new control system 501 is produced. For example, when a new control system 501-N is produced, it is expected that the product value and manufacturing efficiency will be improved by using it. However, it is necessary to change the control system 501 stored in the control device 511 to the new control system 501-N. In addition, in this case, it is necessary to verify the effectiveness of the control system 501-N, the adjustment of the optimal control gain, the range of the state quantity of the control object device 510 that can be used, etc.

[0119] The controlled device 510 is usually operated for product manufacturing. In order to verify the new control system 501-N, it is necessary to avoid the impact of the implementation of the verification on the product as much as possible. Therefore, it is necessary to find a period in which the new control system 501-N can be verified based on the operating status of the controlled device 510, the product manufacturing plan, etc., and replace the previous control system 501 with the new control system 501-N during this period to implement verification of its effect, control gain, usable range, etc. Moreover, as of now, the new control system 501-N is verified by skilled operation technicians, control technicians and other technicians. The controlled device 510 is often operated 24 hours a day, 365 days a year, so the verification of the new control system 501-N is sometimes also carried out at night on weekends, which is a heavy burden on the technicians.

[0120] There are usually multiple manufacturers that can manufacture the control device 511 of a certain control target device 510. However, replacing a new control system 501-N developed by a different manufacturer from the manufacturer of the currently used control device 511 with the control device 511 is difficult because it requires understanding the internal structure of the control device 511. Therefore, in the past, even if a control system 501-N was developed as the latest control system 501 for the control target device 510, it was difficult to introduce the control system.

[0121] Therefore, in the control device 511 of the present embodiment, the solution to this problem is achieved using the method described below.

[0122] That is, the control device 511 of this embodiment also includes a new control system 501-N developed by other manufacturers, Fig. 9 The control system created by the method shown can be easily introduced into other control systems 501. In addition, in the control device 511 of this embodiment, it is possible to introduce and adjust other control systems 501 including a new control system 501-N while reducing the burden on engineers and the like.

[0123] Back to Figure 5 The control system S also includes a control device 511. The control device 511 includes a control object state grasping device 601, a control system switching device 602, a control system adjustment device 603, a control system selection DB (database) 604, a registration control system DB 605, an abnormality determination device 606, a production planning device 609, and an adjustment result DB 621. Figure 5 In FIG. 5 , a control object 500 is also illustrated.

[0124] The control object 500 and the control device 511 are the same as those in the above case. That is, the control object 500 is a general control object device 510. In addition, the control device 511 is a device that selects and executes the control system 501.

[0125] The controlled object state grasping device 601 obtains the state quantity of the controlled object 500 and grasps the state of the controlled object 500 .

[0126] The control system switching device 602 switches the control system 501. Here, as the control system 501, a general control system 614 and registered control systems 615B to 615Z are prepared, and the control system switching device 602 selects and switches the control system 501 from among them, and the details will be described later.

[0127] The control system adjustment device 603 adjusts the control system 501. That is, it adjusts the control gain, etc. In this case, the control system adjustment device 603 mainly adjusts the registered control systems 615B to 615Z.

[0128] The control system selection DB 604 registers information for defining the state of the control object 500 .

[0129] The registration control system DB 605 registers input data and output data required by each of the registration control systems 615B to 615Z.

[0130] The abnormality determination device 606 determines whether an abnormality has occurred in the control object 500 or a product manufactured by the control object 500.

[0131] The production planning device 609 stores a production plan for a product manufactured by the control object 500 .

[0132] The adjustment result DB 621 stores the results of the adjustment of the control system 501 by the control system adjustment device 603 .

[0133] In addition, the control device 511 includes an input data connection device 611, a control output switching device 612, an output data connection device 613, a general control system 614, and registration control systems 615B to 615Z. The registration control systems 615B to 615Z include Fig. 9 The control system is made by the method shown.

[0134] The input data connection device 611 supplies input data to the control system 501. At this time, the input data is supplied to one or more control systems 501 selected from the general control system 614 and the registered control systems 615B to 615Z.

[0135] The control output switching device 612 switches the control system 501 applied to the control object 500. At this time, the control output switching device 612 outputs its control command to the control object 500.

[0136] The output data connection device 613 receives output data from the control system 501 .

[0137] The general control system 614 is a generally used control system 501. The general control system 614 is a control system that has a performance on the control object 500 (proportional integral control, etc.), and the control device 511 generally controls the control object 500 using the general control system 614.

[0138] The registered control system 615 is a control system pre-registered for the purpose of improving the control function of the general control system 614. In the registered control system 615, multiple control systems 501 can be pre-registered. Here, in order to identify each registered control system 615, it is shown as a registered control system 615x (x is assigned an appropriate symbol, and it is assumed that B to Z are assigned here). In addition, as a device for executing the registered control system 615, the input data connection device 611, the output data connection device 613, and the registered control system 615 are sometimes referred to as a registered control system execution device 620. And, in the case where the control system switching device 602 determines to use one of the registered control systems 615B to 615Z instead of the general control system 614, the general control system 614 stops control, and the registered control system execution device 620 implements control of the control object 500 through the selected registered control system 615.

[0139] <Detailed description of data used in control system S>

[0140] like Fig.12 As described in , the state quantity detection device 513 detects the state quantity of the control target device 510. In addition, the control system 501 of the control device 511 performs control calculations and outputs control instructions to the operating end working device 512. In addition, the operating end working device 512 operates the control target device 510. In this case, the input data is used as the output of the state quantity detection device 513, and the output data is used as the input of the operating end working device 512, and the control target device 510 is controlled.

[0141] These input data and output data are determined according to the purpose of the control system 501. The input data is, for example, data output from the state quantity detection device 513. In addition, the output data is data input to the operation end working device 512. Therefore, by connecting the required input data and output data to the control device 511, the control system 501 can be replaced.

[0142] Therefore, in this embodiment, the input data and output data required for each of the registration control systems 615B to 615Z are pre-registered in the registration control system DB 605 as a database. Then, the registration control system DB 605 is connected to the input data connection device 611. Thus, the input data output to the input data connection device 611 is set.

[0143] In addition, the registration control system DB 605 is connected to the output data connection device 613. Thus, the output data output from the output data connection device 613 is set.

[0144] Furthermore, on the basis of implementing the control of the control object 500, there is also information required for control gain calculation, control timing determination, etc., so the registration control system DB605 also registers this information together. Such information is, for example, the mechanical characteristics of the control object 500, the specifications of the detector, the control operation end, the interlocking conditions, the manufacturing product specifications, etc. In addition, hereinafter, this information is sometimes referred to as "device information". And, this device information is also used as input data. In addition, in order to confirm the action of the control system 501, in addition to the output to the control operation end, the internal state quantity of the control system 501 is also required. Therefore, in the registration control system DB605, in addition to the control output (control instruction) to the control operation end, the internal state quantity of the control system 501 can also be registered. In addition, these data can also be used as the data required for the analysis of the control system 501, and can also be seen in the control system adjustment device 603.

[0145] In the control of the control object 500, for performance evaluation, steady-state deviation removal characteristics (removing steady-state errors of the control model, corresponding to the case where interference changes in a step or ramp shape), frequency characteristics (improving the frequency characteristics of the control object, detector, and control operation end), interference removal characteristics (eliminating interference to the control system), etc. are required. Since it is difficult to make the control system 501 have characteristics that improve all of them, the development of the control system 501 is usually implemented in a manner that improves one or more characteristics.

[0146] There are many situations where the generation of interference to the control object 500, the factors of change of the state quantity, and the frequency characteristics can be investigated and roughly clarified. Therefore, according to the state quantity of the control object 500 and the production plan, the required control characteristics are predefined so that they can be grasped and identified by the control object state grasping device 601. In addition, the state quantity of the control object 500 and the production plan from the production planning device 609 are input to the control object state grasping device 601. The production planning device 609 is a device that manages the production status of the products manufactured by the control object 500, and outputs what products are produced in what order and time to the control object state grasping device 601.

[0147] When a control system 501 is newly developed, its performance confirmation and adjustment of control gain and the like are required. In this case, depending on the control system 501, oscillation or divergence may occur. Therefore, initially, a product that has no problem even if the product quality is slightly deteriorated, or a product for testing that has nothing to do with product quality is used for testing. Furthermore, once it can be confirmed that there is no problem with the control operation, it is necessary to gradually perform testing using product materials.

[0148] Therefore, input data, output data, and control characteristics to the registration control system 615 are pre-registered in the registration control system 615. Then, based on this information, the input data connection device 611 provides the registration control system 615 with data on the state quantity of the appropriate control object 500. Furthermore, in order to output an appropriate control output to the control object 500, the output data connection device 613 receives appropriate output data.

[0149] In addition, as control characteristics, the design specifications representing the characteristics of the control system 501 (information related to the characteristics of the control system, such as frequency characteristics, factors affecting the change in the state quantity of the object), and the adjustment specifications of the control system 501 (initial settings and adjustment ranges of control parameters such as control gain and phase delay correction) are also registered in the registration control system 615.

[0150] Information on these registered control systems 615 is also registered in the registered control system DB 605 .

[0151] Fig.13 This is a diagram showing the contents of data registered in the registration control system DB 605 .

[0152] In the registration control system DB 605, data of the contents shown in the figure are registered for each of the registration control systems 615B to 615Z. Here, the case of one registration control system 615 is taken as an example for explanation. In addition, this content can also be said to be the data structure of the registration control system DB 605.

[0153] In the registration control system DB 605, for example, as input data, detector data indicating which detector is used is registered. Here, as detectors, there are detector 1, detector 2, ..., and as detector data detected by these detectors, 1 is set for detectors required for the registration control system 615, and 0 is set for unnecessary detectors. In addition, in the registration control system DB 605, for example, device information is registered as input data. As device information, there are information 1, information 2, ..., and 1 is set for device information required for the registration control system 615, and 0 is set for unnecessary device information.

[0154] Furthermore, in the registered control system DB 605, for example, as output data, operation terminal data indicating which operation terminal is used is registered. Here, as operation terminals, there are operation terminals 1, operation terminals 2, ..., and 1 is set for operation terminals used by the registered control system 615, and 0 is set for operation terminals not used. In addition, in the registered control system DB 605, for example, as output data, internal information data indicating which internal information of the internal information of the control system 501 is used is registered. Here, as internal information, there are state quantity 1, state quantity 2, ..., and 1 is set for internal information used by the registered control system 615, and 0 is set for internal states not used.

[0155] It can be said that the registration control system DB605 registers the relationship between the input data (in this case, detector 1, detector 2, ..., information 1, information 2, ...) respectively input to each registration control system 615 and the output data containing information of the output destination (in this case, operation terminal 1, operation terminal 2, ..., state quantity 1, state quantity 2, ...) of the control instruction output from the registration control system 615 to the control object 500. These relationships are prepared in advance in multiple forms for each registration control system 615. In addition, as shown in the figure, in the registration control system DB605, there are multiple input data and output data respectively, and the above relationship associates at least one of the multiple input data with at least one of the multiple output data. Then, the control output switching device 612 selects the registration control system 615 that controls the control object 500 based on the combination of the associated input data and output data.

[0156] In addition, in the registration control system DB 605, as design specifications representing the characteristics of the control system 501, state quantity change factors, frequency characteristics, control system structure, etc. are registered. The state quantity change factors define what kind of state quantity change is the control object. The frequency characteristics register the control method (FF (feedforward) control, PID control, whether there is an offset removal function, etc.) for obtaining the attenuation effect of the state quantity with respect to the frequency.

[0157] Furthermore, the adjustment specifications for adjusting the control system 501 are registered in the registered control system DB 605. Here, the adjustable ranges of control parameters such as control gain and delay time setting are registered according to the adjustment purpose such as amplitude reduction and offset removal of the state quantity.

[0158] In addition, the registration control system DB 605 registers the adjustment status as the result of the adjustment of the control system 501. The adjustment status is, for example, the stage of operation confirmation completion, rough adjustment completion, and fine adjustment completion.

[0159] On the other hand, information defining the state of the control object 500 is registered in the control system selection DB 604. Thus, according to the state of the control object 500 grasped by the control object state grasping device 601, an appropriate control system 501 can be selected from the registered control systems 615 and used.

[0160] Fig.14 This is a diagram showing the contents of data registered in the control system selection DB 604 .

[0161] Here, product information, product characteristics, and device status are registered as the control system selection DB 604. In addition, this content can also be said to be the data structure of the control system selection DB 604.

[0162] Product information is information that defines the type of product. Here, as product information, product conditions (product conditions A to C) and allowable accuracy are registered for the three materials, namely, test materials, ordinary materials, and strict materials. When the registration control system 615 is applied to implement the adjustment of the control system 501, the product accuracy may sometimes deteriorate. Therefore, it is necessary to predefine the types of products to be produced. As the types of products to be produced, for example, it is registered whether it is a test material that may become waste due to deterioration of product accuracy, an ordinary material with a wide allowable range of product accuracy, or a strict material with a narrow allowable range. In addition, in addition to product accuracy, it is also necessary to predefine the allowable accuracy of product quality that will not cause damage to the control object 500.

[0163] In addition, product characteristics are state change factors that are factors assigned to the state quantity of the control object 500, and information related to the size of the change in the state quantity of the control object 500 relative to this. The influence of interference factors on the state quantity of the control object 500 varies depending on the product. Therefore, as a factor assigned to the state quantity of the control object 500, this information is registered as product characteristics. As an example listed here, a condition in which the change caused by factor 1 is large is set. As a condition, for example, in addition to the product conditions produced by the control object equipment, state quantity conditions related to the production status such as speed are also set. In addition, conditions such as a large amplitude of the state quantity of the control object and a large offset error are also registered in the same way.

[0164] The equipment status is the operating status of the control object. Here, three equipment statuses are registered: repair work in progress, stopped, and production operation in progress.

[0165] <Detailed description of the operation of the control system S>

[0166] Fig.15 This is a diagram showing the operation flow of the control system S when the control object 500 is controlled using the general control system 614 or the registered control systems 615B to 615Z.

[0167] In order to make the pre-registered multiple registered control systems 615B to 615Z executable, the registered control system execution device 620 is connected to the input data connection device 611 and the output data connection device 613. The input data and output data of each registered control system 615B to 615Z are pre-registered in the registered control system DB 620. Then, the connection device 611 is connected to each registered control system 615B to 615Z so that the detected value of the state quantity of the control object 500 can be input as input data. In addition, the output data connection device 613 is connected to each registered control system 615B to 615Z so that the output data output to the control operation terminal of the control object 500 can be output.

[0168] The controlled object state grasping device 601 obtains information related to the product manufactured by the controlled object 500 from the production planning device 609. "Information related to the product" is, for example, the production plan of the product manufactured by the controlled object 500. Then, the controlled object state grasping device 601 uses the information related to the product and the state quantity of the controlled object 500 to generate product conditions and state quantity conditions (step S101). "Product conditions" are conditions such as the material of the product, the allowable range of product accuracy, and the shipping destination. "State quantity conditions" are conditions such as the type of state quantity and the allowable range of state quantity. The controlled object state grasping device 601 functions as an acquisition unit for acquiring a predetermined state quantity of the controlled object 500.

[0169] Next, the control system switching device 602 uses the information of the control system selection DB 604 to obtain the product condition and state quantity condition generated by the control object state grasping device 601. Fig.14 The control system switching device 602 uses the information registered in the registered control system DB 605 to select a registered control system 615 that matches the product information and product characteristics from each registered control system 615B to 615Z (step S102). Specifically, the control system switching device 602 selects, for example, a product condition that matches the product information (in Fig.14In the example, the registration control system 615 is consistent with the product conditions A to C). In addition, the control system switching device 602 selects, for example, a registration control system 615 that is consistent with the allowable accuracy of the product information. And, the control system switching device 602 selects, for example, a registration control system 615 that can suppress product characteristics that are easily generated due to the type of product. That is, in a case where an amplitude is easily generated depending on the type of product, a registration control system 615 that can suppress the amplitude is selected. And, in a case where an offset is easily generated depending on the type of product, a registration control system 615 that can suppress the offset is selected. In addition, the registration control system 615 can also be selected using a combination of multiple conditions in product information and product characteristics, priority, etc.

[0170] The control system switching device 602 functions as a selection unit for selecting the state quantity of the controlled object 500 acquired by the controlled object state grasping device 601 and the control system 501 for controlling the controlled object 500 .

[0171] Then, the control system switching means 602 instructs the output data connection means 613 to output the output from the registered control system 615 determined to be applicable to the control output switching means 612 .

[0172] Next, the output data connection means 613 outputs the output of the selected registration control system 615 to the control output switching means 612 (step S103).

[0173] In addition, when the registered control systems 615B to 615Z are performing action confirmation and adjustment, sometimes an action failure occurs, including a state quantity of the control object 500 that becomes abnormal. For example, in the control system selection DB 604, the state quantity of the control object 500 is worse than the allowable accuracy set as product information. In this case, the abnormality determination device 606 detects the abnormality and switches the control output for the control object 500 from the output of the registered control system execution device 620 to the output of the general control system 614. That is, the output of the selected registered control system 615 is switched to the output of the general control system 614. In this way, the action confirmation and adjustment of the registered control system 615 can be performed while avoiding the abnormality of the control object 500.

[0174] Therefore, the control object state grasping means 601 determines whether the abnormality determining means 606 has detected an abnormality (step S104).

[0175] As a result, when the abnormality determination device 606 detects no abnormality and determines that the controlled object state grasping device 601 is normal, the control output switching device 612 outputs the output of the selected registered control system 615 to the controlled object 500 (step S105).

[0176] The control system adjustment means 603 determines whether the adjustment of the selected registered control system 615 is completed (step S106).

[0177] As a result, when the control system adjustment device 603 determines that the adjustment of the registered control system 615 has not been completed (not completed), the control system adjustment device 603 performs the adjustment operation of the registered control system 615 (step S107). Based on the adjustment specifications registered in the registered control system DB 605, the adjustment operation is performed on the selected registered control system 615. For example, when the amplitude of the state quantity of the control object 500 is large, the control system adjustment device 603 adjusts the registered control parameters 1 and 2. In addition, for example, when the correction of the offset error takes time, the control system adjustment device 603 adjusts the control parameters 3 and 4.

[0178] Furthermore, information on the adjustment process (setting values ​​of control parameters and actual values ​​of state quantities of the control object 500, etc.) is collected by the control system adjustment device 603 and stored in the adjustment result DB 621. The creator of the registration control system 615 can further improve the performance of the registration control system 615 by later checking the adjustment results stored in the adjustment result DB 621.

[0179] On the other hand, in step 104, when the abnormality judgment device 606 detects an abnormality and determines that the control object state grasping device 601 is abnormal, the registration control system execution device 620 stops the control of the selected registration control system 615 and implements the control of the control object 500 through the general control system 614 (step S108).

[0180] In addition, the registration control system 615 output to the control object 500 is not limited to one, and a plurality of registration control systems 615 can be used in combination. For example, different registration control systems 615 can be applied to FF control (feedforward control) and offset removal control. Moreover, it is also possible to implement adjustments to each registration control system 615 applied to different controls. In this case, the control method for controlling the control object 500 is composed of a plurality of control methods, and it can be said that the control output switching device 612 selects a control system selected from the general control system 614 and the registration control system 615 among these plurality of control methods.

[0181] When the product produced by the control object 500 is changed and the product conditions and state quantity conditions change, the control system 501 is switched according to the instruction from the control system switching device 602. At this time, the control system 501 is selected from the general control system 614 and the registered control systems 615B to 615Z.

[0182] The control system adjustment device 603 registers the adjustment state of the registered control system DB 605 according to the action confirmation of the registered control system 615 and the state of the adjustment operation. The adjustment state can be indicated by flags that respectively mean "action confirmation completed", "coarse adjustment completed", and "fine adjustment completed". Regarding the action confirmation completed, when the result of outputting the output of the registered control system 615 to the control object 500 is that the control effect is obtained, it is set to ON (1). In addition, the coarse adjustment completed is set to ON when a certain degree of control effect can be confirmed. Moreover, when the control effect is greater than that of the general control system 614, the fine adjustment completed is set to ON. In addition, any one of these flags becomes ON, and the other becomes OFF (0).

[0183] The control system adjustment device 603 refers to the adjustment status registered in the registration control system DB 605. When the fine adjustment completion flag is on, the control system adjustment device 603 determines that the adjustment is completed, stops the control system adjustment operation by the control system adjustment device 603, and uses the control system 501 as a normal control system.

[0184] The control system adjustment device 603 monitors the operation state of the registered control system 615, and resets the flag of the adjustment state when the control effect decreases. For example, when the damping effect deteriorates as the state quantity of the controlled object 500 and the flag of the fine adjustment is set to OFF, the adjustment operation of the registered control system 615 is performed again. On the other hand, when the flag of the fine adjustment is turned ON, the control system adjustment device 603 continues to use the registered control system 615 according to the state of the controlled object 500. In this way, the optimal control system 501 can be selected according to the state of the controlled object 500.

[0185] <Detailed description of the registration control system execution device 620>

[0186] Fig.16 6 is a diagram showing an overview of the processing performed by the registration control system execution device 620. Fig.17 It is a diagram showing input data and output data registered in the registration control system DB 605 for each registration control system 615 .

[0187] like Fig.17As shown, in the registered control system DB 605, the input data and output data to be used are registered for the general control system 614 and each registered control system 615B to 615Z. Here, in the control object 500, detectors 550-1 to 550-n are set as detectors 1 to n for detecting state quantities. In addition, 551 to 551-m are set as operating terminals 1 to m for operating the control object 500. In addition, it is assumed that the control object 500 has information 553-1 to 553-k as information 1 to k other than the detection values ​​in the detectors 550-1 to 550-n. The information 1 to k is information of various setting values, etc.

[0188] Here, as an example, consider the case where the state quantity 1 detected by the detector 550-1 is used. In this case, the target value 552-1 is set in advance as the target value of the control, that is, the state quantity 1. Moreover, in the general control system 614 and the registered control systems 615B~615Z, the control deviation is calculated as necessary information. The control deviation is the deviation between the detection value in the detector 550-1 and the target value 552-1. Moreover, the control deviation is necessary information for the general control system 614 and the registered control systems 615B~615Z, and is unconditionally input to each of these control systems. Whether other information is used in each of these control systems is arbitrary, so the use or not is defined by a flag (0 or 1) in the column of the input data of the registered control system DB605. That is, when not used, it is defined as 0 in the column of the input data, and when used, it is defined as 1.

[0189] exist Fig.17 In the example of , the registration control system 615B (registration control system B) uses only the output of the detector 550-n as input data, so in the column of input data, the column of the input data of the detector n is 1. On the other hand, the columns of the other input data are 0. In addition, the registration control system 615C (registration control system C) uses only the output of the detector 550-1 and the detector 550-2 as input data. Therefore, in the column of input data, the columns of the input data of the detectors 1 and 2 are 1, but the columns of the other input data are 0.

[0190] In addition, in the registration control system 615Z (registration control system Z), only the information 553-1 is used as input data. Therefore, in the input data column, the column of the input data of the information 1 is 1, but the other input data columns are 0.

[0191] Thus, in the registration control system DB 605, when the general control system 614 and each of the registration control systems 615B to 615Z do not use the above information as input data, 0 is set. On the other hand, when the above information is used as input data, 1 is set.

[0192] Based on the information of the registration control system DB 605, the input data selected from the detection values ​​of each detector 550-1 to 550-n and the information 553-1 to 553-k is input to the corresponding registration control system 615 in the input data connection device 611. Generally, the processing performed by the control device 511 is implemented by a computer and software processing is performed, so it is possible to automatically create software for performing the processing.

[0193] The control object 500 has a plurality of control operation terminals 551 for changing the state quantity. Fig.16 In the figure, m operation terminals 551-1 to 551-m are illustrated as multiple operation terminals 551. The relationship between the control operation terminal 551 and the state quantity is generally complex, so that the influence of the change of the control operation terminal 551 affects multiple state quantities. Therefore, when the state quantity of the control object 500 is controlled, there are multiple control operation terminals 551 operated by the control object 500, and the control output is output to different operation terminals 551 according to the control system. Therefore, the control operation terminal 551 is registered as output data in the registration control system DB 605. The registration control system 615 defines the control operation terminal 551 of the control output destination according to the control characteristics.

[0194] As the control output to the control operation terminal 551, it is necessary to switch and output the outputs from the general control system 614 and the registration control system 615. Therefore, it is necessary to make the difference of the control output of each control system (the difference from the control output one sampling ago), add the difference of the output of each control system, and integrate it before outputting it to the operation terminal 551.

[0195] To achieve this, the following processing is performed in the output data connection device 613. The output of each control system is taken as the difference from the previous output value, multiplied by the gain, and the output to each operation terminal 551 is added. Each registered control system 615 determines which control operation terminal 551 to output based on the output data of the registered control system DB 605 and the flag (0 or 1) of whether there is an output. Then, after the output of each control system is differentiated, the output gain G is applied. XM Here, the subscript X indicates which control system it is (0 indicates the general control system 614, B to Z indicate the registered control systems 615B to 615Z), and the subscript M indicates which of the control operation terminals 551-1 to 551-m it is (for example, when M is 1, it indicates the control operation terminal 551-1).

[0196] In the control output switching device 612, the switching process of the control output of the general control system 614 and the control output from the output data connection device 613 is implemented. When considering the case where the general control system 614 outputs the control output to the control operation terminal 551-1, as shown in FIG. Fig.16 As shown, taking the difference of the output from the general control system 614, multiplying it by the gain G 01 The signal and the output from the output data connection device 613 for the control operation terminal 551-1 are multiplied by the gain G R1 The signals are added and integrated as the control output to the control operation terminal 551-1. Figure 7 As shown, the output from the output data connection device 613 to the operation terminal 551-2 is multiplied by the gain G R2 The value obtained by integration is used as the control output to the operating terminal 551-2.

[0197] As mentioned above, by setting the gain G 01 and gain G R1 , G R2 , the switching between the general control system 614 and the registration control system 615 can be realized.

[0198] In addition, when the universal control system 614 is used, the gain G 01 and gain G R1 , gain G R2 The settings are as follows.

[0199] G 01 =1.0, gain G R1 =0.0, G R2 =0.0

[0200] In addition, when the registration control system 615 is used, the gain G 01 and gain G R1 , G R2 The settings are as follows.

[0201] G 01 =0.0, G R1 =1.0, G R2 =1.0

[0202] In addition, when using the registration control systems 615B to 615Z, when switching to any of them, the gain G B1 , G C1 , G C2 , G Z2 The settings are as follows. Here, the case where the control system is switched to the registration control system 615B, the registration control system 615C, and the registration control system 615Z is exemplified and described.

[0203] In the case of using the registration control system 615B, G B1 =1.0, G C1 =1.0, G C2 =1.0, G Z2 =1.0.

[0204] In the case of using the registration control system 615C, G B1 =0.0, G C1 =1.0, G C2 =1.0, G Z2 =0.0

[0205] In the case of using the registration control system 615Z, G B1 =0.0, G C1 =0.0, G C2 =0.0, G Z2 =1.0

[0206] The output data connection device 613 and the control output switching device 612 are generally processed by software, so the above-mentioned software can be automatically created.

[0207] When the abnormality determination device 606 determines that the control object is abnormal (such as the state quantity exceeds a predetermined value), the control gain is changed according to the situation of using the above-mentioned general control system 614, thereby switching from the registration control system 615 to the control performed by the general control system 614 to avoid the abnormality.

[0208] [Second embodiment]

[0209] Next, a second embodiment of the control system S to which this embodiment is applied will be described. In the second embodiment, the control system S uses a single-stand rolling mill as a control target 500. In this case, the product manufactured by the single-stand rolling mill is a rolled material such as a steel plate.

[0210] In the single-stand rolling mill as one of the control target devices 510, control systems having various characteristics may be selected and combined as appropriate. In this case, it is necessary to implement the control system in a manner that optimizes the thickness accuracy of the final product obtained by rolling according to the rolling state of the single-stand rolling mill (the state of the rolling mill, the state of the rolled material, etc.). If the control system is not implemented, the predetermined thickness accuracy cannot be obtained, and the product required by the customer may not be obtained.

[0211] Therefore, in the plate thickness control applied to maintain the plate thickness accuracy, a plurality of control systems are applied according to the rolling state, and the optimal control system is selected and used at an appropriate time.

[0212] In a single-stand rolling mill, various methods have been developed and applied to the rolled materials such as thin plates that become products, especially the plate thickness accuracy, which is an important control object directly related to product quality. When a newly developed control method is applied, it is necessary to switch from the existing control and change the gain according to the rolling state, and these conditions need to be determined. In determining the conditions, it is also necessary to increase the thickness variation that is important for product quality, so it is necessary to use test materials and rolled materials with loose required plate thickness accuracy.

[0213] Fig.18 It is a schematic diagram showing a control system S in the second embodiment.

[0214] As shown in the figure, the control system S includes a rolling mill A, an entry tension reel 2 (hereinafter also referred to as "entry TR2"), and an exit tension reel 3 (hereinafter also referred to as "exit TR3"). The rolling mill A, entry TR2, and exit TR3 are control objects 500 of the control system S.

[0215] In addition, in the present embodiment, the "entry side" refers to the side where the rolled material m is sent toward the rolling mill A (the upstream side of the rolling mill A), and the "exit side" refers to the side where the rolled material m is sent from the rolling mill A (the downstream side of the rolling mill A). In addition, the "deviation" refers to the difference between the set value, the predicted value, and the actual value (actual value).

[0216] In addition, the control system S shown in the figure includes a control device 411, a control object state grasping device 401, a control system switching device 402, a control system adjustment device 403, a control system selection DB 404, a registration control system DB 405, an abnormality determination device 406, and a production planning device 409. They are respectively Figure 5 The control device 511, the control object state grasping device 601, the control system switching device 602, the control system adjustment device 603, the control system selection DB 604, the registration control system DB 605, the abnormality determination device 606, and the production planning device 609 correspond to each other and have the same functions. Figure 5 The control object analysis device 701, the control system design device 702, the control system registration device 703, the control object characteristic DB 711, the control system template DB 712, and the control object influence DB 713 are records of functional parts equivalent to each other.

[0217] The control system S shown in the figure uses three control systems as control systems, namely, a press thickness control 414 as a general control system, a speed ratio thickness control 415B as a registration control system, and a mill speed thickness control 415C.

[0218] The rolling mill A is an example of a single-stand rolling mill. The rolling mill A has a roll pair consisting of an upper working roll R1 (hereinafter, also referred to as "roll R1") and a lower working roll R2 (hereinafter, also referred to as "roll R2"). The rolling mill A receives signals from a roll gap control unit 21 and a grinding speed control unit 31 in the rolling control device 11, which will be described in detail later. In addition, the grinding speed is set by a grinding speed setting unit 81. Moreover, the rolling mill A adjusts the interval (hereinafter, also referred to as "roll gap") between the rolls (upper working roll R1 and lower working roll R2) in the roll pair rotating at a predetermined circumferential speed based on the signal, thereby rolling the rolled material m passing through the roll pair.

[0219] The entry TR2 and the exit TR3 receive signals from the entry TR control unit 42 and the exit TR control unit 52, respectively, which will be described in detail later, in the rolling control device 11. Then, the motors (not shown) provided at the entry TR2 and the exit TR3 are used to deliver the rolled material m to the rolling mill A at the entry TR2, and to coil the rolled material m rolled by the rolling mill A at the exit TR3.

[0220] Here, the rolling phenomenon related to the thickness variation of the rolled material m in the rolling mill A using the roll pair is described. The thickness of the rolled material m after rolling is important in terms of product quality, so thickness control is performed. In this thickness control, the actual value of the thickness of the rolled material m detected by the exit-side thickness gauge a2 is used, and the roll gap between the roll R1 and the roll R2 is operated by the roll gap control unit 21, for example, to adjust the thickness of the rolled material m on the exit side.

[0221] In the past, the plate thickness control of a single-stand rolling mill used the following control: FF control (feedforward control) and FB control (feedback control) were performed to change the roll gap using the plate thickness deviation detected by the entry-side plate thickness gauge a1 and the exit-side plate thickness gauge a2 of the rolling mill A, and the control output was output to the roll gap control unit 21. However, the method of using the roll gap to control the exit-side plate thickness sometimes cannot achieve sufficient results depending on the set plate thickness and rolling speed. Therefore, it is necessary to add a new control method, but in a single-stand rolling mill that rolls a variety of materials, it is difficult to properly implement the confirmation and actual application of the new control method according to various situations. Therefore, if a new control system is registered, a system that automatically implements action confirmation, control system adjustment, and actual application can be realized. In this case, it is possible to provide optimal control according to the rolling state while reducing the burden on operating technicians and control technicians.

[0222] When the controlled object 500 is replaced by the rolling mill A, the input (disturbance) 901, the input (operation amount) 902, and the output (state amount) 903 are as follows: Fig.19 shown.

[0223] That is, the input (disturbance) 901 is set to (a) roll gap, (b) entry TR speed, and (c) grinding speed. In addition, the input (operation amount) 902 is (a) entry plate thickness, (b) roll eccentricity, and (c) bending pressure. And the output (state amount) 903 is set to (a) exit plate thickness, (b) rolling load, (c) entry tension, and (d) exit tension.

[0224] Fig. 20 It is a diagram showing the change in shape of the rolled material m caused by changing the bending machine.

[0225] In the rolling mill A, the rolled material m, which is a metal plate, is rolled. However, the corrugation (called shape) of the metal plate is also an important quality factor, and the operator manually operates the press brake to reduce the corrugation. The press brake is a mechanical device used to change the force applied to both ends of the rollers R1 and R2 of the rolling mill A, and to change the shape by bending the rollers R1 and R2. When the operator operates the press brake to make changes, the force (load) applied from the rollers R1 and R2 to the rolled material m changes, and sometimes the plate thickness changes. Therefore, in Fig.19 In the example, as input (disturbance) 901(c), the bending pressure (at Fig.18 , the bending pressure 920 is shown.

[0226] The plate thickness variation caused by the change of the bending pressure as the input (disturbance) 901 (c) varies according to the material, plate thickness, plate width, and other operating conditions of the rolling mill A of the rolled material m. Therefore, in the case of a large variation, FF control is effective to change the roll gap as the input (operating end) 902 (a) according to the change of the bending pressure as the input (disturbance) 901 (c) and suppress the variation of the plate thickness at the outlet side as the output (state quantity) 903 (a).

[0227] In this case, similarly to the first embodiment, the FF control 905 (see FIG. 1 ) is designed to take the bending pressure as input (disturbance) 901 (c) as input and the roller gap as input (operating end) 902 (a) as output. Fig.18 ) is automatically designed and added as a control for rolling mill A.

[0228] <Explanation of control method>

[0229] Here, in Fig. 9The processing performed by the control system S described in the figure can be understood as the following control method: obtaining a predetermined state quantity of the control object 500, detecting an abnormality in the state quantity of the control object 500 based on the actual operation performance of the control object 500, inferring the correlation between the state quantities of the control object 500, determining the input state quantity, output state quantity and type of control system required for controlling the control object 500, and setting a transfer function as the time response of the control object 500 and control parameters of the control system.

[0230] <Program description>

[0231] The processing performed by the control system S in the present embodiment described above is realized by cooperation between software and hardware resources. That is, a processor such as a CPU provided in the control system S executes a program for realizing each function of the control system S, thereby realizing these functions.

[0232] Furthermore, the program for realizing the present embodiment may be provided by a communication unit, or may be provided by being stored in a recording medium such as a CD-ROM.

[0233] Although the present embodiment has been described above, the technical scope of the present invention is not limited to the scope described in the above embodiment. According to the description of the scope of the patent protection requested, various changes or improvements to the above embodiment are also included in the technical scope of the present invention.

[0234] [Industrial Applicability]

[0235] The present invention relates to a control method and device for industrial equipment or a rolling mill A as one of the equipment, and there is no problem in actual application.

Claims

1. A control device, characterized in that: have: an acquisition unit that acquires a predetermined state quantity of a control object; a detection unit for detecting an abnormality of the state quantity of the controlled object based on the operation performance of the controlled object; a determination unit that estimates a correlation between the state quantities of the control object and determines an input state quantity, an output state quantity, and a type of control system required for controlling the control object; as well as A setting unit sets a transfer function as a time response of the control object and a control parameter of the control system.

2. The control device according to claim 1, characterized in that: The decision unit calculates the input state quantity, the output state quantity, and the relationship between the input state quantity and the output state quantity, which have a relatively large correlation, and determines the input state quantity, the output state quantity, and the type of control system required to control the control object based on the calculated relationship.

3. The control device according to claim 2, characterized in that: The correlation is obtained based on the degree of influence of past operation performance on the input state quantity.

4. The control device according to claim 1, characterized in that: The input state quantity is an operation quantity on the control object and a disturbance on the control object.

5. The control device according to claim 4, characterized in that: The transfer function includes an operating-end working device transfer function as a time response to the operation amount and a disturbance transfer transfer function as a time response to the disturbance.

6. The control device according to claim 5, characterized in that: The transfer function also includes a state quantity detection device transfer function as a time response to the state quantity detection device, and a control object device transfer function as a time response to the control object.

7. The control device according to claim 6, characterized in that: The control object device transfer function is a conversion gain without time response.

8. The control device according to claim 6, characterized in that: The operating end working device transfer function, the state quantity detection device transfer function, and the disturbance transfer transfer function are predetermined by the characteristics of the controlled object.

9. The control device according to claim 1, characterized in that: The types of control systems include feedforward control and feedback control.

10. The control device according to claim 9, characterized in that: The control parameter includes a gain of at least one of the feedforward control and the feedback control.

11. The control device according to claim 1, characterized in that: The control device also includes: a selection unit, which pre-prepares a plurality of relationships between input data input to the control system and output data including information on an output destination for outputting control instructions from the control system to the control object, and selects a control system for controlling the control object based on the acquired state quantity and the relationship.

12. The control device according to claim 1, characterized in that: The control object is the plate thickness of the rolled material rolled by the rolling mill, The control system controls the plate thickness of the rolled material.

13. A control method, characterized in that: The following steps are required: Obtaining a predetermined state quantity of a control object; detecting an abnormality in the state quantity of the controlled object based on the operational performance of the controlled object; estimating the correlation between the state quantities of the control object, and determining the input state quantity, output state quantity and type of control system required for controlling the control object; as well as A transfer function as a time response of the control object and control parameters of the control system are set.

14. A control system, characterized in that: have: Predetermined control objects; and A control device, which selects a control system applied to the control object, The control device comprises: an acquisition unit, which acquires the state quantity of the control object; a detection unit for detecting an abnormality of the state quantity of the controlled object based on the operation performance of the controlled object; a determination unit that estimates a correlation between the state quantities of the control object and determines an input state quantity, an output state quantity, and a type of control system required for controlling the control object; as well as A setting unit sets a transfer function as a time response of the control object and a control parameter of the control system.

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