Data collection and regeneration system

Abstract

The purpose of the present invention is to provide a data collection / reproduction system which is suitable for analyzing the cause of an abnormality, and which is capable of checking, without a time error, images and process data before and after the occurrence of the abnormality. The data collection and regeneration system is applicable to an industrial plant equipped with a machine that acts on a conveyed sheet. A camera (6) captures a still image by including a portion of a sheet in an imaging range. A process data collection unit (12) collects process data of a machine at periodic sampling timings. The camera control unit (14) matches the periodic imaging timing of the camera (6) to the periodic sampling timing. A synchronous display unit (18) displays a graph indicating the process data at each time point collected by the process data collection unit (12) in synchronization with a band-shaped still image formed by connecting still images at each time point captured by the camera (6).

Description

[0001] This application is a divisional application of the original application with application date of May 22, 2019, application number 201910428688.6, and invention name “Data Collection and Regeneration System”. Technical Field

[0002] The present invention relates to a data collection and regeneration system for industrial complete sets of equipment. Background Art

[0003] Industrial plants (plants) that produce raw materials or resources required for industrial activities (paper plants, steel plants, power plants, petroleum plants, chemical plants, etc.) are known. The plant monitoring control system of the industrial plant has a structure in which input and output devices (I / O) connected to many field machines (including actuators and sensors) constituting the plant and programmable logic controllers (hereinafter referred to as PLCs) that control many field machines are interconnected via a control network.

[0004] The input and output signals of PLC and input and output devices are called process data. In large-scale complete equipment, there are thousands or tens of thousands of input and output points, and there are various process data. These process data are collected by data collection and regeneration devices with data collection and data regeneration functions, and are used for data analysis during testing, adjustment, operation, and failure.

[0005] A conventional data collection and reproduction device for a plant monitoring control system (eg, Patent Document 1) is connected to a control network to collect process data input and output from a PLC. An operator can understand the status of the industrial plant by referring to the process data displayed on a screen.

[0006] Patent Document 1: International Publication No. 2014 / 002176

[0007] In addition, in order to find abnormalities in manufactured products, specifically abnormalities (scratches or defects) generated on the surface of sheet materials such as paper, film, and steel plate, and analyze the causes, it is sometimes necessary to confirm the image of the sheet material taken together with the process data. These sheets are long, ranging from tens of meters to tens of kilometers, and it is impossible to take a picture of the entire sheet material at once.

[0008] As one method, it is possible to replay the image obtained by photographing the conveyed sheet with an area scan camera. However, the image replay displays the image of each frame within the camera's field of view. Therefore, the operator rewinds the replay time to the past or forwards it to the future to store the images before and after the abnormality occurs, and infers the cause based on the stored images. In the method that relies on the operator's storage, it is difficult to grasp the dynamics before and after the abnormality occurs, and it is difficult to perform high-precision analysis.

[0009] In addition, in papermaking plants or steel plants that convey sheet materials at high speed, an operator checking the image may miss an abnormality on the surface of the sheet material. In addition, the sampling timing of process data is high-speed compared to the frame rate of the area scan camera, so when an abnormality is found on the image, the process data associated with the abnormality cannot be fully locked, making it difficult to analyze the cause. In addition, when a camera continuously captures still images, the sampling cycle of process data is inconsistent with the camera's shooting cycle, and when these data are reproduced simultaneously, an error corresponding to the camera's shutter timing occurs. Summary of the invention

[0010] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a data collection and reproduction system that can confirm images and process data before and after an abnormality occurs without time error and is suitable for analyzing the cause of the abnormality.

[0011] In order to achieve the above-mentioned object, the data collection and reproduction system according to the present invention is constructed as follows.

[0012] The data collection and reproduction system according to the present invention is suitable for an industrial plant equipped with a machine that acts on a sheet-like object being conveyed.

[0013] The data collection and reproduction system includes a camera, a process data collection unit, a camera control unit, a process data storage unit, a still image storage unit, and a synchronous display unit.

[0014] The camera includes a portion of the sheet in the shooting range and continuously shoots still images. Preferably, the camera is a line scan camera that shoots the sheet in the entire width direction. The line scan camera is arranged above the sheet in such a way that the arrangement direction of one row of imaging elements is orthogonal to the conveying direction of the sheet.

[0015] The process data collection unit collects process data of the device at a periodic sampling timing. The sampling period is, for example, 1 millisecond to several tens of milliseconds.

[0016] The camera control unit matches the periodic imaging timing of the camera with the periodic sampling timing of the process data collection unit.

[0017] The process data storage unit stores the collected process data in association with time information.

[0018] The still image storage unit stores still images captured by the camera in association with time information.

[0019] The synchronous display unit synchronously displays a graph representing process data at each time point collected by the process data collection unit and a strip-shaped still image formed by connecting still images at each time point captured by the camera based on time information. The horizontal axis of the graph is time, and the vertical axis is data value. The strip-shaped still image is still images connected in the order of the capturing time points, and is displayed so that the length direction (transportation direction) of the strip-shaped still image corresponds to the horizontal axis of the graph.

[0020] In one technical solution, an industrial plant is provided with a control network having a plurality of nodes having a shared memory, and process data on the shared memory is synchronized by periodic multiple access transmission between the plurality of nodes. A machine is connected to one node to send and receive process data. A process data collection unit is connected to one node to collect process data from the shared memory at each sampling timing.

[0021] In another technical solution, the data collection and reproduction system includes a marking processing unit. The marking processing unit stores the position specified on the strip-shaped still image or the curve graph in a table, and when an arbitrary position is selected from the table, the strip-shaped still image and the curve graph are displayed in a manner that includes the selected position in the screen. In this way, the display range of the strip-shaped still image and the curve graph can be jumped to the position (time) selected from the table. Therefore, the stored information can be redisplayed immediately.

[0022] Effects of the Invention

[0023] According to the present invention, since the camera's shooting timing is matched to the sampling timing of the process data, it is possible to associate the still image at each moment with the process data at each moment. Therefore, when an abnormality is found from the still image, the process data before and after the abnormality can be easily identified, and the analysis of the cause of the abnormality can be made more efficient.

[0024] In addition, by connecting still images at each moment to form a belt-shaped still image, a range larger than the shooting range of the area scan camera can be displayed together, making it easy to find abnormalities (scars, defects) of sheet objects. Furthermore, since the length direction of the belt-shaped still image composed of still images at each moment means the time direction (the closer to the downstream of the conveying direction, the more past the still image), it is synchronized with the time axis of the graph. Therefore, the belt-shaped still image can be used to find abnormalities, and the changes in process data before and after the abnormality occurs can also be confirmed from the graph. Therefore, the causes of scars, dirt, etc. of products produced by industrial complete sets of equipment can be easily determined, and the signs of abnormalities can be easily grasped, which can be beneficial to improving the quality of products. In addition, since abnormalities can be found earlier online, the cost of subsequent inspection processes can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram showing the configuration of a plant monitoring control system for an industrial plant according to the first embodiment.

[0026] Figure 2 This is a conceptual diagram of a data collection and reproduction system as part of a plant monitoring and control system.

[0027] Figure 3 This is a functional block diagram of the data collection and reproduction device related to the first embodiment.

[0028] Figure 4 This is a timing diagram used to explain control timing, sampling timing, and shooting timing.

[0029] Figure 5 This is a block diagram showing a hardware configuration example of a processing circuit included in the data collection and reproduction device.

[0030] Figure 6 This is a functional block diagram of a data collection and reproduction device related to the second embodiment.

[0031] Figure 7 This is an example of a tag information storage table related to implementation mode 2.

[0032] Description of symbols

[0033] 1Data collection and reproduction device

[0034] 2PLC

[0035] 3 Input and output devices

[0036] 4HMI

[0037] 5 Control network

[0038] 6. Camera

[0039] 7 Image Network

[0040] 8 flakes

[0041] 9 Black Spot

[0042] 11 Control cycle determination unit

[0043] 12 Process Data Collection Department

[0044] 13 Process data storage unit

[0045] 14 Camera control unit

[0046] 15 Still image storage unit

[0047] 16 Data combination

[0048] 17 Combined data storage unit

[0049] 18 Synchronous display unit

[0050] 19 Marking Processing Unit

[0051] 40 Display area

[0052] 41 Strip still images

[0053] 42 Graph

[0054] 60 cursor

[0055] 61 Table display area

[0056] 70 Marking information storage table

[0057] 71 Marker number

[0058] 72 Curve name

[0059] 73 Moments

[0060] 74 Comments

[0061] 111CPU

[0062] 112 Memory

[0063] 113, 113a, 113b memory, program storage unit, data storage unit

[0064] 114 External device I / F

[0065] 115a, 115b: control network I / F unit, image network I / F unit

[0066] 116 Internal bus

[0067] 117 Monitor

[0068] 118 Keyboard

[0069] 119 Mouse DETAILED DESCRIPTION

[0070] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, when the numerical values ​​of the number, quantity, amount, range, etc. of each element are mentioned in the embodiments shown below, the present invention is not limited to the numerical values ​​mentioned, except for the cases that are particularly clearly stated or the cases that are clearly determined to be such numerical values ​​in principle. In addition, the structures and the like described in the embodiments shown below are not necessarily necessary for the present invention, except for the cases that are particularly clearly stated or the cases that are clearly determined to be such numerical values ​​in principle. In addition, the same reference numerals are given to common elements in each figure, and repeated descriptions are omitted.

[0071] Implementation method 1.

[0072] (System Structure)

[0073] Figure 1 This is a schematic diagram showing the configuration of a plant monitoring control system for an industrial plant according to the first embodiment.

[0074] The data collection and reproduction device 1 is connected via a control network 5 to an input / output device (I / O) 3 connected to a group of machines (including actuators and sensors) constituting an industrial plant, a programmable logic controller (PLC) 2 for controlling the group of machines, and a human-machine interface (HMI) 4 which is a monitoring and control device used by an operator in the operation and monitoring of the industrial plant.

[0075] The control network 5 has a plurality of nodes with a shared memory, and the process data on the shared memory is synchronized by periodic multiple address transmission between the plurality of nodes. Thus, the data collection and reproduction device 1 connected to the node A5a, the PLC 2 connected to the node B5b, the input and output device 3 connected to the node C5c, and the HMI 4 connected to the node D5d virtually share the same storage space. The shared memory is allocated a storage area (address) for each data. The devices connected to each node can send and receive process data by writing to and reading from the shared memory.

[0076] The camera 6 transmits still image data of a sheet object as an imaging target to the data collecting and reproducing device 1 via the image network 7 .

[0077] Figure 2 This is a conceptual diagram of a data collection and reproduction system as part of a plant monitoring and control system.

[0078] The camera 6 includes a part of the conveyed sheet 8 in the shooting range and continuously shoots still images. Preferably, the camera 6 is a line scan camera that shoots the sheet 8 in the entire width direction. The line scan camera is arranged above the sheet 8 in a manner that the arrangement direction of one line of imaging elements is orthogonal to the conveying direction of the sheet 8. The shooting timing is controlled by the data collection and regeneration device 1. The line scan camera sends the shot still image to the data collection and regeneration device 1 every time it scans. In addition, the PLC 2 sends the process data to the data collection and regeneration device 1 at each sampling timing.

[0079] The data collection and reproduction device 1 matches the shooting timing of the camera with the sampling timing of the process data. In addition, the data collection and reproduction device 1 generates a belt-shaped still image connecting the still images at each time and a graph representing the process data at each time. Furthermore, the data collection and reproduction device 1 displays the belt-shaped still image and the graph synchronously on the screen. Based on the belt-shaped still image, it is easy to detect the black spot 9 of the sheet 8 at a glance. In addition, by referring to the graph of the process data synchronized with the belt-shaped still image, the change of the process data before and after the occurrence of the black spot 9 can be confirmed, and the cause of the black spot 9 becomes easy to analyze.

[0080] (Data collection and reproduction device)

[0081] Reference Figure 3 and Figure 4 , the detailed functions of the data collection and reproduction device 1 according to the first embodiment are described. Figure 3 This is a functional block diagram of the data collection and reproduction device 1 according to the first embodiment. Figure 4 This is a timing diagram used to explain control timing, sampling timing, and shooting timing.

[0082] The data collection and reproduction device 1 includes a control cycle determination unit 11 , a process data collection unit 12 , a process data storage unit 13 , a camera control unit 14 , a still image storage unit 15 , a data combination unit 16 , a combined data storage unit 17 , and a synchronous display unit 18 .

[0083] The control cycle determination unit 11 determines Figure 4 The control timing is periodic as shown. The control timing is managed based on the hardware clock or system clock of the data collection and reproduction device 1. The process data collection unit 12 and the camera control unit 14 described later operate according to the control timing. The control cycle is, for example, 1 millisecond to several tens of milliseconds.

[0084] The process data collection unit 12 is as follows Figure 4 As shown, the determined control timing is used as the sampling timing, and the process data of the equipment is collected at the periodic sampling timing.

[0085] The process data storage unit 13 associates the count value (time information) with the process data collected at each sampling timing and stores the count value. The count value is incremented at each control timing. In addition, the process data storage unit 13 can calculate each time based on the count value by storing the data collection start time in advance.

[0086] The camera control unit 14 is as follows Figure 4 As shown, the camera 6 is controlled by using the determined control timing as the shooting timing. That is, the camera control unit 14 matches the periodic shooting timing of the camera 6 with the periodic sampling timing. The camera 6 shoots a still image at each shooting timing and sends it to the data collection and reproduction device 1. In addition, the shooting timing is preferably synchronized with the sampling timing of the process data, and does not need to be earlier than the sampling timing.

[0087] The still image storage unit 15 receives the still image from the camera 6 and stores it in association with the count value. The count value is incremented at each control timing. In addition, the still image storage unit 15 can calculate each time based on the count value by storing the data collection start time in advance.

[0088] The data combining unit 16 generates combined data that associates the process data having the same count value with the still image for the process data stored in the process data storage unit 13 and the still image stored in the still image storage unit 15. In addition, the data combining unit 16 generates a strip-shaped still image 41 that connects the still images taken at each moment by the camera 6. When the captured still images have a predetermined width in the conveying direction and a portion of adjacent still images overlap, the still images are combined based on the conveying speed, taking the overlapping portion into consideration. In addition, the data combining unit 16 generates a graph 42 (42a, 42b) representing the process data at each moment. The horizontal axis of the graph 42 is time, and the vertical axis is data value. The strip-shaped still image 41 is a still image connected in the order of the shooting time, and the length direction of the strip-shaped still image 41 is displayed corresponding to the horizontal axis (time axis) of the graph.

[0089] The combined data storage unit 17 stores the combined data generated by the data combining unit 16 , the strip-shaped still image 41 , and the graph 42 .

[0090] The synchronous display unit 18 outputs combined data obtained by combining a graph 42 of process data synchronized with the same count value with a strip-shaped still image 41. The synchronous display unit 18 synchronously displays a graph 42 indicating process data at each time point collected by the process data collection unit 12 and a strip-shaped still image 41 obtained by combining still images at each time point taken by the camera 6. These are displayed in the display area 40 of the monitor 117.

[0091] As described above, according to the data collection and reproduction device 1 of the first embodiment, since the shooting timing of the camera is matched with the sampling timing of the process data, it is possible to associate the still image at each time with the process data at each time. Therefore, when an abnormality is found from the still image, the process data before and after the abnormality occurs can be easily identified, and the analysis of the cause of the abnormality can be made more efficient.

[0092] In addition, according to the strip-shaped still image 41 formed by connecting the still images at each moment, a larger range can be displayed together compared to the case of reproducing the image taken by the area scan camera, and the abnormality of the sheet 8 (the location of welding, the start of plating, scars, and defects) can be easily found. Furthermore, the length direction of the strip-shaped still image 41 composed of the still images at each moment means the time direction, so it is synchronized with the time axis of the curve chart 42. Therefore, the strip-shaped still image 41 can be used to find the abnormality, and the change of the process data before and after the abnormality occurs can also be confirmed from the curve chart 42. Therefore, it is easy to determine the cause of the scars, dirt, etc. of the products produced by the industrial complete set of equipment, and it is easy to grasp the signs of the abnormality, which can be conducive to improving the quality of the product. In addition, since the abnormality can be found earlier online, the cost in the subsequent inspection process can be reduced.

[0093] (Hardware Configuration Example)

[0094] Reference Figure 5 The hardware configuration of the data collecting and reproducing device 1 will be described. Figure 5 It is a block diagram showing a hardware configuration example of a processing circuit included in the data collecting and reproducing device 1 . Figure 3 Each unit of the data collection and reproduction device 1 shown in the figure represents a part of the functions of the data collection and reproduction device 1, and each function is realized by a processing circuit. For example, the processing circuit is composed of a CPU 111, a memory 112, a storage 113 such as a HDD or a large-capacity memory, an external device I / F (interface) unit 114, a control network I / F unit 115a, and an image network I / F unit 115b connected via an internal bus 116.

[0095] The CPU 111 implements the program storage unit 113a of the memory 113 by executing various application programs stored in the program storage unit 113a of the memory 113. Figure 4 The functions of each department.

[0096] The memory 112 is used as a calculation area for temporarily storing or expanding data when the CPU 111 executes various application programs.

[0097] The memory 113 includes a program storage unit 113a and a data storage unit 113b. The program storage unit 113a stores an OS (operating system) and various application programs. The data storage unit 113b stores collected process data and still image data.

[0098] In addition, Figure 5 In the example shown, the program storage unit 113 a and the data storage unit 113 b are provided in one memory 113 , but the program storage unit 113 a and the data storage unit 113 b may be divided and arranged in a plurality of memories.

[0099] The external device I / F unit 114 is an interface for connecting external devices such as a monitor 117 , a keyboard 118 , and a mouse 119 to the data collection and reproduction device 1 .

[0100] The control network I / F unit 115a is an interface for connecting the control network 5 to the data collection and reproduction device 1. The image network I / F unit 115b is an interface for connecting the image network 7 to the data collection and reproduction device 1.

[0101] In addition, the data collection and reproduction device 1 of the above-mentioned embodiment 1 does not include Figure 5 Although the monitor 117, keyboard 118, and mouse 119 are shown, they may be included in the data collection and reproduction device 1. This point is also the same in the following embodiments.

[0102] Implementation method 2.

[0103] Next, refer to Figure 6 and Figure 7 Embodiment 2 is described. According to the data collection and reproduction system of embodiment 1, it is possible to display a graph of process data synchronously with a still image in a strip shape. In embodiment 2, a position specified on a still image in a strip shape or a graph is stored in a table, and when an arbitrary position is selected from the table, the still image in a strip shape and the graph are displayed in a manner that includes the selected position in the screen. Thus, the display range of the still image in a strip shape and the graph can be jumped to the position (time) selected from the table. Therefore, the stored information can be immediately redisplayed.

[0104] Figure 6 This is a functional block diagram of the data collection and reproduction device 1 according to the second embodiment. Figure 6 The data collection and reproduction device 1 shown in the figure has Figure 3 In addition to the illustrated configuration, a marking processing unit 19 is further provided.

[0105] The marking processing unit 19 adds a mark to a position (cursor 60 ) designated by the operator on the display area 40 . Figure 7This is an example of the tag information storage table 70 . Figure 7 Each row of represents a tag. Tags such as Figure 7 As shown, it is stored in the mark information storage table 70, and the graph name 72, the time 73, and the comment 74 are recorded in association with the mark number 71. The time 73 is inputted with the time indicated by the cursor 60.

[0106] The marking processing unit 19 records a mark related to the position (time) indicated by the cursor 60 displayed in the display area 40 in the marking information storage table 70 . Information in the marking information storage table 70 is displayed in the table display area 61 .

[0107] When the operator operates the keyboard or the mouse to select one of the marks in the mark information storage table 70, the graph 42 and the still image strip 41 are displayed in the display area 40 based on the graph name 72 of the selected mark. At this time, the cursor 60 moves to the time recorded in the time 74. In this way, the graph 42 and the still image strip 41 at the time specified by the mark can be easily displayed.

[0108] According to the second embodiment, the display range of the still image strip and the graph can be jumped to a position (time) selected from the table. Therefore, the stored information can be immediately redisplayed.

[0109] As mentioned above, although embodiment of this invention was described, this invention is not limited to the said embodiment, It can be implemented by making various deformation|transformation in the range which does not deviate from the summary of this invention.

Claims

1. A data collection and reproduction system, which is a data collection and reproduction system of an industrial plant equipped with a machine acting on a sheet-like object being conveyed, characterized in that: have: A camera, which includes a portion of the sheet-like object in a shooting range and captures a still image; A process data collection unit collects process data of the above-mentioned machine at a periodic sampling timing; A camera control unit, which makes the periodic shooting timing of the camera match the periodic sampling timing; A process data storage unit, storing the collected process data in association with time information; A still image storage unit that associates the still image taken by the camera with the time information and stores the still image; a synchronous display unit for synchronously displaying, on a display screen having a time axis, a graph representing the process data at each moment collected by the process data collecting unit and a strip-shaped still image formed by combining still images at each moment captured by the camera, based on the time information, in such a manner that the process data at the same moment and the still image are located at the same position along the time axis, wherein, in a case where the still images at each moment have a predetermined width in a conveying direction of the sheet-like object and a part of adjacent still images overlap, the strip-shaped still image is formed by combining the still images at each moment based on the overlapping part estimated based on a conveying speed of the sheet-like object; as well as The marking processing section stores in a table the positions where abnormalities occur on the sheet object, which are designated by an operator of the data collection and reproduction system on the strip-shaped still image or the curve graph, and displays the strip-shaped still image and the curve graph in a manner that includes the selected positions in a screen when any of the positions where abnormalities occur on the sheet object is selected from the table.

2. The data collection and reproduction system according to claim 1, characterized in that: The camera is a line scan camera that captures an image of the sheet-like object in its entire width direction.

3. The data collection and reproduction system according to claim 1, wherein: The industrial equipment set is provided with a control network having a plurality of nodes with a shared memory, and the process data on the shared memory is synchronized by periodic multi-address transmission between the plurality of nodes; The above-mentioned machine is connected to one of the above-mentioned nodes to send and receive process data; The process data collection unit is connected to one of the nodes, and collects process data from the shared memory at each sampling timing.

4. The data collection and reproduction system according to claim 2, wherein: The industrial equipment set is provided with a control network having a plurality of nodes with a shared memory, and the process data on the shared memory is synchronized by periodic multi-address transmission between the plurality of nodes; The above-mentioned machine is connected to one of the above-mentioned nodes to send and receive process data; The process data collection unit is connected to one of the nodes, and collects process data from the shared memory at each sampling timing.

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