Control system

Abstract

To allow a controller to properly operate even when a processing load increases.SOLUTION: A control system 100 includes a controller (for example, a second controller 140), a management device 110 that is connected to the controller over a first communication channel (for example, a network 112) so that the management device can communicate with the controller and manages the controller, and an information processor 150 that is connected to the controller so that the information processor can communicate with the controller over a second communication channel (for example, a local network 142) independent of the first communication channel.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a control system that controls a controlled device. [Background technology]

[0002] In a control system, one or more control devices are connected to a higher-level management device. The control device controls one or more controlled devices. An example of a control device is a programmable logic controller (PLC). PLCs are highly versatile and can be connected to a variety of controlled devices. However, PLCs have poor scalability and limited processing power, so they may not be able to handle high-load processing, such as real-time analysis of large amounts of detected information. Therefore, it is possible to transfer detected information from the control device to the management device, and have the management device perform analysis independently of the control device. For example, in Patent Document 1, a branching device transmits contact-related information to an analysis device via a network, and the analysis device statistically processes the contact-related information to obtain statistical data. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-080844 Summary of the Invention [Problem to be solved by the invention]

[0004] In a control system, not only control devices but also various other devices are connected to a host management device via a single network. Therefore, if the control devices transmit a large amount of detection information to the management device via a common network for analysis, this may result in an increase in communication traffic. Furthermore, the control devices may experience a decrease in real-time control of the controlled devices due to the increased processing load caused by transmitting a large amount of detection information via the common network.

[0005] An object of the present disclosure is to provide a control system that is capable of operating a control device appropriately even when the processing load increases. [Means for solving the problem]

[0006] A control system according to one embodiment of the present disclosure includes a control device, a management device that is communicatively connected to the control device via a first communication path and manages the control device, and an information processing device that is communicatively connected to the control device via a second communication path independent of the first communication path; Equipped with.

[0007] The control device may be capable of switching between a case where it is connected to another control device without connecting an information processing device, and a case where it is connected to another control device while connecting an information processing device.

[0008] The control device may be configured to operate in parallel in an internal processing mode in which it is connected to a sensor and performs processing based on the detection information detected by the sensor entirely within the control device, and an external processing mode in which it transmits the detection information to an information processing device via a second communication path and causes the information processing device to perform processing based on the detection information.

[0009] The control device may analyze the detection information in an internal processing mode, and in an external processing mode, transmit the detection information and the analysis method to the information processing device via a second communication path, and the information processing device may analyze the detection information according to the analysis method and transmit the analysis results to the control device via the second communication path.

[0010] The control device may wait until the amount of detected information reaches a predetermined amount before transmitting the detected information to the information processing device.

[0011] The control device may update a predetermined flag when preparation for transmitting the detection information is complete, and the information processing device may read out the detection information from the control device in response to the update of the predetermined flag. [Effects of the Invention]

[0012] According to the present disclosure, it is possible to operate a control device appropriately even if the processing load increases. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is an explanatory diagram showing the schematic relationship between the devices that make up the control system. [Figure 2] FIG. 2 is an explanatory diagram showing the schematic relationship between the devices when the control system is applied to a centrifuge. [Figure 3] FIG. 3 is a flowchart illustrating the operation of the control device. [Figure 4] FIG. 4 is a flowchart illustrating the operation of the information processing device. [Figure 5] FIG. 5 is an explanatory diagram for explaining the ring buffer. [Figure 6] FIG. 6 is an explanatory diagram showing a communication mode between the control device and the information processing device. [Figure 7] FIG. 7 is an explanatory diagram for explaining the data structure of the command area and the response area. DETAILED DESCRIPTION OF THE INVENTION

[0014] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Specific dimensions, materials, numerical values, etc. shown in the embodiments are merely examples for ease of understanding and do not limit the present disclosure unless otherwise specified. In this specification and drawings, elements having substantially the same functions and configurations are designated by the same reference numerals to avoid redundant explanation, and elements not directly related to the present disclosure are not shown.

[0015] (Control system 100) 1 is an explanatory diagram showing the schematic relationship between the devices that make up the control system 100. The control system 100 includes a management device 110, a first control device 120, a controlled device 130, a second control device 140, and an information processing device 150.

[0016] The management device 110 is configured as a higher-level system such as a manufacturing execution system (MES) or a supervisory control and data acquisition system (SCADA). The management device 110 is connected to a network (first communication path) 112 such as Ethernet (registered trademark). The management device 110 manages one or more control devices, for example, a first control device 120 and a second control device 140, through the network 112. Specifically, the management device 110 reads status information from the first control device 120 and outputs various control commands to the first control device 120 in accordance with the process flow in the entire control system 100. The management device 110 also acquires various analysis results from the second control device 140.

[0017] The first control device 120 is configured by an edge device such as a PLC (Programmable Logic Controller), etc. The first control device 120 includes a power supply module 120a, a CPU module 120b, a first communication module 120c, a second communication module 120d, and an input / output module 120e.

[0018] The power supply module 120a supplies power to each module of the first control device 120. The CPU module 120b includes a processor, a ROM in which programs and the like are stored, and a RAM as a work area. The CPU module 120b controls the entire first control device 120 in accordance with the programs.

[0019] The first communication module 120c is connected to the network 112 and establishes communication with at least the management device 110. The second communication module 120d establishes communication with the second control device 140 through a local network 122, such as Ethernet, RS232, or RS485, which is independent of the network 112.

[0020] The input / output module 120e converts a serial signal or a parallel signal input from the controlled device 130 into data and transmits it to the CPU module 120b. The input / output module 120e also converts data received from the CPU module 120b into a serial signal or a parallel signal and outputs it to the controlled device 130.

[0021] Here, the modules of the first control device 120 are listed as the power supply module 120a, the CPU module 120b, the first communication module 120c, the second communication module 120d, and the input / output module 120e, but this is not limiting. For example, modules having other functions may be added, or unnecessary modules may be removed. Furthermore, multiple modules may be integrated into a single module, or a single module may be divided into multiple modules.

[0022] The controlled devices 130 are configured from various electrical devices in FA (Factory Automation). Examples of the controlled devices 130 include electric motors, encoders, and sensors. The controlled devices 130 are connected to the input / output module 120e via dedicated connection lines.

[0023] In the control system 100, the first control device 120 controls the controlled device 130 based on control commands received from the management device 110 and detection information of the controlled device 130 input through the input / output module 120e, in accordance with a control program for sequence control generated using a ladder diagram or the like. In this way, the control system 100 can comprehensively perform production support management such as process management, quality management, and production volume management. Furthermore, the first control device 120 transmits the detection information collected from the controlled device 130 in this way to the second control device 140. In this way, the second control device 140 can analyze the detection information collected by the first control device 120.

[0024] The second control device 140 is configured with an edge device such as a PLC, similar to the first control device 120. The second control device 140 includes a power supply module 140a, a CPU module 140b, a first communication module 140c, a second communication module 140d, a third communication module 140e, and an AD / DA module 140f.

[0025] The power supply module 140a supplies power to each module of the second control device 140. The CPU module 140b includes a processor, a ROM in which programs and the like are stored, and a RAM as a work area. The CPU module 140b controls the entire second control device 140 in accordance with the programs.

[0026] The first communication module 140c is connected to the network 112 and establishes communication with at least the management device 110. The second communication module 140d establishes communication with the first control device 120 through a local network 122 independent of the network 112. The third communication module 140e establishes communication with the information processing device 150 through a local network (second communication path) 142 such as Ethernet, RS232, or RS485, independent of the network 112.

[0027] The AD / DA module 140f converts an analog signal input from the outside into a digital signal and transmits it to the CPU module 140b. The AD / DA module 140f also converts a digital signal received from the CPU module 140b into an analog signal and outputs it to the outside.

[0028] Here, the modules of the second control device 140 are listed as the power supply module 140a, the CPU module 140b, the first communication module 140c, the second communication module 140d, the third communication module 140e, and the AD / DA module 140f, but this is not limiting. For example, modules having other functions may be added, or unnecessary modules may be removed. Furthermore, multiple modules may be integrated into one module, or one module may be divided into multiple modules.

[0029] As described above, the second control device 140 is used as an edge device between the management device 110 and the first control device 120. This is for the following reason: The second control device 140 can quickly analyze a large amount of detection information collected from the controlled devices 130 via the first control device 120 near the first control device 120 and the controlled devices 130. Therefore, maintenance personnel at a facility such as a factory can quickly and easily perform detailed data analysis of each individual controlled device 130 using the second control device 140. Furthermore, the second control device 140 can extract only necessary information from the analysis results of the detection information, perform a predetermined protocol conversion, and transmit the information to the management device 110, thereby reducing the network load. In this way, by disposing the second control device 140 between the management device 110 and the first control device 120, it is possible to improve the availability of the controlled devices 130 in a facility such as a factory and to streamline maintenance.

[0030] Here, a PLC is used as the second control device 140 for the following reasons: PLCs are compatible with a variety of communication protocols, and therefore can be easily connected to a variety of devices. PLCs also have high real-time and reliability in processing operations, and can be stably applied to applications in which analysis results are fed back to the first control device 120 and the controlled device 130. PLCs are also widely used because they have solid manufacturer support systems and are highly versatile. Therefore, maintenance personnel are often familiar with PLCs, and can easily use and maintain them, as well as easily transfer their operations.

[0031] In this way, a PLC as the second control device 140 is highly versatile and can be connected to a variety of devices. On the other hand, a PLC has poor expandability and limited processing power, so it may not be able to handle high-load processing such as real-time analysis processing of a large amount of detected information.

[0032] Here, it is conceivable that the second control device 140 transfers the detection information to the management device 110, and the management device 110 performs real-time analysis of the large amount of detection information independently of the second control device 140. However, in the control system 100, from the viewpoint of diversity, not only the management device 110 and the second control device 140 but also various other devices such as the first control device 120 are connected to the network 112. Therefore, if the second control device 140 transmits a large amount of detection information to the management device 110 through the common network 112 in order to have the management device 110 analyze the detection information, there is a risk of an increase in communication traffic.

[0033] It is also conceivable to add a program execution unit using C language, Python, or the like to the second control device 140 to execute high-load processing. However, in such a configuration, the hardware architecture of the second control device 140 becomes special, so a package specialized for the second control device 140 is required, which increases the cost and may result in a decrease in stability of the second control device 140.

[0034] It is also possible to add a separate real-time OS to the second control device 140 itself to execute high-load processing. However, in such a configuration, the maintenance personnel who manage the control device would have to operate a special real-time OS, which would result in problems such as an increased design load on the control device with the added real-time OS and a lack of a support system.

[0035] Therefore, in the control system 100 of this embodiment, a highly versatile information processing device 150 is placed separately from the second control device 140, and the second control device 140 and the information processing device 150 form separate, independent networks, allowing the second control device 140 to operate appropriately regardless of an increase in processing load.

[0036] The information processing device 150 includes one or more processors, a ROM storing programs and the like, a RAM as a work area, and a communication unit. The information processing device 150 is configured, for example, as a general-purpose personal computer. The OS installed in the information processing device 150 is not limited to Windows, and various OSs can be applied, such as Linux (registered trademark)-based OSs such as Ubuntu. The RAM of the information processing device 150 also includes storage media such as an HDD (Hard Disk Drive) and an SSD (Solid State Drive).

[0037] The information processing device 150 is connected to the third communication module 140e of the second control device 140 through the local network 142 and establishes communication with the second control device 140. The information processing device 150 acquires detection information detected by a sensor in the second control device 140 through the communication unit and executes high-load processing such as analysis processing. The information processing device 150 also stores the acquired detection information in a storage medium such as RAM. The information processing device 150 has a large capacity storage medium, and additional storage media can be easily added. Therefore, the information processing device 150 can quickly store a large amount of detection information read from the second control device 140.

[0038] Furthermore, the information processing device 150 is configured to be detachable from the second control device 140. Therefore, the second control device 140 can switch between connecting to the first control device 120 or other devices without connecting the information processing device 150, and connecting to the first control device 120 or other devices with the information processing device 150 connected.

[0039] Here, by connecting a user interface such as a mobile monitor, display, keyboard, or touch panel to the information processing device 150, the software developer can easily add, change, or delete software in the information processing device 150. Note that a tablet PC can also be used as the user interface. In this case, the software developer can establish direct communication with the second control device 140 through the tablet PC even if the operation of the information processing device 150 is unstable.

[0040] Here, the second control device 140 establishes exclusive communication with the information processing device 150 through a local network 142 that is independent of the network 112. Therefore, the second control device 140 can reliably and appropriately transmit a large amount of detected information to the information processing device 150 through the local network 142. In this way, by providing the local network 142, it becomes possible to absorb an increase in communication traffic. Furthermore, because the local network 142 is independent of the network 112, the information processing device 150 is resistant to external cyber attacks and is less susceptible to virus infection.

[0041] As described above, the network 112 connecting the management device 110, the first control device 120, and the second control device 140 is independent from the local network 142 connecting the second control device 140 and the information processing device 150. Therefore, the management device 110 cannot directly exchange information with the information processing device 150. The management device 110 exchanges information indirectly with the information processing device 150 through the second control device 140, for example, by temporarily storing information in the second control device 140.

[0042] The following describes an example of a specific operation of the control system 100. Here, a centrifuge will be used as an example of the controlled device 130.

[0043] 2 is an explanatory diagram showing the schematic relationship between the devices when the control system 100 is applied to the centrifuge 10. The control system 100 includes a management device 110, a first control device 120, a second control device 140, an information processing device 150, as well as the centrifuge 10 as a controlled device 130, a user interface 12, and an acceleration sensor 14.

[0044] The centrifuge 10 includes a storage unit 10a, a motor 10b, a motor driver 10c, and a scraper 10d. The storage unit 10a stores the mixture. The motor 10b drives the storage unit 10a and the scraper 10d to rotate. The motor driver 10c controls the motor 10b in response to a drive command from the first control device 120. The scraper 10d scrapes off material accumulated on the inner periphery of the storage unit 10a and discharges it to the outside. In this way, the centrifuge 10 uses the centrifugal force generated by the rotation of the motor 10b to separate the mixture stored in the storage unit 10a into, for example, a liquid and a solid.

[0045] The user interface 12 is configured by a computer having a touch panel and a display, such as a tablet PC. The user interface 12 is connected to the motor driver 10c via a serial line 16, such as RS485. The user interface 12 outputs a drive command for the centrifuge 10 and displays the operating status of the centrifuge 10 on the display in response to inputs made to the touch panel by a facility maintenance officer.

[0046] The acceleration sensor 14 detects the acceleration applied to itself. In the example of FIG. 2, two acceleration sensors 14 are used. The first acceleration sensor 14a is installed, for example, on the side surface of the housing section 10a. The second acceleration sensor 14b is installed, for example, near the motor 10b. The acceleration sensors 14 are connected to an AD / DA module 140f of the second control device 140 via an analog line 18. The second control device 140 converts the analog signals of the acceleration sensors 14a and 14b into digital signals using the AD conversion function of the AD / DA module 140f.

[0047] Here, an example has been given in which the second control device 140 acquires detection information such as the rotation speed of the motor 10b from the first control device 120, and acquires detection information such as acceleration from the acceleration sensor 14. However, this is not the only case, and the second control device 140 can acquire various detection information depending on the specifications of the controlled device 130 such as the centrifuge 10 and each sensor, and the use of the detection information.

[0048] In such a control system 100, the first control device 120 controls the rotation of the centrifuge 10 in accordance with a drive command received from the user interface 12. Specifically, the first control device 120 receives various operating parameters, such as the rotation speed of the motor 10b of the centrifuge 10, and issues commands such as a rotation speed to the motor 10b of the centrifuge 10 so as to follow the drive command. The first control device 120 transmits the operating status of the centrifuge 10, whose rotation is being controlled, to the user interface 12.

[0049] The second control device 140 also analyzes whether the centrifuge 10 is operating normally. For example, the second control device 140 checks in real time whether the motor rotation speed obtained through the first control device 120, the average value of acceleration detected by the acceleration sensor 14, the maximum value of acceleration, and the RMS (Root Mean Square) value of acceleration are within a predetermined normal range.

[0050] Furthermore, the second control device 140 transmits the operating status of the centrifuge 10 and the analysis results of the centrifuge 10 to the management device 110 via the network 112. The management device 110 displays the operating status of the centrifuge 10 and the analysis results on a display.

[0051] The second control device 140 analyzes detection information such as the motor rotation speed, the average value of acceleration detected by the acceleration sensor 14, the maximum value of acceleration, and the RMS value of acceleration, and maintains normal operation of the centrifuge 10. However, the second control device 140 cannot execute high-load processing such as real-time analysis processing of a large amount of detection information, such as Fourier transform (FFT) of the detection information. Therefore, the second control device 140 causes the information processing device 150 to execute all or part of the analysis processing.

[0052] Specifically, the second control device 140 operates in parallel in an internal processing mode in which processing based on the detection information is executed entirely within the second control device 140, and an external processing mode in which the detection information is sent to the information processing device 150 via the local network 142 and the information processing device 150 executes processing based on the detection information.

[0053] FIG. 3 is a flowchart illustrating the operation of the second control device 140, and FIG. 4 is a flowchart illustrating the operation of the information processing device 150. The second control device 140 determines whether or not the timing for acquiring detection information, for example, the rotation speed or acceleration of the motor, has arrived from the first control device 120 or the acceleration sensors 14a, 14b (S100). The second control device 140 acquires such detection information, for example, at intervals of 1 msec. If the acquisition timing has not arrived (NO in S100), the second control device 140 repeats the process of step S100. On the other hand, if the acquisition timing has arrived (YES in S100), the second control device 140 acquires the rotation speed or acceleration of the motor and stores it in RAM in association with the acquisition time (S102).

[0054] Furthermore, if the received detection information is acceleration (YES in S104), the second control device 140 also stores the acceleration in a ring buffer in association with the time of acquisition (S106). Such a ring buffer will be described in detail later.

[0055] The second control device 140 determines whether the motor rotation speed or acceleration has been stored for a predetermined number of samples (S108). If the motor rotation speed or acceleration has not been stored for the predetermined number of samples (NO in S108), the second control device 140 repeats the process from step S100. On the other hand, if the motor rotation speed or acceleration has been stored for the predetermined number of samples (YES in S108), the second control device 140 identifies representative values ​​such as the average acceleration value, maximum acceleration value, and RMS acceleration value based on the stored motor rotation speed or acceleration, and stores them in RAM in association with the identified time (S110).

[0056] The second control device 140 determines whether the identified representative values, such as the motor rotation speed, the average acceleration value, the maximum acceleration value, and the RMS acceleration value, are within a predetermined normal range (S112). If each value is not within the predetermined normal range (NO in S112), the second control device 140 notifies the user of an abnormality through the display (S114). On the other hand, if each value is within the predetermined normal range (YES in S112), the second control device 140 proceeds to step S116.

[0057] Furthermore, if the detection information stored for the predetermined number of samples is not acceleration (NO in S116), the second control device 140 repeats the process from step S100. On the other hand, if the detection information stored for the predetermined number of samples is acceleration (YES in S116), the second control device 140 transmits the acceleration to the information processing device 150 based on the fact that the acceleration has been stored for the predetermined number of samples (S118), and has the information processing device 150 perform analysis processing based on the acceleration, and repeats the process from step S100.

[0058] 3, the process enclosed by the dashed line on the left side corresponds to the internal processing mode, and the process enclosed by the dashed line on the right side corresponds to the external processing mode. Here, the motor rotation speed, average acceleration value, maximum acceleration value, and RMS value of acceleration are analyzed in the internal processing mode, while the value obtained by Fourier transforming the acceleration is analyzed in the external processing mode. However, this is not the only case, and for example, the RMS value of acceleration analyzed in the internal processing mode can also be analyzed in the external processing mode to reduce the processing load on the second control device 140.

[0059] 4, the information processing device 150 determines whether or not acceleration has been received as detection information from the second control device 140 (S150). If acceleration has not been received (NO in S150), the information processing device 150 repeats the process of step S150. On the other hand, if acceleration has been received (YES in S150), the information processing device 150 stores the received acceleration in RAM (S152). Note that the acceleration is associated with the time at which the second control device 140 acquired it.

[0060] The information processing device 150 has a larger RAM storage capacity than the second control device 140, and storage media such as RAM can be added inexpensively and easily, so that the information processing device 150 can store a large amount of detection information received from the second control device 140. Therefore, the information processing device 150 can also reanalyze the detection information after the fact.

[0061] The information processing device 150 performs analysis processing such as Fourier analysis of the received acceleration, and stores the result in RAM in association with the time when the analysis was completed (S154).

[0062] The information processing device 150 determines whether the intensity of a specific frequency region among the values ​​obtained by Fourier transforming the acceleration falls within a predetermined normal range (S156). If the intensity of the specific frequency region does not fall within the predetermined normal range (NO in S156), the information processing device 150 notifies the user of an abnormality through a display (S158) and transmits an error code indicating the abnormality and the details of the error to the second control device 140 (S160). On the other hand, if the intensity of the specific frequency region falls within the predetermined normal range (YES in S156), the information processing device 150 repeats the processing from step S150.

[0063] The second control device 140 can determine whether the controlled device 130 is deteriorating or abnormal, based on the error code and the content of the error received from the information processing device 150. For example, the second control device 140 can determine whether the controlled device 130 is deteriorating or abnormal based on an increase in the intensity of a specific frequency range, and can determine whether the controlled device 130 is abnormal based on a sudden increase in the intensity of a specific frequency range.

[0064] Here, analytical processing has been used as an example of processing performed by the second control device 140 and the information processing device 150 based on the detection information detected by the sensor, but it is sufficient to perform some kind of calculation based on the detection information, and various types of processing can be applied, such as arithmetic operations, statistical processing, and cumulative processing.

[0065] Although the second control device 140 and the information processing device 150 each independently detect an abnormality, the present invention is not limited to this example. The detection information and analysis results of each device may be comprehensively evaluated. For example, if there is a correlation between the motor rotation speed acquired by the second control device 140 and the value obtained by the information processing device 150 through a Fourier transform of acceleration, the second control device 140 may determine that a disturbance in the correlation is an abnormality. In this case, the second control device 140 and the information processing device 150 may refer to the time associated with the detection information and the analysis results and synchronize the respective analysis results, thereby enabling appropriate abnormality evaluation. The second control device 140 may not only continuously acquire detection information, but also acquire detection information only at necessary timings in accordance with the operation of the controlled device 130.

[0066] Here, the information processing device 150, which is a general-purpose personal computer, is used as the device for performing advanced analysis, so a wide variety of general-purpose software can be used. Software developers can use familiar general-purpose software to appropriately set up analysis processing with a high degree of freedom. This improves development efficiency. Software developers do not need to understand the detailed operations of the control system 100 or the second control device 140; they only need to have knowledge of analysis processing. Furthermore, the information processing device 150 allows the CPU and memory capacity to be easily and inexpensively changed depending on the amount of detected information, the detection frequency, and the load of analysis processing, thereby increasing the versatility of analysis processing.

[0067] Furthermore, although analytical processing with a high processing load is executed by the information processing device 150, the second control device 140 is the main body of overall operation. Therefore, facility maintenance personnel can quickly and easily define analytical processing through the second control device 140, which they are familiar with. Specifically, maintenance personnel can directly operate the second control device 140 to arbitrarily define analytical processing such as analysis methods and arguments (described later), and freely set what analytical results to obtain from what detected information. Therefore, maintenance personnel can adjust and test the control system 100 on-site.

[0068] Here, an example is given in which the information processing device 150 analyzes the acceleration acquired by the second control device 140, but this is not limited to this case, and various detection targets such as audio, images, etc., which have large fluctuations per unit time, can be analyzed.

[0069] However, if the second control device 140 were to immediately transmit the detection information to the information processing device 150 every time it acquires it, the transmission process would become complicated and the frequency of determining whether the detection information is appropriate, for example, performing a checksum, would increase, which could unnecessarily increase communication traffic. Therefore, the second control device 140 temporarily stores the detection information in a ring buffer, and when the detection information reaches a predetermined amount, it transmits the accumulated detection information to the information processing device 150 all at once.

[0070] Fig. 5 is an explanatory diagram for explaining the ring buffer. As shown in Fig. 5, a holding area for detection information is set in a predetermined area of ​​the RAM of the second control device 140. The holding area is divided into a plurality of areas, for example, five equal areas. Here, these areas are tentatively referred to as a first holding area to a fifth holding area.

[0071] When the second control device 140 acquires detection information, it stores the acquired detection information in the first storage area in order from the first address, as shown by the hatching in FIG. 5(a). Then, as shown by the hatching in FIG. 5(b), when the detection information reaches a predetermined amount and is stored in the entire first storage area, the second control device 140 stores the acquired detection information in the second storage area in order from the first address, and transmits the detection information in the first storage area to the information processing device 150 all at once. Similarly, when the detection information is stored in the entire second storage area, the second control device 140 stores the acquired detection information in the third storage area in order from the first address, as shown by the hatching in FIG. 5(c), and transmits the detection information in the second storage area to the information processing device 150 all at once. Furthermore, when the detection information is stored in the entire fifth storage area, the second control device 140 stores (overwrites) the acquired detection information again in order from the first address in the first storage area, and transmits the detection information in the fifth storage area to the information processing device 150 all at once, as shown by the cross-hatching in FIG. 5(d).

[0072] With this configuration, it is possible to reduce the frequency with which detection information is transmitted from the second control device 140 to the information processing device 150. Furthermore, since the frequency with which the detection information is judged to be appropriate can be reduced, it is possible to reduce communication traffic. Furthermore, since the detection information remains in the RAM until the entire storage area is overwritten with new detection information, even if it becomes necessary to resend the detection information to the information processing device 150 due to some malfunction, the second control device 140 can resend the detection information from the RAM.

[0073] Here, as described above, the second control device 140 is the subject of overall operation. However, if the second control device 140 were to manage communication between the second control device 140 and the information processing device 150, complex communication settings would have to be configured on the second control device 140 side. On the other hand, the information processing device 150, which is a general-purpose personal computer, can use a variety of general-purpose software and can easily and appropriately configure communication settings. For example, the information processing device 150 can read information from the second control device 140 or write information to the second control device 140 simply by specifying the IP address and port number of the second control device 140. Therefore, here, the second control device 140 is the subject of control, while the information processing device 150 is the subject of communication.

[0074] FIG. 6 is an explanatory diagram showing the communication mode between the second control device 140 and the information processing device 150. Here, the information processing device 150 is the main device that manages communication. Therefore, communication is initiated from the information processing device 150. The second control device 140 has a fixed information storage area reserved in advance as a storage area used for information exchange with the information processing device 150. This storage area is composed of a "command execution trigger," a "command area," a "response area," and a "command execution completion signal." The "command area" and "response area" of this information storage area will be described in detail later. In addition, the second control device 140 has a variably reserved data storage area as a storage area for storing detection information and analysis results. This storage area is composed of an "input data area" and an "output data area." The addresses of the "input data area" and "output data area" are identified based on the information in the command area. Here, the "input data area" may be the holding area itself composed of the ring buffer described above.

[0075] The information processing device 150 monitors whether the second control device 140 is ready to transmit at a predetermined cycle by so-called polling (S200). When the second control device 140 is ready to transmit the detected information, it updates a predetermined flag. For example, the second control device 140 sets a command execution trigger consisting of one bit as a flag to 1b.

[0076] When the information processing device 150 detects that the command execution trigger is set to 1b (S202), it first reads information from the command area (S204). At this time, the information processing device 150 can determine the analysis method and arguments based on the information in the command area. Then, the information processing device 150 reads the detection information held in the input data area based on the address of the input data area included in the command area (S206). Then, when reading of the detection information is completed, the information processing device 150 sets the command execution trigger to 0b (S208).

[0077] Furthermore, when the information processing device 150 completes the analysis process of the read detection information based on the analysis method and arguments, it writes the analysis results to the output data area of ​​the second control device 140 based on the address of the output data area included in the command area (S210). When the information processing device 150 completes writing the analysis results, it updates a predetermined flag (S212). For example, the information processing device 150 sets 1b to an instruction execution completion signal consisting of 1 bit as a flag.

[0078] The second control unit 140 processes the received analysis result in response to the update of a predetermined flag, and sets the command execution trigger to 0b.

[0079] With this configuration, the second control device 140 is the main operator, while the information processing device 150 is the main operator in managing communications. The information processing device 150 can use a large number of general-purpose software programs and can easily and appropriately set up communications, thereby reducing the design load of the control system 100 as a whole.

[0080] Note that, here, an example has been described in which the information processing device 150 mainly reads out the detection information of the second control device 140 and writes the analysis results to the second control device 140. However, this is not the only case, and various communication standards can be applied, for example, socket communication using TCP / IP, file transmission and reception using FTP, etc.

[0081] Furthermore, by providing a WDT (Watch Dog Timer) or the like in the information processing device 150, even if the information processing device 150 becomes unstable, the information processing device 150 can be restored by a system reset, and stable operation can be continued.

[0082] 7 is an explanatory diagram for explaining the data structure of the command area and the response area, which shows the contents and word lengths of the command area and the response area.

[0083] The instruction area consists of a total of 40 words, and the starting address is fixed to an arbitrary value. Data is arranged in the instruction area in the following order from the beginning: instruction code, input data area starting address, input data area size, output data area starting address, output data area size, and arguments.

[0084] The instruction code consists of a single unsigned integer word and indicates the analysis method, such as Fourier transform, RMS value, or wavelet transform. The input data area start address consists of a 10-word ASCII code and indicates the start address of the input data area. The input data area size consists of a 2-word unsigned integer and indicates the storage capacity of the input data area. The output data area start address consists of a 10-word ASCII code and indicates the start address of the output data area. The output data area size consists of a 2-word unsigned integer and indicates the storage capacity of the output data area. The argument consists of a 15-word integer and indicates parameters related to the analysis, such as the number of samples for the Fourier transform, the window function, and the overlap rate.

[0085] Here, as described above, the maintenance personnel can define the analysis process, such as the analysis method and arguments, through the second control device 140, making it possible to set what analysis results will be obtained from what detection information.

[0086] As described above, since the input data area is configured by a ring buffer, the input data area start address is the start address of the holding area currently storing the detection information, and the input data area size is fixed to the storage capacity of the holding area. When the detection information is stored in all of the holding areas storing the detection information at that time, the second control device 140 sets the command execution trigger to 1b, indicating that transmission preparation is complete. In this way, the detection information in the holding area is transmitted all at once to the information processing device 150, as shown in Figures 5 and 6.

[0087] The response area consists of a total of 20 words, and the starting address is fixed to an arbitrary value different from that of the command area. The response area contains data in the following order from the beginning: the command code that was executed, the error code, and any other return values.

[0088] The instruction code that has been executed consists of a single unsigned integer word, and like the instruction code in the instruction area, indicates the analysis method, such as Fourier transform, RMS value, wavelet transform, etc. The error code consists of a single unsigned integer word, and indicates 0 when normal, and a value other than 0 when abnormal. Other return values ​​consist of 18 unsigned integer words, and indicate the specified return value defined for each instruction code.

[0089] In the above description, an example has been given in which the control system 100 already includes the acceleration sensor 14 and the information processing device 150. However, this is not limiting, and the configuration of the control system 100 may be changed depending on the state of the controlled device 130 as described below. For example, as described above, the second control device 140 can switch between connecting to the first control device 120 without connecting the information processing device 150, and connecting to the first control device 120 with the information processing device 150 connected.

[0090] For example, suppose a facility has a controlled device 130 that is prone to failure. A maintenance technician estimates the cause of the failure based on the appearance and timing of the failure, but does not resolve the cause. Therefore, the maintenance technician installs, for example, an acceleration sensor 14 in the controlled device 130 and investigates the cause of the failure based on the detection information of the acceleration sensor 14 in the second control device 140. However, the maintenance technician does not resolve the cause. Here, the maintenance technician subsequently connects the information processing device 150 to the controlled device 130 and investigates the cause of the failure based on the detection information of the acceleration sensor 14 using the second control device 140 and the information processing device 150. The information processing device 150 can perform a more detailed analysis than the second control device 140, so the cause of the failure can be identified. In this case, the detailed analysis process is performed by the information processing device 150, and the impact on the load of the second control device 140 is limited, so the operation of the control system 100 is not affected.

[0091] Thereafter, the maintenance person processes the controlled device 130 so that it is less likely to fail. In addition, the maintenance person extracts an analysis process that is effective in identifying the failure from the multiple analysis processes performed by the second control device 140 and the information processing device 150, and if possible, executes the extracted analysis process by the second control device 140. In this way, the information processing device 150 can be removed from the second control device 140. In this way, the information processing device 150 can be reused for another second control device 140.

[0092] In this way, by adding any sensors or information processing devices 150 when necessary and removing them when they are no longer needed, it is possible to perform detailed analysis processing and to make effective use of resources.

[0093] As described above, the information processing device 150, which is a general-purpose personal computer, is used as the device for performing advanced analysis, allowing for the use of a wide variety of general-purpose software. Software developers can use familiar general-purpose software to appropriately set up analysis processing with a high degree of freedom. This improves development efficiency. Software developers do not need to understand the detailed operations of the control system 100 or the second control device 140; they only need to have knowledge of the analysis processing. Furthermore, the information processing device 150 allows for easy and inexpensive changes to the CPU and memory capacity depending on the amount of detected information, the detection frequency, and the load of the analysis processing, thereby increasing the versatility of the analysis processing.

[0094] Furthermore, although analytical processing with a high processing load is executed by the information processing device 150, the second control device 140 is the main body of overall operation. Therefore, facility maintenance personnel can quickly and easily define analytical processing through the second control device 140, which they are familiar with. Specifically, maintenance personnel can directly operate the second control device 140 to arbitrarily define analytical processing such as analysis methods and arguments, and freely set what analytical results to obtain from what detected information. Therefore, maintenance personnel can adjust and test the control system 100 on-site.

[0095] In short, the maintenance personnel can set up the necessary analysis processing through the second control device 140, which they are familiar with, and the software developers can perform the analysis processing using general-purpose software, which they are familiar with, through the general-purpose information processing device 150, making it possible to achieve efficiency through division of labor that takes advantage of the advantages of both parties.

[0096] Although the embodiments have been described above with reference to the accompanying drawings, it goes without saying that the present disclosure is not limited to such embodiments. It is clear that a person skilled in the art can conceive of various modifications or alterations within the scope of the claims, and it is understood that such modifications also fall within the technical scope of the present disclosure.

[0097] For example, in the above-described embodiment, an example has been described in which one information processing device 150 is connected to one second control device 140 via the local network 142. However, this is not limited to such a case, and multiple information processing devices 150 can be connected to one second control device 140 via the local network 142. In this case, different analysis processes can be executed in each of the multiple information processing devices 150. Furthermore, even if one of the multiple information processing devices 150 becomes unstable, redundancy can be utilized by having another information processing device 150 perform the analysis process instead.

[0098] Furthermore, one information processing device 150 can be connected to multiple second control devices 140 via the local network 142. In this case, for example, one information processing device 150 can avoid conflicts in the timing of acquiring detection information by making the monitoring timing by so-called polling shown in step S200 of Fig. 6 different among the multiple second control devices 140.

[0099] In the above-described embodiment, an example was described in which the second control device 140 acquires the rotation speed of the motor and the acceleration of the acceleration sensor 14 as detection information. However, this is not limited to this case, and the second control device 140 can acquire various values ​​indicating the state of the controlled device, sensors, etc. as detection information. In the above-described embodiment, an example was described in which the second control device 140 or the information processing device 150 analyzes the rotation speed of the motor, the average value of the acceleration detected by the acceleration sensor 14, the maximum value of the acceleration, the RMS value of the acceleration, and a value obtained by Fourier transforming the acceleration. However, this is not limited to this case, and the second control device 140 or the information processing device 150 can analyze various detection information or various representative values ​​obtained by processing the detection information (average value, maximum value, RMS value, Fourier transformed value, etc.).

[0100] In the above-described embodiment, an example has been given in which the acceleration sensor 14 is connected to the second control device 140, and the second control device 140 transmits the detection information acquired from the acceleration sensor 14 to the information processing device 150. However, this is not limiting, and the acceleration sensor 14 may be directly connected to the information processing device 150, and the information processing device 150 may acquire the detection information directly from the acceleration sensor 14 and perform analysis processing. When such a configuration is adopted, in order to synchronize the time between the second control device 140 and the information processing device 150, the information processing device 150 may associate the detection information with the synchronized time and store it.

[0101] In the above-described embodiment, an example has been described in which the maintenance person directly operates the second control device 140 to set the analysis method and arguments. However, this is not the only case, and for example, the analysis method and arguments may be set in the management device 110. For example, the management device 110 can indirectly cause the information processing device 150 to execute the analysis process by writing each piece of data to the information storage area of ​​the second control device 140.

[0102] Note that the steps executed by the second control device 140 and the information processing device 150 shown in Figures 3 and 4 do not necessarily have to be processed in chronological order according to the order described in the flowchart, and may include parallel or subroutine processing.

[0103] The present disclosure can contribute to, for example, Goal 12 of the Sustainable Development Goals (SDGs), "Ensure sustainable consumption and production patterns," by using the control system 100 to promote energy conservation and resource efficiency and build sustainable consumption and production. [Explanation of symbols]

[0104] 10. Centrifuge 14 Acceleration sensor 100 Control System 110 Management device 112 Network (first communication path) 120 First control device 122 local network 130 Controlled equipment 140 Second control device (control device) 142 Local Network (Second Communication Path) 150 Information processing equipment

Claims

1. a control device; a management device that is communicably connected to the control device via a first communication path and manages the control device; an information processing device communicably connected to the control device via a second communication path independent of the first communication path; A control system comprising:

2. The control device A case where the information processing device is not connected to another control device, A case where the information processing device is connected to another control device, 2. The control system according to claim 1, wherein the control system is capable of switching between:

3. The control device connected to the sensor, an internal processing mode in which processing based on the detection information detected by the sensor is executed entirely within the control device; an external processing mode in which the detection information is transmitted to the information processing device via the second communication path and a process based on the detection information is executed by the information processing device; The control system according to claim 1 , wherein the steps are performed in parallel.

4. The control device In the internal processing mode, the detection information is analyzed; In the external processing mode, the detection information and the analysis method are transmitted to the information processing device via the second communication path; The information processing device includes: The control system according to claim 3 , wherein the detection information is analyzed according to the analysis method, and the analysis result is transmitted to the control device via the second communication path.

5. The control device 4. The control system according to claim 3, wherein the control system waits until the detected information reaches a predetermined amount, and transmits the detected information to the information processing device.

6. the control device updates a predetermined flag when preparation for transmission of the detection information is completed; The control system according to claim 3 , wherein the information processing device reads out the detection information from the control device in response to updating of the predetermined flag.

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