Alarm notification system

Abstract

This invention provides an alarm notification system that can notify alarms with a simple configuration, even when using a detection device that outputs a signal different from the communication standard supported by the alarm notification device. [Solution] The alarm notification system is provided for multiple types of equipment in a factory and includes multiple detection devices that output signals indicating detection information that detects the status of the equipment, the multiple detection devices including a first detection device that outputs the signal in a first communication standard and a second detection device that outputs the signal in a second communication standard, a converter that converts the signal output from the first detection device and outputs the signal in a second communication standard, and an alarm notification device that notifies a higher-level device of an alarm by email based on the signal output from the converter and the signal output from the second detection device.

Description

Technical Field

[0001] The present invention relates to an alarm notification system.

Background Art

[0002] Conventionally, a system for process control of a plant and a plant control system using an OPC UA-based machine-to-machine (M2M) network is known (for example, Patent Document 1). In this system, a plant associated with a plant control system includes a plurality of interlock elements of one or more operating parts of the plant. The operation of the operating part is controlled by the plant control system using elements interlocked with the plant control system. The plant control system is accessible in the machine-to-machine (M2M) network via a network interface by an independent process control system, and messages including signal data and operation commands are transmitted between the process control system and the plant control system. An OPC UA client based on the OPC unified architecture is formed in each of the process control system and the plant control system. The transport layer between the OPC UA client of the process control system and the OPC UA client of the plant control system is extended bidirectionally using a defined bit sequence including an encoded programmable logic controller message. For the operation and control of the plant, the process control system encodes a PLC command message for the OPC UA transport layer and transfers it within the OPC UA transport layer using the defined bit sequence to transmit the programmable logic controller command message to the plant control system.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0004] The technology described in Patent Document 1 above involves process control of a plant and plant control system using an OPC UA-based network.

[0005] However, Patent Document 1 mentioned above does not describe how to handle cases where the communication standard used by the detection device to output a signal indicating detection information differs from the communication standard that the alarm notification device can support.

[0006] This invention has been made in view of the above circumstances, and aims to provide an alarm notification system that can notify alarms with a simple configuration, even when a detection device that outputs a signal different from the communication standard that the alarm notification device can support is used. [Means for solving the problem]

[0007] The alarm notification system according to the first embodiment includes a plurality of detection devices provided for multiple types of equipment in a factory, which output signals indicating detection information that detects the status of the equipment, the plurality of detection devices including a first detection device that outputs the signal in a first communication standard and a second detection device that outputs the signal in a second communication standard, a converter that converts the signal output from the first detection device and outputs the signal in the second communication standard, and an alarm notification device that notifies a higher-level device of an alarm based on the signal output from the converter and the signal output from the second detection device. In this way, even when detection devices that output signals different from the communication standard that the alarm notification device can support are used, an alarm can be notified with a simple configuration.

[0008] The alarm notification system according to the second embodiment is an alarm notification system according to the first embodiment in which the plurality of detection devices include a first detection device group consisting of at least one first detection device and a second detection device group consisting of at least one second detection device, each of the first detection devices included in the first detection device group is connected to the converter and the alarm notification device via a first communication line, and each of the second detection devices included in the second detection device group is connected to the alarm notification device via a second communication line. In this way, even when using a first detection device group that outputs signals different from the communication standards that the alarm notification device can support, an alarm can be notified with a simple configuration.

[0009] The alarm notification system according to the third embodiment is the alarm notification system according to the first embodiment, wherein the first communication standard is OPC-UA (OPC Unified Architecture) and the second communication standard is Modbus TCP. In this way, even when using a detection device that outputs a signal different from Modbus TCP, which the alarm notification device can support, an alarm can be notified with a simple configuration.

[0010] The alarm notification system according to the fourth embodiment is an alarm notification system according to the first embodiment in which the plurality of types of equipment include a bioreactor.

[0011] The alarm notification system according to the fifth embodiment is an alarm notification system according to the first embodiment, wherein the plurality of detection devices include a bioreactor control device. [Effects of the Invention]

[0012] According to one aspect of the present invention, an alarm notification system can be used to notify alarms with a simple configuration, even when a detection device that outputs a signal different from the communication standard that the alarm notification device can support is used. [Brief explanation of the drawing]

[0013] [Figure 1]This is a block diagram showing the configuration of an alarm notification system according to an embodiment of the present invention. [Figure 2] This is a block diagram showing the configuration of a converter according to an embodiment of the present invention. [Figure 3] This is a block diagram showing the configuration of an alarm notification device according to an embodiment of the present invention. [Modes for carrying out the invention]

[0014] Embodiments of the present invention will be described in detail below with reference to the drawings.

[0015] <Summary of Embodiments of the Invention>

[0016] While systems that automatically notify users of events such as alarms and equipment operation / shutdown via email are commercially available, they do not comply with the OPC standard adopted by some overseas manufacturers. Therefore, it is difficult for small factories to implement alarm notification systems, and equipment abnormalities are detected by employees conducting regular patrols. In the case of processes that last several days, such as cultivation, this places a heavy burden on employees, and if the factory is left unattended at night, there is a risk of manufacturing failure due to delays in detecting abnormalities.

[0017] Therefore, in this embodiment, a commercially available industrial communication gateway is used as a converter to enable the commercially available alarm notification system to acquire process values ​​and event data in OPC standard communication (OPC-UA, OPC-DA, OPC-AE, etc.).

[0018] Specifically, no customization such as communication standard changes is performed on the manufacturing equipment of overseas manufacturers. Also, instead of adopting a high-function and high-cost system such as SCADA (Supervisory Control And Data Acquisition), the system is constructed with a commercially available alarm notification system. In addition, industrial communication gateways are generally used in the following cases. That is, they are often used to convert signals output in communication standards such as SLMP and Modbus TCP into signals in communication standards of OPC standard specifications (OPC-UA, OPC-DA, OPC-AE, etc.). In the present embodiment, the industrial communication gateway is used as a converter that converts signals output in OPC standard specifications (OPC-UA, OPC-DA, OPC-AE, etc.) into signals in the communication standard of Modbus TCP.

[0019] <System Configuration>

[0020] Hereinafter, the alarm notification system according to an embodiment of the present invention will be described.

[0021] As shown in FIG. 1, the alarm notification system 100 according to an embodiment of the present invention includes a plurality of detection devices 12A to 12F provided for a plurality of types of devices 10A to 10F in a factory, communication devices 20A and 20B, a converter ۳۰, an alarm notification device 4۰, a repeater 5۰, and an upper device 6۰. Note that the detection devices 12A and 12B are an example of the first detection device group, and the detection devices 12C and 12D are an example of the second detection device group.

[0022] Between the plurality of detection devices 12A and 12B and the communication device 20A, between the communication device 20A and the converter 30, and between the converter 30 and the alarm notification device 40, they are respectively connected by a LAN cable as the first communication line. Between the plurality of detection devices 12C and 12D and the communication device 20B, and between the communication device 20B and the alarm notification device 40, they are respectively connected by a LAN cable as the second communication line. Between the detection device 12E and the alarm notification device 40, and between the detection device 12F and the alarm notification device 40, they are respectively connected by hard wires. Between the alarm notification device 40 and the repeater 50, they are connected by a LAN cable. Between the repeater 50 and the upper device 60, they are connected via the network N.

[0023] <Configuration of Detection Device>

[0024] The plurality of detection devices 12A to 12F according to the embodiment of the present invention are provided for a plurality of types of devices 10A to 10F in the factory, and output signals indicating detection information obtained by detecting the states of the devices 10A to 10F.

[0025] Specifically, the plurality of detection devices 12A to 12F output signals indicating detection information detected by sensors provided for the devices 10A to 10F. The plurality of devices 10A to 10F include, for example, bioreactors (for example, Ready To Process WAVE 25 manufactured by Cytiva) for culturing animal cells and insect cells, and sub-culturing cells for antibody pharmaceuticals and vaccine production. The plurality of detection devices 12A to 12F include a bioreactor control device (for example, UNICORN for WAVE 25 manufactured by Cytiva) that controls the bioreactor. The sensors include, for example, temperature sensors, pressure sensors, CO2 concentration sensors, O2 concentration sensors, dissolved O2 concentration sensors, gas flow sensors, rotation speed sensors, weight sensors, pH sensors, and the like.

[0026] The detection devices 12A and 12B output signals to the converter 30 via a LAN cable through the communication device 20A using a communication standard that is an OPC standard (for example, OPC-DA, OPC-UA, OPC-AE, etc.).

[0027] Detection devices 12C and 12D use the Modbus TCP communication standard to output abnormal signals to the alarm notification device 40 via a LAN cable through the communication device 20B.

[0028] Detection devices 12E and 12F output an abnormal signal to the alarm notification device 40 via a contact signal.

[0029] Detection devices 12A and 12B are examples of first detection devices, and the OPC standard communication specification is an example of first communication specification. Detection devices 12C and 12D are examples of second detection devices, and Modbus TCP is an example of second communication specification.

[0030] <Converter Configuration>

[0031] As shown in Figure 2, the converter 30 includes a first communication unit 32, a conversion unit 34, and a second communication unit 36.

[0032] The first communication unit 32 transmits and receives signals using the OPC standard communication protocol.

[0033] The second communication unit 36 ​​transmits and receives signals using the Modbus TCP communication standard.

[0034] When the conversion unit 34 receives a signal in the first communication unit 32, it converts the signal so that it can be transmitted from the second communication unit 36 ​​using the Modbus TCP communication standard.

[0035] Furthermore, when the conversion unit 34 receives a signal in the second communication unit 36, it converts the signal so that it can be transmitted from the first communication unit 32 using the OPC standard communication protocol.

[0036] <Configuration of the alarm notification device>

[0037] As shown in Figure 3, the alarm notification device 40 includes a first communication unit 42, a second communication unit 44, a third communication unit 45, an anomaly detection unit 46, and an alarm notification unit 48.

[0038] The first communication unit 42 receives signals using the Modbus TCP communication standard. Specifically, the first communication unit 42 receives signals output from the detection devices 12A and 12B from the converter 30.

[0039] The second communication unit 44 receives abnormal signals output from detection devices 12C and 12D via the communication device 20B.

[0040] The third communication unit 45 receives abnormal signals output from the detection devices 12E and 12F.

[0041] The abnormality detection unit 46 detects abnormal conditions from the signals received by the first communication unit 42. For example, the abnormality detection unit 46 detects high temperature or low temperature conditions of devices 10A and 10B as abnormal conditions.

[0042] The alarm notification unit 48 notifies the host device 60 of an alarm via email through the repeater 50 when an abnormal condition is detected by the abnormality detection unit 46, when the second communication unit receives an abnormality signal, or when the third communication unit receives an abnormality signal.

[0043] <How the alarm notification system works>

[0044] Next, the operation of the alarm notification system 100 according to an embodiment of the present invention will be described.

[0045] Multiple detection devices 12A to 12F repeatedly output signals at regular intervals, indicating the detection information of the state of various types of equipment 10A to 10F within the factory, which is detected by sensors installed on those equipment 10A to 10F.

[0046] At this time, when the converter 30 receives signals from the detection devices 12A and 12B, it converts the signals to be transmitted using the Modbus TCP communication standard and outputs them to the alarm notification device 40.

[0047] The alarm notification device 40 detects an abnormal condition from the received signal each time it receives a signal. If an abnormal condition is detected, the alarm notification device 40 sends an alarm notification to the higher-level device 60 via email through the repeater 50.

[0048] As described above, according to the alarm notification system 100 of the embodiment of the present invention, the converter 30 converts the signals output from the detection devices 12A and 12B in OPC-UA format and outputs the signals in Modbus TCP format, and the alarm notification device 40 notifies the higher-level device of the alarm via email based on the signals output from the converter and the signals output from the detection devices 12C and 12D. This makes it possible to notify alarms with a simple configuration even when using detection devices that output signals different from the communication standards that the alarm notification device can support.

[0049] It should be noted that the present invention is not limited to the embodiments described above, and various modifications and applications are possible without departing from the spirit of the invention. [Explanation of Symbols]

[0050] 10A~10F equipment 12A~12F Detection device 20A, 20B communication device 30 Converters 40 Alarm notification device 50 Repeaters 60 Higher-level equipment 100 Alarm Notification System

Claims

1. Multiple detection devices provided for multiple types of equipment within a factory, which output signals indicating detection information that detects the status of the equipment, including a first detection device that outputs the signal in a first communication standard and a second detection device that outputs the signal in a second communication standard, A converter that converts the signal output from the first detection device and outputs the signal in the second communication standard, An alarm notification device that notifies a higher-level device of an alarm based on the signal output from the converter and the signal output from the second detection device, An alarm notification system including this.

2. The plurality of detection devices include a first detection device group consisting of at least one first detection device and a second detection device group consisting of at least one second detection device. Each of the first detection devices included in the first group of detection devices is connected to the converter and the alarm notification device via a first communication line. The alarm notification system according to claim 1, wherein each of the second detection devices included in the second group of detection devices is connected to the alarm notification device via a second communication line.

3. The aforementioned first communication standard is OPC-UA (OPC Unified Architecture), The alarm notification system according to claim 1, wherein the second communication standard is Modbus TCP.

4. The alarm notification system according to claim 1, wherein the aforementioned multiple types of equipment include a bioreactor.

5. The alarm notification system according to claim 1, which includes the plurality of detection devices, a bioreactor control device.

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