Industrial system, anomaly detection system, and anomaly detection method

Abstract

This industrial system is characterized by being provided with: a storage unit that stores design data that has been used when constructing an industrial line; a simulation execution unit that executes simulation of movement of the industrial line, on the basis of the design data; and a detection unit that detects abnormality of components of the industrial line by making a comparison between a result of the simulation and movement in operation of the industrial line. The configuration and movement can be utilized for operation assistance for the line and high-resolution abnormality detection.

Description

[Technical field]

[0001] The present invention relates to an industrial system, an anomaly detection system, and an anomaly detection method. [Background technology]

[0002] Patent Document 1 describes a manufacturing line evaluation support method including a simulation result data input process for collecting simulation result data of each element of a manufacturing line configured on a virtually designed simulator and transmitting it to an evaluation support device; a data sorting process for importing the collected simulation result data and sorting it into a format according to operation rate, production volume, and evaluation index; and a problem analysis process for evaluating the simulation result data using evaluation rules consisting of evaluation items, evaluation standard values, and evaluation flows for result data for each type of manufacturing line that are stored in advance, and extracting problems related to the components of the manufacturing line.

[0003] Patent Document 2 describes a method for constructing a production line simulation model, which includes the steps of: constructing a prediction formula that approximately predicts the lead time of each process from the results of a simulation performed in the past or from production records; calculating the error between the prediction formula and a simulation performed in the past, or the error between the prediction formula and production records, for each process; determining, based on the calculated information on the error for each process, for which process a simplified simulation using the prediction formula should be applied; and, for the process for which it has been decided to apply the simplified simulation, executing a production line simulation applying the process lead time using the prediction formula. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2003-280730 A [Patent Document 2] Patent No. 5775803 Summary of the Invention [Problem to be solved by the invention]

[0005] Conventional line simulation models have been difficult to apply to applications that require more detailed information than productivity evaluation or line configuration evaluation, and it has been difficult to build models for such purposes.

[0006] Therefore, an object of the present invention is to provide a system and method that can be utilized for supporting line operations and high-resolution anomaly detection by using a line simulator for design verification. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, one representative industrial system of the present invention is characterized by comprising a memory unit that stores design data used when constructing an industrial line, a simulation execution unit that executes a simulation of the operation of the industrial line based on the design data, and a detection unit that detects abnormalities in components of the industrial line by comparing the results of the simulation with the operation of the industrial line during operation.

[0008] Furthermore, one representative industrial system of the present invention is an industrial system having a sensor that acquires information about industrial equipment and a calculation means that performs calculations based on the information acquired by the sensor, wherein the sensor acquires information about the moving part of the industrial equipment during operation of the industrial equipment, the information including one or more of position information, speed information and acceleration information of the moving part, and the calculation means performs a process of comparing the information about the moving part acquired by the sensor with information about a virtual moving part obtained by a simulation of the industrial equipment, and outputs the result of the comparison process.

[0009] Furthermore, one representative industrial system of the present invention is characterized by comprising a memory unit that stores design data used when constructing an industrial line including a plurality of processes, a simulation execution unit that executes a simulation of the operation of the industrial line based on the design data, and a detection unit that detects abnormalities in the industrial line by comparing virtual relationships between a plurality of processes in the results of the simulation with relationships between the plurality of processes during operation of the industrial line.

[0010] Furthermore, one representative industrial system of the present invention is characterized by including a simulation execution step of executing a simulation of the operation of the industrial line based on design data used when constructing the industrial line, an information acquisition step of acquiring information indicating the operation of the industrial line during operation, and a detection step of detecting an abnormality in a component of the industrial line by comparing the result of the simulation with the operation of the industrial line during operation. Effect of the Invention

[0011] According to the present invention, it is possible to utilize the present invention for supporting line operations and for detecting abnormalities with high resolution. Problems, configurations, and effects other than those described above will become apparent from the following description of the embodiments. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is an explanatory diagram of an industrial system and anomaly detection according to the present invention. [Diagram 2] Diagram of the industrial system configuration. [Diagram 3] 4 is a flowchart showing a processing procedure when a simulation is executed. [Figure 4] 11 is a flowchart showing a processing procedure during operation. [Diagram 5] 11 is a flowchart showing a processing procedure for estimating a cause of a failure. [Figure 6] FIG. 4 is an explanatory diagram of a specific example of sensor data. [Figure 7] FIG. [Figure 8]Variations in the configuration of industrial systems. [Figure 9] FIG. 1 is an explanatory diagram of a configuration for causing a control system to perform simulation and anomaly detection. [Figure 10] FIG. 1 is an explanatory diagram of the overall operation of an industrial system. [Figure 11] FIG. 11 is an explanatory diagram of anomaly detection. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the embodiments described below do not limit the invention according to the claims, and all of the elements and combinations thereof described in the embodiments are not necessarily essential to the solution of the invention.

[0014] In the following description, identification numbers are used as identification information for various objects, but other types of identification information (for example, identifiers including alphabetic characters or symbols) may be used instead.

[0015] In addition, in the following description, when describing elements of the same type without distinguishing between them, reference signs (or common signs among the reference signs) may be used, and when describing elements of the same type with distinction between them, the identification numbers (or reference signs) of the elements may be used. EXAMPLES

[0016] FIG. 1 is an explanatory diagram of an industrial system and anomaly detection according to the present invention. The line shown in FIG. 1 is an industrial line that manufactures goods and transports goods, such as material handling. Here, the industrial line refers to equipment that sequentially executes specified processes to manufacture objects and handle materials (including processing, assembly, painting, inspection, transport, sorting, picking, palletizing, storage, etc.). In other words, the industrial line refers to a line that includes not only manufacturing lines and production lines but also lines that perform transport, etc. In addition, in this embodiment, industrial equipment is included as a component of the industrial line. The industrial equipment has a movable part such as an arm, and performs manufacturing, material handling, etc. by controlling the operation of the movable part. In addition, the industrial equipment includes a link mechanism having multiple actuators, a mechanism having a self-propelled means and a gripping means having a chuck or clamp, a transport means such as a hoist, a conveyor, or a crane, a movable body that performs position control by a linear rail or a ball screw, a rotating body that performs angle and acceleration control, and other motors, inverters, compressors, etc.

[0017] When constructing an industrial line, the line builder in charge of constructing the line performs engineering such as design based on the requirements of the customer who requested the construction of the line. Customer requirements 10 include, for example, work information on the target goods, processing specifications, production capacity, operation plans, etc. Engineering 11 includes process information, function design, control design, structural design, computer-aided design (CAD: Computer Aided Design), computer-aided engineering (CAE: Computer Aided Engineering), bill of materials (BOM), etc.

[0018] After engineering 11, actual equipment production 12 is carried out on the industrial line, and then the industrial line operation 13 is carried out. The actual equipment production 12 includes hardware production, sensor placement, sequence control, etc. The operation 13 includes the production of the target goods and maintenance of the line, etc.

[0019] Of these, engineering 11 and actual production 12 are called the line build phase, and operation 13 is called the operation phase.

[0020] In the line build phase engineering 11, a simulation model is constructed from design information and verified by simulation. This line simulation 21 virtually determines the flow of the entire line and the operation of industrial equipment, including robots and devices, and can verify whether the desired operation can be achieved.

[0021] Conventionally, this simulation model for design verification has been used by the line SIer that created it, mainly for operational verification during the line build phase. The present invention develops this simulation and realizes an operation support system 23 that is utilized during the operation phase.

[0022] Specifically, the operation support system 23 uses various design information used when constructing the line (line build phase) as design data, executes a simulation of the operation phase based on the design data and information obtained during operation in production and maintenance, and detects abnormalities in the components of the line by comparing the results of the simulation with the actual operation of the line during operation. Here, abnormalities include not only cases where something actually occurs in industrial equipment or industrial lines, but also signs that an abnormality may occur. Signs that an abnormality may occur can be detected or identified by changing a value for identifying or determining an abnormality, which will be described later, or a threshold value for the difference between a predetermined operation of the actual equipment and the simulation.

[0023] In the simulation, the operation support system 23 uses the shape of the industrial equipment specified by the design data to calculate the position information, speed information, and acceleration information of the moving part of the industrial equipment to obtain information on a virtual moving part. In addition to the shape of the specified industrial equipment, data sheets provided by the manufacturers of the industrial equipment can be used as references for the simulation.

[0024] On the other hand, the operation support system 23 uses information output by sensors installed on the line and industrial equipment to calculate position information, speed information, and acceleration information of the moving parts of the industrial equipment during operation, thereby obtaining information on the actual moving parts.

[0025] When a comparison between the information of the actual moving part and the information of the virtual moving part reveals a discrepancy exceeding a predetermined range, the operation support system 23 detects that an abnormality has occurred and outputs a warning. For example, if the time required for a given operation of the actual moving part is longer than the time required for a given operation in the simulation and the difference exceeds a threshold, it detects that an abnormality has occurred.

[0026] As the sensor and output for acquiring information on the actual moving part, a sensor and output provided for another purpose can be used. A sensor may be added for detecting the above-mentioned abnormality. For example, it is preferable to newly place a camera and capture an image of the moving part to identify the position, speed, and acceleration of the moving part. In this case, the state of the moving part can be detected with high accuracy by identifying the vicinity of the tip of the moving part. The vicinity of the tip is an area from the tip to a predetermined position from the tip, or an area from the tip to a first predetermined position to a second predetermined position without including the tip. This is effective when the tip itself cannot be detected by the camera. In addition, if a marker is attached to the moving part and a configuration is adopted in which the marker is identified, the state of the moving part can be easily identified. By attaching a marker and storing the distance from the marker to the actual tip position in a storage means, the tip position that is difficult to detect by the camera can be specified by calculation, and more accurate information on the moving part can be obtained. It is also possible to combine direct detection of the vicinity of the tip by the camera and detection of the marker. In this case, it is effective when detecting a moving body in which the marker is hidden by a rotating body.

[0027] In system development 22, the entire system is constructed based on a line simulation 21 for line building, by arranging detection cameras, determining algorithms for detecting people, and linking with the system that executes production, so that information used for the operation of an operation support system 23 can be obtained.

[0028] Fig. 2 is a configuration diagram of an industrial system. As shown in Fig. 2, the industrial system 30 includes a control system 50, an anomaly detection system 60, and a simulation system 70. The control system 50 acquires various information from the industrial line and controls the operation of the industrial line.

[0029] The simulation system 70 is, for example, a computer, and includes an input unit 71, a display unit 72, a communication unit 73, a control unit 74, and a storage unit 75. The input unit 71 is a keyboard, a mouse, or the like. The display unit 72 is a liquid crystal display or the like. The communication unit 73 is a communication interface that communicates with the anomaly detection system 60 and the like.

[0030] The control unit 74 realizes various functions by executing a predetermined program using a calculation device such as a CPU (Central Processing Unit). In particular, in this embodiment, the control unit 74 realizes a function as a simulation execution unit. The storage unit 75 is a magnetic storage device, a flash memory, or the like, and stores line design data, process plan data, simulation result data, and the like. The control unit 74 executes a simulation using the line design data and the process plan data stored in the storage unit 75 to obtain a virtual operation of the industrial line 40 and generate simulation result data. The control unit 74 stores the simulation result data in the storage unit 75 and transmits it to the anomaly detection system 60.

[0031] When a design change is made to the industrial equipment on the industrial line 40, the line design data in the storage unit 75 is updated, the simulation is executed again by the control unit 74, and the simulation result data in the storage unit 75 and the anomaly detection system 60 is updated, so that the simulation result data in the storage unit 75 is updated and transmitted again to the anomaly detection system 60. Therefore, the simulation result data reflects the latest state of the industrial line 40.

[0032] The abnormality detection system 60 is, for example, a computer, and has an input unit 61, a display unit 62, a communication unit 63, a control unit 64, and a memory unit 65. The input unit 61 is a keyboard, a mouse, or the like. The display unit 62 is a liquid crystal display or the like. The display unit 62, the input unit 61, and the communication unit 62 can be implemented as a tablet terminal integrated together, and input / output and communication can be performed using a touch panel. In this case, it is preferable that the control unit 64 and the storage unit 65 are separate entities for the sake of calculation processing. The communication unit 63 is a communication interface that communicates with the simulation system 70, the control system 50, and the like.

[0033] The control unit 64 realizes various functions by executing a predetermined program using a calculation device such as a CPU (Central Processing Unit). In particular, in this embodiment, the control unit 64 realizes the functions of an abnormality detection unit and a fault estimation unit. That is, the control unit 64 corresponds to the calculation means in the claims. The storage unit 65 is a magnetic storage device, a flash memory, or the like, and stores simulation result data, comparison condition data, measurement data, process plan data, etc. The simulation result data in the storage unit 65 is data received from the simulation system 70. The measurement data in the storage unit 65 is data received from the control system 50, and indicates the outputs of various sensors in the industrial line 40, etc.

[0034] The control unit 64 operates as an anomaly detection unit by comparing the information of the virtual moving part indicated by the simulation result data with the information of the real moving part indicated by the measurement data and issuing an alarm if the discrepancy between them exceeds a predetermined range. The conditions for comparing the simulation result data with the measurement data are indicated in the comparison condition data. Furthermore, when an abnormality is detected by the abnormality detection unit, the control unit 64 operates as a failure cause estimation unit that estimates the cause of the failure by detecting the operation of a component of the industrial line that caused the abnormality.

[0035] FIG. 3 is a flowchart showing a processing procedure when a simulation is executed. The simulation system 70 first acquires line design data and process plan data (step S101) and creates a simulation model (step S102). After that, the simulation system 70 executes a simulation of the industrial line and calculates the position, time, and speed of a predetermined operation or work on the computer of the entire industrial line or the industrial equipment (step S103). That is, it calculates information of a virtual moving part and stores the calculation result in the storage unit. The control unit 74 stores the simulation result data in the storage unit 75 (step S104) and ends the process. The stored simulation result data is transmitted to the anomaly detection system 60 at any timing. The simulation model may be created in advance in the storage unit, and may be read from the storage device in step S102.

[0036] 4 is a flowchart showing a processing procedure during operation. During operation, first, the control system 50 inputs production instruction data (step S201), operates the industrial line 40, and causes the anomaly detection system 60 to start anomaly detection.

[0037] The industrial line 40 inputs sensor data while operating the line (step S202), and calculates the position, time, and speed of a predetermined operation, task, etc. (step S203). The calculation results of the industrial line 40 are transmitted to the anomaly detection system 60 as measurement data indicating information on the actual moving parts.

[0038] The anomaly detection system 60 reads the simulation result data (step S204) and compares the measurement data received from the industrial line 40 with the simulation result data (step S205). If the comparison shows that the deviation is equal to or greater than a threshold, the anomaly detection system 60 outputs a message indicating that an anomaly has occurred (step S206) and ends the process. In other words, if there is a difference between the operation of the virtual moving part, which is the ideal operation, and the operation of the moving part of the actual machine, it is considered that some anomaly or a symptom of an anomaly has occurred in the actual machine, and it is therefore possible to notify a user or administrator before a major problem occurs in the industrial line.

[0039] 5 is a flowchart showing a processing procedure for estimating the cause of a failure. This estimation of the cause of a failure is executed by a failure estimation unit of the anomaly detection system 60 when an anomaly is detected by the anomaly detection unit of the anomaly detection system 60. For example, when an anomaly occurs in the entire industrial line 40, such as a decrease in the throughput of the industrial line 40, the estimation is used to estimate the cause of the anomaly.

[0040] Specifically, the anomaly detection system 60 receives measurement data acquired from the industrial line 40 (step S301), and collects the positions, times, and speeds of predetermined operations and tasks in a plurality of processes (step S302). The anomaly detection system 60 compares the calculated information of the actual moving parts with the simulation results for each process, and outputs information about processes with large deviations (step S303).

[0041] According to this estimation of the cause of failure, even if the deviation from the simulation results does not exceed a threshold, it is possible to estimate the process that caused the abnormality by relatively comparing the information of multiple processes. For example, when an abnormality is detected in a series of processes involving motions A, B, and C, it is possible to identify and estimate the motion with the greatest deviation and the mode with the greatest deviation (axis corresponding to the motion axis of the robot or the rotation axis of the actuator) by comparing the simulation results for each of motions A, B, and C with the motion times corresponding to each motion calculated based on the detection values ​​of the sensor.

[0042] Fig. 6 is an explanatory diagram of a specific example of sensor data. As shown in Fig. 6, examples of sensor data that can be used include position data of a robot or workpiece identified by a camera, encoder output of a robot arm, torque sensor, and control sequence data of a PLC (Programmable Logic Controller), an IPC (Industrial PC), or an IoT controller. For sequence data, ladder diagrams, ST (Structured Text), IL (Instruction List), SFC (Sequential Function Chart), etc. can be read.

[0043] Fig. 7 is an explanatory diagram of the simulation. The components of the simulation include customer requirement data, engineering data, and operating condition data. The customer requirement data includes work information, processing specifications, production capacity, and operation plans. The engineering data includes process information, function design, control design, structural design, CAD / CAE / BOM, and the like. The operating condition data includes sensor setting values, sequences, control parameters, and production instruction data.

[0044] A simulation performed using these data as components can obtain the period of a specified operation A, the coordinates of the arm tip at a specified timing of operation A (which may be the position of a marker, other parts, or the processed product), and the moving speed of the arm (including the processed product and other parts) at the specified coordinates of operation A. In addition, the required time for process B, which includes operation A, can also be obtained as a result of the simulation.

[0045] Fig. 8 shows a modified example of the configuration of an industrial system. The industrial system shown in Fig. 8 differs from that shown in Fig. 2 in that a network is interposed between the control system 50 and the anomaly detection system 60. In this configuration, the anomaly detection system 60 and the simulation system 70 may be located away from the industrial line 40, or may be realized as a cloud service.

[0046] Although FIG. 8 shows a modified example in which a network is interposed between the control system 50 and the anomaly detection system 60, a modified example in which a network is interposed between the anomaly detection system 60 and the simulation system 70 is also possible.

[0047] Fig. 9 is an explanatory diagram of a configuration in which a control system performs simulation and anomaly detection. In Fig. 9, an industrial system 30a includes a control system 50a. The control system 50a acquires various information from an industrial line 40 and controls the operation of the industrial line.

[0048] The control system 50 a is, for example, a computer, and includes an input unit 51 , a display unit 52 , a communication unit 53 , a control unit 54 , and a storage unit 55 . The input unit 51 is a keyboard, a mouse, or the like. The display unit 52 is a liquid crystal display or the like. The communication unit 53 is a communication interface for communicating with other devices.

[0049] The control unit 54 realizes various functions by executing a predetermined program using a calculation device such as a CPU (Central Processing Unit). In particular, in this embodiment, the control unit 54 realizes functions as a simulation execution unit, a production execution unit, and an anomaly detection unit. The storage unit 55 is a magnetic storage device, a flash memory, or the like, and stores line design data, process plan data, simulation result data, measurement data, and the like.

[0050] The control unit 54 operates as a simulation execution unit by executing a simulation using the line design data and process plan data stored in the memory unit 55 to determine a virtual operation of the industrial line 40 and generate simulation result data.

[0051] The control unit 54 also acquires sensor outputs from the industrial line 40 to generate measurement data, and controls the operation of the industrial line 40, thereby operating as a production execution unit.

[0052] Furthermore, the control unit 54 operates as an anomaly detection unit by comparing information about the virtual moving part indicated by the simulation result data with information about the actual moving part indicated by the measurement data, and issuing an alarm if the discrepancy exceeds a predetermined range.

[0053] FIG. 10 is an explanatory diagram of the overall operation of the industrial system. As shown in FIG. 10, the industrial system 30 (including the industrial system 30 shown in FIG. 1 etc. and the industrial system 30a shown in FIG. 9) executes C1 to C5 in a cyclical manner. In C1, the industrial system 30 acquires operation information of each component. In C2, the industrial system 30 accumulates operation records and monitors trends. In C3, the industrial system 30 compares operation times and issues a warning if the deviation exceeds a threshold. In C4, the industrial system 30 focuses on investigating the warning location and identifies the cause of the abnormality. In C5, the industrial system 30 adjusts the actual equipment and returns it to normal operation.

[0054] Fig. 11 is an explanatory diagram of anomaly detection. In Fig. 11, the change over time in the coordinates of the arm tip obtained by simulation is shown as a dashed line on the graph. Also, the change over time in the coordinates of the arm tip identified by capturing an image with a camera is shown as a solid line on the graph. For ease of explanation, only one dimension of the arm coordinates is shown. Furthermore, in Fig. 11, the discrepancy between the results of the simulation and the results of identification by the camera is shown as a shaded area.

[0055] In this way, by overlaying the simulation results and the classification results on the same graph, it is possible to clearly show the deviation between them. The criteria for detecting anomalies recorded as comparison condition data can be the distance of coordinates reached when a specific part of the arm performs a specific operation in the simulation result and in the actual machine. It can also be compared with the moving speed during the specific operation. It can also be compared with the position and arrival time of the object to be processed or transported for a series of processes, for example, from when robot arm A starts and completes a specific operation on an object, after which the object is transported, and until robot arm B completes the specific operation.

[0056] As described above, in this embodiment, the industrial system 30 includes a memory unit 65 that stores design data used when constructing the industrial line, a control unit 74 that functions as a simulation execution unit that executes a simulation of the operation of the industrial line based on the design data, and a control unit 64 that functions as a detection unit that detects abnormalities in components of the industrial line by comparing the results of the simulation with the operation of the industrial line during operation. With such a configuration and operation, the industrial system 30 can be utilized for supporting line operations and for high-resolution anomaly detection.

[0057] In addition, in an industrial system 30 having a sensor that acquires information about industrial equipment and a calculation means that performs calculations based on the information acquired by the sensor, the sensor acquires information about the moving part of the industrial equipment during operation of the industrial equipment, including one or more of position information, speed information and acceleration information of the moving part, and the calculation means performs a process of comparing the information about the moving part acquired by the sensor with information about a virtual moving part obtained by a simulation of the industrial equipment, and outputs the result of the comparison process. In the industrial system 30, the simulation is performed based on the design data used in the design of the industrial equipment. With such a configuration and operation, the industrial system 30 can utilize the simulation performed at the time of line construction during operation, thereby providing operational support and detecting anomalies.

[0058] Furthermore, in the industrial system 30, the calculation means compares the information of the moving part acquired by the sensor with the information of the virtual moving part, and outputs a warning if a deviation occurs in the operation time of the moving part that exceeds a predetermined range. The sensor is also characterized in that it acquires the information by identifying the vicinity of the tip of the movable part. The sensor may be an imaging means, and may acquire the information by identifying a marker attached to the movable part. These configurations and operations make it possible to easily obtain information about the moving parts, and by comparing with simulations that have not been used in the past, it is possible to obtain abnormalities or signs of abnormalities in the actual device.

[0059] In addition, the industrial equipment constitutes at least a part of a manufacturing line, and the simulation is a simulation using computer-aided design data used at the time of designing the manufacturing line, so that the data used in the design of the manufacturing line can be directly utilized.

[0060] Furthermore, when a design change is made to the industrial equipment, the simulation result data is updated, so that it is possible to detect anomalies with high accuracy by adapting to the latest state.

[0061] Furthermore, by simulating the operation of an industrial line using design data used when constructing an industrial line including multiple processes, and comparing the virtual relationships between multiple processes in the simulation results with the relationships between the multiple processes when the industrial line is in operation, it is possible to detect abnormalities in the industrial line and estimate the locations that are relatively likely to be the cause of the abnormality.

[0062] The present invention is not limited to the above-mentioned embodiment, and includes various modified examples. For example, the above-mentioned embodiment has been described in detail to explain the present invention in an easy-to-understand manner, and is not necessarily limited to those having all of the described configurations. Furthermore, it is possible to replace or add configurations, not to limit the deletion of such configurations.

[0063] In addition, each of the above configurations, functions, processing units, processing means, etc. may be realized in part or in whole by hardware, for example, by designing them as integrated circuits. The present invention can also be realized by software program code that realizes the functions of the embodiments. In this case, a storage medium on which the program code is recorded is provided to a computer, and a processor included in the computer reads the program code stored in the storage medium. In this case, the program code itself read from the storage medium realizes the functions of the above-mentioned embodiments, and the program code itself and the storage medium storing it constitute the present invention. Examples of storage media for supplying such program code include flexible disks, CD-ROMs, DVD-ROMs, hard disks, SSDs (Solid State Drives), optical disks, magneto-optical disks, CD-Rs, magnetic tapes, non-volatile memory cards, ROMs, etc.

[0064] Furthermore, the program code for realizing the functions described in this embodiment can be implemented in a wide range of program or script languages, such as assembler, C / C++, perl, Shell, PHP, Java (registered trademark), and the like.

[0065] In the above-mentioned embodiment, the control lines and information lines are shown as those considered necessary for the explanation, and not all the control lines and information lines are shown in the product. All the components may be connected to each other. [Explanation of symbols]

[0066] 30: industrial system, 40: industrial line, 50: control system, 60: anomaly detection system, 61, 71: input unit, 62, 72: display unit, 63, 73: communication unit, 64, 74: control unit, 65, 75: memory unit, 70: simulation system

Claims

1. A storage unit that stores design data used for verifying the operation of industrial equipment when constructing an industrial line; a simulation execution unit that executes a simulation of an operation of the industrial line based on the design data; a detection unit that detects an abnormality in a component of the industrial line by comparing a result of the simulation with an actual operation of the industrial line; Equipped with the industrial line includes a plurality of the industrial machines; The design data includes data for specifying a shape of the industrial equipment, the simulation execution unit executes a simulation of a series of processes using the plurality of industrial machines; The industrial system is characterized in that the detection unit compares data based on measurement results of sensors installed in the industrial line with data based on results of a simulation of the series of processes, and outputs the comparison results.

2. 2. The industrial system according to claim 1, The sensor includes a camera, and the data based on the measurement result of the sensor is data obtained by the camera photographing a moving part of the industrial equipment, The industrial system is characterized by comprising a failure cause estimation unit that compares data indicating the results of a simulation of the industrial line with data based on the measurement results of sensors installed in the industrial line, and when an abnormality is determined, detects the operation of a component of the industrial line that caused the abnormality.

3. An industrial system having a sensor that acquires information about an industrial device and a calculation means that performs calculations based on the information acquired by the sensor, The sensor acquires information about a moving part of the industrial equipment, the information including at least one of position information, speed information, and acceleration information of the moving part of the industrial equipment, during operation of the industrial equipment; The calculation means is performing a process of comparing information about the moving part acquired by the sensor with information about a virtual moving part obtained by a simulation of the industrial equipment, and outputting a result of the comparison process; the simulation is performed based on design data used in the design of the industrial equipment, The design data includes data for specifying a shape of the industrial equipment.

1. An industrial system comprising:

4. 4. The industrial system according to claim 3, The industrial system is characterized in that the calculation means outputs a warning when a discrepancy occurs in the operation time of the moving part that exceeds a predetermined range as a result of comparing the information of the moving part obtained by the sensor with the information of the virtual moving part.

5. 4. The industrial system according to claim 3, the sensor is a camera that captures an image of the movable part, The industrial system is characterized in that the sensor identifies the vicinity of the tip of the movable part and acquires the information.

6. 4. The industrial system according to claim 3, The industrial system is characterized in that the sensor is an imaging means and identifies a marker affixed to the movable part to acquire the information.

7. 4. The industrial system according to claim 3, The industrial equipment constitutes at least a part of a manufacturing line, The industrial system is characterized in that the simulation is a simulation using computer-aided design data generated when the manufacturing line was designed.

8. 4. The industrial system according to claim 3, the calculation means reads out simulation result data indicating information of the virtual moving part from a predetermined storage unit and performs the comparison; When a design change is made to the industrial equipment or the operation of the industrial equipment, the simulation result data in the storage unit is updated.

1. An industrial system comprising:

9. 4. The industrial system according to claim 3, A plurality of the industrial machines are provided in an industrial line, The calculation means is An industrial system characterized by: executing a simulation of a series of processes using the plurality of industrial devices; comparing data based on measurement results of sensors installed in the industrial line with data based on the results of the simulation of the series of processes; and outputting the comparison results.

10. 4. The industrial system according to claim 3, A plurality of the industrial machines are provided in an industrial line, The calculation means compares data showing the results of a simulation of the industrial line with data based on the measurement results of sensors installed in the industrial line, and when an abnormality is determined, detects the operation of a component of the industrial line that caused the abnormality.

11. A storage unit that stores design data used for verifying the operation of industrial equipment when constructing an industrial line including a plurality of processes; a simulation execution unit that executes a simulation of an operation of the industrial line based on the design data; a detection unit that detects an abnormality in the industrial line by comparing a virtual relationship between a plurality of processes in the result of the simulation with an actual relationship between the plurality of processes during operation of the industrial line; Equipped with the industrial line includes a plurality of the industrial machines; The design data includes data for specifying a shape of the industrial equipment. The anomaly detection system according to the present invention is characterized in that

12. a simulation execution step of executing a simulation of an operation of the industrial line during operation based on design data used for verifying the operation of the industrial equipment when the industrial line is constructed; An information acquisition step of acquiring information indicating an operation during operation of the industrial line; a detection step of detecting an abnormality in a component of the industrial line by comparing a result of the simulation with an actual operation of the industrial line; Including, the industrial line includes a plurality of the industrial machines; The design data includes data for specifying a shape of the industrial equipment. The anomaly detection method according to the present invention is characterized in that

13. creating a simulation model for verifying the operation of industrial equipment when constructing an industrial line based on design data indicating requirements for the industrial line; Executing a simulation of an operation of the industrial line using the simulation model; storing result data indicative of a result of the simulation; An information acquisition step of acquiring actual operation during operation in an industrial line constructed based on the results of the simulation; a detection step of detecting an abnormality in a component of the industrial line by comparing the result data with an actual operation of the industrial line during operation; Including, the industrial line has a plurality of industrial machines; The design data includes data for specifying a shape of the industrial equipment. The anomaly detection method according to the present invention is characterized in that

14. The anomaly detection method according to claim 13, a step of re-executing the simulation and updating the result data in response to a change in the configuration of the industrial line; detecting an abnormality in a component of the industrial line by comparing the updated result data with an operation of the industrial line in which the configuration has been changed; The anomaly detection method further comprising:

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