Data management device and data management method

Abstract

To provide a data management apparatus which builds a database with small memory capacity, the database including control information and event information associated with the control information.SOLUTION: A data management apparatus includes: data collection means which collects control signals; time-series data storage means which stores time-series data of the control signals; first data processing means which extracts tracking information for calculating a moving distance of a product from the control signals; second data processing means which associates a product ID for identifying the product with an event ID for identifying a state of a process of the product set for each equipment constant and the time at which the event ID is acquired, on the basis of the tracking information and the equipment constants representing distances from reference positions of multiple pieces of equipment; and event map storage means which stores the product ID, the event ID, and the time at which the event ID is acquired together with the associations between them.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] FIELD An embodiment of the present invention relates to a data management device and a data management method. [Background technology]

[0002] For example, a data collection device disclosed in Patent Document 1 has been proposed as a device for managing data in a plant control system that controls plant equipment. This data collection device collects both control information and steel plant event information output by the control device to the steel plant system as binary data. A common key is then added to the control information and event information collected at the same time, and the binary data of the control information with the common key added is stored, as well as the binary data of the event information with the common key added. This data collection device thereby associates the control information with the event information, making it possible to use the stored data. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-271850 Summary of the Invention [Problem to be solved by the invention]

[0004] Such data collection devices accumulate various production data and process data output from the control devices, as well as all event information data, and therefore require large-capacity storage media.

[0005] The present invention has been made to solve the above-mentioned problems, and aims to provide a data management device and a data management method that can build a database containing control information and event information associated with the control information with a small storage capacity. [Means for solving the problem]

[0006] An embodiment of the present invention includes a data collection means for controlling a plurality of facilities in a plant that manufactures a product and sequentially collecting control signals acquired from the plurality of facilities from a control network, a time-series data storage means for storing time-series data of the control signals, a first data processing means for extracting tracking information for calculating the moving distance of the product from the control signals, a second data processing means for associating a product ID for identifying the product with an event ID for identifying the processing state of the product set for each of the facility constants and the time at which the event ID was acquired based on the tracking information and facility constants representing the distance from a reference position of each of the plurality of facilities, and an event map storage means for storing the product ID, the event ID, and the time at which the event ID was acquired together with their association. The second data processing means associates the product ID and the event ID with the time at which the leading end and the trailing end of the product arrive at each of the plurality of facilities. [Effects of the Invention]

[0007] According to the embodiments, a data management device and a data management method are provided that build a database containing control information and event information associated with the control information with a small storage capacity. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a schematic block diagram illustrating a plant control system to which a data management device according to an embodiment is applied; [Figure 2] FIG. 1 is a schematic block diagram illustrating a data management device according to an embodiment. [Figure 3] 10 is an example of a flowchart for explaining the operation of the data management device according to the embodiment. [Figure 4] FIG. 2 is a schematic diagram for explaining the operation of the data management device according to the embodiment. [Figure 5]2 is a schematic diagram illustrating a plant facility to which the plant control system of FIG. 1 is applied. [Figure 6] FIG. 2 is a schematic table diagram illustrating a part of the data management device according to the embodiment. [Figure 7] FIG. 2 is a schematic table diagram for explaining data association in an event map DB generated by the data management device according to the embodiment. [Figure 8] 1 is an example of a flowchart illustrating a data management method using a data management device according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments will be described with reference to the drawings. The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the size ratio between parts, etc. are not necessarily the same as those in reality. Furthermore, even when the same part is shown, the dimensions and ratios may be different depending on the drawing. In the present specification and the drawings, elements similar to those described above with reference to the previous drawings are designated by the same reference numerals, and detailed descriptions thereof will be omitted as appropriate.

[0010] FIG. 1 is a schematic block diagram illustrating a plant control system to which a data management device according to an embodiment is applied. 1, the plant control system 100 includes a data management device 10, a control device 20, and a display device 30. The data management device 10 and the control device 20 are connected to each other so as to be able to communicate with each other via a control network 102. As in this example, a plurality of control devices 20 may be connected to the control network 102, or only one control device 20 may be connected to the control network 102. The control device 20 is, for example, a programmable logic controller (PLC).

[0011] The data management device 10 and the display device 30 are connected to each other so as to be able to communicate with each other via a higher-level network 104. The higher-level network 104 is, for example, a general-purpose Ethernet (registered trademark) or the like. The display device 30 is, for example, a general-purpose computer device.

[0012] The data management device 10 collects, as time-series data, control signals on the control network 102 and control signals input / output by the control device 20 via the control network 102. The control signals include those related to various types of data such as the following. The various types of data include, for example, manufacturing instruction data, manufacturing performance data, alarm data, roll data, model calculation data, model learning data, constant data, and parameter data. The control signals are time-series data that include these various types of data.

[0013] The data management device 10 extracts control signals used for product tracking as tracking information from the collected time-series data. The data management device 10 associates product IDs with event IDs based on the extracted tracking information and equipment constants. The event IDs are set in advance. The data management device 10 stores a database in which product IDs are associated with event IDs as an event map DB. The equipment constants and event IDs are information for identifying the location of equipment installed in a plant and the product transport status set for each piece of equipment, respectively, as will be described in detail later.

[0014] Tracking information is time-series data of signals output by sensors and other devices installed in the equipment that makes up the plant. The signals extracted as tracking information are set in advance. The tracking information can be derived from control signals that indicate when a product has entered the equipment or when it has been discharged from the equipment.

[0015] The tracking information may be, for example, an output signal from a CMD (Cold Metal Detector), an HMD (Hot Metal Detector), a sensor for detecting a joint between materials in a continuous rolling system, or a detected value of a drive current output by a drive device that drives a motor that drives a rolling mill.

[0016] The tracking information also includes a control signal that indicates the speed at which the product is transported between facilities, such as a signal output by a speed sensor attached to the table roller, or an actual speed value or a speed command value of the motor stored in the motor's driver.

[0017] The data management device 10 calculates the distance traveled by the product by integrating the time-series data of the control signal, which indicates the speed of the product, for each acquisition time. The data management device 10 can track the product by calculating the distance traveled by the product from the facility using the control signal output by a sensor or the like installed in the facility.

[0018] The data management device 10 associates a product ID, which identifies a product manufactured in a plant, with the tracking information. By associating the product ID with the tracking information, it becomes possible to obtain information about which product is located where.

[0019] The data management device 10 according to the embodiment determines whether the leading edge of the product is entering, the leading edge of the product is exiting, or the trailing edge of the product is entering or exiting, and reflects this in the tracking information. This allows for more accurate tracking when the length of the product changes as a result of processing by the equipment. Furthermore, there are cases where a product is processed multiple times by a single piece of equipment, and tracking in such cases is also possible.

[0020] More specifically, in order to reflect the entry of the leading edge of a product in tracking information, the data management device 10 has a pre-defined equipment constant table that defines equipment constants and event IDs. The equipment constant is information about the equipment name and the location of the equipment associated with the equipment name. The equipment name can be any name that can identify the equipment, and can be simple alphanumeric characters or symbols. An event ID is set for each piece of equipment and is set to identify the entry of the leading edge of a product for each piece of equipment. The event ID is set to identify whether a product has passed through a piece of equipment once or whether the product has been processed multiple times by a single piece of equipment. By associating tracking information with event IDs, the data management device 10 generates information indicating which product has been processed by which piece of equipment and how many times, and stores this information in the event map DB.

[0021] The configuration of the data management device 10 according to the embodiment will be specifically described. FIG. 2 is a schematic block diagram illustrating a data management device according to the embodiment. 2, a data management device 10 according to an embodiment includes a data collection unit 11, a time-series data DB (referred to as "time-series DB" in FIG. 2) 12, a first data processing unit 13, a tracking information DB 14, a second data processing unit 15, an equipment constant table (referred to as "equipment constant" in FIG. 2) 16, and an event map DB 17. The time-series data DB 12 and the event map DB 17 are connected to a higher-level network 104 via an external interface 18. The display device 30 can access the time-series data DB 12 and the event map DB 17 via the higher-level network 104 to extract desired data.

[0022] The data collection unit 11 is connected to the control network 102 and collects preset control signals as time-series data. The time-series data is data in which the value of a control signal is associated with a time stamp for each time that the value was acquired. The acquisition period of the control signal is set in advance. By setting the acquisition period of the control signal to the control period of the control network 102 or an integer multiple thereof, the time-series data can be time-synchronized data between multiple control signals.

[0023] The time-series data DB 12 stores the time-series data of the control signals set in advance from the data collecting unit 11 in a database for each control signal, for example. The format of the database is arbitrary, and may be, for example, a table format.

[0024] The first data processing unit 13 extracts time-series data of control signals related to tracking information from the time-series data DB 12 and stores the extracted data in the tracking information DB 14. The control signals related to tracking information include signals indicating that a product enters each facility constituting the plant equipment and that the product is discharged from each facility. Such control signals are, for example, output signals from a CMD, HMD, or other laser detector that optically detects the end of a material. Furthermore, such control signals may include current signals supplied to a motor that drives a rolling mill. Furthermore, data such as a speed detector for a table roller that transports the product and the actual speed of the motor that drives the rolling mill are also extracted.

[0025] The second data processing unit 15 associates the control signal with a product ID based on the control signal related to the tracking information in the tracking information DB 14. The second data processing unit 15 associates the product ID with an equipment constant (event ID) in the equipment constant table 16 via the control signal. The event ID is data for identifying which of multiple pieces of equipment the item relates to. As will be described later, the event ID is set to identify multiple processes for one piece of equipment. The second data processing unit 15 stores event map data in the event map DB 17 that associates the product ID, event ID, and the time when the event ID was acquired.

[0026] FIG. 3 is an example of a flowchart illustrating the operation of the data management device according to the embodiment. The flowchart in FIG. 3 simply shows the functions and operations of each part of the data management device 10 configured in FIG. As shown in FIG. 3, in step S1, the data collection unit 11 determines whether collection of time-series data of preset control signals has been completed normally. The data collection unit 11, for example, performs an error check to determine whether there are any abnormalities in the collected time-series data. The data collection unit 11 determines that data collection has been completed normally if the error check results in a rate of abnormal data being equal to or less than a predetermined value. Note that, in some plants, if another data management device that has already accumulated data is connected to the control network 102, the data collected by that other data management device may be collected and stored in the time-series data DB 12.

[0027] If it is determined in step S1 that the data collection has been completed normally, the process proceeds to step S2. If it is determined in step S1 that the data collection has not been completed normally, the data collection unit 11 executes data collection again, for example, according to a preset schedule.

[0028] In step S2, the data collection unit 11 stores each collected control signal as time-series data in the time-series data DB 12.

[0029] In step S3, the first data processing unit 13 extracts time-series data of control signals related to preset tracking information from the time-series data DB 12, and stores the data in the tracking information DB .

[0030] In step S4, the second data processing unit 15 associates the time-series data with a product ID using the control signal stored in the tracking information DB 14. Normally, a product introduced into the production line is not directly assigned a product ID; instead, the value of an internal counter in the plant control system 100 is used instead of a product ID. Each time a product is introduced into the production line, a value is set in the internal counter, and the product can be tracked based on the value of the internal counter assigned to the product. Once a product has been assigned an internal counter value, it completes its processing on the production line and is assigned a product ID by a piece of equipment located later in the line, such as a quality checker. In other words, the value of the internal counter used for product tracking corresponds one-to-one to the product ID. In the following, to avoid complication, it is assumed that a product ID, rather than a value of the internal counter, is assigned each time a product is introduced into the production line.

[0031] For example, when the leading edge of a product introduced into a production line is introduced into the first piece of equipment, a sensor detects this and sets the value of the control signal output by the sensor to a value indicating that the signal is active. The first data processing unit 13 extracts this control signal from the time-series data DB 12 and stores it in the tracking information DB 14. The second data processing unit 15 associates a product ID with the time when the sensor's control signal became active, thereby making it possible to track the position of the leading edge of the product and identify its location on the line. The same applies to the position of the tail end of the product.

[0032] The second data processing unit 15 associates the control signal related to the tracking information with an event ID. The event ID is set in advance in the equipment constant table 16. The association between the time-series data of the control signal and the event ID will be described later with reference to FIGS. 4 to 6.

[0033] The second data processing unit 15 stores the associated product ID, event ID, and the time when the event ID occurred in the event map DB 17 as a database.

[0034] The data stored in the tracking information DB 14 is temporarily stored data, and may be erased or overwritten after the second data processing unit 15 has completed data generation and updating of the event map DB 17. This has the advantage that the storage capacity of the tracking information DB 14 may be small.

[0035] In the data management device 10 according to the embodiment, an event ID is associated with a product ID. The event ID is an identification code for each piece of equipment in a plant, and the event ID makes it possible to identify each product when the same product goes through the same process multiple times. Therefore, the data management device 10 according to the embodiment detects the positions of the leading and trailing ends of the product using control signals output by sensors or the like installed in each piece of equipment.

[0036] For example, in a plant control system applied to a steel rolling plant, the length of a product fed into a production line changes over time and as it passes through the equipment. Furthermore, depending on the equipment, such as in a reverse rolling process, a product may pass through the same equipment multiple times, moving back and forth from upstream to downstream and from downstream to upstream. The data management device 10 according to the embodiment tracks both the leading and trailing ends of the product, enabling tracking of products whose length changes as they pass through the equipment.

[0037] Furthermore, in the data management device 10 according to the embodiment, an equipment constant is set which indicates the distance from the reference position to the equipment position where each piece of equipment is located. The data management device 10 tracks the leading and trailing end positions of a product using tracking information, and sets an event ID which indicates the processing status of that product in that equipment based on the leading and trailing end positions and equipment constant of the tracked product, and associates this with the product ID of that product.

[0038] The data management device 10 according to the embodiment determines whether the tracking information represents the passage of a product from upstream to downstream or from downstream to upstream by determining whether the product is entering or exiting the facility at the front or rear end. This makes it possible to separate and store multiple events for one facility in the database.

[0039] FIG. 4 is a schematic diagram for explaining the operation of the data management device according to the embodiment. In the data management device 10 according to the embodiment, the second data processing unit 15 enables tracking when the same product M repeatedly passes through the same equipment by determining four types of conditions for the leading edge position and the trailing edge position of the product M. The four types of conditions are conditions for leading edge ON determination, leading edge OFF determination, trailing edge ON determination, and trailing edge OFF determination.

[0040] As shown in FIG. 4, the leading edge ON determination is a condition for determining that the leading edge of the product M has passed the position of a sensor or the like provided on the equipment when the product M is transported from upstream to downstream. The leading edge OFF determination is a condition for determining that the leading edge of the product M has passed the position of a sensor or the like provided on the equipment when the product M is transported from downstream to upstream. The tail edge ON determination is a condition for determining that the trailing edge of the product M has passed the position of a sensor or the like provided on the equipment when the product M is transported from downstream to upstream. The tail edge OFF determination is a condition for determining that the trailing edge of the product M has passed the position of a sensor or the like provided on the equipment when the product M is transported from upstream to downstream.

[0041] The ▼ symbols in Fig. 4 indicate the positions of sensors, etc. of the target equipment, and the arrows in the conceptual diagram column of Fig. 4 indicate the direction in which product M is transported. The left side of Fig. 4 is the upstream direction of the production line, and the right side of Fig. 4 is the downstream direction of the production line. Note that with regard to the upstream side of the production line, the position where the product is input is considered to be the most upstream, and with regard to the downstream side of the production line, the position where the product, after being processed by each piece of equipment, becomes the final product is considered to be the most downstream.

[0042] The "tip position," "tail position," and "equipment position" in the condition column of Figure 4, as well as the "tip ON judgment," "tip OFF judgment," "tail ON judgment," and "tail OFF judgment" in (i) to (iv) of Figure 4 are defined as follows:

[0043] The "leading edge position" represents the position when tracking the leading edge of the product M, and the "tail edge position" represents the position when tracking the tail edge of the product M. Specifically, the speed at which the product is conveyed is multiplied by the measurement cycle of that speed and the result is integrated to calculate the distance from the reference position to the leading edge and tail edge as the "leading edge position" and the "tail edge position," respectively.

[0044] "Equipment location" refers to the location of equipment installed in a plant, and is preset in the equipment constant table. As will be described later in relation to Figures 5 and 6, "equipment location" is expressed as a distance from a reference location. The reference location is preset for each plant. The reference location is, for example, the location of the equipment where product processing begins, and in the tracking information, an initial value, for example, "0," is set.

[0045] "Tip end ON determination" refers to the second data processing unit 15 determining that the tip end of the product M has entered the equipment. In the tip end ON determination, when the tip end position is greater than the equipment position, as shown in (i) of FIG. 4, the second data processing unit 15 determines that the product M has been transported from upstream to downstream and that the tip end of the product M has entered the equipment. The second data processing unit 15 stores the time when the tip end of the product M entered the equipment as the time when the event ID corresponding to tip end ON of the equipment was acquired.

[0046] "Tip OFF determination" refers to the second data processing unit 15 determining that the tip of the product M has been discharged from the equipment. In the tip OFF determination, when the tip position is smaller than the equipment position as shown in (ii) of FIG. 4, the second data processing unit 15 determines that the product M has been transported from downstream to upstream and that the tip of the product M has been discharged from the equipment. The second data processing unit 15 stores the time when the tip of the product M was discharged from the equipment as the time when the event ID corresponding to tip OFF of the equipment was acquired.

[0047] "Tail end ON determination" refers to the second data processing unit 15 determining that the tail end of the product M has entered the equipment. In the tail end ON determination, when the tail end position is greater than the equipment position, as shown in (iii) of Figure 4, the second data processing unit 15 determines that the product M has been transported from upstream to downstream and that the tail end of the product M has entered the equipment. The second data processing unit 15 stores the time when the tail end of the product M entered the equipment as the time when it acquired the event ID corresponding to the tail end ON of the equipment.

[0048] "Tail end OFF determination" refers to the second data processing unit 15 determining that the tail end of the product M has been discharged from the equipment. In the tail end OFF determination, when the tail end position is less than the equipment position, as shown in (iv) of Figure 4, the second data processing unit 15 determines that the material has been transported from downstream to upstream and that the tail end has been discharged from the equipment. The second data processing unit 15 stores the time when the tail end of the product M was discharged from the equipment as the time when the event ID corresponding to the tail end OFF of the equipment was acquired.

[0049] There can be multiple patterns for a product's entry into and discharge from a facility. For example, one pattern is when a product enters a facility, is discharged, and then heads to the next facility. In this case, the determination of (i) in FIG. 4 is followed by the determination of (iv). Another pattern is when a product repeatedly enters and discharges from a facility multiple times. In this case, the determinations of (i) and (iv) in FIG. 4 are followed by the determination of (iii) and then the determination of (ii). This indicates that the product has traveled back and forth through the facility. The data management device 10 can reproduce the product processing status by combining event IDs based on the determinations of (i) to (iv) in FIG. 4, not only when the product passes through the facility but also when the product enters the facility and is discharged upstream instead of downstream.

[0050] In this way, in the data management device 10 according to the embodiment, the second data processing unit 15 extracts, from the tracking information DB 14, control signals output by sensors or the like installed in the target equipment and data on the material conveying speed between the target equipment and the equipment immediately preceding it.Then, the time series data of the extracted control signals is determined to be the time in which the target product ID was conveyed and processed at the equipment, and stores the time.

[0051] A method for associating an event ID with a product ID using leading edge ON determination, leading edge OFF determination, trailing edge ON determination, and trailing edge OFF determination will be described. FIG. 5 is a schematic diagram illustrating a plant facility to which the plant control system of FIG. 1 is applied. As shown in FIG. 5, the plant equipment has a plurality of processes, and one or more pieces of equipment are arranged for each process.

[0052] This example shows an example of a hot rolling plant. In this rolling plant, facilities A to N are arranged. Facilities A to N are arranged from upstream to downstream of the production line. For example, facility A is a heating furnace 1, facility B is a scale breaker 2, facility C is a roughing rolling mill 3, facility D is a finishing scale breaker 4, facility E is a finishing rolling mill 5, facility F is a run-out table 6, and facility N is a down coiler 7. The product is fed into the most upstream heating furnace 1, and is wound into a coil by the most downstream down coiler 7 to form the final product.

[0053] The data management device 10 collects signals from sensors and other devices installed in each facility as time-series data, associates the time a product entered that facility with the time it left, and manages the data as a database. The signals from the sensors and other devices mainly include an initialization signal that starts tracking and a speed signal that directly or indirectly indicates the product's transport speed.

[0054] In the example of Figure 5, the sensors that generate the initialization signal are sensors SC1 and SC2 provided on the inlet side of the scale breakers 2 and 4, respectively, and sensor SC3 provided on the run-out table 6. To detect entry into and exit from the roughing mill 3 and finishing mill 5 equipment, load cells provided on the rolling mills and current values ​​output by the driving devices of the motors that drive the rolling mills are used. By providing sensors at multiple locations, it is possible to reduce errors in the product transport distance calculated by tracking.

[0055] A plurality of these sensors are provided as in the example of FIG. 5 in order to reduce errors in the transport distance of the product calculated by integrating the speeds contained in the speed signals.

[0056] The conveying speed at which materials are conveyed between facilities or during processing within the facilities is detected by speed sensors attached to the motors that drive the table rollers and the facilities, and collected as time-series data. The data management device 10 can calculate the positions of the leading and trailing ends of the product by integrating the initialization signals generated and output by sensors SC1 and the like and the time-series data of the speed signals.

[0057] FIG. 6 is a schematic table diagram illustrating a part of the data management device according to the embodiment. FIG. 6 shows an example of preset values ​​in the equipment constant table 16 shown in FIG. As shown in Fig. 6, equipment constant table 16 has data entered for each piece of equipment on the position of that piece of equipment from a reference position (shown as "distance" in Fig. 6). Equipment constant table 16 has input for each piece of equipment an event ID set according to the number of times a product has passed through that piece of equipment. The event ID is assigned a set value that can identify each of the leading edge ON judgment, leading edge OFF judgment, trailing edge ON judgment, and trailing edge OFF judgment when each result is true, for each number of times a product has been processed (shown as "pass count" in Fig. 6).

[0058] In this example, the event IDs are assigned different integers equal to or greater than 1. For example, when a product passes through equipment A for the first time and a leading edge ON determination is made, the event ID is "1," and when a leading edge OFF determination is made, the event ID is "2." The second data processing unit 15 of the data management device 10 associates the event ID "1" with the time when a leading edge ON determination is made and the event ID "2" with the time when a leading edge OFF determination is made, among the time-series data of the control signal output by the sensor provided in equipment A, and stores the data in the event map DB 17.

[0059] Furthermore, for example, when a product passes through equipment D for the second time, the event ID is "53" when the leading edge is determined to be ON, and the event ID is "54" when the leading edge is determined to be OFF. The second data processing unit 15 associates the event ID "53" with the time when the leading edge is determined to be ON and the event ID "54" with the time when the leading edge is determined to be OFF, among the time-series data of the control signal output by the sensor provided in equipment D, and stores them in the event map DB 17. The event IDs associated with these times are also associated with the product IDs, respectively.

[0060] By setting the equipment constant table 16 in this way, the data stored in the event map DB 17 can identify how many times a target product has passed through one piece of equipment. It also becomes possible to identify whether the multiple trips of the product through the same equipment have been processed by passing the entire product from its front to its rear end, or whether the product has been processed by passing only a portion of its length from its front to its rear end.

[0061] FIG. 7 is a schematic table diagram for explaining data association in the event map DB generated by the data management device according to the embodiment. As shown in FIG. 7, the event map DB 17 stores product IDs, event IDs, and the times at which the event IDs occurred (represented as "data date and time" in FIG. 7) in association with each other. According to the data stored in the event map DB 17, by identifying a product ID, it is possible to obtain information about when, which equipment, and how many times a product having that product ID passed through. Furthermore, by identifying multiple event IDs, it is possible to obtain information about when and which products passed through for each event ID. Because the data stored in the event map DB 17 is an association between product IDs, event IDs, and the times at which the event IDs occurred, it is possible to store the data in a storage device with a small storage capacity.

[0062] A data management method using data stored in the time-series data DB 12 and the event map DB 17 of the data management device 10 will be described. FIG. 8 is an example of a flowchart illustrating a data management method according to the second embodiment. As shown in Fig. 8, the data management method according to this embodiment manages time-series data of control signals in a plant control system through the following steps: An operator can access the data management device 10 via the upper network 104 using the display device 30 shown in Fig. 1.

[0063] In step S11, the data management device 10 determines whether the request input from the display device 30 is only time-series data of the control signal, or whether it also includes information such as a product ID. If the request is only time-series data, the data management device 10 transitions the process to step S12. If the request includes items other than time-series data, the data management device 10 transitions the process to step S14.

[0064] If it is determined in step S11 that only time series data is being requested, in step S12 the data management device 10 requests input of the signal name of the control signal, the time range to be searched, etc., and sets the values ​​input by the operator.

[0065] In step S13, the data management device 10 searches the time-series data DB 12 based on the set signal name and the like, and outputs the results to the display device 30 via the upper network 104.

[0066] If it is determined in step S11 that the request is for an item other than time-series data, the data management device 10 requests product information (product ID) and the range of data to be output in step S14. The operator inputs the product information, etc., and the data management device 10 sets the input data.

[0067] In step S15, the data management device 10 searches the event map DB 17 based on the set data.

[0068] In step S13, the data management device 10 searches the time-series data DB 12 based on the data extracted by searching the event map DB 17, and outputs the desired data to the display device 30 via the upper network 104.

[0069] The operations of steps S14, S15, and S13 described above will be explained using a specific example. A specific example is a case where the data management device 10 outputs thickness information of a product having product ID="12345" and the tip thickness information is obtained from the output result.

[0070] It is assumed that a thickness gauge is installed as a sensor for equipment F. In other words, the position of the thickness gauge is the position of equipment F on the equipment constant table 16. The process data (control signal) output by the thickness gauge is signal FF. Note that the thickness gauge measures not only the thickness of the tip of the product but also the entire length of the product, and signal FF is time-series data of the thickness from the tip to the tail of the product.

[0071] The data management device 10 sets the product ID and the range in which data is searched and acquired (S14). The range in which data is searched and acquired is from the leading end to the trailing end of the product. Therefore, the data management device 10 sets the product ID, leading end ON, and trailing end OFF.

[0072] The data management device 10 searches the event map DB 17 to find the event ID associated with the input product ID (S15). Here, the event ID corresponds to the head ON and tail OFF of the equipment F.

[0073] The data management device 10 extracts and outputs data of the signal FF that matches the product ID and the time of the event ID (the tip end ON and the tail end OFF of the equipment F) associated with the extracted product ID from the time-series data DB 12. The measurement value at the time the tip end of the equipment F turns ON is the desired tip thickness information.

[0074] The effects of the data management device 10 according to the embodiment will be described. The data management device 10 according to the embodiment extracts preset tracking information from time-series data of control signals collected and stored from the plant control system 100. The extracted tracking information becomes unnecessary after the event ID is extracted, so data can be overwritten, and the storage capacity does not increase due to the collection of tracking information.

[0075] The data management device 10 has a preset equipment constant table. The equipment constant table contains the location of each piece of equipment, so it is possible to associate product IDs with event IDs that set the location of the equipment based on tracking information. Therefore, time-series data of control signals that are not associated with product IDs can be associated with product IDs as well as event IDs, making it possible to determine which product is performing which equipment processing based on time.

[0076] The data management device 10 includes a second data processing unit 15 that determines the leading edge entry, leading edge discharge, trailing edge entry, and trailing edge discharge of a product from the tracking information. The equipment constant table 16 also includes an event ID that identifies the number of times a product passes through equipment. Therefore, even for a plant facility that has equipment that a product passes through multiple times, it is possible to create an event map DB 17 that identifies which product is in which state at which equipment.

[0077] The event map DB 17 stores data relating to product IDs, event IDs, and times corresponding to the event IDs, and therefore requires a small storage capacity. Therefore, by specifying a desired product ID and event ID from the time-series data of the control signal, it is possible to extract data relating to equipment that constitutes the plant equipment of the product without increasing the storage capacity.

[0078] Although the application of the data management device 10 to a plant control system 100 corresponding to a hot rolling plant has been described above as a specific example, the application of the data management device 10 is not limited to plant control systems corresponding to hot rolling plants. As mentioned above, the data management device 10 can be applied to control systems for other steel manufacturing plants, paper plants, automobile assembly plants, chemical plants, etc. Furthermore, it goes without saying that the application of the data management device is not limited to the above-mentioned industrial plants, but can also be applied to public systems such as water supply and sewerage systems.

[0079] In this way, it is possible to realize a data management device and a data management method that can build a database containing control information and event information associated with the control information with a small storage capacity.

[0080] Although several embodiments of the present invention have been described, these embodiments are presented as examples and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, and are also included in the scope of the invention and its equivalents as defined in the claims. [Explanation of symbols]

[0081] 1...heating furnace, 2, 4...scale breaker, 3...roughing mill, 5...finishing mill, 6...run-out table, 7...down coiler, 10...data management device, 11...data collection unit, 12...time series data DB, 13...first data processing unit, 14...tracking information DB, 15...second data processing unit, 16...equipment constant table, 17...event map DB, 18...external interface, 20...control device, 30...display device, 100...plant control system, 102...control network, 104...host network

Claims

1. a data collection means for controlling a plurality of pieces of equipment in a plant for manufacturing a product and sequentially collecting control signals obtained from the plurality of pieces of equipment from a control network; a time-series data storage means for storing time-series data of the control signal; a first data processing means for extracting tracking information from the control signal for calculating a distance traveled by the product; a second data processing means for associating a product ID for identifying the product with an event ID for identifying a processing state of the product, which is set for each of the equipment constants, and a time at which the event ID was acquired, based on the movement distance of the product from a reference position calculated from the tracking information and equipment constants representing the distances of each of the plurality of pieces of equipment from the reference position; an event map storage means for storing the product ID, the event ID, and the time when the event ID was acquired together with the association therebetween; Equipped with The second data processing means is a data management device that associates the time when the front and rear ends of the product reach each of the plurality of pieces of equipment with the product ID and the event ID as the time when the event ID was acquired.

2. A plurality of event IDs are set so as to be identifiable for each facility, The plurality of event IDs are a first event ID indicating that the product is transported from upstream to downstream and the leading edge of the product has entered the facility; a second event ID indicating that the product has been transported from downstream to upstream and the leading edge of the product has been discharged from the equipment; and a third event ID indicating that the product has been transported from downstream to upstream and the tail end of the product has entered the equipment; a fourth event ID indicating that the product has been transported from upstream to downstream and the tail end of the product has been discharged from the equipment; Including, 2. The data management device according to claim 1, wherein the second data processing means associates the first to fourth event IDs with the times at which the first to fourth event IDs were acquired, respectively.

3. a data collection means for controlling a plurality of pieces of equipment in a plant for manufacturing a product and sequentially collecting control signals obtained from the plurality of pieces of equipment from a control network; a time-series data storage means for storing time-series data of the control signal; a first data processing means for extracting tracking information from the control signal for calculating a distance traveled by the product; a second data processing means for associating a product ID for identifying the product with an event ID for identifying a processing state of the product, which is set for each of the equipment constants, and a time at which the event ID was acquired, based on the movement distance of the product from a reference position calculated from the tracking information and equipment constants representing the distances of each of the plurality of pieces of equipment from the reference position; an event map storage means for storing the product ID, the event ID, and the time when the event ID was acquired together with the association therebetween; Equipped with a data management method using a data management device, wherein the second data processing means associates the times when the front end and the tail end of the product arrive at each of the plurality of facilities with the product ID and the event ID as the times when the event ID was acquired, determining whether the output request is for only the time-series data or the output request includes the time-series data and the event ID by the data management device; the data management device requests input of the product ID and a time range to be searched in the case of an output request including the event ID; The data management method includes searching the event map storage means based on the input product ID and the input time range by the data management device.

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