Information processing methods, information processing devices, production systems, methods for manufacturing articles, programs, and recording media.

Abstract

To provide an information processing apparatus capable of easily grasping the operation state of a mechanical installation.SOLUTION: There is adopted an information processing apparatus for indicating the state of a machine, a control unit of which displays chronologically a process related to an operation of a machine, a control signal related to the process and a range of timing related to a start or an end of the process and / or timing related to an output of the control signal.SELECTED DRAWING: Figure 12

Description

Technical Field

[0001] The present invention relates to an information processing apparatus.

Background Art

[0002] In a production line composed of a plurality of pieces of machinery and equipment controlled by a control device such as a sequence control device, it is desired to quickly and appropriately grasp the operating state of the machinery and equipment and perform maintenance on the machinery and equipment. Therefore, a function has been proposed to detect an operation deviating from the normal operating state by monitoring the operating state of the machinery and equipment and notify the user. For example, in Patent Document 1, a monitoring system is described that records the ON / OFF states of signals such as sensors and actuators mounted on machinery and equipment a predetermined number of times while operating the machinery and equipment, and monitors the operating state of the machinery and equipment based on the ON / OFF states of the signals.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in order to monitor using the time from the operation start timing of the machinery and equipment to the ON / OFF of the machine signal as in Patent Document 1, it is necessary to teach the monitoring system the operation start timing of the machinery and equipment that serves as the measurement reference for each signal. Further, conventionally, on the screen displaying the operating state of the machinery and equipment, the control signals were simply listed and displayed, so when identifying an abnormal location, it was necessary to check one by one whether there were any abnormalities in the components constituting the machinery and equipment. Therefore, it took a very long time to identify when and where an abnormality occurred in the machinery and equipment.

[0005] Therefore, in view of the above problems, the present invention aims to provide an information processing device that can easily grasp the operating status of machinery and equipment. [Means for solving the problem]

[0006] To solve the above-mentioned problems, the present invention provides an information processing method for acquiring the state of a device that performs a first operation and a second operation according to the instructions of a control device, comprising: first process information indicating the period during which the first operation is being performed; and second process information indicating the period during which the second operation is being performed. , obtain , signals communicated between the control device and the device and , A signal for the control device to instruct the device to start an operation performed by the device, or a signal for the device to notify the control device of the completion of an operation performed by the device. The information processing method employed is characterized by acquiring the first process information, identifying the signal communicated during the period indicated by the first process information as the first signal associated with the first operation, and identifying the signal communicated during the period indicated by the second process information as the second signal associated with the second operation. [Effects of the Invention]

[0007] According to the present invention, the operating status of machinery and equipment can be easily determined. [Brief explanation of the drawing]

[0008] [Figure 1] This is a control block diagram of the production system 100 in the embodiment. [Figure 2] This is a schematic diagram of production line 100 in the embodiment. [Figure 3] This is a flowchart showing the operation of each unit in the embodiment. [Figure 4] This figure shows each process number 130 and control signal 131 in the embodiment. [Figure 5] This figure shows a list of signals used in the embodiment, 133. [Figure 6] This figure shows a list of decision conditions in the control signal in the embodiment. [Figure 7]This figure shows a list of decision conditions in the process according to the embodiment. [Figure 8] This figure shows the state of each control signal in processes 1 to 5 of the input unit 203 in the embodiment. [Figure 9] This figure shows the average and standard deviation of the measurement results of the control signals at the ON / OFF timing of each control signal in the embodiment, as well as the judgment threshold at the ON / OFF timing. [Figure 10] This figure shows an example of a screen that the display unit 126 displays on the display device 150 in the embodiment. [Figure 11] This figure shows an example of a screen that the display unit 126 displays on the display device 150 in the embodiment. [Figure 12] This figure shows an example of a screen that the display unit 126 displays on the display device 150 in the embodiment. [Figure 13] This is a control flowchart of the display unit 126 in the embodiment. [Figure 14] This figure shows an example of a screen that the display unit 126 displays on the display device 150 in the embodiment. [Figure 15] This figure shows an example of a screen that the display unit 126 displays on the display device 150 in the embodiment. [Modes for carrying out the invention]

[0009] The embodiments for carrying out the present invention will be described below with reference to the attached drawings. The embodiments described below are merely examples, and for example, the detailed configuration can be modified as appropriate by those skilled in the art without departing from the spirit of the present invention. Furthermore, the numerical values ​​mentioned in these embodiments are for reference only and do not limit the present invention.

[0010] (First embodiment) FIG. 1 is a control block diagram showing a production system 1000 including a production line 100 and a monitoring device 120 in the present embodiment. The production line 100 is composed of a plurality of machines 101 to 103 that can operate independently. The machines 101 to 103 are each composed of a plurality of sensors, pneumatic devices, robots, and the like. The machines 101 to 103 are sequence-controlled by a single PLC (Programmable Logic Controller) 110.

[0011] The monitoring device 120 is configured by programming a general-purpose computer and includes a CPU (Central Processing Unit), a RAM (Random Access Memory), a ROM (Read Only Memory), and the like. Furthermore, it includes a large-capacity non-volatile storage device such as a memory and a magnetic disk device. The monitoring device 120 also includes a display device 150 such as a display and an input device 140 such as a mouse and a keyboard. The program part of the monitoring device 120 is mainly composed of a CPU as a control part, and the functions of each control block of the program part are executed by the CPU. Thus, the monitoring device 120 functions as an information processing device.

[0012] Next, the transfer of information from the PLC 110 in FIG. 1 to the monitoring device 120 will be described. Inside the monitoring device 120, there are a program part and a database part, and the program part is divided into a program for monitoring machines and a program for creating conditions for monitoring machines. Information such as a process number 111 and a control signal 112, which is the history of control by the PLC 110 and is stored in the transfer area memory in the PLC 110, is transferred from the transmission part 113 to the reception part 121 of the monitoring device 120.

[0013] This process number 111 indicates a number that identifies the minimum operation unit of each unit, with each of the machines 101 to 103 as a single unit. For example, the operation of opening the chuck of the robot arm of the machine 101 is defined numerically by the PLC 110 as the process number (1).

[0014] Moreover, the control signal 112 indicates the signal output by the PLC 110 to control the machines 101 to 103. For example, the control signal 112 is used to inform the PLC 110 that sensors attached to the machines 101 to 103 have detected a workpiece, or for the purpose of the PLC 110 instructing the machines 101 to 103 to start operation, and its state is represented by ON (1) or OFF (0). Furthermore, in the recording unit 122 of the monitoring device 120, the process number 111 and the control signal 131 received by the receiving unit 121 are structured for easy retrieval later and recorded in the database. The definition of the above-mentioned process number 111 and the recording of the control signal 112 are executed, for example, by describing the specification of the definition of the process number 111 and the specification of the recording of the control signal 112 in a ladder program or the like referred to by the PLC 110.

[0015] Next, the analysis unit 123 and the determination creation unit 124, which are programs for creating the conditions for monitoring the above-mentioned machines, will be described.

[0016] The analysis unit 123 automatically determines, from the information of the process number 130 and the control signal 131 in the database of the monitoring device 120, which signal each process in each unit constituting the production line 100 is using. Then, this result is recorded in the database as a used signal list 133 (Fig. 5).

[0017] The determination creation unit 124 measures the variation in the operation time of each process in each unit, and determines, for example, from its maximum value and minimum value, a threshold value for determining whether the machine is normal or abnormal. After determining the threshold values for the normal / abnormal determination conditions for all processes, the results are stored in the database as a determination condition list 133.

[0018] Next, the determination unit 125 and the display unit 126, which are programs for monitoring the above-mentioned machines, will be described.

[0019] When the determination unit 125 is created, it automatically starts processing. Specifically, when a new process number 130 or control signal 131 is recorded in the monitoring system 120, the determination unit 124 determines whether the control signal in each process is normal or abnormal based on the determination condition list 133. If an abnormal signal that falls outside the threshold of the determination conditions is detected, the time of the abnormality and the signal symbol that caused the abnormality are recorded in the database as an abnormality history 134.

[0020] The display unit 126 is responsible for notifying and / or displaying the occurrence of an anomaly to the operator. When the anomaly history 134 is updated, the display unit 126 compiles the anomaly history 134, process number 130, control signal 131, and judgment condition list 133 into a highly visible chart, which will be described later, and displays it on the display device 150.

[0021] Figure 2 is a schematic representation of each unit present in the production line 100 in this embodiment. Figure 3 is a flowchart of the minimum operation (process) for each unit in Figure 2. The units of the production line 100 in Figure 2 include an input unit 203, a conveyor 204, an adhesive application unit 207, and an discharge unit 209, and these mechanical units are assumed to be controlled by a single control device (PLC). By performing predetermined operations on the workpiece 201 using these units, goods are manufactured. The input unit 203, adhesive application unit 207, and discharge unit 209 in Figure 2 correspond to machines A (101), B (102), and C (103) in Figure 1.

[0022] Next, the operation of each unit will be explained using Figures 2 and 3. Figure 3(a) shows the operation flow of the input unit 203, Figure 3(b) shows the operation flow of the adhesive application unit 207, and Figure 3(c) shows the operation flow of the discharge unit 209. Note that for the sake of simplicity, the control of the conveyor 204 will not be explained using a flow chart.

[0023] First, as shown in Figure 3(a), once the input pallet 202 is set, the input unit 203 retrieves the workpiece 201 from the input pallet 202 and carries it onto the conveyor. In process 1 of Figure 3(a), the chuck 1 of the input unit 203 is closed to grip the workpiece on the pallet. Then, in process 2, the X-axis of the robot 1 of the input unit 203 is rotated, and in process 3, the chuck 1 is opened to place the workpiece onto the conveyor 204.

[0024] When workpiece 201 is placed on conveyor belt 204, sensor 205 determines whether or not process 4 has detected workpiece 201. If workpiece 201 is detected by sensor 205, process 4:ON is activated, and process 5 controls robot 1 to rotate its X-axis to move chuck 1 onto pallet 202 in order to retrieve workpiece 201 again. At this time, conveyor belt 204 operates and continues to operate until workpiece 201 is detected by sensor 206. If workpiece 201 is not detected by sensor 205 and process 4:OFF remains in the OFF state for a predetermined time, an ERROR is notified.

[0025] Next, as shown in Figure 3(b), when the workpiece 201 is detected by the sensor 206, the adhesive application unit 207 turns process 1: ON in Figure 3(b) and begins applying adhesive to the workpiece 201. Process 1 in Figure 3(b) is configured to loop in the process 1: OFF state unless the workpiece 201 is detected by the sensor 206.

[0026] Process 1: If ON, in Process 2, the X-axis controlling the dispenser in the adhesive application unit 207 is advanced to turn the dispenser ON and apply a predetermined amount of adhesive to the workpiece 201. Then, proceed to Process 3 and retract the X-axis controlling the dispenser.

[0027] At this point, simultaneously with the start of operation of the adhesive application unit 207 by process 1: ON in Figure 3(b), the input unit 203 executes processes 1 to 3 in Figure 3(a) in order to take the next workpiece 201 from the input pallet 202 and place it on the conveyor 204.

[0028] Next, as shown in Figure 3(c), once the adhesive application by the adhesive application unit 207 and the workpiece placement by the input unit 203 are both completed, the conveyor 204 transports the workpiece 201. At this time, the conveyor 204 operates until the workpiece 201 that was being processed by the adhesive application unit 207 is detected by the sensor 208.

[0029] When the sensor 208 detects the workpiece 201, process 1 in Figure 3(c) is turned ON, and the discharge unit 209 begins the process of storing the workpiece 201 into the discharge pallet 210. Simultaneously with the start of operation of the discharge unit 209, the input unit 203 and the adhesive application unit 207 each begin processing the next workpiece 201.

[0030] As shown in Figure 3(c), when the discharge unit 209 detects a workpiece with the sensor 208, it retrieves the workpiece 201 from the conveyor 204 and transports it to the discharge pallet 210. In process 2 of Figure 3(c), the chuck 2 of the discharge unit 209 is closed to grip the workpiece 201 on the conveyor 204. Then, in process 3, the X-axis of the robot 2 of the discharge unit 209 is rotated, and the chuck 2 is opened in process 3 to place the workpiece 201 onto the discharge pallet 210. Then, in process 5, the X-axis of the robot 2 is rotated again to retrieve the workpiece 201, and the chuck 2 is controlled to move onto the conveyor 204. Process 1 in Figure 3(c) also loops in the state of process 1: OFF unless the workpiece 201 is detected by the sensor 208.

[0031] The above operations are repeated until there are no more workpieces 201 on the input pallet 202. During this time, the period in which each unit works on one workpiece 201 is called a cycle. When the production line 100 starts operating with no workpieces 201 on the conveyor 204, only the input unit 203 operates in the first cycle, the input unit 203 and the adhesive application unit 207 operate in the second cycle, and all units operate in the third cycle. From the third cycle onward, each unit operates until there are no more workpieces 201 in the input pallet 202.

[0032] When the workpieces 201 in the input pallet 202 are gone, the input unit 203 enters a standby state, and at the end of the next cycle, the adhesive application unit 207 enters a standby state, and at the end of the next cycle, all units enter a standby state. The standby state of the input unit 203 is when chuck 1 is positioned on the pallet 204, the standby state of the adhesive application unit 207 is when the X-axis is retracted, and the standby state of the discharge unit 209 is when chuck 2 is positioned on the conveyor 204.

[0033] From the above, if the initial number of workpieces 201 in the input pallet 202 is N, then each unit will perform N cycle operations until there are no more workpieces 201 in the input pallet 202 and each unit stops operating.

[0034] Next, we will explain how to identify the control signals used in each process within each unit in order to set monitoring conditions. Figure 4 is a time chart illustrating the control operation timing of each machine, which is a unit that makes up the production line 100 shown in Figures 2 and 3. The upper section shows the operating status of the machines (units), specifically the input unit 203 of machine number 1, the adhesive application unit 207 of machine number 2, and the discharge unit 208 of machine number 3. In addition, the execution status of the operation processes indicated by each process number 130 is shown in a timing chart with the horizontal axis being the time axis.

[0035] The lower section specifically shows the various control signals 131 in the operating processes indicated by process number 130 for each unit indicated by machine numbers 1 to 3. The signal symbol representing each control signal 131, the signal name indicating the control operation of that control signal 131, and the ON / OFF state of each control signal are shown as a timing chart with the horizontal axis representing time.

[0036] First, the monitoring device 120 is connected to the PLC 110, which controls each unit of the production line 100, so that it can communicate with it, and the production line 100 is put into operation. The recording unit 122 of the monitoring device 120 structures 10 seconds' worth of information from the PLC 110 regarding the process number 111 and control signal 112 of each unit, and records it in the database as process number 130 and control signal 131.

[0037] This process number 130 indicates which of the processes shown in Figure 3 each unit is executing at a given time. The analysis unit 123 uses the property that the processes of each unit shown in Figure 3 sequentially perform operations on the workpiece 201 to determine the control signals used in each process.

[0038] Next, the method for determining the control signals of the analysis unit 123 described above will be explained in detail. The analysis unit 123 automatically starts processing if the list of signals used 132 in Figure 5 has not been generated. First, the analysis unit 123 reads the process number 130 and control signals 131 from the database for a period that includes the time from when there are no workpieces 201 on the production line 100 and each unit is stopped, until the workpiece 201 is fed into the production line 100 and the finished product is discharged.

[0039] One way the analysis unit 123 obtains the above-mentioned period is, for example, from the operational data of the production line 100 that has been accumulated in the past. The period from when all the process numbers 130 of each unit are 0, that is, when no unit is executing a process, until at least one of the process numbers 130 of each unit becomes non-zero, that is, when one of the units starts moving, is defined as the period from when one of the units starts moving until all the process numbers 130 become 0, that is, when all the units stop, is defined as the period until the finished product is discharged.

[0040] Figure 4 shows the process number 130 and control signal 131 for each process number 130 and control signal 131 during the period from when there are no workpieces 210 on the production line 100 and each unit is stopped until each unit operates at least once (one cycle of each flowchart in Figure 3).

[0041] In Figure 4, Y1, X1, Y6, X6, etc., represent the symbols and addresses used by the PLC110 when managing the control signals 131, and will be referred to as signal symbols from now on. The column labeled 400 in Figure 4 represents the process number 130 in each unit, and the analysis unit 123 determines that the process is executed only for the period corresponding to process number 130.

[0042] For example, in the upper section of Figure 4, during period 401, it is determined that process 2 of the input unit 203 is being executed. In the upper section of Figure 4, period 402 and the lower section, region 431, represent the first operating state of the input unit 203 of machine number 1, period 403 represents the second operating state of the input unit 203 of machine number 1, and period 404 represents the third operating state of the input unit 203 of machine number 1. From the above, it can be seen that in periods 402 to 404, each process in a certain unit is executed in stages.

[0043] Similarly, period 411 and region 432 represent the first operating state of the adhesive application unit 207 of machine number 2, period 412 represents the second operating state of the adhesive application unit 2 of machine number 2, and period 421 and region 433 represent the first operating state of the discharge unit 209 of machine number 3.

[0044] Based on this information, the analysis unit 123 recognizes signals that are always ON or OFF when each process is running within the same unit as signals used by that machine. Then, it associates each process with each control signal, assuming that each signal is used by only one unit. In the example above, period 402 corresponds to area 431, period 411 corresponds to area 432, and period 421 corresponds to area 433.

[0045] Here, as shown in periods 404, 412, and 421 in Figure 4, it is not easy to determine the signals used by each process from the ON / OFF information of the control signals when all units are operating. However, by utilizing the nature of units and processes operating in stages, it becomes possible to easily and accurately establish the relationship between control signals and the processes of the units.

[0046] For example, in period 401 of Figure 4, only process 2 of the input unit 203 is being executed. That is, the signals that change between ON and OFF during that period (shown in period 434) are the signals used in process 2 of the input unit 203, and it can be determined that the signals with signal symbols Y6 and X6 are being used.

[0047] Next, focusing on period 411 and region 432, during this period, the input unit 203 and the adhesive application unit 207 are operating simultaneously. However, by considering the difference between period 402, when only the input unit 203 was operating, and period 411, it is also possible to identify the control signals used in each process of the adhesive application unit 207.

[0048] Similarly, during the period when the input unit 203, adhesive application unit 207, and discharge unit 209 are operating simultaneously, the difference between the operating information for this period and the operating information for the period when the input unit 203 and adhesive application unit 207 were operating independently is taken. In this way, only the control signals used in each process of the discharge unit 209 during period 421 and region 433 can be identified.

[0049] Furthermore, the method described above utilizes the property that units and processes operate in stages, from a state where each unit does not have workpiece 201 to a state where each unit is working on workpiece 201, to identify the control signals used in each process. On the other hand, from the state where each unit is working on workpiece 201 until all workpiece 201 is discharged, the number of processes being executed decreases in stages, so it is possible to similarly identify the control signals used in each process during this period as well.

[0050] Therefore, the operator may identify the period from when all machines (units) on the production line 100 have workpieces 201, to when the input of workpieces 201 is stopped, until all workpieces 201 being processed in each unit are discharged, and then create a list of signals used 132 using the process numbers 130 and control signals 131 for that period.

[0051] Furthermore, depending on the production line, multiple units may work on a single workpiece simultaneously. For example, in Figure 2, there are two adhesive application units 207, and both units apply adhesive to a single workpiece 201 simultaneously.

[0052] In this case, using the signal identification method described above, it is possible to determine that a certain signal is used in either the first or second adhesive application unit 207, but it is not possible to determine which unit a particular signal is used in.

[0053] In such cases, the slight timing difference in the ON / OFF state of the signal, which occurs in each unit, is used to identify the process using a particular signal. The timing difference in the signal can be slight even with the same control signal, due to various factors such as the response speed of each sensor, the transmission time of the control signal, or the sliding resistance of the unit.

[0054] Furthermore, the time difference between when the control signal used in a unit's process turns ON and when the process ends tends to be smaller than the time difference in units that are not using the control signal. For example, suppose there are units A and B that work on a workpiece simultaneously, and control signal a is used in process 1 of unit A.

[0055] In this case, the time difference between when signal a turns ON and when process 1 ends will be smaller than the time difference between when process 1 of unit B ends and when signal a ends.

[0056] Based on the above, when multiple units are working on a single workpiece, the process that may be using the control signal to be identified is narrowed down using the method described above. Then, as shown in period 434 of Figure 4, the "time from when a certain signal is turned ON until the process ends" is measured for multiple cycles, and the process with the smallest difference between the maximum and minimum times is determined to be using that signal. In this way, even when multiple units are operating simultaneously, the control signals used by each process can be identified.

[0057] Figure 5 is a table that associates each unit and process obtained using the methods described above with the control signals used in each process. The table shown in Figure 5 is recorded in the database as the signal usage list 132.

[0058] Next, we will explain how to create monitoring conditions for the machine (unit). The judgment creation unit 124 automatically starts processing when the usage signal list 132 in Figure 5 has been created and the judgment condition list 133 has not been created.

[0059] The judgment creation unit 124 refers to the signal usage list 132 shown in Figure 5, which is created by the analysis unit 123 and stored in the database, and creates the judgment condition list 133, shown in Figures 6 and 7, which determines whether each process and Bible signal is normal or abnormal. Figure 6 is the judgment condition list for the control signal 131, and Figure 7 is the judgment condition list for the process corresponding to process number 130. The derivation process of these will be explained below.

[0060] Here, multiple judgment conditions can be set for a single signal symbol in the signal usage list 132. The method for determining whether a control signal is normal or abnormal is predetermined, and in this embodiment, normality and abnormality are determined using the ON / OFF timing of each control signal. This ON / OFF timing is defined as the time from when each process in the unit starts executing until the control signal used by that process is turned ON or OFF.

[0061] Figure 8 shows the state of each control signal in processes 1 to 5 of the input unit 203, recorded multiple times n times (n=1 to N). t1, t2, and tn represent the ON timing of control signal X1, while T1, T2, and Tn represent the OFF timing of control signal X1. The natural numbers subscripts t and T indicate the ON / OFF timing of the nth recorded control signal X1.

[0062] As mentioned above, slight differences in the ON / OFF timing of each sensor occur due to various factors such as reaction speed, control signal transmission time, and mechanical sliding resistance. Therefore, this property is utilized to measure the ON / OFF timing of each control signal over multiple cycles, and the range from the minimum to the maximum value is defined as the "range in which variation in ON / OFF timing under normal conditions is acceptable."

[0063] Next, we will explain the process for measuring the ON / OFF timing of each control signal in each process over multiple cycles.

[0064] First, the process number 130 of the unit and the signal symbols of each control signal 131 are obtained from the usage signal list 132 stored in the database. Then, from this information, the ON / OFF timing of the control signals used in each process of each unit is measured for n times (n=1 to N).

[0065] Figure 9 shows the mean and standard deviation of the measurement results for n times (n=1 to N) of each control signal at the ON / OFF timing, as well as the judgment threshold at the ON / OFF timing. The upper and lower limits of the judgment threshold used for normal and abnormal determination are calculated from the statistical values ​​of the measurement results. The calculation method may be, for example, the mean ± 6 × standard deviation, or the maximum and minimum values ​​may be used.

[0066] These judgment thresholds are calculated for the control signals shown in the signal usage list 132, and a list of judgment conditions for the control signal 131 shown in Figure 6 is generated. Similarly, for each unit's process, the process execution time is calculated from the process number 130, and the upper and lower limits of the judgment threshold are calculated from the statistical values ​​(e.g., mean, deviation) of n measurement results (n=1 to N), just like in the calculation of the control signal judgment thresholds. Then, a list of judgment conditions for the process corresponding to process number 130, shown in Figure 7, is generated. Finally, the judgment condition lists shown in Figures 6 and 7 are combined and stored in the database as judgment condition list 133.

[0067] Next, we will describe how to monitor each unit and each process. Once the judgment condition list 133 shown in Figures 8 and 9 is stored in the database, the monitoring system 120 starts monitoring the process number 130 and each control signal 131 transmitted from the PLC 110.

[0068] The determination unit 125 then determines whether each process and each control signal is normal or abnormal based on the determination condition list 133. In this embodiment, the process determination is made when the process turns OFF (when the process ends), and the control signal determination is made when the control signal turns ON.

[0069] This is because each control signal is a signal, and therefore does not affect the process itself even if it remains in the ON state, so the OFF timing is not suitable for evaluation. Also, since a process turns ON when a control signal is turned ON, the start of a process can be determined by looking at the ON state of the control signal. Furthermore, if the ON timing is incorrect, the OFF timing will inevitably be incorrect as well, so the timing when the process is correctly turned OFF is more suitable for evaluation.

[0070] If either or both of the process OFF timing and / or the control signal ON timing fall outside the judgment thresholds listed in the judgment condition list 133, the time when the judgment thresholds were exceeded, along with the machine number, process number, signal symbol, and signal name, are recorded in the abnormality history 134.

[0071] Figure 10 shows an example of a screen displayed by the display unit 126 on the display device 150. In this embodiment, the display device 150 is described using a display used in a PC or the like as an example, but it may also be configured as a touch panel. Furthermore, when the abnormality history 134 is updated, the display unit 126 displays the update result on the display device 150, and if an abnormality has occurred, it notifies the operator of the abnormality.

[0072] Block 1001 in Figure 10 shows the history period in the anomaly history 134. In this embodiment, the anomaly history for the past 10 days from the date and time when the anomaly history 134 was last updated is displayed first. The operator can also change the display period by manipulating block 1001.

[0073] Table 1002 in Figure 10 shows the total delay time and number of delays for each process in each unit in tabular format. Table 1003 is displayed when a cell in the total delay time column in Table 1002 is selected, and shows the time and duration of the delay for the selected item. For example, if a cell showing a total delay time of 2.45 is selected, the display format, such as the color of the row (left to right direction as you face the page) of that cell changes, and Table 1003 displays the delay time and timing of occurrence in process 3 of input unit 203.

[0074] Graph 1004 is a bar chart showing the total delay time per day across all processes for all units during the period indicated by block 1001. For example, bar 1005 shows that a total delay of 5 minutes occurred on production line 100 on 2 / 11 / 2015.

[0075] Figure 11 shows the error history that occurred during the display period indicated by block 1101, displayed by the number of delay occurrences. The display can be switched to the screen and display method shown in Figure 11 using the display switching button 1006. Table 1102 in Figure 11 shows the error history 134 that occurred during the display period indicated by block 1101 in tabular format.

[0076] Graph 1103 in Figure 11 shows the total number of delays per day for all processes across all units, compiled from the anomaly history 134, displayed in bar chart format. For example, bar 1104 in Figure 11 indicates that 60 delays occurred on production line 100 on 2 / 11 / 2015. Workers check the anomaly history in Figures 10 and 11 to understand the occurrence of anomalies.

[0077] In the example above, the display was switched using the display switching button 1006, but it would also be possible to configure it so that selecting the cell for the total number of delays in Table 1002 switches to the display screen shown in Figure 11.

[0078] The operator then selects the anomaly they wish to investigate further from the tabular anomaly history shown in Table 1003 in Figure 10 or Table 1102 in Figure 11. For example, if the first row in Table 1003 in Figure 10 (occurrence time: 2015 / 2 / 1 14:30:55) is selected, the screen of the display device 150 transitions to Figure 12.

[0079] Figure 12 shows an example of displaying the operating status of each process and control signal in each unit using a bar chart with time on the horizontal axis. Block 1201 in Figure 12 displays a total of 10 seconds, including 5 seconds before and after the date and time when the anomaly occurred, as selected in Table 1003 in Figure 10. The time before and after can be set as appropriate by the operator. The operator can change the display period by operating block 1201. Tab 1202 in Figure 12 is a tab for selecting the unit whose operating status of each process and control signal is displayed in bar chart format.

[0080] Next, we will explain the control flow that displays the operating status of each process and control signal in each unit in a bar chart format, as shown in Figure 12, using Figure 13. Figure 13 is a control flowchart that displays the operating status of each process and control signal in each unit in a bar chart format, as shown in Figure 12. The control flow in Figure 13 is executed by the CPU, which functions as the display unit 126. The blocks described below are explained as examples, and similar blocks in Figure 12 have the same functions as described below.

[0081] First, in S101, the process number 130 and control signal information 131 for the display period 1201 in Figure 12 are obtained from the anomaly history 134. Then, in S102, the period during which each obtained process was operating is displayed from top to bottom in order of start time as a single rectangle shown in block 1203 of Figure 12. In addition, areas without a bar chart indicate that the process is in standby mode (0).

[0082] Next, in S103, the judgment condition list 133 is referenced to obtain the upper and lower judgment limits (judgment thresholds) for each process, and in S104, these are displayed as dashed rectangles (block 1205) superimposed on the rectangles (block 1203) of processes that are in operation. The width of these dashed rectangles (block 1205) indicates the range within which each process is judged to have completed successfully. As each process is executed at regular intervals as shown in Figure 8, each dashed rectangle is displayed on the time chart at regular intervals while maintaining the width of the judgment threshold.

[0083] Next, in S105, the decision condition list 133 is referenced to obtain the control signals used in each process, as well as the upper and lower decision limits (decision thresholds) for those signals. Then, in S106, the period during which a signal is ON is represented by a single rectangle (block 1204), and the blocks 1204 are displayed from top to bottom in the order of control for each process. In addition, the absence of a bar chart indicates that the control signal is in standby mode (0).

[0084] In this embodiment, the patterns of process blocks and control signal blocks are different in order to make the display easier to understand, but other display formats may be used.

[0085] Next, in S107, the upper and lower limits (judgment thresholds) for each control signal are displayed as dashed rectangles (1206) superimposed on the rectangle (block 1204) where the signal is in the ON state. The width of these dashed rectangles indicates the range within which it is determined that the timing for each signal to be in the ON state is normal. Since each control signal is generated at a constant period as shown in Figure 8, each dashed rectangle is displayed on the time chart at a constant period while maintaining the width of the judgment threshold. This concludes the display control flow.

[0086] In this embodiment, the process and control signal determination thresholds are explained using dashed rectangles, but this is not the only example. For example, they may be displayed with a higher transparency than the process blocks and control signal blocks, or they may be displayed using a different pattern than the process blocks and control signal blocks.

[0087] For example, in blocks 1207 and 1208 of Figure 12, the start of time T during which the chuck 1 open signal (control signal X2) is in the ON state does not fall within the normal range (block 1208). Therefore, the start timing of time t during which process 3 related to control signal X2 is in the execution state is delayed, and the end of time t does not fall within the normal range (block 1207), indicating that it is judged as abnormal.

[0088] Furthermore, if the third row of Table 1102 in Figure 11 (time: 2015 / 2 / 1 14:32:17) is selected, the screen of the display device 150 transitions to Figure 14, which is similar to Figure 12. Figure 14, like Figure 12, is an example of displaying the operating status of each process and each control signal in each unit using a bar chart with time on the horizontal axis.

[0089] The explanation of the display period, unit tabs, and bar charts of the operating status of processes and each control signal in Figure 14 is the same as in Figure 12. Block 1301 in Figure 14 shows an example of a location where the sensor for the chuck 1 open command signal (control signal Y2) failed to turn ON, resulting in an abnormality. In both cases, 1208 in Figure 12 and 1301 in Figure 14, the abnormal part that falls outside the normal range can be identified at a glance.

[0090] At this time, in order to further improve visibility, as shown in Figure 15, control signals whose ON timing is not within the judgment threshold, and / or process signals whose OFF timing is not within the judgment threshold, and the judgment thresholds associated with them may be displayed in a different format than before. In Figure 15, the display format of process 3 and chuck 1 open signal (control signal X2), and blocks 1207 and 1208 have been changed. By using a different color or display format from the normal parts, it can be made easier to distinguish them.

[0091] As described above, by dividing the operating status of each unit into process units, identifying the control signals associated with each process, and displaying the processes and control signals in order on a time chart, operators can easily grasp the situation regarding the occurrence of abnormalities.

[0092] Furthermore, by displaying the abnormal process and control signals in a different format than the normal state, the scope of verification when an anomaly occurs can be narrowed. Moreover, by tracking the control signals chronologically, it becomes possible to see at a glance how much the ON / OFF timing of the signals deviates from the normal state and at what point the deviation occurred. Therefore, the time wasted in identifying anomalies can be significantly reduced. And even if the number of units, processes, and signals increases, the monitoring conditions can be automatically set simply by operating the production line as usual, making it easy to build a monitoring system.

[0093] The control methods of the various embodiments described above were specifically explained as being executed by the CPU constituting the program unit of the monitoring device 120. However, the control program of software capable of executing the above functions and the recording medium on which that program is recorded may also be implemented by mounting them on, for example, another information processing device. Therefore, the control program of software capable of executing the above functions, the recording medium on which that program is recorded, the communication device, and the application constitute the present invention.

[0094] The control program for carrying out the present invention may be recorded on any recording medium that is computer-readable. For example, an HDD, external storage device, recording disk, etc. may be used as the recording medium for supplying the control program.

[0095] (Other embodiments) Furthermore, while the various embodiments described above have explained the case in which a robot having a joint that drives one axis is used as a unit of the production line 100, the number of joints is not limited to this. The same configuration can be implemented with different types of joints, such as vertical multi-axis type and parallel link type, as well as with the robot arm.

[0096] Furthermore, the various embodiments described above are applicable to machines that can automatically perform movements such as extension and retraction, bending and straightening, vertical movement, horizontal movement, or rotation, or combinations thereof, based on information stored in a memory device provided in the control device.

[0097] It should be noted that the present invention is not limited to the embodiments described above, and many modifications are possible within the technical concept of the present invention. Furthermore, the effects described in the embodiments of the present invention are merely a list of the most preferred effects arising from the present invention, and the effects of the present invention are not limited to those described in the embodiments. [Industrial applicability]

[0098] It can be used as an information processing device to monitor the operating status of machinery and equipment used in industry. [Explanation of Symbols]

[0099] 110 Control devices (PLC) 111 Process number 112, 131 control signals, 120 Monitoring device (computer) 123 Analysis Department 124 Judgment Creation Department 125 Judgment section 126 Display section 130 Process number 150 Display device Blocks 1203, 1204, 1205, and 1206

Claims

1. An information processing method for acquiring the status of a device that performs a first operation and a second operation according to instructions from a control device, First process information indicating the period during which the first operation is being performed, and second process information indicating the period during which the second operation is being performed are obtained. A signal is communicated between the control device and the device, and the control device receives a signal to instruct the device to start an operation performed by the device, or a signal to notify the control device of the completion of an operation performed by the device. The signals communicated during the period indicated by the first process information are identified as the first signals associated with the first operation, and the signals communicated during the period indicated by the second process information are identified as the second signals associated with the second operation. An information processing method characterized by the following:

2. In the information processing method described in claim 1, The aforementioned devices include a first device and a second device. The first and second operations are performed by the first device, and the second device performs the third operation. Obtain third process information indicating the period during which the third operation is being performed, Among the signals communicated during the period in which the third operation is performed, the signals excluding the first and second signals are identified as the third signal associated with the third operation. An information processing method characterized by the following:

3. In the information processing method according to claim 1 or 2, The device performs the first operation and the second operation in stages. An information processing method characterized by the following:

4. In the information processing method according to any one of claims 1 to 3, The first operation or the second operation is the smallest unit of operation performed by the device. An information processing method characterized by the following:

5. In the information processing method according to any one of claims 1 to 4, The signal transmitted from the control device to the device instructing the device to start an operation performed by the device is a signal that changes between an ON state indicating that it is transmitting and an OFF state indicating that it is not transmitting. The signal transmitted from the device to the control device to notify the control device of the completion of an operation performed by the device is a signal that changes between an ON state indicating that a sensor in the device has detected a specific state and an OFF state indicating that it has not detected a specific state. An information processing method characterized by the following:

6. In the information processing method described in Claim 5, If the signal transmitted from the device to the control device to notify the control device of the status of the operation performed by the device is OFF for a predetermined time, the device notifies the control device of an ERROR. An information processing method characterized by the following:

7. In the information processing method according to any one of claims 1 to 6, The first process information, the second process information, the first signal, and the second signal are structured and recorded in a database. An information processing method characterized by the following:

8. In the information processing method described in Claim 7, The database can be used to search for the first process information, the second process information, the first signal, and the second signal recorded in the database. An information processing method characterized by the following:

9. In the information processing method according to any one of claims 1 to 8, On the display unit, The first block corresponding to the first process information, the second block corresponding to the second process information, the third block corresponding to the first signal, and the fourth block corresponding to the second signal are displayed in chronological order in the order in which the first operation, the second operation, the transmission of the first signal, and the transmission of the second signal were performed. An information processing method characterized by the following:

10. In the information processing method described in claim 9, The display unit, The third block is displayed below the first block, and the fourth block is displayed below the second block. An information processing method characterized by the following:

11. In the information processing method according to claim 9 or 10, The display unit, The following are displayed: the name of the earlier first operation for the user to identify the earlier first block, the name of the earlier second operation for the user to identify the earlier second block, the name of the earlier first signal for the user to identify the earlier third block, and the name of the earlier second signal for the user to identify the earlier fourth block. An information processing method characterized by the following:

12. In the information processing method described in claim 11, The display unit, A symbol indicating the first signal for the user to identify the third block, and a symbol indicating the second signal for the user to identify the fourth block are displayed. An information processing method characterized by the following:

13. In the information processing method according to any one of claims 9 to 12, The display unit, The display shows a first range defining the range of a first timing for which the control device should transmit a signal to the device to initiate the execution of the first or second operation, and a second range defining the range of a second timing for which the control device should receive a signal transmitted by the device to the control device to notify that the first or second operation has been executed. An information processing method characterized by the following:

14. In the information processing method described in claim 13, The display unit, The first range is displayed overlaid on the third block, and the second range is displayed overlaid on the fourth block. An information processing method characterized by the following:

15. In the information processing method according to claim 13 or 14, The display unit, The third block in which the transmission timing of the first signal does not fall within the first range is displayed with a different display pattern than the third block in which the transmission timing of the first signal falls within the first range, and the fourth block in which the reception timing of the second signal does not fall within the second range is displayed with a different display pattern than the fourth block in which the reception timing of the second signal falls within the second range. An information processing method characterized by the following:

16. In the information processing method according to any one of claims 9 to 15, The display unit, A third range is displayed that defines the range of a third timing in which the first or second operation should be completed. An information processing method characterized by the following:

17. In the information processing method described in claim 16, The display unit, The third range is displayed overlaid on the first block and the second block. An information processing method characterized by the following:

18. In the information processing method according to claim 16 or 17, If the timing at which the first operation is determined to have ended does not fall within the third range, the first block is displayed with a different display pattern than the first block where the timing at which the first operation is determined to have ended falls within the third range. Similarly, if the timing at which the second operation is determined to have ended does not fall within the third range, the second block is displayed with a different display pattern than the second block where the timing at which the second operation is determined to have ended falls within the third range. An information processing method characterized by the following:

19. In the information processing method according to any one of claims 13 to 15, The display unit, The first range or the second range is displayed as a dashed rectangle. An information processing method characterized by the following:

20. In the information processing method according to any one of claims 16 to 18, The display unit, The third range is represented by a dashed rectangle. An information processing method characterized by the following:

21. In the information processing method according to any one of claims 9 to 20, The display period for the aforementioned time series can be set. An information processing method characterized by the following:

22. In the information processing method according to any one of claims 13 to 15, The first range and the second range are set based on the first and second timings obtained by performing the first and second operations multiple times. An information processing method characterized by the following:

23. In the information processing method according to any one of claims 16 to 18, The third range is set based on the third timing obtained by performing the first and second operations multiple times. An information processing method characterized by the following:

24. In the information processing method according to any one of claims 1 to 23, On the display unit, Displaying at least one of the following during the execution of the first or second operation: delay time, number of delay occurrences, and delay timing. An information processing method characterized by the following:

25. In the information processing method according to any one of claims 1 to 24, The program referenced by the control device includes a description of the definitions of the first process information and the second process information, and a description of the recording of signals communicated between the control device and the device. An information processing method characterized by the following:

26. In the information processing method according to any one of claims 1 to 25, The control device is a PLC (Programmable Logic Controller) that references a ladder program. An information processing method characterized by the following:

27. A production system comprising the device whose state is acquired by the information processing method described in any one of claims 1 to 26.

28. A method for manufacturing an article, characterized in that the article is manufactured using the equipment whose state has been acquired by the information processing method described in any one of claims 1 to 26.

29. An information processing device that acquires the status of a device that performs a first operation and a second operation according to instructions from a control device, First process information indicating the period during which the first operation is being performed, and second process information indicating the period during which the second operation is being performed are obtained. The control device and the device communicate a signal, which is a signal for the control device to instruct the device to start an operation performed by the device, or a signal for the device to notify the control device of the completion of an operation performed by the device. The signals communicated during the period indicated by the first process information are identified as the first signals associated with the first operation, and the signals communicated during the period indicated by the second process information are identified as the second signals associated with the second operation. An information processing device characterized by the following:

30. A program capable of executing the information processing method described in any one of claims 1 to 26.

31. A computer-readable recording medium having the program described in claim 30 recorded on it.

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