CONTROL PROGRAM, MONITORING AND CONTROL SYSTEM, GATEWAY DEVICE, AND CONTROL METHOD

Abstract

A message acquisition unit (110) of a gateway device (100) in which a control program is installed acquires messages including signal data from devices (211-214). A priority determination unit (130) determines the priority of signal data included in the acquired messages based on abnormality determination related data, which is data related to the type of signal data used in the monitoring control server (300) to determine an abnormality in the facilities (201, 202). A message transmission unit (140) transmits the acquired messages to the monitoring control server (300), and, when an abnormality occurs in the network (400) and then is resolved, transmits messages including signal data having the determined high priority to the monitoring control server (300) in preference to messages having a low priority.

Description

[Technical field]

[0001] The present disclosure relates to a control program, a monitoring and control system, a gateway device, and a control method. [Background technology]

[0002] Conventionally, there is known a monitoring and control system in which a gateway device installed at a production site such as a factory transmits data collected from devices installed in a facility to be monitored to a monitoring and control server via a public communication network, and the monitoring and control server centrally manages the collected data to perform monitoring such as abnormality judgment of the facility and control of the facility. In such a monitoring system, there is a demand for a technology that enables the monitoring and control server to reliably judge abnormalities in the facility while reducing the delay in abnormality judgment.

[0003] Patent Document 1 discloses a time-series data collection system in which a gateway device installed in each facility transmits collected data to a monitoring control device via a communication network. In Patent Document 1, the gateway device accumulates collected data in a data accumulation area and transmits it to the monitoring control device, and when a data recollection request is received from the monitoring control device, the gateway device retransmits the data accumulated in the data accumulation area. In other words, the system described in Patent Document 1 is a data buffering system that can prevent data loss and simplify data management during communication abnormalities by storing data that has failed to be transmitted to the monitoring control device in the gateway device and retransmitting it when the quality of the communication network deteriorates.

[0004] Patent Document 2 discloses a monitoring and control system including a gateway device that receives messages including signal data of each device from multiple devices monitored and controlled by the monitoring and control device and transmits the received messages to the monitoring and control device via a network. In Patent Document 2, the gateway device determines the priority of messages based on the state indicated by the relational data of each signal data obtained by analyzing drawing information of a plant in which equipment including multiple devices is installed, and transmits messages with the determined higher priority to the monitoring and control device with priority. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2004-246438 A [Patent Document 2] JP 2020-162063 A Summary of the Invention [Problem to be solved by the invention]

[0006] In the collection system disclosed in Patent Document 1, the monitoring control device can determine an abnormality in each facility after sequentially receiving retransmitted data in response to a data recollection request received by the gateway device. As a result, the collection system disclosed in Patent Document 1 has a problem in that when an abnormality in the communication network is resolved, the abnormality determination is delayed.

[0007] On the other hand, in the monitoring and control system disclosed in Patent Document 2, the gateway device analyzes the configuration of the plant from the drawing information of the plant, and transmits messages including signal data of equipment with high importance to the monitoring and control device with priority. However, in the monitoring and control system disclosed in Patent Document 2, the gateway device automatically determines the priority based on the drawing information of the plant, and does not consider whether the message is actually used by the monitoring and control device for abnormality judgment. For this reason, for example, there are cases where a message determined by the gateway device to have a high priority is not used for abnormality judgment, and a message determined by the gateway device to have a low priority is used for abnormality judgment. In this case, the monitoring and control system disclosed in Patent Document 2 also has the problem of delaying abnormality judgment when the network abnormality is resolved, similar to the collection system disclosed in Patent Document 1.

[0008] The present disclosure has been made in consideration of the above-described circumstances, and aims to reduce delays in determining an abnormality in equipment when a network abnormality is resolved. [Means for solving the problem]

[0009] In order to achieve the above object, a control program according to the present disclosure causes a gateway device that transmits signal data acquired from an apparatus arranged in a facility to be monitored in a monitoring and control system via a network to a monitoring and control server that monitors the facility to function as a message acquisition unit that acquires a message including signal data from the apparatus, a priority determination unit that determines a priority of signal data included in the message acquired by the message acquisition unit based on abnormality determination related data that is data related to the type of signal data used in the monitoring and control server to determine an abnormality in the facility, and a message transmission unit that transmits the message acquired by the message acquisition unit to the monitoring and control server, wherein, when an abnormality occurs in the network and then is resolved, the message transmission unit transmits a message including signal data with a high priority determined by the priority determination unit to the monitoring and control server in preference to a message including signal data with a low priority. The abnormality determination related data is data indicating the number of times each type of signal data is used in the abnormality determination conditions used in the equipment abnormality determination in the monitoring control server, and the priority determination unit determines a higher priority for the signal data as the number of times the abnormality determination related data is used increases. . Effect of the Invention

[0010] According to the present disclosure, when a network abnormality is resolved, the priority of signal data included in a new message transmitted from a gateway device to a monitoring control server is determined based on abnormality determination-related data, which is data related to the type of signal data used in the monitoring control server to determine an abnormality in the equipment. As a result, the control program according to the present disclosure can reduce the delay in determining an abnormality in the equipment when the network abnormality is resolved, compared to a control program in which the priority of signal data is not determined based on the abnormality determination-related data. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is an overall explanatory diagram of a monitoring and control system according to an embodiment of the present invention; [Diagram 2] FIG. 1 is a block diagram showing a hardware configuration of each device according to an embodiment. [Diagram 3] FIG. 1 is a diagram showing a display example of signal data according to an embodiment; [Figure 4] FIG. 13 is a diagram showing an example of display of abnormality determination condition data according to the embodiment; [Diagram 5] FIG. 13 is a diagram showing a display example of abnormality determination related data according to the embodiment; [Figure 6] Flowchart of message transmission process according to an embodiment [Figure 7] 1 is a timing chart showing values ​​of signal data of each device received by a monitoring and control server of a monitoring and control system according to an embodiment when no network failure occurs. [Figure 8] A timing chart showing the signal data values ​​of each device received by the monitoring control server of a conventional monitoring system when a network failure occurs. [Figure 9] 1 is a timing chart showing values ​​of signal data of each device received by a monitoring and control server of a monitoring and control system according to an embodiment when a network failure occurs. [Figure 10] FIG. 1 is an overall explanatory diagram of a monitoring and control system according to a modified example of the embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, a control program, a monitoring and control system, a gateway device, and a control method according to embodiments of the present disclosure will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals.

[0013] (Regarding monitoring and control system 1 according to the embodiment) A monitoring and control system 1 according to an embodiment of the present disclosure is a remote monitoring and control system that monitors and controls equipment 200 at a production site, such as a factory or a plant, from a remote location based on data collected from the equipment 200. As shown in FIG. 1, the monitoring and control system 1 includes a gateway device 100 and the equipment 200 installed at the production site, and a monitoring and control server 300 installed at a remote location to monitor and control the equipment 200. The gateway device 100 and the monitoring and control server 300 can transmit and receive data via a network 400 configured by a WAN (Wide Area Network), such as the Internet or a wide area line. Thus, in the monitoring and control system 1, the monitoring and control server 300 can monitor and control the equipment 200 from a remote location by transmitting and receiving data related to the equipment 200 via the gateway device 100 and the network 400.

[0014] (Regarding the facility 200 according to the embodiment) The facility 200 is, for example, one or more facilities such as processing machines included in a production line that is the subject of monitoring and control by the monitoring control server 300. For example, the facility 200 includes a first facility 201 and a second facility 202. A plurality of devices are arranged in each of the facilities 201 and 202. For example, the first facility 201 includes a first device 211 and a second device 212, and the second facility 202 includes a third device 213 and a fourth device 214.

[0015] Each of the devices 211-214 is a so-called FA (Factory Automation) device such as a programmable logic controller (hereinafter referred to as "PLC"), and has a configuration as a computer device such as a controller and a memory. Each of the devices 211-214 is capable of transmitting and receiving data to and from the gateway device 100 via a wireless or wired LAN (Local Area Network) 500. Each of the devices 211-214 includes a signal data generating unit 221 that generates signal data described below, a date and time data adding unit 222 that adds date and time data indicating the date and time when the signal data was generated, a signal data storage unit 223 that stores the signal data, and a message output unit 224 that outputs a message.

[0016] (Gateway Device 100 According to the Embodiment) The gateway device 100 is a computer device that acquires and stores data from each of the devices 211-214 of the facility 200, and transmits the acquired data to the monitoring control server 300. The gateway device 100 includes a message acquisition unit 110 that acquires messages, an abnormality determination related data storage unit 120 that stores abnormality determination related data described below, and a priority determination unit 130 that determines the priority of signal data described below. The gateway device 100 also includes a message transmission unit 140 that transmits messages, and a retransmission message storage unit 150 that stores messages to be retransmitted.

[0017] (Regarding the monitoring control server 300 according to the embodiment) The monitoring control server 300 is, for example, a server computer that functions as a so-called cloud server. The monitoring control server 300 centrally manages data collected from each of the devices 211-214 of the facility 200, and monitors and controls each of the facilities 201, 202. The monitoring control server 300 includes a message receiving unit 310 that receives messages, an abnormality determination condition data storage unit 320 that stores abnormality determination condition data described below, and an abnormality determination unit 330 that performs abnormality determination for each of the facilities 201, 202.

[0018] (Hardware Configuration of Gateway Device 100 According to the Embodiment) 2, the gateway device 100 includes, for example, a control unit 51 that executes processing according to a control program 59. The control unit 51 includes a CPU (Central Processing Unit). According to the control program 59, the control unit 51 functions as the priority determination unit 130 shown in FIG.

[0019] 2, the gateway device 100 includes a main storage unit 52 into which a control program 59 is loaded and which is used as a working area for the control unit 51. The main storage unit 52 includes a RAM (Random Access Memory).

[0020] The gateway device 100 also includes an external storage unit 53 that stores a control program 59 in advance. The external storage unit 53 supplies data stored by this program to the control unit 51 in accordance with an instruction from the control unit 51, and stores the data supplied from the control unit 51. The external storage unit 53 includes a recording medium such as a flash memory, a hard disk drive (HDD), or a solid state drive (SSD). The external storage unit 53 functions as the abnormality determination related data storage unit 120 and the resent message storage unit 150 shown in FIG. 1.

[0021] The gateway device 100 also includes a transmission / reception unit 56 that transmits and receives information. The transmission / reception unit 56 includes information communication components such as a communication network terminal device and a wireless communication device that connect to the network 400 or the LAN 500. The transmission / reception unit 56 functions as the message acquisition unit 110 and the message transmission unit 140 shown in FIG.

[0022] Returning to FIG. 2, in the gateway device 100 , the main memory unit 52 , the external memory unit 53 and the transmission / reception unit 56 are all connected to the control unit 51 via the internal bus 50 .

[0023] 1 by the control unit 51 using the main memory unit 52, the external memory unit 53, and the transmission / reception unit 56 as resources. For example, the gateway device 100 executes a message acquisition step performed by the message acquisition unit 110, an abnormality determination related data storage step performed by the abnormality determination related data storage unit 120, and a priority determination step performed by the priority determination unit 130. The gateway device 100 also executes a message transmission step performed by the message transmission unit 140, and a retransmission message storage step performed by the retransmission message storage unit 150.

[0024] (Hardware configuration of each of the devices 211 to 214 according to the embodiment) Similarly to the gateway device 100, each of the devices 211-214 includes a control unit 51, and a main memory unit 52, an external memory unit 53, and a transmission / reception unit 56 connected to the control unit 51 via an internal bus 50. The control unit 51 functions as the signal data generation unit 221 and the date and time data attachment unit 222 shown in Fig. 1, the external memory unit 53 functions as the abnormality determination condition data storage unit 320 shown in Fig. 1, and the transmission / reception unit 56 functions as the message output unit 224 shown in Fig. 1. Similarly to the gateway device 100, each of the devices 211-214 also realizes the functions of the above-mentioned units 221-224 shown in Fig. 1 by the control unit 51 using the main memory unit 52, the external memory unit 53, and the transmission / reception unit 56 as resources. For example, each of the devices 211 to 214 executes a signal data generating step performed by a signal data generating unit 221, a date and time data assigning step performed by a date and time data assigning unit 222, a signal data storing step performed by a signal data storing unit 223, and a message output step performed by a message outputting unit 224.

[0025] (Hardware Configuration of the Monitoring Control Server 300 According to the Embodiment) Similarly to the gateway device 100 and the devices 211 to 214, the monitoring control server 300 also includes a control unit 51, a main memory unit 52, an external memory unit 53, and a transmission / reception unit 56 connected to the control unit 51 via an internal bus 50. The control unit 51 functions as the abnormality determination unit 330 shown in FIG. 1, the external memory unit 53 functions as the abnormality determination condition data storage unit 320 shown in FIG. 1, and the transmission / reception unit 56 functions as the message receiving unit 310 shown in FIG. 1. Similarly to the gateway device 100 and the devices 211 to 214, the monitoring control server 300 also realizes the functions of the above-mentioned units 210 to 230 shown in FIG. 1 by the control unit 51 using the main memory unit 52, the external memory unit 53, and the transmission / reception unit 56 as resources. For example, the monitoring control server 300 executes a message receiving step performed by the message receiving unit 310, an abnormality determination condition data storage step performed by the abnormality determination condition data storage unit 320, and an abnormality determination step performed by the abnormality determination unit 330.

[0026] (Details of Functional Configuration of Each Device 211-214 According to the Embodiment) The signal data generating unit 221 generates signal data of each of the devices 211-214. Here, the signal data includes various types of signal data, such as signal data that is internal signal data of each of the devices 211-214 if each of the devices 211-214 is a PLC, and input signal data that is signal data input from a sensor (not shown) connected to each of the devices 211-214. Note that the internal signal data is data that includes a value indicating whether the state of each of the devices 211-214 is "operating normally", "operating abnormally", or "stopped". Also, the input signal data is data that indicates whether the state of a machine that is the object of measurement by the sensor is "operating normally", "operating abnormally", or "stopped".

[0027] The date and time data adding unit 222 adds a time stamp as an example of date and time data indicating the date and time when the signal data was generated to the signal data, and the signal data storage unit 223 stores the signal data to which the time stamp has been added. Therefore, the signal data stored in the signal data storage unit 223 is, for example, data indicating the state of each of the devices 211 to 214 at each time, and can be displayed in a list format in a table as shown in FIG.

[0028] 3, the signal data includes data corresponding to the items of "time" indicating the time when the signal data was generated and "value" indicating the value of the signal data. For example, the signal data stored in the signal data storage unit 223 of the first device 211 is data that can identify that the "value" is "0" when the "time" is "10:10:20.12".

[0029] The message output unit 224 outputs a message including the signal data stored in the signal data storage unit 223 to the gateway device 100 based on an acquisition request from the gateway device 100. When there is an acquisition request from the gateway device 100 for specific signal data, which is signal data to which a timestamp indicating a specific time has been added, the message output unit 224 outputs a message including signal data to which a timestamp of a time closest to the specific time has been added from among the signal data stored in the signal data storage unit 223. For example, when there is an acquisition request from the gateway device 100 for specific signal data with a "time" of "10:10:20.12", the message output unit 224 of the first device 211 outputs a message including specific signal data with a "time" of "10:10:20.12" and a "value" of "0" stored in the signal data storage unit 223 of the first device 211 to the gateway device 100.

[0030] (Details of Functional Configuration of Monitoring Control Server 300 According to the Embodiment) The message receiving unit 310 receives a message transmitted by the gateway device 100. In addition, when an abnormality such as a fault occurs in the network 400 and the gateway device 100 fails to transmit a message, and then the abnormality is resolved, the message receiving unit 310 receives a message retransmitted by the gateway device 100.

[0031] The abnormality determination condition data storage unit 320 stores a plurality of types of abnormality determination condition data. Here, the abnormality determination condition data is data indicating conditions for determining whether or not each of the facilities 201, 202 is abnormal. In this embodiment, the abnormality determination condition data is data indicating a condition equation for determining whether or not each of the facilities 201, 202 is abnormal, and can be displayed in a list format in a table as shown in FIG.

[0032] 4, the abnormality determination condition data includes data corresponding to the items of "facility name" indicating the name of the production site, "gateway" indicating the name of the gateway device 100, and "equipment name" indicating the names of each piece of equipment 201, 202. For example, the abnormality determination condition data also includes data corresponding to the items of "error ID" indicating the identification number of the abnormality, "equipment name" indicating the name of each piece of equipment 211-214 causing the abnormality, and "signal ID" indicating the identification number of the signal data. For example, the abnormality determination condition data also includes data corresponding to the items of "signal" indicating the sign of the operator, "determination destination" indicating whether the determination destination is a fixed value or the value of other signal data, "equipment name" indicating the name of the equipment 211-214 that generated the other signal data, and "fixed value / signal ID" indicating a fixed value or the identification number of other signal data, for the abnormality determination condition formula.

[0033] For example, the abnormality determination condition data is data that can identify that the "facility name" is "Factory X Line Y," the "gateway" is "Gateway 1," the "equipment name" is "Processing machine A," the "error ID" is "E001," the "equipment name" is "PLC1," the "signal ID" is "0001," and the abnormality determination condition formula is that the "sign" is "<," the "determination destination" is "fixed value," the "equipment name" is "-" or "none," and the "fixed value / signal ID" is "10."

[0034] The abnormality determination unit 330 performs abnormality determination for each of the facilities 201, 202 based on the signal data of each of the devices 211-214 included in the message received by the message receiving unit 310 and the abnormality determination condition data stored in the abnormality determination condition data storage unit 320. For example, when the abnormality determination unit 330 receives a message including signal data with the identification number of the device 211 of "PLC1" being "0001" from the gateway device 100 of "gateway 1", if the value of the signal data is smaller than "10", it determines that an abnormality with the identification number "E001" has occurred.

[0035] (Details of Functional Configuration of Gateway Device 100 According to the Embodiment) The message acquiring unit 110 acquires a message including signal data output from each of the devices 211 to 214. The message acquiring unit 110 can acquire a message including specific signal data from each of the devices 211 to 214. For example, when the message acquiring unit 110 requests the first device 211 to acquire specific signal data having a "time" of "10:10:20.12", the message acquiring unit 110 can acquire a message including specific signal data having a "time" of "10:10:20.12" from the first device 211.

[0036] The abnormality determination related data storage unit 120 stores abnormality determination related data, which is data related to the type of signal data used in the abnormality determination of each piece of equipment 201, 202 in the monitoring control server 300. Here, the abnormality determination related data is data indicating the number of times each type of signal data is used in the abnormality determination condition equation used in the abnormality determination of each piece of equipment 201, 202 in the monitoring control server 300. Specifically, the abnormality determination related data is data indicating the number of times each identification number of signal data used in each abnormality determination condition equation is used, by analyzing all abnormality determination condition data stored in the abnormality determination condition data storage unit 320 of the monitoring control server 300, and can be displayed in a list format in a table as shown in FIG.

[0037] As shown in Fig. 5, the abnormality determination related data includes data corresponding to the items of "device name" indicating the name of each device 211-214, "signal ID" indicating the identification number of signal data, and "number of uses" indicating the number of times the abnormality determination condition formula is used. For example, the abnormality determination related data is data that can identify that the "device name" is "PLC1", the "signal ID" is "0002", and the "number of uses" is "3". In order to control in this way, the gateway device 100 needs to acquire and analyze all abnormality determination condition data previously stored in the abnormality determination condition data storage unit 320 from the monitoring control server 300, and generate and store the abnormality determination related data.

[0038] The priority determination unit 130 determines the priority of signal data included in the message acquired by the message acquisition unit 110 based on the abnormality determination related data stored in the abnormality determination related data storage unit 120. The priority determination unit 130 increases the priority of the signal data included in the message acquired by the message acquisition unit 110 as the "number of uses" indicated by the abnormality determination related data increases. For example, in the example shown in Fig. 5, the priority determination unit 130 increases the priority of signal data with an "equipment name" of "PLC1", a "signal ID" of "0002", and a "number of uses" of "3" over the priority of signal data with an "equipment name" of "PLC1", a "signal ID" of "0001", and a "number of uses" of "2".

[0039] The message sending unit 140 sends the message acquired by the message acquiring unit 110 to the monitoring control server 300 .

[0040] When an abnormality occurs in the network 400 and transmission of a message to the monitoring control server 300 fails, the resent message storage unit 150 stores, as messages to be resent, the message that failed to be transmitted and the unsent message acquired by the message acquisition unit 110 after the abnormality occurred in the network 400. When an abnormality occurs in the network 400 and transmission of a message fails, the gateway device 100 stores the message to be resent in the resent message storage unit 150, and then transmits the message stored in the resent message storage unit 150 when the abnormality is resolved.

[0041] At this time, the message transmitting unit 140 transmits to the monitoring control server 300 a message including signal data with a high priority determined by the priority determining unit 130 in preference to a message with a low priority. Specifically, the message transmitting unit 140 transmits messages in the order of priority, that is, in the order of messages including signal data with a large "usage count" indicated by the abnormality determination related data. For example, in the example shown in FIG. 5, the message transmitting unit 140 transmits a message including signal data with a "signal ID" of "0002" and a "usage count" of "3" as the highest priority. The message transmitting unit 140 transmits a message including signal data with a "signal ID" of "0001" and a "usage count" of "2" as the second highest priority. The message transmitting unit 140 transmits signal data with a "signal ID" of "0011" or "0012" and a "usage count" of "1" as the third highest priority.

[0042] (Message sending process according to the embodiment) Next, an operation of the gateway device 100 transmitting messages acquired from the devices 211-214 to the monitoring control server 300 will be described with reference to a flowchart. When the gateway device 100 starts the control program 59, it starts executing the message transmission process shown in Fig. 6. First, the gateway device 100 causes the message acquisition unit 110 to acquire messages including signal data output from the devices 211-214 (step S101), and causes the message transmission unit 140 to transmit the acquired messages to the monitoring control server 300 (step S102). After transmitting the messages, the gateway device 100 determines whether an abnormality has occurred in the network and the transmission of the messages has failed (step S103).

[0043] If no abnormality occurs in the network and the message transmission is successful (step S103; N), the gateway device 100 returns to step S101 and repeats the processes of steps S101 to S103 until an abnormality occurs in the network and the message transmission fails. On the other hand, if an abnormality occurs in the network and the message transmission fails (step S103; Y), the gateway device 100 stores the message that has failed to be transmitted in the retransmission message storage unit 150 (step S104) and determines whether the network abnormality has been resolved (step S105). If the network abnormality has not been resolved (step S105; N), the gateway device 100 causes the message acquisition unit 110 to acquire the message (step S106) and stores the acquired message in the retransmission message storage unit 150 (step S107).

[0044] After storing the message, the gateway device 100 returns to step S105 and repeats the processes of steps S105 to 107 until the network abnormality is resolved. On the other hand, if the network abnormality is resolved (step S105; Y), The message acquisition unit 110 is caused to transmit messages in the order of decreasing priority determined by the priority determination unit 130, i.e., starting with messages containing signal data with the greatest “number of times used” indicated by the abnormality determination-related data stored in the abnormality determination-related data storage unit 120 (step S108), and the process returns to step S101.

[0045] As described above, according to the monitoring and control system 1 of this embodiment, the gateway device 100 transmits a message including signal data acquired from each of the devices 211-214 arranged in each of the facilities 201, 202 to be monitored, via the network 400 to the monitoring and control server 300 that monitors and controls each of the facilities 201, 202.

[0046] Therefore, the monitoring control server 300 can perform abnormality judgment for each facility 201, 202 based on the signal data of each device 211-214 contained in the message received from the gateway device 100 and the abnormality judgment condition data stored in the abnormality judgment condition data storage unit 320.

[0047] Here, for example, consider a case where the monitoring control server 300 monitors the first facility 201 using, as an example of signal data, the first signal data and the second signal data which are two types of signal data of the first device 211, and the third signal data which is one type of signal data of the second device 212. In this case, assume that the condition for abnormality determination based on the abnormality determination condition equation indicated by the abnormality determination condition data is "the value of the first signal data is 10 or more and the value of the third data is 5 or less," and that the monitoring control server 300 receives messages including each signal data every second from "9:00" to "9:18," as shown in Fig. 7.

[0048] 7, the values ​​of the first signal data and the third signal data used by the monitoring control server 300 to determine whether or not an abnormality has occurred in the first facility 201 are "9" and "14" at "9:08," and "10" and "5" at "9:09." Therefore, the monitoring control server 300 determines that the condition "the value of the first signal data is 10 or more and the value of the third data is 5 or less" is met at "9:09," and can determine that an abnormality has occurred in the first facility 201.

[0049] According to the monitoring and control system 1 of the present embodiment, in the gateway device 100, the message acquisition unit 110 acquires messages including signal data from the devices 211 to 214. The priority determination unit 130 determines the priority of the signal data included in the message acquired by the message acquisition unit 110 based on the abnormality determination related data stored in the abnormality determination related data storage unit 120, i.e., data related to the type of signal data used in the abnormality determination of each facility 201, 202 in the monitoring and control server 300. The message transmission unit 140 transmits the message acquired by the message acquisition unit 110 to the monitoring and control server 300. When an abnormality occurs in the network 400 and then the abnormality is resolved, the message transmission unit transmits to the monitoring and control server 300 a message including signal data with a high priority determined by the priority determination unit 130 in preference to a message with a low priority.

[0050] In this way, the monitoring and control system 1 of this embodiment can reduce the delay in abnormality determination for each piece of equipment 201, 202 when a network abnormality is resolved, compared to conventional monitoring and control systems such as Patent Documents 1 and 2 in which the priority of signal data is not determined based on data regarding the type of signal data used in the monitoring and control server 300 to determine an abnormality for each piece of equipment 201, 202.

[0051] Here, for example, in a conventional monitoring and control system, a monitoring and control server monitors the first facility using the above-mentioned first signal data, second signal data, and third signal data, and the condition for abnormality determination is "the value of the first signal data is 10 or more and the value of the third data is 5 or less." In this case, as shown in Fig. 8, the monitoring and control server receives messages every second from "9:00" to "9:05," and then becomes unable to receive messages due to a network failure for more than five seconds from before "9:06" to before "9:11," and then recovers from the failure and receives messages every second from "9:11" to "9:18." In this case, after the gateway device recovers from the network failure, it resumes sending messages in the order in which they failed to be sent.

[0052] In this case, the message received by the monitoring control server from "9:11" contains signal data delayed by 5 seconds compared to the case where the network failure shown in FIG. 7 does not occur. For example, as shown in FIG. 8, the values ​​of the first signal data and the third signal data used by the monitoring control server to determine an abnormality of the first equipment are "9" and "14" at "9:13" and "10" and "5" at "9:14". Therefore, if the period during which the message could not be received due to the network failure is 5 seconds, the monitoring control server determines that the condition "the value of the first signal data is 10 or more and the value of the third data is 5 or less" is satisfied at "9:14" with a delay of 5 seconds, and determines that an abnormality has occurred in the first equipment. As a result, in the conventional monitoring control system, the period during which the message could not be received due to the network failure is the period during which the abnormality determination of the first equipment is delayed.

[0053] In contrast, in the monitoring and control system 1 according to the present embodiment, after the gateway device 100 recovers from a failure in the network 400, the gateway device 100 resumes transmission of messages including the first signal data and the third signal data used for abnormality determination of the first facility 201, preferentially among the signal data that it failed to transmit. Therefore, the monitoring and control server 300 can quickly receive messages including the first signal data and the third signal data that could not be received due to the failure, by the amount that it did not receive messages including the second signal data from "9:11" to "9:18" when the network was recovered from the failure.

[0054] For example, as shown in FIG. 9, the values ​​of the first signal data and the third signal data used by the monitoring control server 300 to determine an abnormality of the equipment are "10" and "5" at "9:12". Therefore, if the network failure lasts for 5 seconds, the monitoring control server 300 determines that the condition "the value of the first signal data is 10 or more and the value of the third data is 5 or less" is satisfied at "9:12" with a delay of 3 seconds, and determines that an abnormality has occurred in the first equipment 201. Therefore, the monitoring control system 1 according to this embodiment shortens the period until the abnormality determination of the first equipment 201 by 2 seconds compared to the conventional monitoring control system. As a result, the monitoring control system 1 according to this embodiment can reduce the delay in the abnormality determination of each equipment 201, 202 compared to the conventional monitoring control system.

[0055] Furthermore, according to the monitoring and control system 1 of this embodiment, the abnormality determination related data is data indicating the number of times each type of signal data is used in the abnormality determination condition equation used for abnormality determination of each of the facilities 201, 202 in the monitoring and control server 300. Then, the priority determination unit 130 increases the priority of the signal data included in the message acquired by the message acquisition unit 110 as the number of times of use indicated by the abnormality determination related data increases.

[0056] In this way, the monitoring and control system 1 of this embodiment can reduce the delay in determining an abnormality in equipment when a network abnormality is resolved, compared to a monitoring and control system in which the priority of signal data does not increase as the number of times it is used increases as described above.

[0057] Here, in the collection system disclosed in Patent Document 1, the gateway device assigns a time stamp to the data collected by itself at the timing of acquiring the data. For this reason, in the collection system disclosed in Patent Document 1, for example, when there are multiple devices that collect data as in the present embodiment, if a time stamp is assigned to the data every time the data is collected from each device, there is a problem that different time stamps are assigned to data generated by each device at the same timing. As a result, in the system disclosed in Patent Document 1, when there are multiple devices that collect data, the accuracy of time synchronization of the data collected from each device is low, and there is a problem that the monitoring control device does not detect an abnormality in each device or erroneously detects an abnormality.

[0058] In particular, in the collection system disclosed in Patent Document 1, when the gateway device acquires data from each device via a network such as a LAN as in this embodiment, there is a problem that the time error of the time stamps added to the data generated at the same timing by each device increases due to the time lag of the network.As a result, in the system disclosed in Patent Document 1, when the gateway device acquires data from each device via the network, the accuracy of time synchronization of the data collected from each device further decreases, and there is a problem that the monitoring control device fails to detect or erroneously detects anomalies in each device increases.

[0059] In contrast, in the monitoring and control system according to the present embodiment, each of the devices 211-214 assigns a time stamp as date and time data to the generated signal data. In the gateway device 100, the message acquisition unit 110 acquires a message including specific signal data to which a time stamp indicating a specific time has been assigned from each of the devices 211-214 via the LAN 500, and the message transmission unit 140 transmits the message including the specific signal data to the monitoring and control server 300.

[0060] By doing this, in the monitoring and control system 1 of this embodiment, when there are multiple devices 211-214 collecting signal data, the accuracy of time synchronization of the signal data collected from each device 211-214 is higher than in a monitoring and control system that does not add date and time data to the signal data generated by each device, and the monitoring and control server can reduce undetection or erroneous detection of abnormalities in each device 211-214.

[0061] (Example of change) In the above embodiment, the monitoring and control system 1 is a remote monitoring and control system in which the monitoring and control server 300 is provided at a remote location of a production base, but the monitoring and control server 300 does not have to be provided at a remote location, and may be provided at, for example, the production site. In this case, for example, a management device, which is a computer device of a manager provided at a remote location of the production site, may receive data indicating the monitoring results of each of the facilities 201, 202 from the monitoring and control server 300 via the network 400, or transmit data indicating an instruction to control each of the facilities 201, 202 to the monitoring and control server.

[0062] In the above embodiment, the monitoring and control server 300 monitors and controls each of the facilities 201, 202, but this is not limited to this as long as it performs abnormality determination for each of the facilities 201, 202. For example, the monitoring and control server 300 may only monitor each of the facilities 201, 202.

[0063] In the above embodiment, the gateway device 100 is separate from the devices 211-214, but is not limited to this as long as it is capable of acquiring messages including signal data from the devices 211-214. For example, the gateway device 100 may be integrated with the first device 211. Specifically, as shown in FIG. 10, the first device 211 may include the units 110-150 of the gateway device 100 and may be capable of acquiring messages including signal data from the second device 212, the third device 213, and the fourth device 214.

[0064] In the above embodiment, the abnormality determination condition data is data indicating a condition equation for determining whether or not each of the facilities 201, 202 is abnormal, but the data does not have to indicate a condition equation as long as the data indicates a condition for determining whether or not each of the facilities 201, 202 is abnormal. For example, the abnormality determination condition data may be data indicating a condition statement that is a sentence of a condition for determining whether or not each of the facilities 201, 202 is abnormal.

[0065] In the above embodiment, when an abnormality occurs in the network 400, the gateway device 100 stores in the retransmission message storage unit 150 the message that has failed to be transmitted and the unsent message acquired after the abnormality occurs, but this is not limited to the above. For example, the gateway device 100 may store all messages acquired from the devices 211 to 214 regardless of whether an abnormality occurs in the network 400. In this case, when an abnormality occurs in the network 400, the gateway device 100 needs to identify all messages acquired for the purpose of transmission after the abnormality occurs in the network 400, and transmit all the identified messages to the monitoring control server 300 after the abnormality is resolved.

[0066] The gateway device 100, which includes the control unit 51, the main memory unit 52, the external memory unit 53, the transmission / reception unit 56, and the internal bus 50, may be configured to execute the above-mentioned processes by distributing a control program 59 for executing the above-mentioned operations by storing it in a recording medium, such as a flash memory, that can be read by the gateway device 100, and installing the control program 59. The gateway device 100 may also be configured by storing the control program 59 in a storage device of a server device on a communication network such as the LAN 500 or the Internet, and downloading the control program 59 to the gateway device 100.

[0067] Furthermore, when the functions of the gateway device 100 are realized by sharing between an OS (Operating System) and an application program, or by cooperation between the OS and the application program, only the application program portion may be stored in a recording medium or storage device.

[0068] It is also possible to superimpose the control program 59 on a carrier wave and provide it via a communication network. For example, the control program 59 may be posted on a bulletin board (BBS, Bulletin Board System) on the communication network and provided via the communication network. Then, the control program 59 may be started and executed under the control of the OS in the same way as other application programs, thereby executing the above-mentioned processing.

[0069] Various embodiments and modifications of the present disclosure are possible without departing from the broad spirit and scope of the present disclosure. The above-described embodiments are for explaining the present disclosure and do not limit the scope of the present disclosure. In other words, the scope of the present disclosure is indicated by the claims, not the embodiments. Various modifications made within the scope of the claims and within the scope of the disclosure equivalent thereto are considered to be within the scope of the present disclosure. [Explanation of symbols]

[0070] 1...monitoring and control system, 50...internal bus, 51...control unit, 52...main memory unit, 53...external memory unit, 56...transmitting and receiving unit, 59...control program, 100...gateway device, 110...message acquisition unit, 120...abnormality determination related data storage unit, 130...priority determination unit, 140...message transmission unit, 150...resent message storage unit, 200...equipment, 201...first equipment, 202...second equipment, 211...first device, 212...second device, 213...third device, 214...fourth device, 221...signal data generation unit, 222...date and time data assignment unit, 223...signal data storage unit, 224...message output unit, 300...monitoring and control server, 310...message reception unit, 320...abnormality determination condition data storage unit, 330...abnormality determination unit, 400...network, 500...LAN.

Claims

1. A gateway device that transmits signal data acquired from an apparatus installed in a facility to be monitored in a monitoring and control system to a monitoring and control server that monitors the facility via a network, a message acquisition unit that acquires a message including the signal data from the device; a priority determination unit that determines a priority of the signal data included in the message acquired by the message acquisition unit based on abnormality determination related data, which is data related to the type of the signal data used for abnormality determination of the facility in the monitoring and control server; a message transmission unit that transmits the message acquired by the message acquisition unit to the monitoring control server, and when an abnormality occurs in the network and then is resolved, the message including the signal data with the high priority determined by the priority determination unit is transmitted to the monitoring control server in priority to the message including the signal data with the low priority; Function as a the abnormality determination related data is data indicating the number of times each type of the signal data is used in an abnormality determination condition used for an abnormality determination of the equipment in the monitoring control server, the priority determination unit determines a higher priority for the signal data as the number of times of use indicated by the abnormality determination related data increases; Control program.

2. The number of uses is the number of types of the abnormality determination condition that are being used when multiple types of the abnormality determination condition are set. The control program according to claim 1 .

3. the device assigns date and time data to the signal data, the date and time data being data indicating a date and time when the signal data was generated; The message acquisition unit is capable of acquiring the message including specific signal data, which is the signal data to which date and time data indicating a specific date and time is added, from the device; The message sending unit is capable of sending the message including the specific signal data. The control program according to claim 1 or 2.

4. The gateway device and the device are integrated together. The control program according to claim 1 .

5. A monitoring and control system comprising a monitoring and control server that performs monitoring and control of a facility to be monitored via a network, a device installed in the facility, and a gateway device that acquires signal data from the device and transmits the signal data to the monitoring and control server, The gateway device includes: a message acquisition unit that acquires a message including the signal data from the device; an abnormality determination related data storage unit configured to store abnormality determination related data, which is data related to the type of the signal data used for abnormality determination of the equipment in the monitoring control server; a priority determination unit that determines a priority of the signal data included in the message acquired by the message acquisition unit based on the abnormality determination related data stored in the abnormality determination related data storage unit; a message sending unit that sends the message acquired by the message acquiring unit to the monitoring control server, and when an abnormality occurs in the network and then is resolved, the message sending unit sends the message including the signal data with the high priority determined by the priority determining unit to the monitoring control server in preference to the message including the signal data with the low priority; Including, the abnormality determination related data is data indicating the number of times each type of the signal data is used in an abnormality determination condition used for an abnormality determination of the equipment in the monitoring control server, the priority determination unit determines a higher priority for the signal data as the number of times of use indicated by the abnormality determination related data increases; Supervisory control system.

6. A gateway device that transmits signal data acquired from a device installed in a facility to be monitored in a monitoring and control system to a monitoring and control server that monitors the facility via a network, a message acquisition unit that acquires a message including the signal data from the device; an abnormality determination related data storage unit configured to store abnormality determination related data, which is data related to the type of the signal data used for abnormality determination of the equipment in the monitoring control server; a priority determination unit that determines a priority of the signal data included in the message acquired by the message acquisition unit based on the abnormality determination related data stored in the abnormality determination related data storage unit; a message sending unit that sends the message acquired by the message acquiring unit to the monitoring control server, and when an abnormality occurs in the network and then is resolved, the message sending unit sends the message including the signal data with the high priority determined by the priority determining unit to the monitoring control server in preference to the message including the signal data with the low priority; Equipped with the abnormality determination related data is data indicating the number of times each type of the signal data is used in an abnormality determination condition used for an abnormality determination of the equipment in the monitoring control server, the priority determination unit determines a higher priority for the signal data as the number of times of use indicated by the abnormality determination related data increases; Gateway device.

7. A method for controlling a gateway device that transmits signal data acquired from a device installed in a facility to be monitored in a monitoring and control system to a monitoring and control server that monitors the facility, comprising: a message acquisition step in which the gateway device acquires a message including the signal data from the device; a priority determination step in which the gateway device determines a priority of the signal data included in the message acquired in the message acquisition step based on abnormality determination related data, which is data related to the type of the signal data used for abnormality determination of the facility in the monitoring control server; a message transmitting step in which the gateway device transmits the message acquired in the message acquiring step to the monitoring control server; Including, In the message transmission step, when an abnormality occurs in the network and then the abnormality is resolved, the gateway device transmits the message including the signal data having the high priority determined in the priority determination step to the monitoring control server in preference to the message including the signal data having the low priority; the abnormality determination related data is data indicating the number of times each type of the signal data is used in an abnormality determination condition used for an abnormality determination of the equipment in the monitoring control server, In the priority determination step, the gateway device determines a higher priority for the signal data as the number of times of use indicated by the abnormality determination related data increases. Control methods.

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