Control device

Abstract

A control device (100) operates an electrical device (120) constituting a production line of a product and acquires data from a measurement device (130) installed on the production line, the control device comprising: a controller unit (110) that operates the electrical device (120); a computation processing unit (104) that includes a function for calculating a parameter for controlling the electrical device (120) and outputting the parameter to the controller unit (110), a function for computing data acquired from the electrical device (120) and / or the measurement device (130), and a function for acquiring procurement information and / or storage information for raw material for the product; and a storage unit (106) that stores the data acquired from the electrical device (120) and the measurement device (130), and the computation processing results of the computation processing unit (104). The computation processing results are associated with the procurement information and / or the storage information. Due to this configuration, it is possible to appropriately manage the quality of a product when using a raw material that often has variations in characteristics or the like.

Description

control device

[0001] The present disclosure relates to a control device.

[0002] Digital transformation (DX) is also progressing in industries related to the manufacturing of chemicals and pharmaceuticals. In chemical and pharmaceutical manufacturing lines, progress is being made in the development of technologies that can acquire and utilize data during reactions.

[0003] Patent Document 1 discloses a parameter management device for a batch process control system that is applied to a batch plant (such as a food plant) that produces a product from a plurality of raw materials by dispensing a plurality of raw materials required for batch production based on recipe parameters from a plurality of raw material tanks, each storing a single type of raw material. The parameter management device for a batch process control system includes a quality control unit, a batch client unit, and a batch server unit that manages batch control, all of which are related to each other, in order to adjust the recipe parameters according to the quality conditions (such as component ratios) of each raw material each time at least one of the plurality of raw material tanks becomes empty and tank switching becomes necessary. The quality control unit manages the quality conditions based on the results of acceptance inspections of each raw material, and performs predetermined processing such as extracting and outputting the raw material blending ratio that is deemed to be most similar to past production conditions.

[0004] Japanese Patent Application Laid-Open No. 2004-280139

[0005] When using raw materials with variations in physical and chemical properties, such as natural products and waste materials, it is not possible to fully control the properties of the raw materials through incoming inspection alone, which can affect the quality of the product.

[0006] Manufacturers adjust the control conditions of their production equipment to desirable conditions according to the characteristics of the raw materials at the time of receiving inspection, thereby maintaining the quality of their products.

[0007] In Patent Document 1, quality conditions are also managed based on the results of the acceptance inspection of each raw material, and the raw material blending ratio is determined.

[0008] However, because incoming inspection alone does not control all of the characteristics of raw materials that affect product quality, it may not be possible to adequately control product quality simply by adjusting the control conditions of production equipment.

[0009] The purpose of the present disclosure is to appropriately control the quality of products when using raw materials that often have variations in properties, etc.

[0010] The control device disclosed herein operates electrical equipment that constitutes a product production line and acquires data from measuring equipment installed on the production line, and is equipped with a controller unit that operates the electrical equipment, a processing unit that has the function of calculating parameters for controlling the electrical equipment and outputting them to the controller unit, a function of processing data acquired from at least one of the electrical equipment and the measuring equipment, and a function of acquiring at least one of procurement information, which is information required by companies and organizations when procuring goods and services such as the model number, lot, purchase source, purchase date, and purchase quantity of the raw materials that constitute the product, and storage information, which is information required by companies and organizations when storing goods and materials such as the storage location, storage temperature, storage humidity, and storage period, and a memory unit that stores the data acquired from the electrical equipment and the measuring equipment and the processing results of the processing unit, and the processing results are associated with at least one of the procurement information and the storage information.

[0011] According to the present disclosure, when raw materials that often have variations in properties, etc. are used, the quality of the product can be appropriately controlled.

[0012] 1 is a schematic diagram showing a control device according to an embodiment of the present invention;

[0013] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. The examples are illustrative for explaining the present disclosure, and for clarity of explanation, appropriate omissions and simplifications have been made. The present disclosure can also be implemented in various other forms. Unless otherwise specified, each component may be singular or plural.

[0014] To facilitate understanding of the invention, the position, size, shape, range, etc. of each component shown in the drawings may not represent the actual position, size, shape, range, etc. Therefore, the present disclosure is not necessarily limited to the position, size, shape, range, etc. disclosed in the drawings.

[0015] Although various types of information may be described using expressions such as "table," "list," and "queue" as examples, the various types of information may also be expressed using data structures other than these. For example, various types of information such as "XX table," "XX list," and "XX queue" may also be expressed as "XX information." When describing identification information, expressions such as "identification information," "identifier," "name," "ID," and "number" are used, but these are interchangeable.

[0016] When there are multiple components with the same or similar functions, they may be described using the same reference numeral with different subscripts. When there is no need to distinguish between these multiple components, the subscripts may be omitted.

[0017] In the embodiments, processing performed by executing a program may be described. Here, a computer executes the program using a processor (e.g., a CPU or a GPU) and performs processing defined by the program using storage resources (e.g., memory) and interface devices (e.g., communication ports). Therefore, the entity performing the processing by executing the program may be the processor. Similarly, the entity performing the processing by executing the program may be a controller, device, system, computer, or node having a processor. The entity performing the processing by executing the program may be any computing unit, and may include a dedicated circuit that performs specific processing. Here, the dedicated circuit may be, for example, an FPGA (Field Programmable Gate Array), an ASIC (Application Specific Integrated Circuit), a CPLD (Complex Programmable Logic Device), or the like.

[0018] A program may be installed on a computer from a program source. The program source may be, for example, a program distribution server or a computer-readable storage medium. When the program source is a program distribution server, the program distribution server may include a processor and storage resources for storing the program to be distributed, and the processor of the program distribution server may distribute the program to be distributed to other computers. In addition, in the embodiments, two or more programs may be realized as one program, or one program may be realized as two or more programs.

[0019] FIG. 1 is a schematic diagram showing the configuration of a control device according to an embodiment of the present invention.

[0020] In this diagram, the control device 100 includes an input unit 102, an arithmetic processing unit 104, a memory unit 106, a display unit 108, and a controller unit 110 (equipment control unit). The controller unit 110 of the control device 100 is connected to electrical equipment 120 that constitutes a product production line. The controller unit 110 and the electrical equipment 120 are configured to be able to transmit and receive data between them. The electrical equipment 120 transmits process data and the like to the controller unit 110, for example, periodically. The controller unit 110 transmits data for operating the electrical equipment 120 to the electrical equipment 120. The arithmetic processing unit 104 is configured to be able to receive product data and the like from measuring equipment 130 installed on the production line, etc. The arithmetic processing unit 104 is connected to a database 140 that stores data such as raw material procurement information and storage information, and is configured to be able to receive the data and the like from the database 140. The database 140 is installed external to the control device 100.

[0021] The electrical equipment 120 is, for example, a mixer installed in a mixing tank that is part of a production line, a pump used to flow a predetermined liquid, etc., and operates at an appropriate output by controlling the supplied power to achieve the desired production process. The motor rotation speed, power consumption, etc. of the electrical equipment 120 operating in this way are called "process data."

[0022] Furthermore, the measuring device 130 measures, for example, the temperature, viscosity, color, moisture content, and ratio of specific components of an unfinished liquid flowing through a pipe that is part of a production line, or a finished product. Therefore, in this specification, "product data" includes not only the state of a finished product, but also measurement data of an incomplete product (unfinished state).

[0023] The calculation processing unit 104 has the function of calculating parameters for controlling the electrical equipment 120 and outputting them to the controller unit 110, the function of calculating and processing data acquired from at least one of the electrical equipment 120 and the measuring equipment 130, and the function of acquiring at least one of procurement information and storage information for the raw materials of the product.

[0024] The storage unit 106 stores data acquired from the electrical equipment 120 and the measuring equipment 130 and the results of the calculation processing performed by the calculation processing unit 104 .

[0025] The display unit 108 preferably has a display that visually shows predetermined data to the user.

[0026] The connection configuration for transmitting and receiving data shown in this diagram is an example, and may be configured so that process data, etc. of the electrical device 120 is transmitted to the arithmetic processing unit 104 or the storage unit 106. Also, product data, etc. of the measuring device 130 may be transmitted to the storage unit 106. Data in the database 140 may also be transmitted once to the storage unit 106. Note that in this diagram, the database 140 may be installed inside the control device 100 and may be one of the components of the control device 100.

[0027] In the figure, the control device 100 is a single computer, but one or more of the components may be connected to each other so as to be able to communicate with each other via wired or wireless communication and may be distributed. For example, the input unit 102 and the display unit 108 may be provided in a mobile terminal such as a smartphone. When the database 140 is installed outside the control device 100, it is capable of communicating with the components of the control device 100 via wired or wireless communication.

[0028] In summary, the control device 100 operates the electrical devices 120 that make up the product manufacturing line and acquires data from the measuring devices 130 installed on the manufacturing line.

[0029] The controller unit 110 operates the electrical device 120 .

[0030] The calculation processing unit 104 has the function of calculating parameters for controlling the electrical equipment 120 and outputting them to the controller unit 110, the function of calculating and processing data acquired from at least one of the electrical equipment 120 and the measuring equipment 130, and the function of acquiring at least one of procurement information and storage information for the raw materials of the product.

[0031] The storage unit 106 stores data acquired from the electrical equipment 120 and the measuring equipment 130 and the results of the calculation processing performed by the calculation processing unit 104 .

[0032] In this specification, the term "raw materials" may be used. "Raw materials" is a term that includes "raw materials" and "materials." "Raw materials" refers to materials that have lost their original form. On the other hand, "materials" refers to materials that have retained their original form. Chemicals and pharmaceuticals are usually manufactured using chemical reactions, so they often do not retain their original form. For this reason, in this specification, when the term "raw materials" is used, it is also intended to include the meaning of "raw materials."

[0033] Examples of raw materials include natural products and waste materials.

[0034] Examples of natural products include potatoes, which contain a lot of starch and serve as a nutrient source for microorganisms when they are cultured to produce pharmaceuticals, and sugarcane (including its pomace), which contains a lot of sucrose. The components of potatoes and sugarcane may vary depending on the place of production, storage conditions, season, etc.

[0035] Examples of waste materials include used resins, particularly polyethylene, polypropylene, etc. Used resins may differ in origin, manufacturing conditions, molecular weight, amount of impurities, etc.

[0036] 2 is a flow chart showing a control method of the embodiment. In the explanation of this figure, the same reference numerals as in FIG. 1 are also used.

[0037] 2 , a user inputs a quality control standard value of a product through the input unit 102 of the control device 100 (step S20). As a result, the arithmetic processing unit 104 receives data on the quality control standard value of the product from the input unit 102. Note that, in step S20, the product name, product code, etc. selected by the user may be input into the input unit 102, and the quality control standard value of the product may be transmitted from the database 140 or the storage unit 106 to the arithmetic processing unit 104.

[0038] Next, the arithmetic processing unit 104 or the memory unit 106 of the control device 100 receives raw material procurement information, storage information, etc. (step S22). Then, the arithmetic processing unit 104, the memory unit 106, or the controller unit 110 of the control device 100 receives data, etc., from the electrical devices 120 and the measuring devices 130 (step S24).

[0039] Next, the arithmetic processing unit 104 performs arithmetic processing using the acquired data (step S26). The arithmetic processing unit 104 then transmits the results of the arithmetic processing to the database 140. The database 140 stores the results of the arithmetic processing in association with procurement information and storage information (step S28). This allows data regarding the association between data on the production line (in the middle of production) and data on raw materials to be accumulated.

[0040] Next, the arithmetic processing unit 104 determines whether the result of the arithmetic processing satisfies the quality control standard value of the product (step S30).

[0041] If the quality control standard values ​​are met in step S30, the display unit 108 displays that the procurement information and storage information are appropriate for maintaining the quality of the product (step S32). In this case, it can be said that the current raw materials are appropriate.

[0042] If the quality control standard is not met in step S30, the procurement and storage information of the raw materials used in the product that do not meet the quality control standard is displayed on the display unit 108 along with information that the product does not meet the quality control standard (step S34). Return to step S22 and start the series of processes again, starting with obtaining the procurement information, storage information, etc. of the raw materials. In this case, since the current raw materials cannot be said to be appropriate, the user considers changing to other raw materials.

[0043] In this way, by determining the raw materials to be supplied to the production line in accordance with the appropriate raw material proposal, it is possible to manufacture desirable products and easily control the quality of the products. Furthermore, in step S28, by storing the results of the calculation using the data from the electrical equipment 120 and the measuring equipment 130 in association with the procurement information and storage information, it is possible to identify raw materials with short reaction times, for example, and select and procure such raw materials as desirable raw materials. Therefore, when raw materials that often have variations in characteristics, etc. are used, it is possible to appropriately control the quality of the products.

[0044] Furthermore, according to the present disclosure, product data can be obtained by measuring the physical and chemical properties of unfinished liquids, such as those flowing through pipes that are part of a production line, or liquids in the middle of a reaction, and by using this product data, procurement data (procurement information) such as the source of raw materials purchases and storage periods, and raw material management data (storage information), it is possible to present procurement sources, procurement methods, raw material storage methods, etc. that are suitable for maintaining product quality.

[0045] Furthermore, according to the present disclosure, even if it is not possible to obtain all of the data necessary for maintaining product quality, such as inspection items for raw materials, data regarding the relationship between data on the production line (during production) and data on raw materials is accumulated, and therefore, information regarding quality control of raw materials suitable for maintaining product quality can be proposed.

[0046] A preferred embodiment of the control device according to the present disclosure will be described below.

[0047] The input unit inputs a range of specifications regarding at least one of the physical characteristics and chemical characteristics of the product.

[0048] The results of the computation include information on at least one of the physical and chemical characteristics of the product.

[0049] The calculation processing unit associates the result of comparing the range of specifications with the calculation processing result with at least one of the procurement information and the storage information, and transmits the associated result to the storage unit. The storage unit then stores the associated result. The display unit displays the associated result.

[0050] 100: control device, 102: input unit, 104: arithmetic processing unit, 106: memory unit, 108: display unit, 110: controller unit, 120: electrical equipment, 130: measuring equipment, 140: database.

Claims

1. A control device that operates electrical equipment that constitutes a product manufacturing line and acquires data from measuring equipment installed on the manufacturing line, comprising: a controller unit that operates the electrical equipment; an arithmetic processing unit having the functions of calculating parameters for controlling the electrical equipment and outputting them to the controller unit, processing data acquired from at least one of the electrical equipment and the measuring equipment, and acquiring at least one of procurement information and storage information for raw materials for the product; and a memory unit that stores the data acquired from the electrical equipment and the measuring equipment and the arithmetic processing results of the arithmetic processing unit, wherein the arithmetic processing results are associated with at least one of the procurement information and the storage information.

2. A control device as described in claim 1, further comprising an input unit for inputting a range of specifications relating to at least one of the physical characteristics and chemical characteristics of the product, wherein the calculation processing result includes information on at least one of the physical characteristics and chemical characteristics of the product, wherein the calculation processing unit associates the result of comparing the range of the specifications with the calculation processing result with at least one of the procurement information and the storage information, and transmits the associated result to the memory unit, and the memory unit stores the associated result.

3. The control device according to claim 2, further comprising a display unit, wherein said display unit displays said associated results.

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