Controller Section Analysis for Faster Abnormality Detection
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Solution Overview
Problem
Comparing data collected within a predetermined period with determination indexes in factory automation systems is time-consuming, leading to delays in analyzing and feeding back results.
Innovation Solution
A controller that divides the analysis period into sections, analyzes section data sequentially, and eliminates further analysis for subsequent sections once a predefined result is detected, allowing for prioritization of control operations and data generation over analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If all data items within a predetermined period are evaluated to determine abnormalities, then measurement precision is improved, but analysis time increases
Solution Approach 1:
The analysis period is divided into multiple sections, and data is analyzed section by section rather than evaluating all data items at once. This segmentation allows the system to detect abnormalities in earlier sections and eliminate the need to analyze subsequent sections, thereby reducing total analysis time while maintaining detection accuracy through systematic evaluation of divided segments
Solution Approach 2:
When a predefined result (abnormality detection) is obtained in an earlier section, the analysis of subsequent sections is eliminated or extracted from the processing queue. This selective elimination removes unnecessary computation steps while preserving the precision of abnormality detection through thorough analysis of relevant sections
2Reliability
If data analysis is performed thoroughly within a predetermined period, then reliability of control feedback is improved, but productivity of control operations decreases
Solution Approach 1:
The analysis process dynamically adjusts its scope based on findings from earlier sections. When abnormalities are detected in preliminary sections, the system dynamically eliminates the need to analyze subsequent sections, making the analysis process adaptive and efficient while maintaining reliable feedback through thorough evaluation of critical sections
Solution Approach 2:
The system performs preliminary analysis on early sections of data first, allowing abnormality detection to occur before completing full data collection. This preliminary action approach enables early termination of analysis when abnormalities are found, improving control operation speed while maintaining feedback reliability through systematic preliminary evaluation
Data Source
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AI summary
A controller includes a control operation unit that cyclically performs a control operation for controlling a control target, a data generator that generates data showing a chronological change in a value associated with a control target, and an analyzer that analyzes data generated by the data generator and outputs an analysis result in a predetermined analysis target period. The analysis target period includes a plurality of sections. The data generator sequentially outputs section data showing a chronological change in a value for each of the plurality of sections included in the analysis target period. The analyzer analyzes the sequentially output section data for each section. When an analysis of section data for a section included in the analysis target period shows a predefined result, the analyzer eliminates an analysis of section data for one or more sections in the analysis target period that are subsequent to the section for which the analysis shows the predefined result.