Section-Based Controller 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 takes a long time, causing delays in analysis feedback and control responses.
Innovation Solution
A controller that divides the analysis period into sections, analyzes section data sequentially, and eliminates subsequent section data analysis 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 are evaluated to determine abnormalities, then measurement precision is improved, but analysis time increases
Solution Approach 1:
The analysis target period is divided into multiple sections, and data is analyzed section by section in chronological order. When an abnormality is detected in one section, the analysis of subsequent sections is eliminated. This segmentation approach maintains abnormality detection accuracy while significantly reducing the time required for complete data evaluation.
Solution Approach 2:
Instead of analyzing all section data completely, the system performs partial analysis by stopping at the first section where an abnormality is detected. This partial action principle allows the system to achieve sufficient measurement precision for abnormality detection without the time cost of evaluating every single data item.
2Productivity
If data analysis is performed with high priority, then analysis speed is improved, but control operation responsiveness deteriorates
Solution Approach 1:
The system performs control operations and data generation with high priority, while analysis is performed with lower priority. The analysis only processes data up to the point where an abnormality is detected, rather than completing full analysis of all sections. This allows control operations to proceed rapidly without being blocked by time-consuming complete data analysis.
Data Source
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 the data 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 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 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.