PLC Operation Record Analysis Using Configuration and Connection Data
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Solution Overview
Problem
Existing programmable logic controllers (PLCs) face challenges in efficiently analyzing large volumes of data to identify abnormal devices and require specialized knowledge for effective trouble analysis and quality control, making it time-consuming to accumulate and analyze data from all devices.
Innovation Solution
An analysis apparatus and method that utilizes PLC-specific information beyond device and variable data, including unit configuration, connection, and communication settings, to efficiently analyze operation records and generate analysis reports, highlighting abnormal symbols, and provide analysis results without requiring extensive expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data of all devices related to the PLC is recorded, then complete analysis information is obtained, but the data volume becomes enormous and analysis becomes time-consuming
Solution Approach 1:
The patent extracts only the necessary PLC-specific information (unit configuration, connection, communication settings) from the complete device data, separating essential analysis elements from redundant information. This extraction approach maintains analysis completeness while significantly reducing data volume for processing.
Solution Approach 2:
The patent segments PLC information into distinct categories (unit configuration, connection, communication settings) and processes them separately through specific analysis units. This segmentation enables efficient handling of different data types and reduces the complexity of analyzing enormous complete device data.
2Measurement precision
If specialized knowledge and experience are used to identify abnormal devices, then accurate trouble analysis is achieved, but the process requires extensive expertise and is not easily scalable
Solution Approach 1:
The patent implements self-service through automated analysis units that independently perform their specific analysis functions without requiring external expert intervention. The abnormal symbol analysis unit, PLC information analysis unit, and determination unit work autonomously to identify abnormal devices, replacing the need for specialized human knowledge while maintaining identification accuracy.
Solution Approach 2:
The patent introduces an intermediary automated analysis system that mediates between raw PLC data and expert judgment. This intermediary process translates complex PLC information into structured analysis results, eliminating the need for experts to directly interpret enormous device data while preserving accurate abnormal device identification.
3Device complexity
If only device and variable data from the basic unit is used, then the analysis scope is limited, but the analysis process is simpler
Solution Approach 1:
The patent applies multi-functionality by creating analysis units that can process multiple types of PLC information (unit configuration, connection, communication settings) through a unified automated analysis framework. This universal approach maintains process simplicity while significantly deepening analysis capability beyond basic device and variable data.
Data Source
AI summary
The present invention aims to efficiently perform analysis from enormous data by utilizing information other than a device and a variable held by a basic unit. In addition, another object thereof is to extract and report important data from an analysis result of the enormous data. An analysis apparatus includes: a storage section that stores PLC information different from a symbol value among pieces of information associated with a programmable logic controller; an execution engine that repeatedly executes a user program; an acquisition section that acquires operation record data including a plurality of time-series symbol values, the operation record data being collected by execution of the user program; and a processing section that outputs an analysis report obtained by analyzing an abnormal symbol that does not satisfy a normal condition regarding the acquired operation record data based on the PLC information stored in the storage section.