阅读说明：本技术 工厂设备作业状态分析系统 (Factory equipment operation state analysis system ) 是由 斋藤章太郎 藤枝宏之 于 2017-05-15 设计创作，主要内容包括：工厂设备作业状态分析系统具备与控制网络(10)和监视网络(20)双方连接、并对控制网络数据和监视画面影像数据的双方进行收集的数据收集装置(1)。数据收集装置(1)具备同步处理部(59)和数据显示处理部(60)。同步处理部(59)将包括视频采集器(4)的编码时间在内的监视网络(20)的由传送导致的延迟时间与控制网络数据的收集时刻相加,而使控制网络数据与监视画面影像数据同步。数据显示处理部(60)对通过同步处理部(59)同步了的控制网络数据以及监视画面影像数据进行再现而显示在画面上。(The plant equipment operation state analysis system is provided with a data collection device (1) which is connected to both a control network (10) and a monitoring network (20) and collects both control network data and monitoring screen image data. A data collection device (1) is provided with a synchronization processing unit (59) and a data display processing unit (60). A synchronization processing unit (59) synchronizes the control network data with the monitoring screen image data by adding a delay time caused by transmission of the monitoring network (20) including the encoding time of the video acquisition unit (4) to the collection time of the control network data. A data display processing unit (60) reproduces and displays the control network data and the monitoring screen image data synchronized by the synchronization processing unit (59) on a screen.)

1. A plant operation state analysis system includes:

a control device that controls field devices constituting the plant device;

a control network connected to the control device and transmitting control network data input/output to the control device;

a monitoring device having a monitoring screen on which operation information of the entire plant equipment other than the control network data is displayed;

a video collector connected to the monitoring device and outputting monitoring picture image data obtained by encoding the image displayed on the monitoring picture;

a monitoring network connected with the video collector and used for transmitting the monitoring picture image data; and

a data collection device connected to both the control network and the monitoring network and collecting both the control network data and the monitoring screen image data,

the data collection device includes:

a synchronization processing unit that adds a delay time due to transmission of the monitoring network including the encoding time of the video acquisition unit to a collection time of the control network data to synchronize the control network data with the monitoring screen image data; and

and a data display processing unit that reproduces and displays the control network data and the monitor screen image data synchronized by the synchronization processing unit on a screen.

2. The plant operational state analysis system of claim 1,

and a network camera connected to the monitoring network for taking an image of the appearance of the field device and outputting field device image data,

the synchronization processing unit synchronizes the control network data, the monitoring screen image data, and the field device image data,

the data display processing unit reproduces and displays the control network data, the monitoring screen image data, and the field device image data synchronized by the synchronization processing unit on the screen.

3. The plant operation state analysis system according to claim 1 or 2,

the data collection device further includes a still image capture processing unit that captures a video currently reproduced on the screen to create a still image.

4. A plant operation state analysis system includes:

a control device that controls field devices constituting the plant device;

a control network connected to the control device and transmitting control network data input/output to the control device;

a monitoring device having a monitoring screen on which operation information of the entire plant equipment other than the control network data is displayed;

a video acquisition unit connected to the monitoring device, for outputting monitoring screen image data obtained by encoding an image displayed on the monitoring screen, with an input time at which the image is input;

a monitoring network connected with the video collector and used for transmitting the monitoring picture image data; and

a data collection device connected to both the control network and the monitoring network and collecting both the control network data and the monitoring screen image data,

the data collection device includes:

a synchronization processing unit that associates two pieces of data, the collection time of which coincides with the input time added to the monitoring screen image data, with each other, and synchronizes the control network data with the monitoring screen image data; and

and a data display processing unit that reproduces and displays the control network data and the monitor screen image data synchronized by the synchronization processing unit on a screen.

5. The plant operational state analysis system of claim 4,

and a network camera connected to the monitoring network for taking an image of the appearance of the field device and outputting field device image data,

the synchronization processing unit synchronizes the control network data, the monitoring screen image data, and the field device image data,

the data display processing unit reproduces and displays the control network data, the monitoring screen image data, and the field device image data synchronized by the synchronization processing unit on the screen.

6. The plant operation state analysis system according to claim 4 or 5,

the data collection device further includes a still image capture processing unit that captures a video currently reproduced on the screen to create a still image.

Technical Field

The present invention relates to a plant operation state analysis system.

Background

A plant includes field devices (including actuators and sensors) constituting the plant, and a Programmable Logic Controller (PLC) for controlling the field devices. The control PLC is input with feedback signals from the field devices and outputs control signals that control the field devices. The field device operates in response to the control signal. The input/output signals (control network data) of the control PLC are collected by the data collection device.

The operating state of the field device and the operating state of the mechanical device including the field device may be photographed by a camera. For example, patent document 1 discloses a plant facility monitoring system including a monitoring camera for capturing an operating state of a machine facility, and capable of storing video information from the monitoring camera.

The monitoring of the entire plant of the plant equipment is performed by the monitoring device. The operation state of the plant equipment, such as the position information of the material, the operation state of the operator, the machine information such as the machine speed and the position, is displayed in a concentrated manner on the monitoring screen of the monitoring device. The operator performs the work by monitoring the screen information of the apparatus and visually observing and confirming the screen information.

Disclosure of Invention

Problems to be solved by the invention

However, the monitoring network to which the monitoring device is connected is different from the control network to which the field devices, the control PLC, and the data collection device are connected. Therefore, in the conventional data collection device, the control network data can be collected, but screen information of the monitoring device cannot be collected. Therefore, when analyzing the abnormality factor in the data collection device, it is necessary to determine the operation state of the plant equipment, such as the position information of the material, the operation state of the operator, the machine speed, and the machine information such as the position, etc., based on the control network data. When an abnormality occurs, the necessary control network data is checked by the hand of a person, and therefore, there is a possibility that accurate information cannot be obtained and the work of analyzing the abnormality factor takes a long time.

In addition, in the conventional data collection device, even when video data obtained by photographing the operating state of the machine equipment by the camera is collected, the mechanical operation in a range not photographed by the camera cannot be confirmed by an image. Therefore, the recording state of the information when the abnormality occurs or when the machine is adjusted cannot be said to be sufficient.

The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a plant operation state analysis system that can support analysis of an operation state of a plant in a data collection device by synchronously displaying control network data and screen information of a monitoring device.

Means for solving the problems

In order to achieve the above object, a plant operation state analysis system according to an embodiment of the present invention is configured as follows.

The plant operation state analysis system is provided with at least a control device, a control network, a monitoring device, a video acquisition (video capture) device, a monitoring network, and a data collection device.

The control device controls field devices constituting the plant equipment. The field device includes an actuator, a sensor. The control device is, for example, a control PLC.

The control network is connected to the control device and transmits control network data input/output to/from the control device. The control network data comprises feedback signals output by the field devices and control signals output by the control device.

The monitoring device has a monitoring screen, and displays operation information of the entire plant equipment other than the control network data on the monitoring screen. The operation information includes information related to the operation of the plant equipment, such as machine information including an operation state, a machine speed, and a position of the operator.

The video acquisition unit is connected to the monitoring device and outputs monitoring screen image data in which an image displayed on a monitoring screen is encoded.

The monitoring network is connected with the video collector and transmits the image data of the monitoring picture.

The data collection device is connected to both the control network and the monitoring network, and collects both the control network data and the monitoring screen image data. The data collection device is provided with a synchronization processing unit and a data display processing unit.

The synchronization processing unit adds a delay time caused by transmission of the monitoring network including the encoding time of the video acquisition unit to the collection time of the control network data, thereby synchronizing the control network data with the monitoring screen image data.

The data display processing unit reproduces and displays the control network data and the monitor screen video data synchronized by the synchronization processing unit on the screen.

Preferably, the plant equipment operation state analysis system further includes a network camera. The network camera is connected to a monitoring network, and photographs the appearance of the field device to output field device image data. The synchronization processing unit synchronizes the control network data, the monitoring screen image data, and the field device image data. The data display processing unit reproduces and displays the control network data, the monitoring screen video data, and the field device video data synchronized by the synchronization processing unit on the screen.

Further, the plant equipment operation state analysis system according to another embodiment of the present invention includes, instead of the video acquisition unit, a video acquisition unit that adds, to the monitoring screen image data obtained by encoding the image displayed on the monitoring screen, the input time at which the image is input, and outputs the image data. In addition, instead of the synchronization processing unit, a synchronization processing unit is provided that associates two pieces of data in which the collection time of the control network data matches the input time added to the monitoring screen video data, and synchronizes the control network data with the monitoring screen video data.

ADVANTAGEOUS EFFECTS OF INVENTION

According to the embodiment of the present invention, in the data collection device, it is possible to reproduce the control network data related to the control of the field devices constituting the plant equipment and the monitoring screen image data including the operation information of the entire plant equipment other than the control network data in synchronization with each other. The data collection device can assist in analyzing the operating state of the plant. In the data collection device, since the operation state of the plant equipment is easily grasped, the speed of analyzing the abnormality factor is increased, and the recovery time when the abnormality occurs can be shortened. By shortening the recovery time, it is possible to reduce the cost of labor cost and increase the production volume for trouble processing.

Drawings

Fig. 1 is a system configuration diagram of a plant operation state analysis system according to embodiment 1 of the present invention.

Fig. 2 is a configuration diagram of a data confirmation screen of the data collection device.

Fig. 3 is a block diagram showing an example of a hardware configuration of a processing circuit included in the data collection device.

Fig. 4 is a functional block diagram of a data collection device.

Fig. 5 is a functional block diagram of a data reproduction processing unit of the data collection device.

Fig. 6 is a functional block diagram of a still image processing section of the data collection device.

Fig. 7 is a system configuration diagram of a plant operation state analysis system according to embodiment 2 of the present invention.

Fig. 8 is a functional block diagram of a data collection device according to embodiment 2 of the present invention.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, the same reference numerals are given to the common elements in the drawings, and redundant description is omitted.