阅读说明：本技术 生产设备在线维护系统及其方法 (Production equipment on-line maintenance system and method thereof ) 是由 川濑辉雄 桥本靖博 于 2018-02-13 设计创作，主要内容包括：提供一种生产设备在线维护系统,其以使用者的数据积累器分成通常的装置管理信息及高紧急性的紧急信息,紧急信息立即传送邮件,以此缩短维护时间。本发明的生产设备在线维护系统的特征是,具有：使用者生产线及维护装置；该使用者生产线包含：连接于网络的网关、连接于该网关的生产设备及数据积累器；该维护装置包含：连接于网络的网关伺服器、及连接于该网关伺服器的伺服器及诊断装置；数据积累器具有：积累生产设备运转数据的数据积累部、及判断所积累的运转数据紧急性的数据判断部；如判断运转数据含有异常数据,有紧急性,则传送紧急信息邮件,如判断无紧急性,则将运转数据进行批处理后,传送到伺服器。(An on-line maintenance system for production facilities is provided, which divides the data accumulator of a user into normal device management information and urgent information of high urgency and immediately transmits mail to the urgent information, thereby shortening the maintenance time. The production equipment on-line maintenance system of the invention is characterized by comprising: user production line and maintenance device; the user production line includes: a gateway connected to a network, a production facility connected to the gateway, and a data accumulator; the maintenance device includes: a gateway server connected to a network, and a server and a diagnostic device connected to the gateway server; the data accumulator has: a data accumulating part for accumulating the operation data of the production equipment and a data judging part for judging the urgency of the accumulated operation data; if the operation data contains abnormal data and has urgency, the emergency information mail is transmitted, and if the operation data does not have urgency, the operation data is transmitted to the server after being processed in batch.)

1. An on-line maintenance system for production equipment, which has a user production line and a maintenance device connected via a network,

The user production line includes: a gateway connected to the network, production equipment connected to the gateway, and a data accumulator;

The maintenance device includes: a gateway server connected to the network, a server connected to the gateway server, and a diagnostic device having an abnormality recovery means;

The data accumulator has: a data accumulating part for accumulating the operation data of the production equipment and a data judging part for judging the urgency of the accumulated operation data;

When the data judging part judges that the operation data contains abnormal data and has urgency, the emergency information mail is transmitted to a mail server of the server, and when the data judging part judges that the operation data does not have urgency, the operation data is transmitted to the server after being batched;

The server includes: the mail server transmits the received emergency information mail to the diagnosis device, the support terminal and the user terminal, and the database stores the operation data which are processed in batch and the diagnosis result diagnosed by the diagnosis device according to the operation data;

The diagnostic device is provided with: an emergency processing unit and a data diagnosis unit; the emergency processing part obtains the operation data of the emergency information mail from the production equipment when receiving the emergency information mail, diagnoses, judges whether the abnormality can be repaired if the abnormality is confirmed, transmits the information for repairing to the production equipment if the abnormality can be repaired automatically, continues to obtain the operation data of the production equipment, transmits a repair completion notification mail to the support terminal and the user terminal when the repair is confirmed and the operation data is recovered normally, and transmits an unrepairable notification mail to the support terminal and the user terminal if the automatic repair is not possible; the data diagnosis unit obtains the operation data from the database of the server, diagnoses the production equipment, and outputs the diagnosis result to be stored in the database of the server.

2. The production facility on-line maintenance system of claim 1, wherein:

The support terminal has a remote control unit, and if the remote control unit receives an unrepairable notification mail, the support terminal accesses the control unit of the production facility in which the abnormality occurs, and remotely controls the diagnosis and repair of the control information.

3. The production facility on-line maintenance system of claim 1, wherein:

the operation data includes at least one of operation information indicating an operation state of the production equipment, consumption information indicating a degree of consumption of parts, abnormality information indicating an abnormality of the production equipment, and sign information indicating a sign of a failure of the production equipment;

If the operation data includes consumption information, the diagnostic device includes predicted life information in the diagnostic result based on the consumption information and reference information of the corresponding component.

4. An online maintenance method for a production facility, comprising:

An accumulation stage, wherein the operation data of the production equipment is accumulated through a data accumulator connected with the production equipment of a user; and

a judging stage, judging the urgency of the production equipment operation data according to the content of the production equipment operation data through a data accumulator;

If the operation data is judged to be urgent, the method further comprises:

a transmission stage of a data accumulator, wherein the data accumulator transmits an emergency information mail to a mail server provided in a server of a maintenance device connected via a network;

A transmission stage of mail server, in which the mail server transmits the received emergency information mail to the diagnosis device, the support terminal and the user terminal, and the diagnosis device has a means for repairing the abnormality;

An acquisition step in which the diagnostic device receiving the emergency mail acquires operation data relating to the emergency mail from the user production facility; and

a judging stage, diagnosing the obtained operation data, if the abnormality is confirmed, judging whether the abnormality can be repaired;

if it is judged that the repair is possible, the method further includes:

In the repairing stage, information used for repairing is transmitted to the production equipment for repairing; and

A repair completion notification mail transmission stage, continuously acquiring the operation data of the production equipment, and transmitting the repair completion notification mail to the support terminal and the user terminal when the repair completion is confirmed and the operation data is recovered to normal;

If it is judged that the repair is impossible, further having a transmission stage of the irreparable notification mail, transmitting the irreparable notification mail to the support terminal and the user terminal;

If the operation data is judged to be not urgent, the method further comprises

The data accumulator sends the operation data to the servo after batch processing.

Technical Field

The present invention relates to an on-line maintenance system and method for production equipment, and more particularly, to an on-line maintenance system and method for production equipment, which divides a data accumulator of a user into general device management information and highly urgent emergency information, immediately transmits the emergency information to a maintenance device and a related terminal by mail, and automatically repairs the information in response to the emergency information to shorten maintenance time.

Background

in a production facility and a production line that continuously process a large number of products, when an abnormality occurs to cause the production facility to malfunction, the products being processed may become defective products, and a large number of defective products may be produced if the defective products cannot be repaired. If the production line is stopped due to an abnormality, a large number of defective products resulting from the line stop are discarded, the production amount of products is reduced due to the line stop, and if food products or the like having a short period of time from the production to the sale are out of stock, the sales opportunity is lost, the credit is lowered due to the out of stock, and the loss becomes enormous. At the same time, manufacturers are forced to over-manufacture products in order not to lose credit due to out-of-stock. If the food with short shelf life cannot be made in advance, the excessive products have to be discarded, and the resource waste is caused.

When the device is completely in the abnormal condition, the manager of the production line can easily detect and process the abnormal condition, but if the abnormal condition is intermittent, the internal abnormality of the production equipment, the fault invisible to the naked eye and the like, the manager of the production line is not easy to detect sometimes, and a large amount of unqualified products can be manufactured unconsciously. At the same time, the goods may be shipped directly to the market without being perceived as bad. In the food field in particular, consumers are increasingly conscious of food safety and are therefore significant risks to manufacturers that are not negligible.

Therefore, in such a production facility and a production line, it is very important to perform a very detailed maintenance in accordance with the status of the production facility to prevent the occurrence of an abnormality, to detect the occurrence of an abnormality immediately, to notify the relevant person of the abnormality, and to perform a repair in a short time.

In maintenance of production facilities, a lot of ordinary and simple maintenance is performed by a manager of a user factory operating the production facilities, but in maintenance of regular maintenance and replacement of main parts, it is common to perform processing from a manufacturer of the production facilities or a maintenance person of a maintenance company to the user factory. However, depending on the use of the production facility, the consumption of parts may be more severe than assumed at the time of design, and parts may have problems before the periodic maintenance period. In order to prevent this, it is important to monitor the condition of the parts in an actual operating state at a short cycle.

In addition, when an abnormality occurs, it is necessary to notify the occurrence of the abnormality to a person including a manager of the user plant at the first time. After learning the abnormal situation, the manager of the user factory is busy taking measures against the abnormality of the production equipment before hand, and then, the manager often contacts the relevant person later.

In this case, there are proposed a method of storing management information of production facilities in a cloud by using online, and making relevant persons share information, a system of collecting data such as operation states of various machines, monitoring a target machine by using a communication network such as the internet, and detecting and notifying an abnormality.

patent document 1 discloses a facility monitoring system in which data collected from each device is transmitted to a monitoring service center via a data collection device using a communication line network, the monitoring service center analyzes conditions registered for each device by an analysis device, transmits the conditions as network information, and notifies a reporter when an abnormality is detected.

Patent document 2 discloses: a remote maintenance system for receiving operation data of a maintenance target device of a customer via a communication network, predicting and notifying the remaining life of the component, and comprising: the remaining life results are received and displayed, and part information is displayed to provide the necessity of judging the parts to be stocked.

In these techniques, a monitoring device receives data of a device to be monitored via a communication network, determines the data, and transmits information on the determination result. Therefore, until the abnormality notification is transmitted, a time lag occurs, and there is a possibility that a defective product at the time lag may have been produced.

A system is required which can monitor the condition of parts in an actual operating state at a short period of time, prevent an abnormality from occurring, and immediately notify a person of the abnormality when the abnormality occurs.

Disclosure of Invention

Technical problem to be solved by the invention

The present invention has been made in view of the above problems occurring in the conventional production facility online maintenance system, and it is an object of the present invention to provide a production facility online maintenance system and a method thereof, which divide general device management information and highly urgent information into a data accumulator, immediately transmit the urgent information to a maintenance device and a related person terminal by mail, notify the occurrence of an abnormality, and automatically repair a repairable abnormality, thereby shortening the maintenance time.

Means for solving the problems

in order to achieve the above object, the on-line maintenance system for a production facility of the present invention comprises: an on-line maintenance system for a user production line and a production facility of a maintenance apparatus connected via a network, characterized in that the user production line comprises: a gateway connected to the network, production equipment connected to the gateway, and a data accumulator; the maintenance device includes: a gateway server connected to the network, a server connected to the gateway server, and a diagnostic device having an abnormality recovery means; the data accumulator has: a data accumulating unit for accumulating operation data of the production equipment and a data judging unit for judging the urgency of the accumulated operation data; when the data judging part judges that the operation data contains abnormal data and has urgency, the emergency information mail is transmitted to a mail server of the server, and when the data judging part judges that the data does not have urgency, the operation data is transmitted to the server after being processed in batch, and the server comprises: the mail server and a database; the mail server transmits the received emergency message mail to the diagnosis device, the support terminal, and the user terminal, the database stores the operation data of the batch processing and the diagnosis result diagnosed by the diagnosis device based on the operation data, the diagnosis device has: an emergency processing unit and a data diagnosis unit; the emergency processing part acquires the operation data of the emergency information mail from the production equipment as long as the emergency information mail is received, diagnoses, judges whether the abnormality can be repaired if the abnormality is confirmed, transmits the information for repairing to the production equipment if the abnormality can be repaired automatically, continues to acquire the operation data of the production equipment, transmits a repair completion notification mail to the support terminal and the user terminal when the repair is confirmed and the operation data is recovered normally, and transmits an unrepairable notification mail to the support terminal and the user terminal if the automatic repair is judged not possible; the data diagnosis part obtains the operation data from the database of the server, diagnoses the production equipment, and outputs the diagnosis result to be stored in the database of the server.

The support terminal preferably has a remote control unit, and if the remote control unit receives an unrepairable notification mail, the remote control unit accesses the production facility control unit in which the abnormality occurs, and diagnoses and repairs the remote operation control information.

Preferably, the operation data includes at least one of operation information indicating an operation state of the production equipment, consumption information indicating a degree of consumption of the parts, abnormality information indicating an abnormality of the production equipment, and warning information indicating a warning of a failure of the production equipment, and if the operation data includes the consumption information, the diagnostic device makes the diagnostic result include the predicted life information based on the consumption information and reference information of the corresponding parts.

In order to achieve the above object, an on-line maintenance method for a production facility according to the present invention includes: an accumulation stage, in which the operation data of the production equipment is accumulated by a data accumulator connected with the production equipment of a user; and a judging stage, judging the urgency of the production equipment operation data according to the content of the production equipment operation data through the data accumulator; if the operation data is judged to be urgent, the method further comprises: a transmission stage of a data accumulator, wherein the data accumulator transmits an emergency information mail to a mail server provided in a server of a maintenance device connected via a network; a transmission stage of mail server, in which the mail server transmits the received emergency information mail to the diagnosis device, the support terminal and the user terminal, and the diagnosis device has a means for repairing the abnormality;

An acquisition step in which the diagnostic device receiving the emergency mail acquires operation data relating to the emergency mail from the user production facility; and a judging stage, diagnosing the obtained operation data, if the abnormality is confirmed, judging whether the abnormality can be repaired; if it is judged that the repair is possible, the method further includes: in the repairing stage, information used for repairing is transmitted to the production equipment for repairing; and a transmission stage of a repair completion notification mail, continuously acquiring the operation data of the production equipment, and transmitting the repair completion notification mail to the support terminal and the user terminal when the repair completion is confirmed and the operation data is recovered to normal; if it is judged that the repair is impossible, further having a transmission stage of the irreparable notification mail, transmitting the irreparable notification mail to the support terminal and the user terminal; if the operation data is judged not to be urgent, the data accumulator is further provided with a stage of processing the operation data in batch and transmitting the processed operation data to the server.

effects of the invention [ 0001 ]

The on-line maintenance system of the production equipment transmits the normal management information containing the data with low urgency to the server in the operation data of the production equipment, and immediately transmits the emergency information containing the data with high urgency to the diagnosis device and the terminal of the related personnel by mail, thereby enabling the related personnel to know the occurrence of the abnormality at the fastest speed and rapidly responding to the abnormality.

In addition, the online maintenance system for manufacturing equipment according to the present invention is characterized in that the diagnostic device for receiving the urgent mail diagnoses the content of the abnormality and determines the coping method, and if the abnormality is repairable, the repair information is directly transmitted to the manufacturing equipment to repair the abnormality, and if the abnormality is unrepairable, the information that cannot be automatically repaired is further notified to the relevant person terminal.

Further, according to the online maintenance system for a production facility of the present invention, since the predicted life information is output based on the operation data of the production facility, even when the parts are consumed faster than the assumed life according to the usage state of the production facility, the maintenance timing can be appropriately notified, and the effect of avoiding the occurrence of the abnormality can be achieved.

drawings

Fig. 1 is a block diagram schematically showing the configuration of an on-line maintenance system for a production facility according to an embodiment of the present invention.

Fig. 2 is an information flow chart for explaining the emergency time of the online maintenance system for production equipment according to the embodiment of the present invention.

Fig. 3 is a flow chart illustrating information of the production facility online maintenance system according to the embodiment of the present invention in a general case.

Fig. 4 is a flowchart for explaining the processing flow of the data accumulator according to the embodiment of the present invention.

Fig. 5 is a flowchart for explaining the processing flow of the diagnostic device according to the embodiment of the present invention.

Fig. 6 is a flowchart for explaining a process flow of supporting remote control of a terminal according to an embodiment of the present invention.

Detailed Description

Specific examples of the manner in which the production facility on-line maintenance system of the present invention is implemented will be described in detail below with reference to the accompanying drawings.

Fig. 1 is a block diagram schematically showing the configuration of an on-line maintenance system for a production facility according to an embodiment of the present invention.

Referring to fig. 1, a production facility online maintenance system 1 according to an embodiment of the present invention includes: a maintenance device 100, a user production line 200, a support terminal 300, and a user terminal 400 connected via a network 50. The maintenance device 100 includes: a gateway server 110 connected to the network 50, a server 120 connected to the gateway server 110, and a diagnostic device 130. In addition, the user production line 200 includes: a gateway 210 connected to the network 50, a data accumulator 220 connected to the gateway 210, and a production facility 230.

The production facility online maintenance system 1 is a maintenance system as follows: the operation data of the production equipment on the user production line is accumulated in the data accumulator, the operation data includes abnormal data, if the data accumulator 220 judges that the operation data is urgent, an emergency information mail is transmitted to the user terminal 400 of the user managing the production line and the support terminal 300 of the personnel responsible for the maintenance of the production equipment, the occurrence of the abnormal data is informed, the emergency information mail is also transmitted to the diagnosis device, initial response is required, the diagnosis device obtains the operation data of the production equipment and diagnoses, the diagnosis device can correct the abnormal data, the information for correcting the abnormal data is transmitted to the production equipment, the abnormal data is corrected, if the abnormal data is not corrected, the unrepairable information mail is transmitted to the support terminal 300 and the user terminal 400, the necessity of the early response is informed, and the maintenance is performed reliably and rapidly. Further, the production facility online maintenance system 1 is a maintenance system as follows: even if the diagnostic device is not able to repair the abnormality, the support terminal 300 has a device for diagnosing/repairing the production facility by remote operation, and therefore, high-level repair can be performed on line, and quick repair can be realized.

In addition, in the maintenance system, since the operation data in the data accumulator is transmitted to the database of the server of the maintenance device and stored, and then the operation data is diagnosed by the diagnosis device, and stored in the database in a readable manner as a diagnosis result including the necessity of maintenance, the maintenance time can be clearly known, and information for properly performing maintenance to prevent an abnormality can be thoroughly notified to the relevant person.

Referring to fig. 1, the user production line 200 serving as a source is described in order. The gateway 210 is an entrance device connected to the external network 50, and connects a device communicably connected in the user line 200 to the external network 50 using a protocol such as a TCP/IP protocol. The network 50 is a wide area network such as the internet.

the data accumulator 220 and the production facility 230 are connected to the gateway 210, and are configured to be able to communicate with the maintenance apparatus 100 via the gateway 210 and the external network 50. The gateway 210, the data accumulator 220, and the production equipment 230 may be connected via a local area network, or may be connected via universal serial communication or the like.

The production facility 230 can have various configurations for manufacturing products, but includes, in addition to a control unit for controlling itself: an input/output unit for communicating with another device; a storage unit for storing a program for controlling the production apparatus 230, received data from the outside, and the like; (ii) a A display unit for displaying the information. In addition, the production facility 230 has a data acquisition section including a sensor for acquiring operation data showing an operation state.

in the case of a production facility having, for example, a motor and an electromagnetic valve, the operation data includes the number of operations, the cumulative operation time, and the like, and in the case of a production facility having combustion, the operation data includes data on parameters that have a significant influence on the operation of the production facility, such as the pressure of the supplied gas and the output of the gas detection alarm device. In addition, such data may also be included: even if the stop position accuracy, vibration state, and the like of the movable portion do not immediately cause a failure, the monitoring is performed for a long time, and maintenance is required at a time point when the critical value is exceeded.

The data accumulator 220 has: a data accumulation unit and a data determination unit; the data accumulating part is connected to the production facility 230 in a communication manner, and acquires and stores operation data from the data acquiring part of the production facility 230; the data judging section judges whether or not the operation data is abnormal based on the data stored in the data accumulating section based on a preset judgment criterion.

in fig. 1, although one data accumulator 220 and one production facility 230 are shown in the user production line 200, the production facility 230 may have a plurality of production facilities, and if there are a plurality of production facilities 230, the data accumulator 220 may be provided for each production facility 230, or the operation data from the plurality of production facilities 230 may be collected and accumulated in one data accumulator 220. At this time, the data accumulation unit stores the operation data so as to be able to identify which production equipment 230 has acquired the operation data. Further, if the operation data of the production facility 230 includes a plurality of sensors and a plurality of different items, the data accumulation unit stores the acquired operation data so as to identify which item or data from which sensor is. These identifications may also be accompanied by, for example, an identifiable header (ヘ ッ ダ) to each operational datum. In addition, the time for acquiring the operation data may be added and stored so that the history of the operation data can be grasped.

The data accumulation unit may acquire the operation data from the production facility 230 in real time or at predetermined intervals. In addition, the acquisition timing may be changed according to the items of the operation data. The data may be acquired in association with the event at a time point when the main power supply of the production facility 230 is turned on, a time point when the movable portion of the processing product starts operating, or the like.

The operation data of the production equipment 230 acquired by the data accumulating unit can be classified into: the information includes at least one of operation information showing an operation state of the production equipment, consumption information showing a degree of consumption of the parts, abnormality information showing an abnormality of the production equipment, and sign information showing a sign of a failure of the production equipment. If the production facility 230 includes parts having a design life of x hours, the time during which the production facility operates normally is one type of operation information, and the accumulated operation time y is calculated by monitoring the operation information. The difference between the accumulated operating time y and the design life x is the remaining time until the part reaches the replacement time, that is, the predicted life information, and therefore the accumulated operating time y is consumption information of the design life x. Similarly, for a component such as an electromagnetic valve whose life is determined according to the number of operations, the number of operations is monitored for the number of operations X times the design life, and the cumulative number of operations Y is obtained, whereby the consumption information can be obtained.

the components that determine the lifetime are installed in the production facility on the assumption of standard use conditions, but the replacement timing thereof varies depending on the operating conditions of the production facility, and therefore, the matching cannot be obtained. In general, a production line is provided with a large number of production facilities, and each production facility has a large number of parts, and therefore it is not easy to accurately grasp the replacement timing of each part. Therefore, monitoring the operation status of the production equipment by means of the data accumulator is a very effective means from the viewpoint of prevention and security against abnormalities.

The warning information in the operation data is not the replacement timing as in the consumption information, but is data in which some kind of failure may occur regardless of the situation, like the trend-managed data. For example, a situation where the stop position of a certain part of the movable portion gradually deviates from a little by little or the vibration of the rotating part becomes large during the long-term use. Such prognostic information, while not immediately causing a failure, must be maintained at the appropriate time. The prognostic information is continuously monitored, thereby helping to prevent imperceptible faults from occurring.

The data determination unit analyzes the operation data received and stored by the data accumulation unit, that is, the accumulated operation data, and then determines the urgency. The urgency is judged by whether or not a preset important item that may cause the line stop reaches a preset condition. A gas detection alarm device used for a combustion furnace for food production or the like determines whether or not a signal for detecting gas leakage is generated. In addition, if the pressure of the supplied air is outputted from a sensor for detecting the pressure of the supplied air, the urgency is determined by whether the pressure exceeds a predetermined threshold value.

If the data judging section judges that the operation data contains abnormal data and the emergency is present, an emergency mail notifying the occurrence of the abnormality is transmitted to a mail server provided in the server 120 of the maintenance apparatus 100. The destination of the emergency mail includes at least: the diagnostic device 130 of the maintenance device 100, the support terminal 300 of the maintenance person in charge of the maintenance, and the user terminal 400 of the manager of the user factory who manages the production facility 230 in which the abnormality occurs.

On the other hand, if the data determination unit determines that the operation data does not include the abnormal data and is not urgent, the operation data is batch-processed and then transmitted to the server 120 of the maintenance device 100.

the gateway server 110 of the maintenance apparatus 100 is an entrance apparatus on the maintenance apparatus 100 side to which the external network 50 is connected, and connects an apparatus communicably connected in the maintenance apparatus 100 to the external network 50 using a protocol like the gateway 210.

Here, although an environment in which transmission and reception are possible can be configured while, for example, a VPN is set between the gateway server 110 and the gateway 210 and high security is ensured, in one embodiment, a communication method for ensuring security may be provided in accordance with a protocol such as TLS1.0 by an encryption method such as AES256 without using a VPN.

The server 120 includes: mail server and database; the mail server receives the urgent message mail from the data accumulator 220 and transmits the urgent message mail to the diagnostic device 130, the support terminal 300, and the user terminal 400; the database stores the batch run data received from the data accumulator 220.

Although fig. 1 shows one user line 200 connected, there may be a plurality of user lines 200. The mail server receives the emergency mail from each user production line 200 and then transmits the received emergency mail to the destination of each emergency mail. Therefore, even if a user production line 200 connected to the maintenance apparatus 100 is newly added, the mail server can be dealt with by the mail server included in the server 120 of the maintenance apparatus 100.

The database stores the operation data from each user production line 200 and each data accumulator 220 in a differentiated manner so that the history can be grasped in accordance with the production facilities and items. The database also stores the diagnostic results of the operating conditions of the production equipment diagnosed by the diagnostic device for each production equipment.

The server 120 provides these pieces of information in a viewable state when there is a request to view the operation data and the diagnosis result stored in the database. For example, the support terminal 300 and the user terminal 400 are provided with a my page (my page) for each terminal at the time of initial registration with the server 120, and data required for the my page of the terminal is displayed for the terminal which has requested viewing.

The diagnostic device 130 includes: an emergency processing unit and a data diagnosis unit; the emergency processing part is used for handling when the emergency information mail is transmitted; the data diagnosis unit diagnoses the operation state of the production facility 230 based on the operation data when it is determined that there is no urgency.

The emergency processing unit receives the emergency mail, acquires operation data on the emergency mail from the production equipment 230, diagnoses the received operation data, determines whether the received operation data is repairable or not if the received operation data is abnormal, transmits information for repair to the production equipment 230 if the received operation data is repairable, and transmits an unrepairable notification mail to the support terminal machine 300 and the user terminal machine 400 if the received operation data is unrepairable.

When receiving the emergency mail from the data storage 220, the emergency processing unit directly accesses the production facility 230 to acquire the operation information without passing through the data storage 220. The emergency processing unit has the same judgment standard as the data accumulator 220 for the operation data, diagnoses the operation data acquired from the production equipment 230, and checks the contents of the abnormality. The emergency processing unit further includes a processing means for handling an abnormality assumed in advance, and determines whether or not the confirmed abnormality can be repaired by associating the abnormality with a spare processing means. As a result, if it is judged that the abnormality is repairable, the abnormality is repaired by the abnormality processing means. The processing means may be information such as a program for instructing reset, automatic alignment, or the like of the movable portion of the production equipment 230, or a command given to a part to be an abnormal object. The emergency processing section transmits information for repair to the production apparatus 230, thereby repairing the abnormality.

the emergency processing unit may continue to acquire the operation data of the production equipment 230, and transmit a repair completion notification mail to the support terminal device 300 and the user terminal device 400 as long as the repair completion is confirmed and the operation data is restored to normal. The abnormality information and the repair information for the abnormality can also be stored as a maintenance record, which contributes to the improvement of the accuracy of detection for the abnormality and the improvement of the repair means. If the maintenance records are accumulated, the automatic repair system is matched with AI and the like, so that the automatic repair accuracy can be improved, and the repair range can be enlarged.

The data diagnosis unit obtains the operation data of the production equipment 230 transmitted from the data accumulation unit 220 and stored in the database, diagnoses the production equipment 230, and outputs the diagnosis results of the operation state of the production equipment, the assumed maintenance timing, and the like. The operation data of the production equipment 230 diagnosed by the data diagnosing section mainly includes operation information, consumption information, and prognostic information.

The data diagnosis unit stores the design life information of the diagnosed component as reference information, and if the operation data includes consumption information, the data diagnosis unit can predict the replacement timing corresponding to the life prediction information based on the consumption information and the reference information of the corresponding component and the elapsed time of the consumption information, and therefore the diagnosis result may include the assumed replacement timing information.

The data diagnosis unit may store a threshold value of a monitoring item for the diagnosed component, and may include a next maintenance timing in the diagnosis result on the basis of the warning information. For example, a threshold value of a stop position of a certain component of the movable part is stored in advance, a deviation trend of the stop position of the component is grasped based on a change of the warning information with time, and a time when the threshold value is exceeded is assumed to be included in the diagnosis result as a next maintenance time, whereby appropriate maintenance time information can be provided to a maintenance worker.

The diagnostic device 130 may periodically count the diagnostic result and the abnormal repair record, and transmit the report to the support terminal 300 and the user terminal 400. In particular, as a result of the diagnosis, when it is necessary to maintain an assumed period early, a mail indicating maintenance and a report may be transmitted each time.

Further, the support terminal 300 includes: an input/output unit for receiving the emergency mail and a display unit for displaying the contents thereof. Further, the remote control unit is provided, and upon receiving an unrepairable notification mail from the diagnostic device 130, the remote control unit accesses the control unit of the production facility in which the abnormality has occurred, and remotely controls the diagnosis and repair of the control information.

The remote control unit stores or adds a processing means for inputting more advanced processing means and a processing means for customizing the processing according to the abnormal condition, in addition to a processing means for assuming the abnormality in advance which the diagnosis apparatus 130 has, and repairs the abnormality of the production equipment 230. For example: searching the feedback value when the control parameter is changed, transmitting the optimal control parameter, adding a batch processing program for modification to the control program, and then transmitting.

Remote control content supporting the terminal and its results may also be transmitted to the server 120 for storage as part of the maintenance record.

The support terminal 300 can be constructed by installing a remote control device in a personal computer having an input/output unit and a display unit, and the remote control device can remotely control the production facility 230.

The user terminal 400 includes: an input/output unit for receiving the emergency information mail and a display unit for displaying the content thereof. In addition, if necessary, a request for viewing the diagnosis result of the diagnosis apparatus 130 is transmitted to the server 120, and the diagnosis result is received and displayed.

The user terminal 400 can be implemented by a personal computer, and can also be implemented by various information processing apparatuses having an input/output device for browsing a web page and transmitting/receiving a mail, such as a tablet terminal and a smart phone.

Fig. 2 is an information flow chart for explaining the emergency real-time operation of the online maintenance system for manufacturing equipment according to the embodiment of the present invention.

FIG. 2 is a diagram showing the flow of information caused by events occurring in the production facility online maintenance system 1 by broken lines F-1 to F-8.

As the production facility 230 operates, various operation data indicating the operation state are acquired by a data acquisition unit such as a sensor and a counter included in the production facility 230, and then output to the data accumulator 220 (dotted line F-1). The operation data can be outputted in real time when the data accumulator 220 is connected to the production apparatuses 230 in 1 to 1, but if a plurality of production apparatuses 230 are connected to one data accumulator 220, a queue insertion request is transmitted from the production apparatuses 230 or polling is applied from the data accumulator 220 to avoid collision of the transmitted operation data.

When the operation data stored in the data accumulating unit contains abnormal data and it is judged that there is urgency, the data judging unit transmits an urgent message mail notifying that abnormality has occurred to the server 120 via the external network 50 (dotted line F-2). At this time, the data determination unit specifies the final destination of the emergency mail and transmits the emergency mail according to a destination list preset for each production facility.

The mail server of the server 120 transmits the received emergency information mail to the designated destination (dotted line F-3). The destination of the emergency message mail includes at least: a diagnostic device 130, a support terminal 300, and a user terminal 400. The emergency mail transmitted to the support terminal 300 and the user terminal 400 is intended to immediately notify the manager of the user factory managing the production facility 230 and the maintenance person in charge of maintenance of the occurrence of an abnormality, but the emergency mail transmitted to the diagnostic device 130 has a meaning of a request signal requesting repair in order to recognize the occurrence of an abnormality in the diagnostic device 130.

Upon receiving the emergency mail, the emergency processing unit of the diagnostic device 130 directly accesses the production facility 230 corresponding to the emergency mail via the external network 50 (dotted line F-4) and acquires operation data relating to the emergency mail (dotted line F-5).

Then, the emergency processing unit diagnoses the acquired operation data, and if an abnormality is confirmed, refers to a processing means for an abnormality assumed in advance, and determines whether or not the confirmed abnormality can be repaired. As a result, if it is judged that the abnormality is repairable, information for repair is transmitted to the production apparatus 230, whereby the abnormality is repaired (dotted line F-6-1). When the emergency processing unit performs the automatic repair as described above, the emergency processing unit may further acquire the operation data of the production facility 230 after the repair as in the information flow shown by the broken lines F-4 and F-5 and check that the abnormality has been repaired. The emergency processing unit may transmit a repair completion notification mail to the support terminal 300 and the user terminal 400 via the mail server (broken line F-6-2) of the server 120 (broken line F-7).

If the emergency processing unit determines that the abnormality is repairable or not, the emergency processing unit transmits an unrepairable notification mail to the support terminal 300 and the user terminal 400 via the mail server (broken line F-6-2) of the server 120 (broken line F-7).

Upon receiving the unrepairable notification mail, the remote control unit of the support terminal 300 directly accesses the production facility 230 via the external network 50 to repair the abnormality (broken line F-8). In fig. 2, the broken line F-8 is indicated by a single-direction arrow from the support terminal 300 to the production equipment 230, but if necessary, the data may be sent and received several times because the data is repaired while feedback values are checked for the status of the production equipment 230.

Fig. 3 is a flow chart for explaining information in a normal state of the production facility online maintenance system according to the embodiment of the present invention.

Referring to fig. 3, the production facility 230 outputs the operation data acquired by the data acquisition unit to the data accumulator 220 as it is operated (dotted line F-1). The data storage unit of the data storage 220 receives the operation data output from the production facility 230 and stores the operation data so that items of the production facility and the operation data can be identified. The data determining part of the data accumulator 220 determines urgency based on whether there is an abnormality in the stored operation data, and if it is determined that there is no urgency, the operation data is transmitted to the server 120 via the external network after being batch-processed (dotted line F-2)

The server 120 stores the received operational data in a database. At this time, since there is no urgency, the support terminal 300 and the user terminal 400 are not transmitted with a notification mail.

The diagnostic device 130 obtains the stored operation data (broken line F-3) from the database of the server 120 at a predetermined timing, and diagnoses the operation state of the production equipment 230. The diagnostic results are transmitted to the server 120 (dotted line F-4) and stored in the database in such a manner that the diagnostic results can identify which item of which production equipment is.

The stored diagnosis results can be read from the support terminal 300 and the user terminal 400, and the diagnosis results of the database can be displayed and confirmed by specifying the production facility and the operation data items.

As a result of the diagnosis, the diagnosis device 130 may transmit a mail instructing or notifying the maintenance to the support terminal 300 and the user terminal 400 via the mail server of the server 120, although not shown in fig. 3, depending on the operation state of the production facility, the next necessary maintenance time may be included, for example, when the maintenance time is faster than the initially assumed maintenance time or the maintenance is necessary recently.

fig. 4 is a flowchart for explaining the processing flow of the data accumulator according to the embodiment of the present invention.

In step S410, the data accumulation unit of the data accumulator 220 accumulates operation data of the production equipment 230. When there are a plurality of production facilities 230 connected to the data accumulator 220, the data accumulator stores the operation data so as to be able to identify from which device the operation data has been acquired. Further, one production facility 230 may have a plurality of sensors, counters, and other data acquisition units, and when the operation data includes a plurality of items of data from the plurality of sensors, counters, and other data, the data accumulation unit may store the operation data so as to identify which item of data is.

In step S420, the data determination unit of the data storage 220 analyzes the stored operation data and determines the urgency. The urgency is determined by whether or not a predetermined condition is reached, such as whether or not a certain item in the operation data exceeds a threshold value, in accordance with a determination condition set in advance for each item.

The data judging part judges that the operation data contains abnormal data, and if the operation data has urgency, the data judging part transmits an urgent message mail. The emergency mail is a mail for notifying the user of the occurrence of an abnormality in the production line 200, and the destination of the emergency mail includes at least: a diagnostic device 130, a support terminal 300, and a user terminal 400. If there are a plurality of support terminals 300 and user terminals 400, depending on the production facility or component, the data determination unit refers to the destination list and transmits an emergency mail to the corresponding destination according to the production facility or component in which an abnormality has occurred. Specifically, the urgent mail is transmitted from the data judging section to the mail server of the server 120 in step S430, and then transmitted from the mail server to each destination designated by the data judging section in step S440.

the emergency mail is not only operation data including abnormality data, but also needs emergency processing to notify which production line, which production facility, and which item are abnormal. In one embodiment, the server 120 may obtain detailed information of the abnormality from the data storage 220 and display the information on the my page of the maintenance staff and the user, in addition to the transmission of the emergency mail, only as a notification of the occurrence of the abnormality and only as a fixed sentence for prompting to view the my page "

On the other hand, if it is determined at step S420 that there is no urgency, the data determination unit performs batch processing of the operation data at step S450, and transmits the batch processed operation data to the server 120 so as to be stored in the database at step S460.

Fig. 5 is a flowchart for explaining the processing flow of the diagnostic device according to the embodiment of the present invention.

Referring to fig. 5, the diagnosis device 130 confirms whether the emergency information mail is received at stage S510.

Upon receiving the emergency mail, the emergency processing unit of the diagnosis device 130 immediately accesses the production facility 230 corresponding to the emergency mail (step S515) and acquires the operation data (step S520).

the diagnostic device 130 diagnoses the abnormality with the same criterion as the data accumulator 220, diagnoses the operation data of the production equipment 230, and then checks the abnormality (step S525).

Next, the diagnostic device 130 determines whether the confirmed abnormality is repairable by a repair means provided in the diagnostic device itself (step S530). The diagnostic device 130 estimates that, when the information for repair such as a correction program and a specific reset signal is transmitted to the production equipment so that the information for repair can be repaired, the abnormality items with high importance among the abnormalities assumed in advance for the production equipment, the information for repair and the abnormality items are stored in advance as the repair means. If the diagnosis result confirms that the abnormality is found, the diagnosis device 130 inquires a repair means corresponding to the confirmed abnormality, and if the corresponding repair means is found, transmits information for repair to the production equipment 230 to repair the abnormality (stage S535)

After the diagnostic device 130 transmits the information for repair, it continues to acquire the operation data from the production equipment 230 and repair it at step S540, thereby making it possible to cancel the previously confirmed abnormality and confirm that the operation status of the production equipment 230 is restored to normal. When the operation state of the production equipment 230 is recovered to normal, the diagnostic device 130 transmits a repair completion mail notifying that the repair is automatically completed to the support terminal 300 and the user terminal 400.

Returning to step S530, if the diagnostic device 130 determines that the abnormality should be dealt with urgently, the diagnostic device 130 sends an unrepairable mail to the support terminal 300 and the user terminal 400, as a result of determining whether the abnormality should be dealt with by the diagnostic device itself having a repair means and if the diagnostic device 130 determines that the abnormality should not be repaired.

In contrast, if the emergency mail is not received at step S510, the diagnosing apparatus 130 determines whether it is a diagnosis implementation period at step S560. If the emergency mail is not transmitted, the operation data transmitted after the batch processing by the data accumulator 220 does not need the emergency processing, and therefore, the diagnosis may be performed at a predetermined timing. The predetermined timing may be set to a time interval of once/hour and once/day, and the operation data newly stored in the database of the server 120 may be stored after the capacity exceeds a predetermined amount, and the operation data transferred by the batch processing in the data accumulator 220 may be stored in the database.

If the storage capacity of the operation data and the timing of storing the operation data in the database are used as the trigger for performing the diagnosis, the operation data is outputted from the server 120 to the diagnosis device 130, and the signal for notifying the diagnosis timing is outputted to prompt the diagnosis, and the determination of the stage S560 may be configured to determine whether the signal for notifying the diagnosis timing is received. In the case of the diagnosis non-execution time, the process returns to step S560 to stand by the urgent message mail or the signal for notifying the timing of executing the diagnosis.

If it is determined in step S560 that the diagnosis is to be performed, the diagnostic device acquires operation data for diagnosis from the database of the server 120. The operation data is acquired in accordance with the setting of the diagnosis timing, and if the diagnosis is made once/day, the operation data for 1 day is acquired, and when the diagnosis is made for a predetermined capacity stored in the database, the operation data for the capacity is acquired.

In step S565, the diagnostic device 130 diagnoses the acquired operation data. The diagnosis is to obtain life prediction information from consumption information of each component included in the operation data and reference information as design life information of each component, and to include the information in the diagnosis result. The next maintenance timing is assumed based on the prognostic information included in the operation data and the threshold value of the monitoring item, and is included in the diagnosis result.

The diagnostic result is outputted to be stored in the database of the server 120 at stage S575. In this way, since the diagnostic results are stored in the database so as to be viewable from the support terminal 300 and the user terminal 400, the maintenance staff can confirm the next maintenance timing at any time, and the line manager in the user factory can grasp the correct operation state of the production equipment 230.

In the diagnosis in the stage S570, if the life prediction information is faster than the first assumption and the next maintenance period based on the prognostic information is closer, the replacement parts may need to be prepared according to the situation, and the maintenance personnel must know the information in advance to prepare for maintenance.

Therefore, in step S580, the diagnostic device 130 determines whether maintenance is necessary, that is, whether maintenance is necessary in the recent period, and if maintenance is necessary, in step S585, transmits maintenance information indicating maintenance to the support terminal 300 and the user terminal 400 by mail.

fig. 6 is a flowchart for explaining a remote control processing flow of the support terminal according to the embodiment of the present invention.

Referring to fig. 6, when the support terminal 300 receives the unrepairable mail from the maintenance apparatus 100 at step S610, the remote control unit of the support terminal 300 immediately accesses the production facility 230 corresponding to the unrepairable mail (step S615), and acquires the operation data (step S620).

The support terminal 300 diagnoses the acquired operation data of the production equipment 230 and checks for an abnormality (step S625).

next, in step S630, the support terminal 300 transmits the repair information stored in the production equipment 230 of the support terminal or the repair information newly input from the input/output unit of the support terminal 300 to the production equipment 230 to repair it.

In order to confirm whether the repair is normally performed, the support terminal 300 acquires the operation data after the repair of the production equipment 230, confirms the repair (step S635), and transmits a repair completion mail to the user terminal 400 if the repair is normally performed.

As described above, according to the processing flow of the data accumulator 220, the diagnostic device 130, and the support terminal 300 shown in fig. 4 to 6, when it is determined that an emergency processing is necessary due to an abnormality in the operation data accumulated in the place near the production facility 230, an emergency mail is immediately transmitted to notify the maintenance staff and the line manager in the user factory of the occurrence of the abnormality and to request the diagnostic device to repair the abnormality, and if the repair is possible, the line abnormality can be repaired automatically, so that the line abnormality can be repaired in the shortest time. In addition, even if the automatic repair is impossible by the diagnosis device, the information can be notified to the support terminal, and the advanced repair can be performed at a remote distance from the support terminal.

Although not shown in fig. 5, the diagnosis device 130 may report the abnormality occurrence status and the repair status together and transmit the report to the support terminal 300 and the user terminal 400, or store the report in a database of the server 120 so that the support terminal 300 and the user terminal 400 can view the report, when the abnormality occurs, or during a predetermined period such as 1 month or half year.

The embodiments of the present invention have been described in detail with reference to the drawings, but the present invention is not limited to the embodiments described above, and various modifications can be made without departing from the technical scope of the present invention.

Description of the reference numerals

1 production equipment on-line maintenance system

50 network

100 maintenance device

110 gateway server

120 server

130 diagnostic device

200 user production line

210 gateway

220 data accumulator

230 production equipment

300 support terminal

400 user terminal.