JP2023031000A - Programmable controller, control method, and program - Google Patents

Abstract

To realize a multivariate analysis by a programmable controller without affecting application program processing.SOLUTION: A programmable controller may comprise an execution unit that executes a task of an application program within a first period of one cycle and executes a task other than the application program within a second period of the one cycle. The execution unit may execute an input process to receive an input of time-series data for indicating a state of a diagnosis target within a first period, and may execute at least part of an accumulation process for accumulating the time-series data received by the input process in a storage unit, and a diagnosis process for diagnosing the state of the diagnosis target based on the accumulation process and the time-series data accumulated in the storage unit in the accumulation process within the second period.SELECTED DRAWING: Figure 5

Description

The present invention relates to programmable controllers, control methods and programs.

Patent Literature 1 discloses a scheduling method in which a user can customize the ratio of allocating one execution cycle time to a ladder application and data processing in a programmable controller. Patent Literature 2 and Patent Literature 3 describe a method of applying multivariate analysis technology to a series of processes called batch processing in a programmable controller.
[Prior art documents]
[Patent Literature]
[Patent Document 1] Japanese Patent No. 4811260 [Patent Document 2] Japanese Patent No. 4911055 [Patent Document 3] Japanese Patent No. 6733164

It is desired to realize multivariate analysis with a programmable controller without affecting the processing of application programs.

A programmable controller according to one aspect of the present invention includes an execution unit that executes a task of an application program within a first period of one cycle and executes a task other than the application program within a second period of one cycle. good. The execution unit executes an input process for accepting an input of time-series data indicating a state of a diagnostic target within the first period, and accumulates the time-series data accepted by the input process in the storage unit during the second period. Accumulation processing and at least a part of diagnosis processing for diagnosing the state of a diagnosis target based on the time-series data accumulated in the storage unit in the accumulation processing may be executed.

The execution unit may perform a single diagnosis of the condition to be diagnosed over multiple cycles by performing the accumulation process and the diagnosis process within the second period of each cycle over multiple cycles. .

When a predetermined amount of time-series data is accumulated in the storage unit by the accumulation process, the diagnosis process includes pre-processing of converting the predetermined amount of time-series data into a data format for diagnosis; Analysis processing for executing multivariate analysis processing based on the time-series data processed in , and determination processing for determining whether or not the state of the diagnosis target is normal based on the analysis result of the analysis processing.

Within the second period, the execution unit may execute generation processing for generating a diagnostic model to be used in the analysis processing based on time-series data indicating that the state of the diagnosis target is normal among the time-series data. .

The execution unit may perform update processing for updating the diagnostic model used in the analysis process with the diagnostic model generated by the generation process while the analysis process is not being performed within the second period.

The execution unit may execute the update processing before starting the preprocessing.

The execution unit may execute control processing for the controlled device related to the diagnosis target within the first period, and the diagnosis processing may include notification processing for notifying the control processing of the determination result of the determination processing.

The accumulation process and diagnostic process may consist of at least one function block.

The programmable controller may further include a reception unit that receives information specifying the respective ratios of the first period and the second period occupied within one cycle. The execution unit may adjust the lengths of the first period and the second period based on the information.

The diagnosis process may include an output process of outputting a message to that effect if one diagnosis of the state to be diagnosed cannot be completed within a predetermined number of cycles.

The execution unit may adjust the lengths of the first period and the second period according to the message so that the proportion of the second period within one cycle increases.

Tasks other than the application program may include data communication processing tasks with a management device that manages the programmable controller.

A control method according to an aspect of the present invention may be a control method for controlling a programmable controller. The control method may comprise executing a task of an application program within a first period of time within a cycle and executing a task other than the application program within a second period of time within a cycle. The execution step may include executing an input process for receiving input of time-series data indicating the state of the diagnostic target within the first period. The execution stage includes, within the second period, an accumulation process for accumulating the time-series data received by the input process in the storage unit, and diagnosing the state of the diagnosis target based on the time-series data accumulated in the storage unit in the accumulation process. performing at least a portion of the diagnostic process.

A program according to one aspect of the present invention may be a program for causing a computer to function as a programmable controller. The program may cause the computer to perform an execution phase of executing tasks of the application program within a first period of time within a cycle and executing tasks other than the application program within a second period of time within a cycle. The execution step may include executing an input process for receiving input of time-series data indicating the state of the diagnostic target within the first period. The execution stage includes, within the second period, an accumulation process for accumulating the time-series data received by the input process in the storage unit, and diagnosing the state of the diagnosis target based on the time-series data accumulated in the storage unit in the accumulation process. performing at least a portion of the diagnostic process.

It should be noted that the above summary of the invention does not list all the features of the invention. Subcombinations of these feature groups can also be inventions.

It is a figure which shows an example of a structure of the system to which a programmable controller is applied. 3 is a diagram showing an example of a schematic hardware configuration of a CPU module; FIG. It is a figure which shows an example of the software structure of a programmable controller. It is a figure for demonstrating the task processing in a programmable controller. FIG. 4 is a diagnostic flowchart of multivariate analysis processing applied to a programmable controller; FIG. 4 is a flow diagram of diagnostic model generation; It is a figure which shows an example of a hardware configuration.

Hereinafter, the present invention will be described through embodiments of the invention, but the following embodiments do not limit the invention according to the claims. Also, not all combinations of features described in the embodiments are essential for the solution of the invention.

FIG. 1 shows an example configuration of a system 10 to which a programmable controller is applied. System 10 may be used in industrial facilities such as factories or plants. System 10 may be used as at least part of factory automation. Programmable controllers control production lines and machine tools in industrial facilities.

The system 10 includes a CPU module 100 , a function module 200 , an I/O module 300 , a management device 400 , a controlled device 250 and a controlled device 350 . The CPU module 100 performs arithmetic processing for controlling the controlled device 250 and the controlled device 350 . The functional module 200 has a function of performing predetermined specific processing. The functional module 200 has, for example, functions such as a servo amplifier or an inverter for controlling actuators such as motors. The I/O module 300 inputs and outputs data to and from the CPU module 100 . The management device 400 supports the setting of the CPU module 100 and the like. The CPU module 100, function module 200, and I/O module 300 are programmable controllers having different functions.

The management device 400 may be configured as software on a general personal computer. The management device 400 may be a device dedicated to managing programmable controllers. Here, for the sake of convenience, a personal computer that manages software is also referred to as a management device 400 . The management device 400 and the CPU module 100 are connected using a communication cable such as RS-232C or USB.

The CPU module 100, the function module 200, and the I/O module 300 are network-connected to each other, and perform input/output data transfer and message communication with each other.

The controlled device 250 and the controlled device 350 are devices to be controlled. Controlled device 250 and controlled device 350 may be, for example, industrial machines. The controlled device 250 and the controlled device 350 may be motors, encoders, pumps, valves, cameras, various sensors, and the like.

The CPU module 100, function module 200 and I/O module 300 can be freely selected according to the scale or configuration of the system that the user wants to control. The user uses the management device 400 to set the configuration of the system and set the operation of each module. The user also uses the management device 400 to create a control application program using a ladder diagram or the like, and downloads the created application program to the CPU module 100 .

FIG. 2 shows an example of the hardware configuration of the CPU module 100. As shown in FIG. CPU module 100 includes CPU 102 , driver/receiver 104 , bus controller 106 , flash memory 108 , program memory 110 and data memory 112 . The driver/receiver 104 may be RS422, USB or the like for connecting with the management device 400 . Bus controller 106 is connected to the network and controls communications between functional modules 200 and I/O modules 300 . The flash memory 108 stores a program for system processing of the CPU module 100 (system management of the CPU module 100, communication processing, failure information collection, etc.) and an application program for control. Program memory 110 is a memory for booting and executing programs from flash memory 108 in order for CPU 102 to execute system processing and application programs faster. Data memory 112 stores data used by the program. The CPU 102 uses programs in the program memory 110 and data in the data memory 112 to perform various calculations. CPU 102 is an example of an execution unit. Data memory 112 is an example of a storage unit.

The hardware configuration shown in FIG. 2 merely schematically shows part of the functions of the CPU module 100, and is not limited to this configuration. The CPU module 100 may further include, for example, a power supply circuit, a reset circuit, an interface with a removable external storage device, and the like. Moreover, when the system 10 includes a plurality of CPU modules 100, all the CPU modules 100 do not have to have the hardware configuration shown in FIG. For example, program memory 110 may be faster SDRAM, or RAM may be built into CPU 102 .

The CPU module 100 configured as described above collects input data from the function module 200 and the I/O module 300 via the network in a constant cycle (scan cycle). The CPU module 100 executes a control application program based on input data, and outputs output data based on the execution result of the application program to the function module 200 and the I/O module 300 via the network.

Here, in order to precisely control the controlled device 250 and the controlled device 350 connected to the functional module 200 and the I/O module 300, the above-described input/output processing via the network is performed accurately, at high speed, and constantly. It is desirable to be performed in a cycle of

A programmable controller usually gives top priority to the execution of a control application program. Therefore, other processes are generally executed in the remaining time after the execution of the application program is finished during one execution cycle.

In recent years, in the field of factory automation (FA), there is a need to apply multivariate analysis technology to programmable controllers for early detection of defects in processed products and abnormalities in equipment. The application program of the programmable controller needs to control the controlled device 250 and the controlled device 350 at high speed and in a constant cycle. On the other hand, when multivariate analysis technology is applied to programmable controllers, multivariate analysis generates a diagnostic model from normal input patterns, gives input data to this diagnostic model, and executes advanced matrix operations. do. Compared to application programs, multivariate analysis requires a large amount of computing time for processing before obtaining diagnostic results. In addition, in multivariate analysis, the time to the diagnosis result may not be decided with certainty because recursive calculation is performed to obtain the analysis result. Therefore, when diagnostic processing based on multivariate analysis is implemented in a control application program, the processing cycle of the application program may fluctuate greatly.

Therefore, in the embodiment, the diagnosis function by multivariate analysis is divided into a plurality of functions (accumulation processing 608, preprocessing 612, analysis processing 614, determination processing 616, and notification processing 618) as shown in FIG. disassemble. Among the functions decomposed in this manner, data input for accumulation processing 608 is executed by an application program, and time-consuming processing such as preprocessing 612, analysis processing 614, and determination processing 616 is performed by data processing described later. to By decomposing the diagnostic function in this way, it becomes possible to realize the multivariate analysis function in the programmable controller while limiting the influence on the processing cycle of the application program to about the input data copy time.

FIG. 3 shows an example of the software structure of the programmable controller. Real-time OS 160 runs on hardware 162 . The real-time OS 160 calls the bandwidth management layer 158 as one processing system, in which the application scheduler 156 and data processing 152 are called. Bandwidth management layer 158 sets the time allocated to application scheduler 156 and data processor 152 in one execution cycle in accordance with user-specified parameters. The application scheduler 156 processes the user application program 150 according to the execution time ratio set by the bandwidth management layer 158, and the data processing 152 uses the remaining time. In data processing 152, multivariate analysis processing is executed along with data communication processing, data transfer processing, failure data collection processing, and the like. This allows the user to specify the time allocation between the application program and the multivariate analysis processing during one execution cycle. The basic system 154 also includes processes belonging to processes for operating the system as a programmable controller, such as initial processes and system maintenance processes. When processing belonging to the basic system 154 is performed after starting the application operation, the basic system 154 is operated within the bandwidth of the data processing 152 .

The user changes the time allocation ratio of the band management layer 158 from the management device 400 . The time allocation ratio is a parameter that specifies how the execution cycle time allocated to the bandwidth management layer 158 in one execution cycle time is allocated between the application scheduler 156 and the data processing 152 . The user considers the overall execution cycle time, the execution time of the user application program 150 and the execution time of the data processing 152, and sets the time allocation ratio suitable for the system.

FIG. 4 is a diagram for explaining task processing scheduling in a programmable controller. The programmable controller has a CPU 102 corresponding to an execution unit. The vertical axis indicates task priority, and the horizontal axis indicates elapsed time. One execution cycle time includes a period 501 during which tasks of the user application program 150 are executed and a period 502 during which tasks other than the user application program 150 are executed. Tasks other than user application programs 150 include data processing 152 tasks. A period 501 is an example of a first period, and a period 502 is an example of a second period.

One execution cycle time is assigned to tasks by the application scheduler 156 that manages execution of the user application program 150 and tasks by the data processing 152 . CPU 102 executes these tasks. The interrupt process 540 of the OS or high-level hardware has the highest priority. Immediately below that priority are the user application program 150 tasks scheduled by the application scheduler 156 .

The CPU 102 executes the tasks of the user application program 150 within the period 501 assigned to the user application program 150 in order of priority: task a 510 , task b 512 , and task c 514 . After completing the execution of the tasks of the user application program 150, the CPU 102 executes the tasks of the data processing 152 in order of priority within the period 502 assigned to the data processing 152: task A520 and task B522. . The task of data processing 152 includes a task of data communication processing with the management device 400 that manages the CPU module 100 .

For example, when the user performs customization by prioritizing the data processing 152 in one execution cycle time, the allocation ratio of the period 502 is set large. In that case, the period 501 allocated to the user application program 150 will be relatively short. Due to the shortening of the period 501 of the user application program 150, the remaining execution processes that have not been executed will be processed in the next execution cycle. In the case of real-time control for positioning or the like, the positioning performance can be exhibited by setting the period 501 of the user application program 150 to a large value. In the case of a monitoring system in which data collected by a program controller is displayed on the screen, the screen display/update performance can be improved by setting the period 502 of the data processing 152 to be large.

FIG. 5 shows an example of a diagnosis flow by multivariate analysis. In an embodiment, the multivariate analysis comprises flow 700 of user application program 150 and flow 600 of data processing 152 . The CPU 102 subdivides a flow 700 of the user application program 150 into tasks and executes them within a period 501 . CPU 102 executes flow 600 of data processing 152 in time period 502 subdivided into tasks.

The CPU 102 executes the time-series data collection start command 702 and starts the flow 700 of the user application program 150 with the time-series data collection start command as a trigger. In a period 501 , the CPU 102 executes input processing 704 for receiving input of time-series data indicating the state of the diagnosis target from the functional module 200 and the I/O module 300 . The input processing 704 may consist of function blocks described later. The diagnosis target may be a workpiece such as a processed product in a manufacturing line, a controlled device 250 controlled by the CPU module 100, or a controlled device 350. FIG. Time-series data is data that changes for each scan cycle, such as various sensor values, speed or torque from a servo amplifier. CPU 102 passes the received time-series data to accumulation processing 608 in flow 600 of data processing 152 . The input processing 704 executes processing for sequentially outputting the time-series data from the functional module 200 and the I/O module 300 to the accumulation processing 608 without accumulating them in the buffer.

During time period 502 , CPU 102 initiates flow 600 of data processing 152 . The CPU 102 executes at least part of the accumulation process 608 and the diagnosis process 610 within the period 502 . Accumulation processing 608 accumulates the time-series data received by input processing 704 in data memory 112 . Diagnosis processing 610 diagnoses the state of a diagnosis target based on the time-series data accumulated in data memory 112 in accumulation processing 608 . Diagnosis processing 610 includes preprocessing 612 , analysis processing 614 , determination processing 616 , and notification processing 618 .

Preprocessing 612 converts a predetermined amount of time-series data into a data format for diagnosis. Analysis processing 614 performs multivariate analysis processing based on the time-series data processed in preprocessing 612 . Analysis processing 614 executes multivariate analysis processing according to a predetermined algorithm to output a value indicating the state of a diagnostic object, such as Q statistic (Q value) and T ² statistic (T ² value). You can Determination processing 616 determines whether the state of the diagnostic object is normal based on the analysis result of analysis processing 614 . The determination processing 616 may determine whether or not the state of the diagnosis target is normal by comparing a value indicating the state of the diagnosis target with a threshold value. The determination processing 616 may determine whether the state of the diagnostic target is normal by determining whether the value indicating the state of the diagnostic target falls within the threshold range according to the diagnostic model. The CPU 102 performs a single diagnosis of the condition to be diagnosed over multiple execution cycles by executing the accumulation process 608 and the diagnostic process 610 within the period 502 of each execution cycle. You can

The CPU 102 executes diagnostic initialization 602 to start initialization of the diagnostic processing program. CPU 102 then executes load model 604 to load the diagnostic model from data memory 112 . Next, the CPU 102 determines whether or not it is time to start time-series data collection for the diagnostic program, based on whether or not a start command for time-series data collection has been output (606). If it is time to start time-series data collection for the diagnostic program, CPU 102 sequentially stores the time-series data from input process 704 in data memory 112 in storage process 608 . The CPU 102 determines whether or not a predetermined amount of time-series data as the number of data required for diagnosis has been accumulated in the data memory 112 (609). After a predetermined amount of time-series data has been accumulated, CPU 102 performs preprocessing 612 . More specifically, the CPU 102 performs preprocessing 612 for shaping the time-series data into diagnostic data, such as interpolation of missing data and conversion to frequency components (FFT). After that, the CPU 102 performs multivariate analysis such as univariate analysis and bivariate analysis based on the diagnostic data. Finally, the CPU 102 performs determination processing 616 to determine whether the operations or processed products of the controlled device 250 and the controlled device 350 are normal or abnormal, and performs notification processing 618 to notify the diagnosis result as the determination result.

If the CPU 102 cannot complete a series of processes constituting one diagnosis from the accumulation process 608 to the notification process 618 within one execution cycle, the CPU 102 performs a series of processes within each period 502 over a plurality of execution cycles. Perform a one-time diagnosis by executing If the time until the series of processes is completed is too long, it will take time to reflect the diagnosis results in the operations of the controlled device 250 and the controlled device 350 . That is, it may take a long time to discover that there is a problem in the operation of the controlled device 250 and the controlled device 350 . In this case, for example, the number of defective products may increase.

Therefore, if the CPU 102 cannot complete a single diagnosis within a predetermined number of execution cycles, the CPU 102 will notify the user of the failure at the completion of a single diagnosis process or during the diagnosis process. An output process that outputs a message may be executed. The output process may be composed of function blocks, which will be described later. In response to the message, the user can specify new parameters to increase the proportion of period 502 in one execution cycle. When specifying new parameters, the CPU 102 adjusts the lengths of the periods 501 and 502 according to the new parameters. As a result, it is possible to shorten the time until the diagnosis result is reflected in the operation of the controlled device 250 and the controlled device 350, and for example, suppress an increase in the number of defective products. When a message indicating that one diagnosis could not be completed within a predetermined number of execution cycles is output, the CPU 102 increases the ratio of the period 502 within one cycle according to the message. Additionally, the length of period 501 and period 502 may be adjusted. The CPU 102 may adjust the lengths of the periods 501 and 502 so that the length of the period 502 is increased by a predetermined ratio. The CPU 102 may set a predetermined ratio based on the number of execution cycles required to complete a series of processes. The CPU 102 may set a predetermined ratio so as to increase in proportion to the number of execution cycles required until the series of processes is completed.

Input processing 704 of the time-series data passed from the user application program 150 to the accumulation processing 608 in the data processing 152 may be composed of function blocks.

A function block (hereinafter referred to as FB) is one of program components in programming language specifications for programmable controllers defined in IEC61131-3. An FB is a program that is repeatedly processed in a sequence program and is made reusable by componentizing it. FB is characterized by being able to perform calculations using internally held data in addition to input parameters, unlike functions that input all necessary parameters for each call.

Also, the accumulation processing 608, the preprocessing 612, the analysis processing 614, the determination processing 616, and the notification processing 618 may be configured by at least one FB. The accumulation processing 608, the preprocessing 612, the analysis processing 614, the determination processing 616, and the notification processing 618 may each be configured by the FB. If the accumulation processing 608 is configured by the FB, it becomes possible to record the input values up to the previous call and the value input this time in the accumulation processing 608 that is called every scan cycle. After accumulating the time-series data for the scan cycle for executing diagnosis, the CPU 102 executes subsequent preprocessing 612 , analysis processing 614 , and determination processing 616 .

Regarding the notification processing 618, methods of stopping the programmable controller and notifying an external display device such as an LED are also conceivable. However, by configuring the notification process 618 itself in the FB, it is possible to reflect the diagnosis result received by the control process 706 on the user application program 150 side to the control by the user application program 150 . For example, when diagnosing a defect in a processed product, feedback of the diagnostic result during processing of the user application program 150 enables timely sorting of defective processed products.

The CPU 102 executes the control processing 706 for the controlled devices 250 and 350 related to the diagnosis target in the user application program 150 within the period 501 . The control processing 706 may be processing for controlling actuators such as motors driven in the production line. Control processing 706 may consist of at least one FB. For the aforementioned feedback, the CPU 102 may execute a notification process 618 for notifying the control process 706 executed by the user application program 150 of the diagnosis result, which is the determination result of the determination process 616 . Notification processing 618 may also be configured in FB. In the control processing 706, the CPU 102 may control an actuator such as a motor driven in the production line according to the diagnosis result, and execute processing for sorting defective products.

When a programmable controller is equipped with a diagnostic function based on multivariate analysis using a diagnostic model, if the load of the diagnostic function is high compared to the load of the user application program 150, it is assumed that the execution of the diagnostic function will take a long time. be. Therefore, the CPU 102 may also function as a reception unit that receives ratio information specifying the respective ratios of the period 501 and the period 502 occupied within one execution cycle. The reception unit may receive, as the ratio information, a user-designated parameter specifying the time allocation ratio. The CPU 102 may adjust the lengths of the periods 501 and 502 based on parameters received from the user. This allows the user to optimally specify the time allocation ratio between the user application program 150 and the data processing 152 .

In general, for generation of a diagnostic model, a diagnostic model is generated based on the normal data obtained by gathering data of a plurality of normal machining patterns. For example, it is conceivable that the user manually generates a diagnostic model using the management device 400 or the like in FIG. At the start of operation, the user loads the diagnostic model into the CPU module 100 and uses the diagnostic model for multivariate analysis diagnosis. However, the model generation processing function can be implemented in the CPU module 100 if the model generation processing is divided into the model generation data accumulation processing and the model generation processing, and the data processing of the CPU module 100 is performed. .

If the product to be processed is changed, or if the cutting tools of the equipment are changed, the diagnostic model will be affected and will need to be changed. For changes such as those described above, the user can perceive the changes themselves. It is possible to manually regenerate the diagnostic model after each such change. However, changes in environmental factors such as temperature and humidity around the apparatus, or deterioration over time of cutting tools or movable parts on the production line in use are relatively gradual changes, and are difficult for users to perceive. Therefore, it is difficult for the user to update the diagnostic model due to factors such as changes in environmental factors or deterioration over time.

Therefore, in the embodiment, within the period 502, the CPU 102 generates a diagnostic model to be used in the analysis processing 614 based on the time-series data indicating that the state of the diagnosis target is normal among the time-series data. Process 628 is executed. The generate process 628 indicates normal according to a predetermined algorithm such as multiple regression analysis, principal component regression, partial least squares (PLS), autoregressive (AR) model, vector autoregressive (VAR) model, etc. A diagnostic model may be generated using time-series data.

CPU 102 may execute update process 630 to update the diagnostic model used in analysis process 614 with the diagnostic model generated by generation process 628 while analysis process 614 is not being performed within time period 502 . As a result, it is possible to prevent the diagnosis model currently being used in the analysis processing 614 from being updated during analysis, which prevents normal analysis from occurring. Before the preprocessing 612 starts, the analysis processing 614 has not been executed, so the CPU 102 may execute the update processing 630 before the preprocessing 612 starts.

FIG. 6 shows an example of a diagnostic model generation and update flow. The CPU 102 executes the time-series data collection start command 710 within the period 501 to start the diagnostic model generation and update flow using the time-series data collection start command as a trigger. During period 501 , CPU 102 executes input processing 712 for receiving input of time-series data indicating the state of a diagnostic object from functional module 200 and I/O module 300 . The input processing 704 may consist of function blocks described later.

CPU 102 executes diagnostic model generation initialization 620 within time period 502 to initiate initialization of the diagnostic model generation program. Next, the CPU 102 determines whether or not it is time to start time-series data collection for diagnostic model generation, based on whether or not a start command for time-series data collection has been output (622). If it is time to start time-series data collection for diagnostic model generation, the CPU 102 executes the model generation data accumulation process 624 within the period 502, and selects diagnostic data from the time-series data received from the input process 712. Time-series data determined to be normal by determination processing 616 in processing 610 is stored in data memory 112 . The CPU 102 determines whether or not a predetermined amount of time-series data has been accumulated as one time-series data (626). Furthermore, the CPU 102 determines whether or not the time-series data for a predetermined number of times has been accumulated in the data memory 112 (627). CPU 102 determines that a predetermined amount of time-series data necessary for generating a diagnostic model has been accumulated at the stage when time-series data for a predetermined number of times has been accumulated.

When a predetermined amount of time-series data necessary for generating a diagnostic model has been accumulated, CPU 102 executes generation processing 628 . In generation processing 628 , CPU 102 uses the time-series data determined to be normal in determination processing 616 in diagnosis processing 610 to generate a diagnostic model used in analysis processing 614 as needed.

The CPU 102 executes the update process 630 at the timing when the analysis process 614 is not executed. For example, the CPU 102 executes the update process 630 before the pre-process 612 starts. The CPU 102 sets a generation completion flag, for example, when generation of a new diagnostic model is completed in the generation process 628 . Further, the CPU 102 sets an analysis completion flag when the analysis processing 614 using the diagnostic model currently in use is completed. The CPU 102 executes update processing 630 when both the generation completion flag and the analysis completion flag are set. By sequentially updating the diagnostic model in this way, the CPU module 100 can always operate the control system using the optimal diagnostic model.

In the actual application of diagnostic model generation, for example, from the viewpoint of quality traceability, the diagnostic model may be updated according to the processing lot. In addition, the change date and time of the diagnostic model and the applied diagnostic model data may be saved. Also, in the unlikely event that the judgment result of the applied diagnostic model is inappropriate, a function of rolling back to the previously used diagnostic model may be used.

FIG. 7 illustrates an example computer 1200 in which aspects of the invention may be implemented in whole or in part. Programs installed on computer 1200 may cause computer 1200 to act as one or more "parts" of or operations associated with apparatus according to embodiments of the present invention. Alternatively, the program may cause computer 1200 to perform the operation or the one or more "parts." The program may cause the computer 1200 to perform a process or steps of the process according to embodiments of the invention. Such programs may be executed by CPU 1212 to cause computer 1200 to perform certain operations associated with some or all of the blocks in the flowcharts and block diagrams described herein.

Computer 1200 according to this embodiment includes CPU 1212 and RAM 1214 , which are interconnected by host controller 1210 . Computer 1200 also includes a communication interface 1222 and an input/output unit, which are connected to host controller 1210 via input/output controller 1220 . Computer 1200 also includes ROM 1230 . The CPU 1212 operates according to programs stored in the ROM 1230 and RAM 1214, thereby controlling each unit.

Communication interface 1222 communicates with other electronic devices over a network. A hard disk drive may store programs and data used by CPU 1212 in computer 1200 . ROM 1230 stores therein programs that are dependent on the hardware of computer 1200, such as a boot program that is executed by computer 1200 upon activation. The program is provided via a computer-readable recording medium such as CR-ROM, USB memory or IC card or network. The program is installed in RAM 1214 or ROM 1230 , which are also examples of computer-readable recording media, and executed by CPU 1212 . The information processing described within these programs is read by computer 1200 to provide coordination between the programs and the various types of hardware resources described above. An apparatus or method may be configured by implementing information operations or processing according to the use of computer 1200 .

For example, when communication is performed between the computer 1200 and an external device, the CPU 1212 executes a communication program loaded into the RAM 1214 and sends communication processing to the communication interface 1222 based on the processing described in the communication program. you can command. The communication interface 1222, under the control of the CPU 1212, reads the transmission data stored in the transmission buffer area provided in the RAM 1214 or a recording medium such as a USB memory, transmits the read transmission data to the network, or Received data received from a network is written in a receive buffer area or the like provided on a recording medium.

The CPU 1212 also causes the RAM 1214 to read all or a necessary portion of a file or database stored in an external storage medium such as a USB memory, and performs various types of processing on the data on the RAM 1214. good. CPU 1212 may then write back the processed data to an external recording medium.

Various types of information, such as various types of programs, data, tables, and databases, may be stored on recording media and subjected to information processing. CPU 1212 performs various types of operations on data read from RAM 1214, information processing, conditional decisions, conditional branching, unconditional branching, and information retrieval, which are described throughout this disclosure and are specified by instruction sequences of programs. Various types of processing may be performed, including /replace, etc., and the results written back to RAM 1214 . In addition, the CPU 1212 may search for information in a file in a recording medium, a database, or the like. For example, if a plurality of entries each having an attribute value of a first attribute associated with an attribute value of a second attribute are stored in the recording medium, the CPU 1212 determines that the attribute value of the first attribute is specified. search the plurality of entries for an entry that matches the condition, read the attribute value of the second attribute stored in the entry, and thereby associate it with the first attribute that satisfies the predetermined condition. an attribute value of the second attribute obtained.

The programs or software modules described above may be stored in a computer-readable storage medium on or near computer 1200 . Also, a recording medium such as a hard disk or RAM provided in a server system connected to a dedicated communication network or the Internet can be used as a computer-readable storage medium, whereby the program can be transferred to the computer 1200 via the network. offer.

A computer-readable medium may include any tangible device capable of storing instructions for execution by a suitable device. As a result, a computer-readable medium having instructions stored thereon provides an article of manufacture that includes instructions that can be executed to create means for performing the operations specified in the flowchart or block diagram. Examples of computer-readable media may include electronic storage media, magnetic storage media, optical storage media, electromagnetic storage media, semiconductor storage media, and the like. More specific examples of computer readable media include floppy disks, diskettes, hard disks, random access memory (RAM), read only memory (ROM), erasable programmable read only memory (EPROM or flash memory), Electrically Erasable Programmable Read Only Memory (EEPROM), Static Random Access Memory (SRAM), Compact Disc Read Only Memory (CD-ROM), Digital Versatile Disc (DVD), Blu-ray (RTM) Disc, Memory Stick, Integration Circuit cards and the like may be included.

The computer readable instructions may comprise either source code or object code written in any combination of one or more programming languages. Source code or object code includes conventional procedural programming languages. Traditional procedural programming languages include assembler instructions, Instruction Set Architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state setting data, or Smalltalk, JAVA, C++. etc., and the "C" programming language or similar programming languages. Computer readable instructions may be transferred to a processor or programmable circuitry of a general purpose computer, special purpose computer, or other programmable data processing apparatus, either locally or over a wide area network (WAN), such as a local area network (LAN), the Internet, or the like. ) may be provided via A processor or programmable circuit may execute computer readable instructions to produce means for performing the operations specified in the flowcharts or block diagrams. Examples of processors include computer processors, processing units, microprocessors, digital signal processors, controllers, microcontrollers, and the like.

Although the present invention has been described above using the embodiments, the technical scope of the present invention is not limited to the scope described in the above embodiments. It is obvious to those skilled in the art that various modifications and improvements can be made to the above embodiments. It is clear from the description of the scope of claims that forms with such modifications or improvements can also be included in the technical scope of the present invention.
The execution order of each process such as actions, procedures, steps, and stages in the devices, systems, programs, and methods shown in the claims, the specification, and the drawings is particularly "before", "before etc., and it should be noted that they can be implemented in any order unless the output of the previous process is used in the subsequent process. Regarding the operation flow in the claims, the specification, and the drawings, even if the description is made using "first,""next," etc. for the sake of convenience, it means that it is essential to carry out in this order. not a thing

10 system 100 CPU module 102 CPU
104 driver/receiver 106 bus controller 108 flash memory 110 program memory 112 data memory 150 user application program 152 data processing 154 basic system 156 application scheduler 158 bandwidth management layer 162 hardware 200 functional modules 250, 350 controlled device 300 I/O module 400 Management device 602 Diagnosis initialization 608 Accumulation processing 610 Diagnosis processing 612 Preprocessing 614 Analysis processing 616 Judgment processing 618 Notification processing 620 Diagnostic model generation initialization 624 Model generation data accumulation processing 628 Generation processing 630 Update processing 702, 710 Time-series data collection start commands 704, 712 input processing 706 control processing 1200 computer 1210 host controller 1212 CPU
1214 RAM
1220 input/output controller 1222 communication interface 1230 ROM

Claims (14)

an execution unit that executes a task of an application program within a first period of one cycle and executes a task other than the application program within a second period of the one cycle;
The execution unit
executing an input process for accepting input of time-series data indicating a state of a diagnostic target within the first period;
Accumulation processing for accumulating the time-series data accepted by the input processing in a storage unit within the second period; A programmable controller that performs at least a portion of diagnostic processing for diagnosing conditions. The execution unit executes the accumulation process and the diagnosis process within a second period of each cycle over a plurality of cycles, thereby diagnosing the state of the diagnosis target once in the plurality of cycles. 2. The programmable controller of claim 1, which performs The diagnostic process includes:
when a predetermined amount of the time-series data is accumulated in the storage unit by the accumulation process, pre-processing for converting the predetermined amount of the time-series data into a data format for diagnosis;
Analysis processing for executing multivariate analysis processing based on the time-series data processed in the preprocessing;
The programmable controller according to claim 1 or 2, further comprising a determination process for determining whether the state of said diagnosis target is normal based on the analysis result of said analysis process. The execution unit performs generation processing for generating a diagnostic model used in the analysis processing based on time-series data indicating that the state of the diagnosis target is normal among the time-series data within the second period. 4. The programmable controller of claim 3, which performs The execution unit performs an update process of updating the diagnostic model used in the analysis process with the diagnostic model generated by the generation process while the analysis process is not performed within the second period. 5. The programmable controller of claim 4. The programmable controller according to claim 5, wherein said execution unit executes said update processing before starting said preprocessing. The execution unit executes control processing for a controlled device related to the diagnosis target within the first period,
7. The programmable controller according to any one of claims 3 to 6, wherein said diagnosis processing includes notification processing for notifying said control processing of a determination result of said determination processing. 8. The programmable controller according to any one of claims 1 to 7, wherein said accumulation processing and said diagnosis processing are configured by at least one function block. Further comprising a reception unit that receives information specifying the ratio of each of the first period and the second period occupied within one cycle,
The programmable controller according to any one of claims 1 to 8, wherein said execution unit adjusts lengths of said first period and said second period based on said information. 10. The programmable device according to claim 9, wherein said diagnosis processing includes output processing for outputting a message to that effect if one diagnosis of said state to be diagnosed cannot be completed within a predetermined number of cycles. controller. 11. The executing unit according to the message, according to claim 10, adjusts the lengths of the first period and the second period so that a ratio of the second period within one cycle increases. programmable controller. 12. The programmable controller according to any one of claims 1 to 11, wherein tasks other than said application program include tasks of data communication processing with a management device that manages said programmable controller. A control method for controlling a programmable controller,
an execution step of executing a task of an application program within a first period within one cycle and executing a task other than the application program within a second period of said one cycle;
The execution step includes:
executing an input process for receiving input of time-series data indicating a state of a diagnostic target within the first period;
Accumulation processing for accumulating the time-series data accepted by the input processing in a storage unit within the second period; and performing at least a portion of a diagnostic process for diagnosing the condition. A program for making a computer function as a programmable controller,
causing the computer to execute an execution step of executing a task of an application program within a first period of one cycle and executing a task other than the application program within a second period of one cycle;
The execution step includes:
executing an input process for receiving input of time-series data indicating a state of a diagnostic target within the first period;
Accumulation processing for accumulating the time-series data accepted by the input processing in a storage unit within the second period; and performing at least part of a diagnostic process for diagnosing the condition.

Images