JPH06304850A - Production control data collector and production controlling terminal device - Google Patents

Abstract

PURPOSE:To simplify a total unit system constitution by outputting a control part data, created in a host part, to a control part through a terminal part, so that the host part can be used for not only producting control but also operation controlling the control part. CONSTITUTION:A production control system comprises a host computer l and an N (for instance 16) quantity of terminals 41 to 4N connected to the host computer 1 through a line controller 2 and a serial communication line 3. The terminals 41 to 4N have a data collecting function and a relay function for relaying data between the host computer 1 and a programmable controller 22. The terminal 4 acquires a production control data from connected equipments 51 to 5N, but this production control data contains data of equipment operation/stop, stop factor, inferiority factor, quantity of production, inferior product detection, etc.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management data totaling device for collecting production management data from a control unit for controlling production equipment and totaling the production management data, and a host unit for obtaining production management data from the control unit for controlling production equipment. And a terminal device for production control to be supplied to.

[0002]

2. Description of the Related Art In a factory that employs factory automation, in order to improve productivity, it is necessary to accurately grasp the status of production equipment stoppages due to defects in products and production equipments, and to identify and improve the causes of production equipment stoppages. It is necessary to go. A production management system is used in order to grasp the stop situation and pursue the stop factors. The production management system includes a data collection terminal device that collects production management data from the production equipment, and a host computer that aggregates the production management data obtained from the data collection terminal device. The data collection terminal device is usually connected to a control unit such as a programmable controller that controls production equipment.

In this type of production management system, when the host computer outputs various requests to the terminal device, the terminal device translates the requests for the control unit of the production equipment and outputs them to the control unit. Further, the terminal device translates the data received from the control unit for the host computer and outputs it to the host computer. What kind of request is made to the control unit of the production equipment via the terminal device is predetermined by the system program of the terminal device or the application program of the host computer. In addition, since the data form changes when the type of the control unit changes, it is possible to collect data only from the control unit that is assumed in advance.

On the other hand, in order to write the control program in the control unit of the production equipment or change the control program, a personal computer can be connected to the control unit in addition to the above-mentioned terminal device. In addition, when there are many control units of the production equipment, in addition to the above-mentioned terminal device, a control computer is connected via a network configuration.

[0005]

SUMMARY OF THE INVENTION In the above conventional configuration,
Since the data can be collected only from the control unit assumed in advance, the flexibility of the system is low. Also, since the data to be collected is predetermined, if you want to add the data you want to collect, you have to change the application program of the host computer, the system program of the terminal, etc. Not easy.

Moreover, the control unit must be connected to the control computer in addition to the production control computer, and the overall system configuration is complicated. An object of the present invention is to simplify the configuration of a production management system.

[0007]

A production management data totaling device according to a first aspect of the present invention is a device for collecting production management data from a control unit for controlling production equipment and totaling the production management data, and includes a host unit and a terminal unit. I have it. The host unit processes the production management data and creates control unit data (for example, control programs and various control parameters) related to the control unit. The terminal unit receives the production management data from the control unit and outputs it to the host unit, and receives the control unit data from the host unit and outputs it to the control unit.

The production management data totaling apparatus according to the second invention comprises a host section and a terminal section. The host unit processes the production management data and controls the control unit data related to the control unit. The terminal unit receives the production management data from the control unit and outputs it to the host unit, and also receives the control unit data from the control unit and outputs it to the host unit.

A production management terminal device according to the third invention is
An apparatus that obtains production management data from a control unit that controls production equipment and supplies the production management data to a host unit, and includes a production management data processing unit and a relay unit. The production control data processing means receives the production control data from the control section and outputs it to the host section. The relay unit relays the exchange of control unit data related to the control unit between the control unit and the host unit.

[0010]

In the production management data totaling apparatus according to the first aspect of the present invention, when the host section creates the control section data, the terminal section receives the control section data and outputs it to the control section. When the terminal unit receives the production management data from the control unit, the data is output to the host unit. The host unit processes the production control data from the terminal unit.

Here, since the control unit data created by the host unit is output to the control unit via the terminal unit, the host unit can be used not only for production control but also for operation control of the control unit. Therefore, the entire system configuration can be simplified. In the production management data totaling device according to the second aspect, when the terminal unit receives the production management data from the control unit, it outputs it to the host unit. When receiving control unit data from the control unit, it outputs it to the host unit. The host unit processes not only production management data from the terminal unit but also control unit data from the terminal unit.

In this case, the host unit can obtain the production management data and the control unit data via the terminal unit. For example, if the control program of the control unit is changed, the host unit can use the data currently used. The control program can be acquired by the host unit. Therefore, the host unit can be used not only for production control but also for operation control of the control unit, and the overall system configuration can be simplified.

In the production control terminal device according to the third aspect of the present invention, when the production control data processing means receives the production control data from the control section, it outputs the data to the host section. Further, the relay unit relays the exchange of control unit data between the control unit and the host unit. Here, since the production control data is received from the control unit and output to the host unit and the exchange of the control unit data is relayed, the host unit and the control unit can directly exchange the control unit data. Therefore, without changing the system program of the terminal device, it is possible to collect data from the control unit, which is not expected in advance, and to upload or download the control program. Therefore, by using this terminal device, the entire system configuration can be simplified.

[0014]

【Example】

[Structure] In FIG. 1, a production management system as an embodiment of the present invention is a system that can perform production management online in real time. The production management system includes a host computer 1, and a terminal 4 ₁ to 4 _N of N connected via the line controller 2 and a serial communication line 3 to the host computer 1 (e.g., 16). Facilities 5 _{1 to} 5 _N are separately connected to the terminals 4 ₁ to 4 _N. For example, the equipments 5 _{1 to} 5 _N are press machines A to D, the equipment 5 ₅ is a die casting machine, the equipments 5 ₆ and 5 ₇ are labeling machines A and B, and the equipments 5 _{N-2 to} 5 _N are packing machines A to D. It is C.

The host computer 1 is composed of, for example, a personal computer, and has a production management function of totalizing and displaying the production management data (including processing data) collected by the terminal 4 and printing processing, and a programmable control for controlling the equipment 5. It has a function of directly communicating various data including a control program with the controller 22 (FIG. 4). The host computer 1 includes a computer body 6, a display 7, a keyboard 8, a mouse 9 and a printer 10.
And have. Further, the host computer 1 is shown in FIG.
The control calculation unit 31 shown in FIG.

The control calculation unit 31 includes a CPU, ROM, RA
It is composed of a microcomputer including M. A display 7, a keyboard 8, a mouse 9, a printer 10, an RS232C interface 32, a floppy disk device 33, and a hard disk device 34 are connected to the control calculation unit 31. The line controller 2 is connected to the RS232C interface 32. In the hard disk device 34, various processed data (described later) collected from terminals and data processed (for example, operating rate and defective rate data) are recorded in daily report units. Further, the hard disk device 34 also records the totalized results, and further records control unit data such as a control program of the programmable controller 22.

The terminals 4 ₁ to 4 _N include a data collecting function, a host computer 1 and a programmable controller 22.
It has a relay function of relaying data between and. Terminal 4 is to obtain the production management data from the connected equipment 5 ₁ to 5 _N, the production management data, equipment operation / stop, the cause, a failure factor, the number of production, the data of the defect detection and the like included. It also includes product data such as product type and lot number.

As shown in FIG. 3, a display unit 11 and a key input unit 12 are arranged on the front surface of each of the terminals 4 ₁ to 4 _N (only the terminal 4 ₁ is shown). The display unit 11 includes an LED display unit 13 including 7-segment LEDs and an LCD display unit 14.
And have. The key input unit 11 includes a ten-key unit 15, various data input key units 16, and a function key unit 17.
And a compulsory key unit 18. In the function key section 17, an indicator lamp 19 including an LED indicating that the function key is pressed is arranged above each key.

As shown in FIG. 4, each of the terminals 4 ₁ to 4 _N (only the terminal 4 ₁ is shown) has a control calculation section 20. The control calculation unit 20 is composed of a microcomputer including a CPU, ROM, RAM and the like. The control calculation unit 20 includes a parallel input unit 21, an RS232C interface 23, a key input unit 12, a DIP switch 29, a link interface 30, a display unit 11, an internal clock 25,
The data storage unit 26 and the setting data storage unit 27 are connected.

An output terminal of a programmable controller 22 attached to the equipment 5 is connected to the parallel input section 21. RS232C interface 23
Is a control calculation unit 20 and a programmable controller 22.
Used for inputting / outputting data when communicating with. The DIP switch 29 is used to set the state of the control calculation unit 20 on the terminal side, and can be set to enable or disable the key input of the compulsory key unit 18, for example.
The link interface 30 is connected to the line controller 2 via the serial communication line 3. The internal clock 25 is used for measuring operating time and setting a timer.

The data storage unit 26 stores the collected production management data, processing data as a processing result thereof, a control program of the programmable controller 22 and its control parameters. The processing data stored in the data storage unit 26 includes state data, total data, direct / lot / product data, time zone data, event data, and message data. The state data is data that determines the state of the terminal. The total data is total data of production management data from the start of operation of the equipment in one day to the present. The shift / lot / variety data is aggregate data of production control data for each shift (working hours in the work system), each lot, and each variety. The time zone data is aggregate data of production management data for each predetermined time (for example, 5 minutes). The event data is data on the occurrence time, the number of events, and the type of the event when the equipment is operating. The message data is data of a message at the time of message input and the time of occurrence.

The setting data storage unit 27 stores terminal setting data set by the host computer 1. For example, when the host computer 1 sets a timetable for data collection, the setting data is stored in the setting data storage unit 27. In addition, the relationship between the function key unit 17 and the processing content assigned to it is also stored. [Operation] Next, the operation of the above-described embodiment will be described. Host First, the operation of the host computer 1 will be described with reference to the control flowchart shown in FIGS.

In the host computer 1, initial setting is performed in step P1 of FIG. In step P2, the operation menu is displayed. Here, "online monitor", "system setting", "program transfer", "data memory change", "utility", other menus and "operation end" are displayed. In step P3, the process selected from the operation menu is accepted. Step P4
Then, the accepted processing is determined.

When the online monitor process is designated, the process proceeds from step P4 to step P5. In Step P5, it is determined whether or not there is data to be collected in the direct mode. For example, when the data in the data memory of the programmable controller 22 is directly collected, this determination is YES. If there is data to be collected in the direct mode, the process proceeds from step P5 to step P6, and the data is collected in the direct mode. In this case, since the header and footer for the direct mode are added to the collected data (step S16 in FIG. 8), the process for removing them is performed.
If there is no data to collect in the direct mode, step P
The process proceeds from step 5 to step P7, and data is collected in the normal mode.

At step P8, various processing such as processing the collected data for display is performed. In Step P9, the input from the keyboard 8 and the mouse 9 such as the change of the display screen is accepted. In Step P10, display is performed based on the received input. In Step P11, it is determined whether or not an instruction to end the online monitor process is given. Until the end is designated, the process returns to step P5 to continue the online monitor process, and when the end is designated, the process shown in FIG.
No. P29.

When the system settings are specified, step P4
To P12. In Step P12,
The settings related to the terminal 4 and this software are accepted.
In step P13, performing a setting related terminal setting of 4 ₁ to 4 _N data acquisition time of the end of setting processing, the other setting processing such as performing a setting for this software. In Step P12, it is determined whether or not the end of the setting process has been instructed. Step P1 until end is specified
Returning to step 2, the setting process is continued, and when the end is designated, the process proceeds to step P14. In Step P14, the set data is transmitted to the terminal 4, and the process proceeds to Step P29.

When the program transfer process is designated, the process proceeds from step P4 to step P15 in FIG. In the program transfer process, the program can be downloaded and uploaded with the programmable controller 22.
In Step P15, the input of the transfer direction of the program (download or upload) and the file name of the program to be transferred (transfer file name for download, storage file name for upload) is accepted. In Step P16, it is determined whether the accepted transfer direction is download. In the case of downloading, the process proceeds to step P17. In step P17, the received transfer file is read from the hard disk device 34.
In Step P18, the reception request is output. Step P
In 19, send the program of the read file,
The process moves to step P29. Here, the header for the direct communication mode is added to the head of the program and the footer for the direct communication mode is added to the end of the program for transmission.

When the transfer direction is upload, the process moves from step P16 to step P20. Step P2
At 0, a transmission request is output. In Step P21, the reception of the program from the programmable controller 22 is waited for. When the program is received, the process proceeds to step P22. In Step P22, the header and footer for the direct communication mode are removed from the received program, written in the hard disk device 34 with the input storage file name, and the process goes to Step P29.

When the data memory change process is designated, the process moves from step P4 to step P23. Step P
At 23, the input of the data memory number and the change data is accepted. In Step P24, the number and the data are set, and the header and the footer are added to the head of the set and transmitted. In Step P25, it is determined whether or not the end of the changing process has been instructed. Step P until end is specified
23, the changing process is continued, and when the end is designated, the process proceeds to step P29.

When the utility process is designated, the process proceeds from step P4 to step P26. Step P26
Then, various utility processes such as program editing and file format change are executed. In Step P27,
It is determined whether or not the end of the utility processing is instructed. Until the end is designated, the process returns to step P26 to continue the utility processing, and when the end is designated, the process proceeds to step P29.

When another process is designated, the process moves from step P4 to step P28. In Step P28, general processing such as printing processing is carried out, and the routine goes to Step P29. In Step P29, it is determined whether or not the end of the process is designated by the operation menu. Until the end is specified, the process returns to step P2 in FIG. 5, and when the end is specified, the process ends. The control operation of the terminal side terminal 4 will be described with reference to the control flowchart shown in FIGS. 7 to 10.

First, in step S1 of FIG. 7, initial setting is performed. At the time of this initial setting, various setting values are set to initial values. In step S2, it is determined whether the key input unit 12 has been operated. When the key input unit 12 is operated, the process proceeds from step S2 to step S4, and the key input process corresponding to the pressed key is performed. In step S3, it is determined whether a command from the host computer 1 has been received. When the command is received from the host computer 1, the process proceeds from step S3 to step S5. In step S5, the host command processing shown in FIG. 8 is executed.

In the host command processing, it is determined in step S11 of FIG. 8 whether the direct communication mode is set. If it is determined that the direct communication mode is not set, the process proceeds to step S12. In step S12, the indirect communication mode process (described later) shown in FIG. 9 is executed. If it is determined that the direct communication mode is set, step S
The process moves from 11 to step S13. In step S13, the header and footer of the data received from the host computer 1 are removed. In step S14, the data with the header and footer removed is transmitted to the programmable controller 22. In step S15, a reply from the programmable controller 22 is waited for. When the reply from the programmable controller 22 is received, the process proceeds to step S16. In step S16, a header and footer are added to the received data. In step S17, the data with the header and footer added is transmitted to the host computer 1.

In the indirect mode processing of step S12, the request from the host computer 1 is interpreted in step S31 of FIG. In step S32, depending on the interpretation result,
It is determined whether the programmable control 22 needs to be inquired. If no inquiry is necessary, the process proceeds to step S33. In step S33, a reply to the host computer 1 is prepared.

When it is necessary to make an inquiry to the programmable controller 22, steps S32 to S32 are performed.
Move to 34. In step S34, an inquiry to the programmable controller 22 is prepared. In step S35, the programmable controller 22 is requested to transmit data. Step S36
Then, it waits to receive data from the programmable controller 22. In step S37, a reply to the host computer 1 is created based on the reception result.

When the processing in step S33 or step S37 is completed, the process proceeds to step S38. Step S
At 38, a reply is transmitted to the host computer 1. On the other hand, the control calculation unit 20 of the terminal 4 has a 3 msec timer interrupt function, and executes the interrupt routine shown in FIG. 10 when a timer interrupt is input. In step S41 of FIG. 10, the parallel input unit 21 or RS232
A data acquisition process for acquiring the data input to the C interface 23 is executed. In step S42, it is determined whether the acquired data contains valid data. If the valid data is included, the process proceeds to step S43. In step S43, the data that needs to be processed is processed, and the processed data is stored in the data storage unit 26.
Remember. Here, six processing data are obtained from the production control data. That is, state data and total data
They are product type / lot data, time zone data, event data, and message data. The various data obtained in step S43 are used in step S33 of FIG. The control operation of the PLC side programmable controller 22 is shown in FIG.
A description will be given according to the control flowchart shown in FIG.

First, initial setting is performed in step Q1 of FIG. In step Q2, it is determined whether or not a transmission request is made from the host computer 1 via the terminal 4. Similarly, in step Q3, it is determined whether or not a reception request is made. At step Q4, other general processing such as control operation is performed and the process returns to step Q2. When a transmission request is made, the process proceeds to step Q5. In step Q5, the requested data is transmitted to the terminal 4. If it is determined that the reception request is made, the process proceeds from step Q3 to step Q6. In step Q6, the data from the terminal 4 is received. In step Q7, it waits until the reception is OK. When the reception is OK, the process returns to the main routine.

Here, since the terminal 4 has a relay function, data can be directly input / output between the host computer 1 and the programmable controller 22 in the direct communication mode. That is, the host computer 1 can create a program and data according to the programmable controller 22 and directly output the data to the programmable controller 22, and the programmable controller 22 can directly output the data to the host computer 1. Therefore, the host computer 1 can transfer various control programs of the programmable controller 22 and change setting values without using another computer.

Further, even if the data is data other than the production control data, which is stored in the data memory of the programmable controller 22 but cannot be collected by the terminal 4, the host computer 1 uses the data in the direct communication mode. Data can be collected. Therefore, it is possible to easily add data to be collected. Moreover, if the direct communication mode is used, the production control can be performed by connecting the terminal 4 to a control unit other than the control unit assumed in advance. [Other Embodiments] (a) Adding the header and footer to perform the direct communication mode is an example, and it is also possible to add only the header or the footer. Further, the data format may be changed between the direct communication mode and the indirect communication mode. (B) The present invention can be similarly implemented in a data collection terminal that directly outputs the production control data to the host computer 1 without storing it.

[0040]

In the production control data totalizing apparatus according to the first aspect of the present invention, the control unit data created by the host unit is output to the control unit via the terminal unit, so that the host unit is not only used for production control. Instead, it can be used for controlling the operation of the control unit. Therefore, the entire system configuration can be simplified.

In the production management data totaling apparatus according to the second aspect of the present invention, the host unit can obtain the production management data and the control unit data via the terminal unit. For example, it is necessary to change the control program of the control unit. Accordingly, the host unit can acquire the control program currently used from the control unit. Therefore, the host unit can be used not only for production control but also for operation control of the control unit, and the overall system configuration can be simplified.

In the production management terminal device according to the third aspect of the present invention, since the production control data is received from the control unit and output to the host unit, and the exchange of the control unit data is relayed, the host unit and the control unit directly The control unit data can be transferred and received. Therefore, by using this terminal device, the entire system configuration can be simplified.

[Brief description of drawings]

FIG. 1 is a configuration block diagram of a production management system that employs an embodiment of the present invention.

FIG. 2 is a configuration block diagram of a host computer.

FIG. 3 is a plan view showing a panel arrangement of the terminal.

FIG. 4 is a configuration block diagram of a terminal.

FIG. 5 is a control flowchart of the host computer.

FIG. 6 is a control flowchart of the host computer.

FIG. 7 is a control flowchart of the terminal.

FIG. 8 is a control flowchart of the terminal.

FIG. 9 is a control flowchart of the terminal.

FIG. 10 is a control flowchart of the terminal.

FIG. 11 is a control flowchart of the programmable controller.

[Explanation of symbols]

 1 Host Computer 4 Terminal 20 Control Arithmetic Section 22 Programmable Controller 23 RS232C Interface

Claims (3)

[Claims] 1. A production management data totaling device for collecting production management data from a control unit for controlling production equipment and totaling the production management data, and processing the production management data and creating control unit data related to the control unit. Production control data including a host unit for receiving the production control data from the control unit, outputting the production control data to the host unit, and receiving the control unit data from the host unit and outputting the control unit data to the control unit. Aggregator. 2. A production management data aggregating apparatus that obtains production management data from a control unit for controlling production equipment and totalizes the production management data, and processes the production management data and the control unit data related to the control unit. And a terminal unit that receives the production control data from the control unit and outputs the production control data to the host unit, and receives the control unit data from the control unit and outputs the control unit data to the host unit. Data data aggregation device. 3. A production management terminal device for obtaining production management data from a control unit for controlling production equipment and supplying it to a host unit, the production management data being received from the control unit and output to the host unit. A production management terminal device comprising: production control data processing means; and relay means for relaying exchange of control section data related to the control section between the control section and the host section.