JP6853218B2 - Sensor data analysis system and sensor data analysis method - Google Patents

Description

The present invention relates to a sensor data analysis system and a sensor data analysis method, and in particular, collects sensor data from a plurality of production facilities in the manufacturing industry, and commonly collects data in various protocols and formats collected from facilities of the entire factory. The present invention relates to a sensor data analysis system and a sensor data analysis method suitable for performing conversion for handling and visualizing in real time.

In the manufacturing industry, data collection of sensors that measure the state of products and production equipment is progressing, but there are many unique protocols provided by the manufacturers of each control device, and old-fashioned protocols continue to remain. Data linkage and utilization have not progressed because it needs to be taken into consideration.

For example, production equipment operation information and product quality information in the manufacturing industry are mainly managed by cloud services linked via the Internet, and are often managed by servers on the Internet cloud for centralization. In addition to this, various system forms can be considered as long as it has a function to collect sensor data of production equipment, but in a system that manages sensor data on a server on the cloud, the sensor data is uploaded to the server. There is a risk that data delays and security may be impaired due to factors arising from the network environment for this purpose, and there is a demand for processing by a system in a closed network in the factory.

However, in the prior art, there was no system that handles sensor data from production equipment in a single operation in a closed network in the factory, except for the system for equipment manufactured in-house. This is because the protocol and data format of the control device that temporarily stores the data are based on the original standards of each control device manufacturer, and the sensor data of the production equipment of other companies is not collected uniformly. is there.

In order to improve work efficiency at the production site, it is necessary to integrate sensor data from production equipment with a wide variety of data throughout the site to realize visualization that can be used as a reference for decision making, and various protocols. A mechanism for collecting sensor data consisting of is conceivable. For example, Patent Document 1 discloses a technique for converting a communication protocol between a PLC (Programmable Logic Controller) and a display into a common protocol between the display and a personal computer.

Japanese Unexamined Patent Publication No. 2001-117612

However, the data collection system described in Patent Document 1 does not describe integrated data visualization, and although it supports a plurality of protocols, it also supports differences in a plurality of data formats. Not done. That is, since various data formats are sent from a plurality of devices, it is not possible to collectively perform data collection, conversion, analysis, and visualization processing.

An object of the present invention is to provide a sensor data analysis system capable of uniformly handling data collected from a factory production facility, visualizing sensor data in real time with a system in the factory, and performing analysis. is there.

The configuration of the sensor data analysis system of the present invention is preferably a sensor data analysis system that analyzes sensor data output from a sensor installed in a production facility in a factory, and includes a data collection device and a data linkage server. The data collection device and the data linkage server are connected by the same network in the factory, the data collection device receives the sensor data, performs protocol conversion, and sends it to the data linkage server. The received sensor data is subjected to data format conversion and data type conversion according to a predetermined data format and data type, and then transmitted to the outside.

According to the present invention, a sensor data analysis system capable of uniformly handling data collected from production equipment in a factory, visualizing sensor data in real time with a system in the factory, and analyzing the sensor data is provided. can do.

It is a schematic block diagram of a sensor data analysis system. It is a hardware / software configuration diagram of a data linkage server. It is a hardware / software configuration diagram of a data visualization server. It is a hardware / software configuration diagram of an external cooperation server. It is a figure which shows an example of the sensor data. It is a figure which shows an example of a data flow. It is a flowchart which shows the process of a sensor data analysis system. It is a figure explaining each protocol and a format at the time of transmitting data by a message base. It is a figure which shows an example of a data format conversion screen. It is a figure which shows an example of the data type conversion screen. It is a figure which shows an example of the destination designation screen. It is a figure which shows an example of the monitoring screen layout definition screen. It is a figure which shows an example of the sensor data monitoring screen.

Hereinafter, embodiments according to the present invention will be described with reference to FIGS. 1 to 13.

First, an outline of the sensor data analysis system according to the embodiment of the present invention will be described.
The sensor data analysis system according to the embodiment of the present invention acquires sensor data from production equipment, converts the data format to facilitate analysis and utilization, and realizes real-time visualization in graphs, tables, and the like. It is a system to do.

In this system, the data linkage server receives the data transmitted from the data collection device. The data to be received is message-based or file-based, and is managed by DBMS (DataBase Management System) by using a protocol such as MQTT (Message Queue Telemetry Transport) or FTP (File Transfer Protocol). It is possible to correspond to the cooperation with the source. In the message base, the data linkage server can be realized as long as it has a transmission function for transmitting a message, a reception function for receiving, and a relay function for mediating them. For receiving large-sized data files and binary data that are not suitable for message-based linkage, only relevant meta information such as file names and data source-related information is expanded on a message-based basis, and real files are expanded in real time. Alternatively, by making an on-demand file transfer request, file-based data reception may be performed by FTP.

After receiving the data, the data linkage server converts the data format and data type set in advance on the browser by the user. Regarding the data format, for example, users can use text-based data formats such as CSV (Comma-Separated Values), JSON (JavaScript (registered trademark) Object Notation), and XML (eXtensible Markup Language) according to the cooperation destination. Convert to the specified format. Other than this, any text-based data format is feasible. As for the data type, the item set on the browser by the user is used as a key to search the data, and the value of the matching item is converted between the character string type and the numerical type. By specifying the item instead of batch conversion, the data can be excluded from the conversion target according to the item like the numerical value that you want to handle as a character string.

Then, the data linkage server uses the converted data to the data visualization server or the external linkage server, the message-based data using MQTT or HTTP (Hyper Text Transfer Protocol), and the file-based data using the FTP protocol. Send. Further, according to the content of the received data, the threshold value is compared with the threshold value set in advance on the browser by the user, and when the threshold value is exceeded, a signal indicating an abnormality is transmitted to the warning device.

The data visualization server receives the data from the data linkage server and stores it in the DB (DataBase). For the stored data, the user sets the screen layout of the table or graph from the browser and realizes real-time data reference on the browser. The user can refer to the data in this way and perform a response at an abnormal time and a predictive analysis at a normal time.

In addition, the external linkage server receives the data from the data linkage server and sends it to the company-wide server outside the factory. Then, the manager of the company-wide server can connect to company-wide management analysis and improvement activities based on the data collected from each factory.

Next, the configuration of the sensor data analysis system according to the present invention will be described with reference to FIGS. 1 to 4.
The sensor data analysis system 100 is, for example, a system realized by a manufacturing company having a head office mechanism and a factory as a production facility, and has two types of networks, a head office network 101 and an in-factory network 102. In the factory network 102, the control device 116 connected to the plurality of production equipment / sensors 117 controls the production equipment, and also acquires and stores data from the production equipment / sensor 117. Then, the data collection device 115 collects the data stored in the control device 116, adds physical value conversion and mapping time stamp of the binary data, and transmits the data to the data linkage server 114. This function can be realized by, for example, software conforming to OPC UA (OPC Unified Architecture).

The data collection device may be a general PC (Personal Computer) or may use dedicated hardware. The control device 116 that controls the production equipment / sensor 117 is, for example, a PLC.

Here, the factory network 102 has a large number of control devices 116 and production equipment / sensors 117, and as shown in FIG. 1, a large number of companies such as those manufactured by company A, company B, and company C, respectively. It is assumed that the products made of are mixed. A control device 116 manufactured by A company is connected to the data collecting device 115 manufactured by A company, and a production facility / sensor 117 manufactured by A company is connected to the control device 116 manufactured by A company. There is. On the other hand, the control device 116 manufactured by B company and the control device 116 manufactured by C company are connected to the data collecting device 115 manufactured by B company, and the control device 116 manufactured by B company is produced by B company. The equipment / sensor 117 is connected, and the production equipment / sensor 117 manufactured by C company is connected to the control device 116 manufactured by C company.

In this way, in the factory, there is a protocol for each manufacturer for the production equipment / sensor 117 provided by the manufacturer that provides the equipment to transmit data to other equipment, and each manufacturer uses its own recommended protocol. Many protocols are mixed to use. Therefore, by providing the data collection device 115, it is possible to unify the protocol with the external server.

The data linkage server 114 is a server that receives data transmitted from the data collection device 115, converts it according to a specified format and data type, and distributes it to another server or device that is a specified destination. is there. The data linkage server 114 receives the data transmitted from all the data collection devices 115 in the factory according to the protocol. Production equipment / sensors 117 manufactured by different equipment manufacturers are sent in various data formats and cannot normally be converted to a common format. Therefore, the user defines the data flow in advance from the browser of the user PC 120 and transmits the data to the data visualization server 112 and the external cooperation server 113. The data flow is data that defines what format and data type the data handled by the data linkage server 114 is converted into and where it is transmitted. The data flow will be described in detail later. In addition, the creator of the data flow notifies the warning device 118 and other operating status by using the reception of abnormal data as a trigger by defining the conditional information in the data flow whose issuance depends on the conditional expression. It is also possible to send to the device.

The data visualization server 112 is a server that receives data from the data linkage server 114, stores it in a DB, and realizes visualization from the user. The user defines the layout of the accumulated data on the browser of the user PC 120 (client device), and the data is displayed in real time in time series. Here, the real-time means that the data output by the production equipment / sensor 117 is converted into a predetermined format at any time and can be confirmed in a continuous state. By installing this data visualization server 112 in the factory network 102, the influence of network delay is reduced, so that real-time data is ensured only in the factory network and data visualization on the user PC 120 is realized. .. In addition, the screen displayed on the browser is automatically updated in seconds, and the production process can be monitored by user monitoring.

The external linkage server 113 is a server for receiving data from the data linkage server 114 and transmitting the data to the company-wide server 111 through the head office network 101. The company-wide server 111 aggregates data from the external cooperation server 113 of each factory, accumulates and analyzes it as company-wide data, so that a manager or a person who plans a company strategy can use the user PC 121 to company-wide. It can be used for general management decision-making.

Next, the hardware / software configuration of each device of the sensor data analysis system will be described with reference to FIGS. 2 to 4.
As shown in FIG. 2, the data linkage server 114 is realized by a general server device configuration as a hardware configuration. For example, the central processing unit 202, the main memory 203, the storage device 201, and the communication control device 204 are BUS. It is a form connected by. The central processing unit 202 executes the program of the main memory 203 to control each part of the data linkage server 114. The main memory 203 is a semiconductor storage device that stores programs and temporary data stored in the storage device 201. The storage device 201 is a large-capacity storage device that stores programs and data, and is realized by a semiconductor storage device such as an SSD (Solid State Drive) or a magnetic storage device such as an HDD. The communication control device 204 is an interface device for connecting to a network such as a LAN board.

In the storage device 201 of the present embodiment, as the program 205, a data receiving program (message) 211, a data receiving program (file) 212, a data format conversion program 213, a data type conversion program 214, a data date format conversion program 215, and data A transmission program (message) 216, a data transmission program (file) 217, and a data flow definition program 218 are installed. Further, the storage device 201 holds a data flow definition file 219 as data. The data receiving program (message) 211 and the data receiving program (file) 212 are programs that receive data on a message basis and a file basis, respectively. The data format conversion program 213 is a program that performs data format conversion. The data type conversion program 214 is a program that performs data type conversion. The data date format conversion program 215 is a program that converts the format related to the date of the received data. The data transmission program (message) 216 and the data transmission program (file) 217 are programs that transmit data on a message basis and a file basis, respectively. The data flow definition program 218 is a program that generates a data flow definition file 219 that defines a data flow according to information input from the user PC.

As shown in FIG. 3, the data visualization server 112 is also realized by a general server device configuration as a hardware configuration, for example, a central processing unit 302, a main memory 303, a storage device 301, and a communication control device 304. It is a form connected by BUS. The functions of each part are the same as those of the data linkage server 114 shown in FIG.

A data storage program 311, a screen layout creation program 312, and a data output program 313 are installed as the program 305 in the storage device 301 of the present embodiment. Further, the storage device 301 holds the data storage DB 314 as a database. The data storage program 311 is a program that stores the output data of the transmitted equipment / sensor data in the data storage DB 314. The screen layout creation program 312 is a program that creates screen layout information for the sensor data monitoring screen (details will be described later) output to the user PC 120. The data output program 313 is a program that outputs sensor data according to the screen layout information to the user PC 120.

As shown in FIG. 4, the external cooperation server 113 is also realized by a general server device configuration as a hardware configuration, for example, a central processing unit 402, a main memory 403, a storage device 401, and a communication control device 404. It is a form connected by BUS. The functions of each part are the same as those of the data linkage server 114 shown in FIG.

A data receiving program (message) 411, a data receiving program (file) 412, a data external transmitting program (message) 413, and a data external transmitting program (file) 414 are installed in the storage device 401 of the present embodiment as the program 405. ing. Further, the storage device 201 holds a data flow definition file 419 as data. The data receiving program (message) 411 and the data receiving program (file) 412 are programs that receive data on a message basis and a file basis, respectively. The data external transmission program (message) 413 and the data external transmission program (file) 414 transmit data on a message basis and a file basis, respectively, to a server outside the network in the factory, for example, a company-wide server 111 connected by the Internet. It is a program.

Next, the data structure handled by the sensor data analysis system will be described with reference to FIGS. 5 to 6.

The sensor data 901 is data output by the production equipment / sensor 117, relayed by the data collecting device 115, and received by the data linkage server 114.

As shown in FIG. 5, the sensor data 901 includes each item of production equipment ID 901a, sensor ID 901b, sensor type 901c, value 901d, and time 901e. The production equipment ID 901a and the sensor ID 901b store a unique identifier of the production equipment that operates the sensor and a unique identifier of the sensor that outputs data, respectively. The sensor type 901c stores the sensor type. The value 901d stores the value of the sensor data. The time when the sensor data is output is stored in the time 901e.

As shown in FIG. 5, the sensor type 901c includes, for example, a pressure (kPa) measured by press working, a motor rotation speed (rpm) for operating a production facility, and an oil flow rate (l). .. In addition, depending on the type of processing work in the manufacturing process, there are counters (pieces) for measuring the presence or absence of objects, temperatures (° C) generated during processing, and the like.

As shown in FIG. 6, the data flow 1200 has data flow ID 1201, data format 1202, conversion item 1203, data type 1204, destination 1205a, 1205b, ..., Condition 1206.

The data flow ID 1201 stores an identifier that uniquely identifies the data flow to be defined. The data format 1202 stores a method of data format conversion. In FIG. 6, it is set to data format the JSON format into the CSV format. The conversion item 1203 stores a data item for converting the data type. The data type 1204 stores the type of data to be converted. In FIG. 6, it is specified to convert a String (character string) to a Number (numerical value). An identifier that uniquely identifies the destination is stored in the destinations 1205a, 1205b, .... The destination can be specified by IP address as shown in FIG. Condition 1206 stores a condition for transmitting data to the destination only when the condition is satisfied. In the example of FIG. 6, when the pressure is larger than 800 kPa, an example of transmitting transmission data to a designated destination is shown. Condition 1206 can be used, for example, to send data to the warning device 118 when an abnormality occurs.

Next, the processing of the sensor data analysis system will be described with reference to FIGS. 7 and 8.
First, the control device 116 acquires the data of the sensor attached to the equipment (S501).
Next, the control device 116 that has acquired the data records the value of the data on the main memory (S502).
Next, the data on the main memory of the control device is collected and distributed to the data linkage server 114 according to the protocol and the time interval set in advance by the data collection device (S503).

In the data linkage server 114, the user executes the data flow definition program 218 in advance and creates a data flow definition file 219 in which transmission conditions and conversion conditions are defined according to the type of data (S504). The data flow definition file 219 is a file that defines a data flow as shown in FIG. Next, the data linkage server 114 executes the data receiving program (message) 211 or the data receiving program (file) 212, and receives the data delivered by the data collecting device 115 (S505). Then, according to the data flow definition file 219, various conversion processing programs such as a data format conversion program 213, a data type conversion program 214, and a data date format conversion program 215 are executed to perform various conversion processes (S506), and data transmission is performed. The program (message) 216 and the data transmission program (file) 217 are executed and distributed to the data visualization server 112 and the external cooperation server 113 (S507). In addition, if the data has an abnormal value or other urgent response, the data is also transmitted to the warning device.

The data visualization server 112 executes the data storage program 312 and stores the data of the data linkage server 114 in the data storage DB 311 in the server (S508). The user accesses the data visualization server 112 in advance, executes the screen layout creation program 313, and defines the screen layout for displaying the data in the DB (S509). The data visualization server 112 outputs the data in the DB based on the screen layout defined by executing the data output program 314 (S510).

The external linkage server 113 executes the data reception program (message) 411 or the data reception program (file) 412, receives the data of the data linkage server 114 (S511), and transmits the data transmission program (message) 413 or the data. The program (file) 414 is executed to transmit data to the company-wide server 111 or the like via the network outside the factory (S512).

When the warning device receives sensor data such as an abnormal value, an alarm is issued (S513).

FIG. 8 shows the flow of each protocol and format when transmitting data on a message basis in the processing of the sensor data analysis system described with reference to FIG. 7.

The factory usually has production equipment / sensors from multiple manufacturers. Production equipment / sensors 601, 602, 603 (eg, A, B, C) manufactured by different manufacturers have different protocols because the corresponding controllers 611, 612, 613 store the data. Data is handled by I, K, and M. Further, since the data format also depends on the production equipment / sensor and the control device like the data formats J, L, and N, it is assumed that data is not normally exchanged and cannot be converted into a common format. Therefore, in order to exchange data, it is generally known that the data collection devices 621 and 622 convert the protocol and make it common. However, the actual data format and data type may not be unified only by protocol conversion, and in particular, due to differences in date formats, it is not possible to make a unified comparison when analyzing and visualizing data. Cannot be handled. Therefore, the data linkage server 114 receives the message by executing the data receiving program (message) 211, and executes the data format converter program 213 from the data formats J, L, and N to the data format P. Unify. As described above, by converting the protocol and data format and data type into a unified format, data collection, conversion, analysis, and visualization can be performed collectively even in environments with different production equipment / sensor manufacturers. Processing becomes possible.

Next, the user interface of the sensor data analysis system will be described with reference to FIGS. 9 to 13.
By connecting to the data linkage server 114 and operating the data format conversion screen 701 shown in FIG. 9, the user can set the conversion method of the format of the data received by the data linkage server 114. On the data format conversion screen 701, one data format conversion method such as CSV, JSON, XML, etc. can be selected from the list box, and the format conversion method can be specified by deploying it on the data flow.

Further, the user can set the data type conversion of the data received by the data linkage server 114 by connecting to the data linkage server 114 and operating the data type conversion screen 801 shown in FIG. On the data type conversion screen 801, data type conversion is performed by selecting one data type conversion method such as character string type or numeric type for the data item specified by the user from the list box and deploying it on the data flow. Can be specified. By converting only the specified items, it is possible to perform data conversion according to the specifications of the linked system instead of uniform conversion, such as when there is numerical data that you want to handle as a character string.

Further, the user can specify the transmission destination of the sensor data and the conditions for transmission by connecting to the data linkage server 114 and operating the transmission destination designation screen 1301 shown in FIG. For the transmission destination of the sensor data, for example, the IP addresses of the data visualization server 112, the external cooperation server 113, and the warning device 118 are specified. As the condition, it is possible to specify an abnormal condition such as when data is transmitted to the warning device 118.

Further, the user connects to the data visualization server 112 and defines the layout for displaying on the sensor data monitoring screen for monitoring each sensor data on the monitoring screen layout definition screen 1100.

The monitoring screen layout definition screen 1100 has a graph display definition area 1101 and a setting area for the digital display definition area 1110.

The graph display definition area 1101 sets the graph type 1102, the X-axis data 1103, the Y-axis first-axis data 1104, the Y-axis second-axis data 1105, the display position 1106, and the data update interval (seconds) 1107. Has an item.

Further, the digital display definition area 1110 has setting items of a display item 1110, a display position 1120, and a data update interval (second) 1130. In the display item 1110, the item to be displayed in the display item 1110 can be specified by selecting the displayed radio boxes 1111 to 1115.

Then, the user connects to the data visualization server 112, displays the sensor data monitoring screen 1000 shown in FIG. 13, and refers to the output data of various sensors used in the factory on one screen. It can be grasped in an extremely short time. The sensor data monitoring screen 1000 includes a graph display area 1001 and a digital display area 1002.

By referring to this graph and numerical values in real time, the user can confirm the signs of abnormalities and failures of production equipment from the relationships and trends of the values.

The sensor data monitoring screen 1000 automatically updates the data based on the update interval defined by the user.

As described above, according to the sensor data analysis system of the present embodiment, the sensor data in the factory is received and the information is displayed on the monitoring screen to analyze and analyze the data throughout the production process. It is possible to respond to the results and carry out improvement activities.

Therefore, it is possible to speed up the recovery from the abnormal stoppage of the operation of the production equipment in the entire factory, and it is possible to suppress the occurrence of defective products by monitoring the state of the products in real time. In addition, data can be centrally managed when the entire factory has production equipment of various equipment manufacturers for the purpose of comprehensively converting and analyzing the data to improve the production of the entire factory.

111 ... Company-wide server 112 ... Data visualization server 113 ... External cooperation server 114 ... Data cooperation server 115 ... Data collection device 116 ... Control device 117 ... Production equipment / sensor 118 ... Warning device 120, 121 ... User PC

Claims (5)

It is a sensor data analysis system that analyzes sensor data output from sensors installed in production equipment in factories.
Equipped with a data collection device and a data linkage server
The data collection device and the data linkage server are connected by the same network in the factory.
The data collecting device receives the sensor data, performs protocol conversion, and transmits the sensor data to the data linkage server.
The data linkage server refers to a data flow in which data format conversion information, data type conversion information, and data destination information are defined.
The data format conversion and data type conversion of the received sensor data are performed according to the data format conversion information and the data type conversion information defined in the data flow, and the sensor is subjected to the data transmission destination information defined in the data flow. A sensor data analysis system characterized by transmitting data to the outside. In addition, it has a data visualization server
The data linkage server and the data visualization server are connected by the same network in the factory.
The data visualization server receives the sensor data from the data linkage server and receives the sensor data.
The sensor data according to claim 1, wherein the data visualization server outputs sensor data to a connected client device, and the client device displays the sensor data in real time on a sensor data monitoring screen. Analysis system. In addition, it is equipped with an external cooperation server.
The data linkage server and the external linkage server are connected by the same network in the factory.
The external cooperation server receives the sensor data from the data cooperation server, and transmits the sensor data to an external server connected to a network different from the same network in the factory. Described sensor data analysis system. In addition, it is equipped with an alarm device
The data linkage server and the alarm device are connected by the same network in the factory.
The data flow includes condition information for transmitting data, and includes condition information.
The sensor data analysis system according to claim 1 , wherein the data linkage server transmits the sensor data to the alarm device according to condition information when transmitting data defined in the data flow. It is a sensor data analysis method of the sensor data analysis system that analyzes the sensor data output from the sensor installed in the production equipment in the factory.
The sensor data analysis system includes a data collection device, a data linkage server, a data visualization server, an external linkage server, and an alarm device.
The data collection device, the data linkage server, the data visualization server, the external linkage server, and the alarm device are connected by the same network in the factory.
A step in which the data collecting device receives the sensor data, performs protocol conversion, and transmits the sensor data to the data linkage server.
The data linkage server refers to a data flow in which data format conversion information, data type conversion information, data destination information, and condition information when transmitting data are defined, and the data format conversion information and the data type conversion information. According to the above, data format conversion and data type conversion of the received sensor data are performed, and the data is transmitted to the data visualization server, the external cooperation server, and the alarm device according to the data transmission destination information and the condition information when transmitting the data. Steps and
The data visualization server receives the sensor data, outputs the sensor data to the connected client device, and the client device displays the sensor data in real time on the sensor data monitoring screen.
A sensor data analysis method comprising the step of receiving the sensor data and transmitting the sensor data to an external server connected to a network different from the same network in the factory. ..

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