KR102672558B1 - Management system and method for smart factory - Google Patents

Abstract

The present invention relates to a management system and method for a smart factory, and includes a state information detection unit that detects the state information of the device, an external factor detection unit that detects environmental information outside the device, and measurement data detected by the state information detection unit. A management control unit that corrects according to the detection result of the external factor detection unit, a deterioration diagnosis module that checks the measurement data corrected by the management control unit to analyze trends and diagnoses the degree of deterioration of the device, and a deterioration diagnosis module A replacement determination module that checks the diagnosis results, predicts maintenance costs incurred in response to the degree of deterioration of the device, and loss costs due to production and quality deterioration of the smart factory, and determines whether to replace the deteriorated device; If replacement is necessary according to the judgment result of the replacement judgment module, it may include a production volume adjustment module that adjusts the production volume and allows the management and control unit to control each device by adjusting the production volume of each device after replacement.

Description

Smart factory management system and method {Management system and method for smart factory}

The present invention relates to a smart factory management system and method, and more specifically, to a smart factory management system and method that evaluates the degree of deterioration of individual devices constituting a smart factory and allows them to be replaced.

Factories that produce specific products have recently been operated by automated systems. Previously, the automation system of these factories was not connected to an external network and was a closed type operated by configuring an independent network for each factory automation system, but recently, these factory automation systems have been connected to an external network to control and produce There are active attempts to reuse data produced from devices for production and management.

Attempts to connect each device of this factory automation system to a network are being made in the form of industrial IoT (INDUSTRIAL IoT) due to the recent increase in interest in the Internet of Things (INTERNET OF THINGS) and the generalization of technology. This industrial IoT does not just network and automate only factory production facilities, but also involves even detailed parts of the factory system in IoT, enabling automatic control and various management, as well as using various internal and external data for factory operation. It is possible to greatly improve operational efficiency.

In particular, by applying IoT, various devices with various protocols can participate in the system, making it possible to configure an advanced system compared to the automation system used in the past.

The individual facilities that make up a large-scale smart factory interact organically with each other. For example, products pretreated in a pretreatment facility are transferred to the next processing facility during the manufacturing process using a transfer robot. In this connection structure of facilities, if a failure occurs in one facility, the entire manufacturing line including the failed facility must be stopped, so predicting facility failure is very important in the operation of a smart factory.

Typically, manufacturing facilities may have self-diagnosis functions, but as explained above, because a large amount of diverse data is shared inside and outside the smart factory, it is difficult to accurately detect abnormal signals from individual facilities.

As a prior art for smart factory control, there is one in Publication Patent No. 10-2019-0062739 (data analysis method, algorithm, and device for predicting equipment failure in the manufacturing process using multiple sensors, published on June 7, 2019). A technology is described that can predict failure of production equipment by attaching multiple sensors to production equipment and comparing the complex pattern of each sensor with an abnormal complex pattern.

However, in the prior art, as multiple sensors must be mounted on production equipment and their signals must be received periodically, the amount of data in a smart factory can be further increased, and costly problems can be predicted.

In addition, in order to replace equipment, it is necessary to comprehensively review the current production volume or production plan, but conventionally, only the failure prognosis of a single piece of equipment is detected, so it is not possible to determine the exact replacement time or automatically establish a production plan during replacement work. The downside was that it couldn't be done.

The purpose of the present invention in consideration of the above problems is to provide a system that checks the deterioration state of individual devices constituting a smart factory and determines whether and when to replace them by considering the maintenance and loss costs of the deteriorated devices. It provides a method.

Another purpose of the present invention is to provide a system and method for re-establishing an entire production plan when replacing a device and controlling other devices according to the production plan.

A smart factory management system according to one aspect of the present invention for solving the above technical problems includes a state information detection unit that detects state information of the device, an external factor detection unit that detects environmental information outside the device, and the state A management control unit that corrects the measurement data detected in the information detection unit according to the detection results of the external factor detection unit, checks the corrected measurement data in the management control unit, analyzes trends, and diagnoses the degree of deterioration of the device. Check the diagnosis results of the module and the deterioration diagnosis module, predict maintenance costs incurred in response to the degree of deterioration of the device, and loss costs due to production and quality deterioration of the smart factory to determine whether to replace the deteriorated device. A replacement judgment module that makes a judgment, and a production volume adjustment module that allows the management and control unit to control each device by adjusting the production volume when replacement is necessary according to the judgment result of the replacement judgment module and also adjusting the production volume of each device after replacement. It can be included.

In an embodiment of the present invention, the replacement determination module may compare the sum of maintenance cost and loss cost with the replacement cost and determine replacement when the replacement cost is less.

In an embodiment of the present invention, the production volume adjustment module may perform production volume adjustment during a replacement operation and production volume adjustment after the replacement operation.

In addition, the smart factory management method according to another aspect of the present invention includes the steps of a) compensating measurement data measuring the state information of the device according to external factors, and b) determining the degree of deterioration of the device using the compensated measurement data. It may include the steps of diagnosing, c) determining whether or not to replace the device using the diagnosed degree of deterioration, and d) adjusting the production volume of each production line if it is determined to be replaced.

In an embodiment of the present invention, step c) may compare the sum of maintenance costs and loss costs with the replacement cost, and determine replacement when the replacement cost is less.

In an embodiment of the present invention, step d) may perform production volume adjustment during the replacement operation and production volume adjustment after the replacement operation.

The present invention checks the deterioration state of the devices that make up the smart factory, determines the cost required for maintenance of the device and the cost incurred when replacing the device, and automatically determines maintenance or replacement of the device, thereby eliminating unnecessary It has the effect of minimizing losses due to device replacement.

In addition, the present invention readjusts the entire production plan of the smart factory in consideration of the time required to replace deteriorated devices that need replacement, and controls all devices according to the readjusted production plan, thereby reducing the risk of replacement of deteriorated devices. It has the effect of preventing decline in productivity.

1 is a configuration diagram of a smart factory management system according to a preferred embodiment of the present invention.
Figure 2 is a flowchart of the process of predicting failure of devices constituting a smart factory in the present invention.
Figure 3 is a flowchart of the device replacement determination process.
Figure 4 is a flowchart of the process of adjusting production volume upon replacement.
Figure 5 is a flow chart of the process of readjusting the production capacity of the device after replacement.
Figure 6 is a flow chart for determining device failure due to factors other than deterioration.

Since the present invention can make various changes and have various embodiments, specific embodiments will be illustrated in the drawings and described in detail. However, this is not intended to limit the present invention to specific embodiments, and should be understood to include all changes, equivalents, and substitutes included in the spirit and technical scope of the present invention.

While describing each drawing, similar reference numerals are used for similar components. In describing the present invention, if it is determined that a detailed description of related known technologies may obscure the gist of the present invention, the detailed description will be omitted.

Terms such as first, second, etc. may be used to describe various components, but the components should not be limited by the terms. The above terms are used only for the purpose of distinguishing one component from another.

For example, a first component may be named a second component without departing from the scope of the present invention, and similarly, the second component may also be named a first component.

The term and/or includes any of a plurality of related stated items or a combination of a plurality of related stated items.

When a component is said to be "connected" or "connected" to another component, it is understood that it may be directly connected to or connected to the other component, but that other components may exist in between. It should be.

On the other hand, when it is mentioned that a component is “directly connected” or “directly connected” to another component, it should be understood that there are no other components in between.

The terms used in this application are only used to describe specific embodiments and are not intended to limit the invention.

Singular expressions include plural expressions unless the context clearly dictates otherwise. In this application, terms such as “comprise” or “have” are intended to designate the presence of features, numbers, steps, operations, components, parts, or combinations thereof described in the specification, but are not intended to indicate the presence of one or more other features. It should be understood that this does not exclude in advance the possibility of the existence or addition of elements, numbers, steps, operations, components, parts, or combinations thereof.

Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meaning as generally understood by a person of ordinary skill in the technical field to which the present invention pertains.

Terms defined in commonly used dictionaries should be interpreted as having meanings consistent with the meanings they have in the context of the related technology, and unless clearly defined in the present application, should not be interpreted in an ideal or excessively formal sense. No.

1 is a configuration diagram of a smart factory management system according to a preferred embodiment of the present invention.

Referring to FIG. 1, the smart factory management system of the present invention includes a state information detection unit 20 that detects device status information, an external factor detection unit 30 that detects environmental information outside the device, and the status information detection unit 20. ) and a management control unit 10 that corrects the measurement data detected in the external factor detection unit according to the detection results of the external factor detection unit, checks the corrected measurement data in the management control unit 10, analyzes trends, and determines the degree of deterioration of the device. Check the deterioration diagnosis module 40 and the diagnosis results of the deterioration diagnosis module 40, maintenance costs incurred in response to the degree of deterioration of the device, and loss costs due to decline in production and quality of the smart factory. a replacement determination module 50 that predicts and determines whether to replace the deteriorated device; and, if replacement is necessary according to the determination result of the replacement determination module 50, adjusts the production volume and increases the production volume of each device after replacement. It is configured to include a production volume adjustment module 60 that adjusts the management and control unit 10 to control each device.

Hereinafter, the configuration and operation of the smart factory management system of the present invention configured as described above will be described in more detail.

First, the status information detection unit 20 detects the status information of each device constituting the smart factory or devices selected according to importance.

The status information at this time varies depending on the type of device, and can be information that can confirm the status of the device, such as pressure, temperature, vibration, voltage, current, and communication status.

Additionally, the external factor detection unit 30 may be a sensor device that detects the temperature, humidity, and dust amount information of the outside air from outside the device.

The information detected by the external factor detection unit 30 can be used to correct the measurement data detected by the state information detection unit 20.

For example, if the temperature of the device is higher than the normal temperature, check the outside temperature. If the outside temperature is higher than the normal outside temperature, you can correct the measured temperature of the device to lower the measured temperature value by the set value. there is.

Conversely, if the outside temperature is lower than the usual outside temperature, correction can be made to increase the temperature of the measured device by a set value.

This correction is made in the management control unit 10.

The management control unit 10 includes at least a processor and may include a communication unit for performing data communication with the status information detection unit 20 and the external factor detection unit 30.

Additionally, the management control unit 10 may include a display unit that displays processing results, an input unit that allows an operator to input settings, and a storage unit that stores the processing results.

The management control unit 10 is assumed to be a computing device that includes a processor and is capable of communication.

In this way, measurement data representing the state of the device considering the influence of external factors is provided to the deterioration diagnosis module 40 to diagnose the degree of deterioration of the device.

Figure 2 is a flowchart of the process of predicting failure of devices constituting a smart factory in the present invention.

As shown in FIG. 2, the processor of the management control unit 10 and the deterioration diagnosis module 40 collect measurement data of the state information detection unit 20 (S21) and detect the external factor detection unit 30. Compensating the measured data using the results (S22), analyzing trends in the compensated measured data using an artificial intelligence algorithm in the deterioration diagnosis module 40 (S23), and according to the analysis results It includes a step of diagnosing the degree of deterioration (S24) and a step of predicting the occurrence of a failure according to the diagnosed degree of deterioration (S25).

In this way, in the process of predicting the occurrence of a failure, the present invention can perform predictions based on the degree of deterioration of the actual device by compensating for the current state information of the device by external factors.

Next, using the obtained failure occurrence prediction result, the replacement determination module 50 can determine whether to replace the corresponding device.

Figure 3 is a flowchart of the replacement determination process of the replacement determination module 50.

As shown, the replacement determination module 50 preferably uses an artificial intelligence algorithm, and includes predicting maintenance costs and loss costs in response to the degree of deterioration (S31), and predicting maintenance costs and loss costs. It includes a step (S32) of considering whether to replace the device.

More specifically, in step S31, the replacement determination module 50 uses an artificial intelligence algorithm based on the degree of deterioration of the device to determine the maintenance cost of the device and the production volume of the smart factory that occur in response to the degree of deterioration of the device. Loss costs due to quality deterioration can be predicted.

The above loss costs due to the decline in production and quality of smart factories may take into account the loss due to the decrease in production due to device deterioration and the rate of defective products expected when using deteriorated devices.

Next, in step S32, the sum of the maintenance cost and loss cost predicted in step S31 is compared with the size of the cost due to replacement of the device, and it can be determined to replace the device when the replacement cost is less.

As described above, when the replacement determination module 50 determines maintenance and repair rather than replacement of the device, the management control unit 10 may output a maintenance decision result for the device.

Conversely, if the replacement determination module 50 determines replacement of the corresponding device, the production volume adjustment module 60 establishes an adjustment plan for the entire production plan.

Figure 4 is a flowchart of the process of adjusting the workload in the production volume adjustment module 60.

Referring to FIG. 4, the production volume adjustment module 60 determines whether to replace a specific device (S41), and when replacing a specific device, determines the maximum production volume of devices that are not replaced, that is, other production lines (S42). , adjust the production volume of other production lines using the determined maximum production volume (S43).

This partially stops operation in order to replace the device, and in this case, the workload of the device that is not replaced can be adjusted to ensure maximum productivity.

The maximum possible workload of each non-replaceable device can be determined, and the workload can be distributed corresponding to the maximum possible workload.

For example, if there are devices A, B, and C, the total production volume is 100, and the workload of each device is 25, 35, and 40, when device A stops operating to replace device A, the non-replaced Considering the maximum possible workload of device B and device C, the workload of device B and device C can be adjusted.

Additionally, the production volume adjustment module 60 can readjust the production volume of each production line after device replacement is completed.

Figure 5 is a flowchart of the process of readjusting the production volume of the device (production line including the replaced device) after replacement.

Referring to FIG. 5, the production volume adjustment module 60 and the management control unit 10 can readjust the production volume to meet the production plan, including the replaced equipment. Specifically, the production readjustment process includes the steps of collecting the degree of deterioration of the same equipment in each production line, including the replaced device (S51), and determining the maximum workable amount of each device in response to the degree of deterioration (S52). , It includes a step of distributing the production amount according to the production plan considering the maximum work capacity of each device (S53), and a step of controlling each device according to the distributed production amount (S54).

Since the degree of deterioration of replaced devices converges to 0, it is possible to work at the device's maximum output, and devices that have not been replaced can be controlled to produce less production than the replaced devices depending on the degree of deterioration.

Through this process, the present invention can maintain the operation rate of the smart factory in accordance with the overall production plan by adjusting the production volume of other devices during replacement work, and when replacement is completed, the production volume of other deteriorated devices is reduced again to reduce deterioration. It is possible to prevent a decrease in yield due to .

Figure 6 is a flow chart for determining device failure due to factors other than deterioration according to another embodiment of the present invention.

Equipment failure may occur due to factors other than deterioration, such as equipment damage or poor contact, and the management control unit 10 can detect failures caused by causes other than deterioration.

First, in step S61, the management control unit 10 corrects the measured data detected by the state information detection unit 20 in response to the degree of deterioration diagnosed by the deterioration degree diagnosis module 40.

The management and control unit 10 stores information on the normal value (or normal value range) of the measured data for each device and stores a correction value of the measured data according to the degree of deterioration.

If the temperature detection result is A and the correction value according to the degree of deterioration is +1, correction is performed by adding 1 to A, which is the detection data.

Next, compare the corrected measurement data with the normal value as in step S62, and check whether they match as in step S63.

If they match, it is determined that there is no cause of failure other than deterioration.

Next, if it is determined that the judgment result in step S63 does not match as in step S64, a failure event is generated and an alarm is generated as in step S65 to propagate the occurrence of a device failure due to a cause other than deterioration.

Through this process, the present invention can detect device failures caused by factors other than deterioration and enable appropriate measures to be taken when a failure occurs.

Although embodiments according to the present invention have been described above, they are merely illustrative, and those skilled in the art will understand that various modifications and equivalent scope of embodiments are possible therefrom. Therefore, the true technical protection scope of the present invention should be determined by the following claims.

10: Management control unit 20: Status information detection unit
30: External factor detection unit 40: Deterioration diagnosis module
50: Replacement judgment module 60: Production volume adjustment module

Claims (6)

A status information detection unit that detects status information of the device;
an external factor detection unit that detects environmental information external to the device;
a management control unit that corrects the measurement data detected by the state information detection unit according to the detection result of the external factor detection unit;
a deterioration diagnosis module that checks the measurement data corrected by the management control unit, analyzes trends, and diagnoses the degree of deterioration of the corresponding device;
Replacement to determine whether to replace the deteriorated device by checking the diagnosis result of the deterioration diagnosis module, predicting the maintenance cost incurred in response to the degree of deterioration of the device and the loss cost due to the production and quality deterioration of the smart factory. Judgment module; and
If replacement is necessary according to the judgment result of the replacement judgment module, it includes a production volume adjustment module that adjusts the production volume and adjusts the production volume of each device after replacement so that the management and control unit controls each device,
The production volume adjustment module is,
Collect the degree of deterioration of the same equipment in each production line, including replaced equipment,
Determine the maximum work capacity of each device in response to the degree of deterioration,
Distribute production volume according to the production plan, taking into account the maximum work capacity of each device,
Control each device according to the distributed production volume,
The smart system is characterized in that the replaced device is controlled to work at the maximum output of the replaced device by determining the degree of deterioration to converge to 0, and the devices that were not replaced are controlled to produce less production than the replaced device depending on the degree of deterioration. Factory management system. According to paragraph 1,
The replacement determination module is,
A smart factory management system that compares the sum of maintenance and loss costs with the replacement cost and determines replacement when the replacement cost is lower. According to paragraph 2,
The production volume adjustment module is,
A smart factory management system characterized by adjusting production volume during replacement work and adjusting production volume after replacement work. delete delete delete