WO2011004454A1 - 操業支援装置、操業支援方法及びプログラム - Google Patents
操業支援装置、操業支援方法及びプログラム Download PDFInfo
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- WO2011004454A1 WO2011004454A1 PCT/JP2009/062351 JP2009062351W WO2011004454A1 WO 2011004454 A1 WO2011004454 A1 WO 2011004454A1 JP 2009062351 W JP2009062351 W JP 2009062351W WO 2011004454 A1 WO2011004454 A1 WO 2011004454A1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
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- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Definitions
- the present invention relates to an operation support apparatus and an operation support method that support the operation of a manufacturing facility that manufactures a product, and a program for causing a computer to execute the operation support method.
- Patent Document 1 Conventionally, as a method of assisting an operator such as an operator when operating a manufacturing facility, guidance on past operation example data in the manufacturing facility has been performed (for example, Patent Document 1 and Patent Document below). 2).
- Patent Document 1 discloses a technology for classifying operation cases into categories and guiding operation patterns of similar operations as a method for supporting operation of a coke factory.
- Patent Document 2 listed below discloses a technique relating to a plant operation support apparatus that performs alarm prediction and process data trend prediction and operation guidance in a system using information equipment such as a computer used in a plant. A technique for automatically accumulating examples of operation patterns is disclosed.
- the present invention has been made in view of such problems, and in the operation of manufacturing facilities, how the operator is concerned with the operation in the future based on the actual values of operational process data related to the equipment. It is an object to provide a technique for assisting so that it is possible to easily and accurately determine whether or not to operate equipment and the like.
- the operation support device of the present invention is an operation support device that supports the operation of a manufacturing facility that manufactures a product.
- the operation support device is process data related to the operation of the manufacturing facility, and is set based on an operation by an operator in the manufacturing facility.
- Operation process data acquisition means for acquiring operation process data having first process data as actual values and second process data including data relating to the quality of the product or the quality of the operation, and the operation process data Operation process data acquired by the acquisition means, which is stored in the past and stores past operation process data in the past operation of the manufacturing facility and current operation process data in the current operation of the manufacturing facility
- Operation process data storage means and the first process data in the current operation process data Based on the second process data, similar operation search means for searching past operation process data similar to the current operation process data from the past operation process data, and the first process data
- an action determination unit that determines whether or not there is an action of an operation by an operator, and an action that stores action data related to the action determined by the action determination unit A
- the operation support method of the present invention is an operation support method by an operation support apparatus that supports operation of a manufacturing facility that manufactures a product, and is process data relating to operation of the manufacturing facility, and is operated by an operator in the manufacturing facility.
- An operation process data acquisition step for acquiring operation process data having first process data that is a performance value set based on the second process data including data relating to the quality of the product or the quality of the operation; Operation process data acquired in the operation process data acquisition step, stored in the past, past operation process data in the past operation of the manufacturing facility, and current operation process data in the current operation of the manufacturing facility Is stored in the operation process data storage means of the operation support device.
- An action past operation search step for searching for action data related to the searched past operation process data, and an evaluation step for evaluating the action data searched in the action past operation search step using the second process data And have.
- the program of the present invention is a program for causing a computer to execute an operation support method by an operation support apparatus that supports operation of a manufacturing facility that manufactures a product, the process data relating to the operation of the manufacturing facility, and the manufacturing facility Operation to obtain operation process data having first process data that is a result value set based on an operation by an operator and second process data including data relating to the quality of the product or the quality of the operation Process data acquisition step, operation process data acquired in the operation process data acquisition step, stored in the past, past operation process data in the past operation of the manufacturing facility, and current operation of the manufacturing facility Current operation process data in the operation support device of the operation support device.
- the current process data storage step stored in the data storage means Whether or not there has been an action of an operation by an operator in the operation of the first process data based on the first process data based on the first process data and a similar operation search step for searching past operation process data similar to the operation process data
- An action determination step for determining the action data, an action data storage step for storing action data relating to the action determined in the action determination step in an action data storage means of the operation support device, and an action data storage means
- Action de Action past operation search step for searching action data related to past operation process data searched in the similar operation search step, and the action past operation search step using the second process data.
- An evaluation step for evaluating the retrieved action data is to be executed by a computer.
- the present invention it is possible to provide a technique for assisting a worker so that an operator can easily and accurately determine how to perform an operation related to the operation in the future in the operation of the manufacturing facility. As a result, for example, it can be expected that even an unskilled worker can appropriately deal with the situation when an operational problem occurs.
- FIG. 1 is a schematic diagram illustrating an example of a schematic configuration of an operation support system according to an embodiment of the present invention.
- FIG. 2 is a schematic diagram illustrating an example of an internal hardware configuration of the operation support apparatus according to the embodiment of the present invention.
- FIG. 3 is a schematic diagram illustrating an example of a functional configuration related to processing of the operation support apparatus according to the embodiment of the present invention.
- FIG. 4 is a schematic diagram showing an example of manufacturing condition data stored in the manufacturing condition data storage area shown in FIG.
- FIG. 5 is a schematic diagram illustrating an example of a similar operation determination table stored in the similar operation determination table storage area illustrated in FIG. 3.
- FIG. 6A is a schematic diagram illustrating an example of past operation process data stored in the operation process data storage area illustrated in FIG. 3.
- FIG. 6B is a schematic diagram illustrating an example of current operation process data stored in the operation process data storage area illustrated in FIG. 3.
- FIG. 7A is a schematic diagram illustrating an example of an image related to processing of the operation support apparatus according to the embodiment of the present invention.
- Drawing 7B is a mimetic diagram showing an example of an image concerning processing of an operation support device concerning an embodiment of the present invention.
- FIG. 7C is a schematic diagram illustrating an example of an image related to processing of the operation support apparatus according to the embodiment of the present invention.
- FIG. 8A is a schematic diagram illustrating an example of an action determination table stored in the action determination table storage area illustrated in FIG. 3.
- FIG. 8B is a schematic diagram showing an image of processing using the action determination table shown in FIG. 8A.
- FIG. 9 is a schematic diagram showing an example of action data stored in the action data storage area shown in FIG.
- FIG. 10 is a schematic diagram showing an example of an action search period definition table stored in the action search period definition table storage area shown in FIG.
- FIG. 11A is a schematic diagram illustrating an example of an action evaluation logic table included in the action evaluation table stored in the action evaluation table storage area illustrated in FIG. 3.
- FIG. 11B is a schematic diagram illustrating an example of an action evaluation weighting table included in the action evaluation table stored in the action evaluation table storage area illustrated in FIG. 3.
- FIG. 11C is a schematic diagram illustrating an example of an action comprehensive evaluation determination table included in the action evaluation table stored in the action evaluation table storage area illustrated in FIG. 3.
- FIG. 12 is a schematic diagram showing an example of a display screen displayed on the CRT display device shown in FIG.
- FIG. 13 is a flowchart illustrating an example of a processing procedure of an operation support method by the operation support apparatus according to the embodiment of the present invention.
- FIG. 1 is a schematic diagram illustrating an example of a schematic configuration of an operation support system according to an embodiment of the present invention.
- the operation support system 100 includes a host computer 110, an operation support device 120, a CRT display device 130, a manufacturing facility 140 (140-1, 140-2,...), And a network 150. (150-1, 150-2).
- the host computer 110 controls the operation of the operation support system 100 in an integrated manner, and communicates with the operation support apparatus 120 via the network 150-1 as necessary.
- the operation support device 120 is a device that supports the operation of the manufacturing facility 140 that manufactures a steel plate (product), and includes, for example, a process computer.
- the operation support device 120 communicates with the host computer 110 via the network 150-1 as necessary, and also communicates with the CRT display device 130 and the facility management device 141 via the network 150-2. .
- the CRT display device 130 is provided, for example, in a production line of a production factory, and communicates with the operation support device 120 and the equipment management device 141 of the production equipment 140 via the network 150-2 as necessary, and various types of devices are provided. Information and various data are displayed. Further, the CRT display device 130 is configured so that an operator (operator) 200 can perform an operation input and the like.
- the manufacturing facility 140 is arranged in each manufacturing process in the manufacturing line, and the operation is performed under the control of the worker 200.
- the manufacturing facility 140 includes a facility management device 141 and a facility adjustment device 142.
- the facility management device 141 performs overall management of the manufacturing facility 140 and is configured to be able to communicate with the operation support device 120 and the CRT display device 130 via the network 150-2.
- the equipment adjustment device 142 includes, for example, a sensor 1421, a motor 1422, a valve 1423, and the like, and has a function of adjusting the operation process of the manufacturing equipment 140. Further, the manufacturing facility 140 is configured such that the operator 200 can automatically adjust the facility adjusting device 142 when the operator 200 inputs an instruction to the facility management device 141, and the worker 200 adjusts the facility. It is configured such that the equipment adjustment device 142 can be manually adjusted by directly operating the device 142.
- a PLC Programmable Logic Controller
- the equipment management device 141 for example, a PLC (Programmable Logic Controller) or the like can be applied as the equipment management device 141.
- a load cell as a rolling force sensor as a sensor 1421
- a rotation detection sensor of a motor 1422 a motor for rotating a rolling roll as a motor 1422
- a hydraulic valve as a valve 1423 Etc.
- the network 150-1 connects the host computer 110 and the operation support apparatus 120 so that they can communicate with each other.
- the network 150-2 allows the operation support apparatus 120, the CRT display apparatus 130, and the facility management apparatus 141 to communicate with each other. To connect to.
- FIG. 2 is a schematic diagram illustrating an example of an internal hardware configuration of the operation support apparatus 120 according to the embodiment of the present invention.
- the operation support apparatus 120 includes a CPU 121, a ROM 122, a RAM 123, a pointing device (PD) 124, a program storage medium 125, an information storage medium 126, a display device 127, a communication interface ( (Communication I / F) 128 and a bus 129.
- the CPU 121 controls the operation of the operation support apparatus 120 in an integrated manner, and controls each component (122 to 128) of the operation support apparatus 120 via the bus 129.
- the ROM 122 stores a BIOS (Basic Input / Output System), an operating system program (OS), and the like related to the operation of the CPU 121.
- BIOS Basic Input / Output System
- OS operating system program
- the RAM 123 functions as a main memory and work area for the CPU 121.
- the CPU 121 loads necessary programs from the ROM 122 and a program storage medium 125 to be described later, and necessary information from the information storage medium 126 to be described later to the RAM 123, and processes the programs and the information.
- Various operations are realized by executing.
- the PD 124 includes, for example, a mouse, a keyboard, and the like, and is an operation input means for an operator (operator 200) to input an operation to the operation support apparatus 120 as necessary.
- the program storage medium 125 is a storage medium that stores various programs including the control program 1251.
- the control program 1251 is a program used when the CPU 121 executes the process of FIG.
- the information storage medium 126 is a storage medium that stores various information (data and the like) necessary when the CPU 121 performs processing, and stores various information (data and the like) obtained by the processing of the CPU 121.
- a storage area for storing these various types of information (data and the like) is provided.
- a manufacturing condition data storage area 126A for storing manufacturing condition data 1261
- a similar operation determination table storage area 126B for storing a similar operation determination table 1262
- operation process data Operation process data storage area 126C for storing 1263
- action determination table storage area 126D for storing action determination table 1264
- action data storage area 126E for storing action data 1265
- a search period definition table storage area 126F and an action evaluation table storage area 126G for storing an action evaluation table 1267 are provided.
- Various information (data etc.) stored in the information storage medium 126 will be described later.
- the display device 127 is a display unit that displays various information, menu images, and the like based on the control of the CPU 121.
- the communication I / F 128 communicates with an external device via the network 150 (150-1, 150-2) based on the control of the CPU 121.
- the bus 129 is a bus for connecting the CPU 121, the ROM 122, the RAM 123, the PD 124, the program storage medium 125, the information storage medium 126, the display device 127, and the communication I / F 128 so that they can communicate with each other.
- the host computer 110, the CRT display device 130, and the facility management device 141 shown in FIG. 1 are also configured with the hardware configuration shown in FIG. In this case, various information (1261 to 1266) shown in FIG. 2 is not stored in the information storage medium 126 of these apparatuses. Further, for example, the CRT display device 130 and the facility management device 141 may further include a speaker for notifying the worker 200 of the manufacturing status by voice.
- FIG. 3 is a schematic diagram illustrating an example of a functional configuration related to processing of the operation support apparatus 120 according to the embodiment of the present invention.
- FIG. 3 shows various storage areas (126A to 126F) configured in the information storage medium 126 shown in FIG.
- the manufacturing condition data acquisition unit 301 acquires manufacturing condition data 1261 related to the manufacturing conditions of the manufacturing facility 140 from the host computer 110. Then, the manufacturing condition data acquisition unit 301 stores the acquired manufacturing condition data 1261 in the manufacturing condition data storage area 126 ⁇ / b> A of the information storage medium 126 in association with identification information for identifying the operation in the manufacturing facility 140.
- FIG. 4 is a schematic diagram showing an example of manufacturing condition data 1261 stored in the manufacturing condition data storage area 126A shown in FIG.
- the manufacturing condition data 1261 various data including the finished size (thickness, width, length) of the steel plate, the finished temperature of the steel plate, and the product type of the steel plate are the operations in the manufacturing facility 140 (that is, It is stored in association with an operation ID which is identification information for identifying a lot of steel plates.
- the manufacturing condition data storage area 126A as shown in FIG. 4, the past manufacturing condition data (manufacturing condition data with operation IDs 1 to 40) in the manufacturing equipment 140 and the current manufacturing condition data (operation ID) 41 manufacturing condition data) is stored.
- FIG. 4 the past manufacturing condition data (manufacturing condition data with operation IDs 1 to 40) in the manufacturing equipment 140 and the current manufacturing condition data (operation ID) 41 manufacturing condition data
- the current manufacturing condition data with the operation ID 41 is a steel plate thickness finish size of 10 mm, a steel plate width finish size of 2700 mm, and a steel plate length finish size of 30 m.
- the finishing temperature of the steel sheet is 735 ° C.
- the product type (hardness etc.) of the steel sheet is AAAA.
- FIG. 5 is a schematic diagram illustrating an example of the similar operation determination table 1262 stored in the similar operation determination table storage area 126B illustrated in FIG.
- This similar operation determination table 1262 shows determination conditions serving as a reference for determining operations similar to the operations in the manufacturing condition data 1261 shown in FIG. More specifically, in the example shown in FIG. 5, the similar operation determination table 1262 has a steel plate thickness finish size within ⁇ ⁇ mm, a steel plate width finish size within ⁇ ⁇ mm, When the finished size of the length is within ⁇ ⁇ m, the finishing temperature of the steel plate is within ⁇ ⁇ ° C, and the product type (hardness) of the steel plate is AA-- (-is optional), etc. Judgment conditions for judging similar operations are shown. In the example shown in FIG. 5, only one determination condition is shown for simplicity of explanation, but a plurality of determination conditions are provided, and one determination condition is selected from among them. There may be.
- the operation process data acquisition unit 302 acquires process data (operation process data 1263) related to the operation of the manufacturing facility 140 from the facility management device 141 of the manufacturing facility 140 before or after rolling the steel sheet in each lot. At this time, the operation process data acquisition unit 302 acquires the operation ID in the operation process data from the manufacturing condition data acquisition unit 301, and inputs and acquires the operation process data 1263 in association with the operation ID. In this case, as shown in FIG. 4, since the operation ID is associated with the manufacturing condition data 1261, as a result, the operation process data acquisition unit 302 acquires the operation process data 1263 in association with the manufacturing condition data 1261. can do. Then, the operation process data acquisition unit 302 stores the operation process data 1263 acquired from the equipment management apparatus 141 in the operation process data storage area 126C of the information storage medium 126 in association with the operation ID acquired from the manufacturing condition data acquisition unit 301. To do.
- the operation process data 1263 acquired by the operation process data acquisition unit 302 includes the past operation process data 1263a in the past operation of the manufacturing facility 140 and the current operation (operation of the manufacturing facility 140). Middle) and the current operation process data 1263b. Then, the current operation process data 1263b is sequentially accumulated, and the past operation process data 1263a is formed.
- FIG. 6A is a schematic diagram showing an example of past operation process data 1263a stored in the operation process data storage area 126C shown in FIG.
- FIG. 6B is a schematic diagram illustrating an example of current operation process data 1263b stored in the operation process data storage area 126C illustrated in FIG.
- one operation process data acquired for each operation (lot) at the time of each rolling of the steel sheet from the equipment management apparatus 141 is similar operation search described later.
- Similar operation search target process data to be searched by the unit 303 operable process data that can be operated by the operator 200 via the equipment adjustment device 142 in the manufacturing facility 140 (can be set by the operator 200 who is the operator), and Assume that evaluation target process data used for evaluation of action data described later based on the operable process data is included.
- the operation process data acquisition unit 302 has, as one operation process data, operable process data corresponding to the first process data and similar operation search corresponding to second process data different from the operable process data.
- Process data including target process data and evaluation target process data is acquired.
- the “rolling force” data of the steel plate corresponds to the above-described similar operation search target process data
- the “rolling position” data of the steel plate is the operable process data described above.
- the data of “plate bending” and “plate flatness” of the steel plate correspond to the above-described evaluation target process data.
- similar operation search target process data and operable process data one example is shown in the examples shown in FIGS. 6A and 6B, but in the present embodiment, a plurality of data can be applied. is there.
- the following data can be applied as the similar operation search target process data, operable process data, and evaluation target process data.
- the similar operation search target process data data including at least one of the measured value by the sensor 1421 disposed in the manufacturing facility 140 and the actual value regarding the state of the manufacturing facility 140 can be applied.
- the operable process data data of actual values set based on the operation by the worker 200 in the manufacturing facility 140 can be applied.
- the evaluation target process data data relating to the quality of the product (for example, the quality of the rolled steel sheet or the like) or the quality of the operation can be applied.
- FIG. 6A shows a plurality of past operation process data 1263a corresponding to the past manufacturing condition data with the operation IDs 1 to 40 shown in FIG. 4 together with the time information. That is, the operation process data storage area 126C is associated with the past manufacturing condition data (manufacturing condition data with the operation ID of 1 to 40) stored in the manufacturing condition data storage area 126A by the operation ID. Operation process data 1263a is stored.
- the current operation process data 1263b corresponding to the current production condition data relating to the current operation (that is, the steel plate in progress) having the operation ID 41 shown in FIG. A plurality of times are also shown. That is, in the operation process data storage area 126C, the current operation process is associated with the current manufacturing condition data (manufacturing condition data with an operation ID of 41) stored in the manufacturing condition data storage area 126A by the operation ID. Data 1263b is stored.
- the operation process data acquisition unit 302 subsequently obtains the next operation ID (operation ID is 42) from the manufacturing condition data acquisition unit 301, the operation process data with the operation ID of 41 is obtained as shown in FIG.
- the operation process data having the operation ID of 40 is stored as the past operation process data 1263a shown in FIG. 6B, and the operation process data having the operation ID of 42 is stored as the current operation process data 1263b shown in FIG. 6B. Processing is performed sequentially.
- the similar operation search unit 303 Based on the similar operation search target process data of the current operation process data 1263b, the similar operation search unit 303 obtains past operation process data 1263a similar to the current operation process data 1263b from the past operation process data 1263b. Perform search processing.
- similar past operation process data 1263a is searched based on similar operation search target process data (in this example, “rolling force” data). It is not limited to this.
- similar operation search target process data in the similar operation search unit 303, based on the operable process data (in this example, “clamping position data”), or evaluation target process data (in this example, “plate bending” data, “plate flatness”)
- a mode of searching for similar past operation process data 1263a based on “degree” data) is also included.
- the similar operation search unit 303 first uses the similar operation determination table 1262 shown in FIG. 5 to store past manufacturing condition data (the operation ID shown in FIG. 4 is stored in the manufacturing condition data storage area 126A). 1 to 40 manufacturing condition data) and search for past manufacturing condition data similar to the current manufacturing condition data in the current operation process data 1263b (the manufacturing condition data having the operation ID 41 shown in FIG. 4). , Narrow down the search range. More specifically, the similar operation search unit 303 selects the current manufacturing condition data with the operation ID 41 shown in FIG. 4 from the past manufacturing condition data with the operation ID 1 to 40 shown in FIG. Are searched for those satisfying the determination conditions defined in the similar operation determination table 1262, and the operation ID of the searched past manufacturing condition data is acquired. Then, using the acquired operation ID, the search range of the past operation process data 1263a shown in FIG. 6A is narrowed down.
- the similar operation search unit 303 uses the past operation process data 1263a that has been narrowed down as a search range, and based on the data of “rolling force” that is the process operation target process data, the current operation process data 1263b and A process of searching for similar past operation process data 1263a is performed.
- a search method using the similar operation search target process data by the similar operation search unit 303 various methods have been conventionally proposed. For example, the method shown in Patent Document 3 described above can be applied. it can.
- FIG. 7A to 7C are schematic views showing an example of an image related to processing of the operation support apparatus 120 according to the embodiment of the present invention.
- FIG. 7A shows “rolling force” data, which is the similar operation search target process data 710 in the current operation process data 1263b, together with the elapsed time.
- 7B and 7C show an example of past operation process data 1263a searched by the similar operation search unit 303 as being similar to the current operation process data 1263b shown in FIG. 7A.
- 7B and 7C show similar operation search target process data (data of “rolling force” shown in FIG. 6A) 711 and 712 in the past operation process data 1263a, respectively.
- FIG. 7B the operable process data 721-1 and 722-1 in the past operation process data 1263a are shown together with the elapsed time, and the evaluation target process data 731 in the past operation process data 1263a is shown together with the elapsed time.
- FIG. 7C shows operable process data 721-2 and 722-2 in the past operation process data 1263a along with the elapsed time, and evaluation target process data 732 in the past operation process data 1263a along with the elapsed time. Has been.
- FIG. 7B and FIG. 7C for example, as the operable process data 721 (721-1 and 721-2), the data of the “rolling position” shown in FIG. 6A is shown, and the operable process data 722 is shown.
- FIG. 7B and 7C show, for example, “plate flatness” data shown in FIG. 6A as the evaluation target process data 731 and 732.
- FIGS. 7B and 7C there is of course the data of “plate bending” shown in FIG. 6A.
- the action determination unit 304 determines the operable process based on the operable process data of the operation process data 1263 stored in the operation process data storage area 126C (such as the data of “crush position” shown in FIGS. 6A and 6B). In the operation on the data, a process for determining whether or not there is an operation action by the operator 200 is performed. At this time, the action determination unit 304 determines whether or not there has been an action of an operation by the worker 200 using the action determination table 1264 stored in the action determination table storage area 126D.
- FIG. 8A is a schematic diagram showing an example of the action determination table 1264 stored in the action determination table storage area 126D shown in FIG.
- FIG. 8B is a schematic diagram showing an image of processing using the action determination table shown in FIG. 8A.
- the action ID of the action determination data information is identification information assigned for each type of action of operation by the worker 200.
- action data 1 with an action ID of 001 corresponds to the operable process data shown in FIGS. 7B and 7C (data of “crushing position” shown in FIG. 6A) 721-1 and 721-2.
- Action data 2 with ID 002 corresponds to the operable process data 722-1 and 722-2 shown in FIGS. 7B and 7C.
- the action determination table 1264 shown in FIG. 8A includes, for each type of action data (also referred to as action determination data), a reference value determination condition based on a detection cycle, a start time and an end time of a reference value measurement time range, and A change detection condition based on a change evaluation time, a significant change amount, a change continuation min (minimum), a change continuation max (maximum) and a significant change coefficient in action data is defined.
- FIG. 8B specifically shows an image of processing by the action determination unit 304 using the action determination table 1264 when the type of operable process data is action data 1 with the action ID 001 shown in FIG. 8A. Yes.
- FIG. 8B shows the start time t11 of the reference value measurement time range, the end time t12 of the reference value measurement time range, and the change evaluation time st1. The current time is assumed to be t0.
- processing of the action determination unit 304 by the action determination table 1264 will be described with reference to FIG. 8B.
- the action determination unit 304 determines that the change of the operable process data has started when the following expression (2) is satisfied (this time corresponds to the reference value measurement start time shown in FIG. 8B). ).
- s1 in the equation (2) corresponds to the value of the significant change defined by the action determination table 1264 shown in FIG. 8A.
- the action determination unit 304 calculates a reference value by the following method. Specifically, a range from (t0-st1-t11) time to (t0-st1-t12) time is set as a reference value measurement time range, and an average value of the operable process data in the reference value measurement time range is set as a reference value dk. Calculate as
- the data value de may be an instantaneous value at the end of change, or may be an average value in a certain time width centered on the end of change, for example.
- the action determination unit 304 is a change coefficient that is a change amount (action change amount ⁇ S) of the operation process data 1263 stored in the operation process data storage area 126C with respect to a predetermined time (change duration time ts).
- A is equal to or greater than a predetermined threshold (significant change coefficient a1), it is determined that there is an operation action by the worker 200.
- the action determination unit 304 determines that there is an action
- the action determination unit 304 stores the data related to the action as action data 1265 in the action data storage area 126E of the information storage medium 126.
- FIG. 7B shows a case where it is determined that the operable process data 722 (722-1) has an action.
- the operable process data 721 (721-2) has an action. Is shown.
- FIG. 9 is a schematic diagram showing an example of action data 1265 stored in the action data storage area 126E shown in FIG.
- the action data 1265 includes an operation ID based on the operation process data shown in FIGS. 6A and 6B, information about the action occurrence time indicating the action occurrence time, and the action ID and action type shown in FIG. 8A.
- the action change amount ( ⁇ S) information are stored in association with each other.
- the action occurrence time information is, for example, the current time t0 in the example shown in FIG. 8A.
- the action past operation search unit 305 searches the action data 1265 stored in the action data storage area 126E for action data in the past operation process data 1263a searched by the similar operation search unit 303 based on the operation ID. .
- the action past operation search unit 305 searches for action data in the past operation process data 1263a searched by the similar operation search unit 303, the current time of the current operation process data 1263b (shown in FIG. 7A). Search of action data within a predetermined period (action search period shown in FIG. 7A) before and after the equivalent time (current equivalent time shown in FIGS. 7B and 7C) of the past operation process data 1263a corresponding to (current time). I do.
- the action search period is set by the action search period definition table 1266 for each type of action.
- FIG. 10 is a schematic diagram showing an example of the action search period definition table 1266 stored in the action search period definition table storage area 126F shown in FIG.
- the action ID and action type information which is information indicating the type of the action data 1265 shown in FIG. 9, and the search indicating the action search period of each action data.
- the start time and search end time are shown.
- the search start time and the search end time represent relative times from the current equivalent time in past similar operations. Therefore, the search start time and the search start time are as follows.
- Search start time current equivalent time + search start time
- Search end time current equivalent time + search end time
- the action search period by the action past operation search unit 305 is from the search start time to the search end time.
- 7A to 7C show an example in which the search start time in the action search period definition table 1266 is a negative value and the search end time is a positive value.
- the search start time and the search end time can be set to arbitrary values as necessary.
- the similar operation evaluation unit 306 uses the action target operation search unit 305 by using the evaluation target process data in the operation process data 1263 (“plate bending” data and “plate flatness” data shown in FIGS. 6A and 6B). Evaluate the retrieved action data.
- FIG. 11A is a schematic diagram showing an example of an action evaluation logic table 12671 included in the action evaluation table 1267 stored in the action evaluation table storage area 126G shown in FIG.
- FIG. 11B is a schematic diagram showing an example of an action evaluation weighting table 12672 included in the action evaluation table 1267 stored in the action evaluation table storage area 126G shown in FIG.
- FIG. 11C is a schematic diagram showing an example of the action comprehensive evaluation determination table 12673 included in the action evaluation table 1267 stored in the action evaluation table storage area 126G shown in FIG. That is, the action evaluation table 1267 includes an action evaluation logic table 12671 shown in FIG. 11A, an action evaluation weighting table 12672 shown in FIG. 11B, and an action comprehensive evaluation determination table 12673 shown in FIG. 11C.
- various types of information are defined for each action ID and action type information indicating the type of action data 1265.
- conditions for obtaining an evaluation value of the evaluation data are defined for each evaluation target process data of the operation process data 1263 according to the type of the action data 1265.
- the evaluation target process data 1 is “plate flatness” data shown in FIGS. 6A and 6B
- the evaluation target process data 2 is “plate bending” data shown in FIGS. 6A and 6B.
- Evaluation conditions up to the evaluation target process data n are defined according to the number n of the evaluation target process data in the data 1263.
- FIG. 11A only the evaluation items of the evaluation conditions of the evaluation target process data 1 are shown in detail, but the evaluation items of the evaluation conditions also for the evaluation target process data 2 and the same as the evaluation target process data 1 Is set in detail.
- the evaluation in the evaluation target process data 1 of the action data 1 (the “plate flatness” data shown in FIGS. 6A and 6B) is set as the evaluation data 11.
- an evaluation period in the evaluation target process data 1 is provided.
- the action occurrence time shown in the action data 1265 of FIG. 9 (in this example, the action occurrence time of action data 1 shown in FIG. 9) is T0, and (T0 + TS11) time to (T0 + TE11) time.
- the range is set for the evaluation period.
- the similar operation evaluation unit 306 first obtains the first value V0, the last value VE, the maximum value Vmax, the minimum value Vmin, and the standard deviation ⁇ 1 in the evaluation period of the evaluation target process data 1.
- the similar operation evaluation unit 306 compares the first value V0 and the last value VE in the evaluation period to obtain a change direction. Then, the obtained change direction is evaluated based on the change direction of the action evaluation logic table 12671 shown in FIG. 11A (“increase” in the example shown in FIG. 11A).
- the similar operation evaluation unit 306 obtains a difference between the maximum value Vmax and the first value V0 when the obtained change direction is an increase, and minimizes the first value V0 and the minimum when the obtained change direction is a decrease.
- the change value is calculated by obtaining the difference between the values Vmin. Then, it is evaluated whether the obtained change value is within the change range ⁇ Vmin11 and change range ⁇ Vmax11 of the action evaluation logic table 12671 shown in FIG. 11A.
- the similar operation evaluation unit 306 obtains the deviation direction of the standard deviation ⁇ 1, and sets the obtained deviation direction to the deviation direction of the action evaluation logic table 12671 shown in FIG. 11A (“decrease” in the example shown in FIG. 11A). Based on evaluation. The similar operation evaluation unit 306 also evaluates whether the standard deviation ⁇ 1 is within the range of the deviation amount ⁇ min11 and the deviation amount ⁇ max11 of the action evaluation logic table 12671 shown in FIG. 11A.
- the similar operation evaluation unit 306 performs comprehensive evaluation on the evaluation target process data 1.
- a method of comprehensive evaluation at this time for example, a method of assigning a score by the establishment / non-establishment of a condition for each evaluation item, or only a designated condition is an absolute condition, and when the condition is not established, another evaluation item It is possible to apply various methods such as a method of multiplying the above score or a method of using an amount of deviation from the condition value of the evaluation item as the evaluation amount.
- an evaluation value is “1” if all evaluation items of the evaluation condition are satisfied, and an evaluation value is “0” when there is even one unsatisfied evaluation item. Apply.
- the evaluation target process data 2 (data of “board bending” shown in FIGS. 6A and 6B), and further shown in FIGS. 6A and 6B Evaluation is performed on the data acquired as the evaluation target process data of the operation process data 1263, and an evaluation value is calculated for each evaluation target process data.
- a process for calculating an evaluation value for each evaluation target process data is performed as in the case of action data 1.
- the similar operation evaluation unit 306 weights the evaluation values using the action evaluation weighting table 12672 shown in FIG. 11B with respect to the evaluation values based on the respective evaluation target process data of the action data 1, and the action data 1 comprehensive evaluation value H1 is calculated.
- the overall evaluation value H1 is (evaluation value in the evaluation target process data 1) ⁇ (weighting coefficient W11) + (evaluation value in the evaluation target process data 2) ⁇ (weighting coefficient W12) +. (Evaluation value in target process data n) ⁇ (weighting coefficient W1n).
- a form in which all 1s are applied to the weighting coefficients that is, a form in which the total evaluation value H1 is simply calculated by adding the evaluation values of the respective evaluation target process data is also included in the present embodiment.
- the comprehensive evaluation value H2 and the like are calculated in the same manner as the action data 1.
- the similar operation evaluation unit 306 evaluates the action data 1 based on the action comprehensive evaluation determination table 12673 shown in FIG. 11C using the calculated comprehensive evaluation value H1. Specifically, when the comprehensive evaluation value H1 is less than K11, it is determined that the operation action based on the action data 1 is defective. When the comprehensive evaluation value H1 is equal to or greater than K11 and equal to or less than K12 (K12> K11), it is determined that the operation action based on the action data 1 is standard (normal). When the comprehensive evaluation value H1 is larger than K12, it is determined that the operation action based on the action data 1 is good.
- the evaluation based on the action comprehensive evaluation determination table 12673 shown in FIG. 11C is performed using the comprehensive evaluation value as in the case of the action data 1.
- the evaluation target process data 731 and 732 shown in FIGS. 7B and 7C indicate the evaluation target process data 1 (data of “plate flatness” shown in FIGS. 6A and 6B).
- the value of the evaluation target process data 731 shown in FIG. 7B is subsequently decreased by the action of the operable process data 722-1.
- an example of a type of failure is shown.
- the evaluation target process data 732 shown in FIG. 7C is increased in value thereafter by the action of the operable process data 721-2, and in this example, an example of a good type is shown.
- the similar operation evaluation unit 306 calculates an evaluation value for the action data searched by the action past operation search unit 305 for each evaluation target process data in the operation process data 1263, and sets each calculated evaluation value. Based on this, the action data is evaluated.
- the past operation guidance notification control unit 307 performs control to display the action data searched by the action past operation search unit 305 on the CRT display device 130 and to notify the operator 200 of this.
- the past operation guidance notification control unit 307 displays the action data searched by the action past operation search unit 305 on the CRT display device 130 together with the evaluation result in the similar operation evaluation unit 306 to notify the operator 200.
- the past operation guidance notification control unit 307 may notify the operator 200 of the action data and its evaluation result by voice in addition to or instead of the display on the CRT display device 130. good.
- the past operation guidance notification control unit 307 displays the similarity among the action data searched by the action past operation search unit 305 when displaying the action data searched by the action past operation search unit 305 on the CRT display device 130. Only the evaluation result “good” in the operation evaluation unit 306 may be displayed, and control for notifying the operator 200 may be performed.
- FIG. 12 is a schematic diagram showing an example of a display screen displayed on the CRT display device 130 shown in FIG.
- the display screen displayed on the CRT display device 130 is performed based on the control of the past operation guidance notification control unit 307.
- the display screen of the CRT display device 130 shown in FIG. 12 includes action data information (action occurrence time information, action type) searched by the action past operation search unit 305 in the action data 1265 shown in FIG. Information, action change amount information), information on evaluation results in the similar operation evaluation unit 306, and a comprehensive evaluation value at that time.
- the past operation guidance notification control unit 307 evaluates the action data searched by the action past operation search unit 305 on the CRT display device 130 which is a display device in the area where the worker 200 exists, in the similar operation evaluation unit 306. Action data is notified by performing control to classify and display for each result (good, standard, defective).
- FIG. 13 is a flowchart illustrating an example of a processing procedure of an operation support method by the operation support apparatus 120 according to the embodiment of the present invention.
- the flowchart shown in FIG. 13 is performed by the CPU 121 executing the control program 1251.
- description will be made in association with the functional configuration shown in FIG. 3.
- the past operation process data 1263a is stored in the operation process data storage area 126C, and the current operation process data 1263b is acquired in the subsequent processing. Shall.
- the manufacturing condition data acquisition unit 301 acquires the current manufacturing condition data 1261 and the operation ID related to the manufacturing conditions of the manufacturing facility 140 from the host computer 110.
- the manufacturing condition data acquisition unit 301 stores the acquired current manufacturing condition data 1261 in association with the operation ID in the manufacturing condition data storage area 126A.
- the manufacturing condition data acquisition unit 301 transmits the acquired operation ID to the operation process data acquisition unit 302.
- step S ⁇ b> 102 the operation process data acquisition unit 302 acquires operation process data 1263 related to the operation of the manufacturing facility 140 from the facility management device 141 of the manufacturing facility 140. Then, the operation process data acquisition unit 302 associates the acquired operation process data 1263 as the current operation process data 1263b with the operation ID obtained from the manufacturing condition data acquisition unit 301, and stores the operation process data storage area of the information storage medium 126. Store in 126C. At this time, as described above, one operation process data includes the similar operation search target process data to be searched by the similar operation search unit 303, and the operator 200 operates in the manufacturing facility 140 via the equipment adjustment device 142. Possible operable process data and evaluation target process data to be evaluated for action data based on the operable process data are included.
- step S103 the similar operation search unit 303 is first stored in the manufacturing condition data storage area 126A using the similar operation determination table 1262 (FIG. 5) stored in the similar operation determination table storage area 126B.
- the similar past manufacturing condition data is searched from the past manufacturing condition data, the operation ID of the similar operation is specified, and the search range is narrowed down.
- the similar operation search unit 303 uses the past operation process data 1263a that has been narrowed down as a search range, and based on the similar operation search target process data of the current operation process data 1263b, from the past operation process data 1263a. Then, a process of searching for past operation process data 1263a similar to the current operation process data 1263b is performed.
- step S104 the action determination unit 304 uses the operable process data of the operation process data 1263 stored in the operation process data storage area 126C to perform the operation on the operable process data by the operator 200. Processing for determining whether or not there has been an action for the operation is performed. At this time, the action determination unit 304 uses the action determination table 1264 (FIG. 8A) stored in the action determination table storage area 126D to determine whether or not there has been an action for the operation by the worker 200. When the action determination unit 304 determines that there is an action, the action determination unit 304 stores the action data 1265 related to the action in the action data storage area 126E in association with the operation ID.
- step S105 the action past operation search unit 305 performs action data related to past operation process data 1263a searched by the similar operation search unit 303 from the action data 1265 stored in the action data storage area 126E. Are searched based on the operation ID.
- step S106 the similar operation evaluation unit 306 uses the evaluation target process data in the operation process data 1263 in the action evaluation table 1267 (FIGS. 11A to 11C) stored in the action evaluation table storage area 126G. Based on this, the action data searched by the action past operation search unit 305 is evaluated.
- step S107 the past operation guidance notification control unit 307 displays the action data searched by the action past operation search unit 305 on the CRT display device 130 together with the evaluation result in the similar operation evaluation unit 306, so that the operator Control to notify 200 is performed.
- step S107 the past operation guidance notification control unit 307 displays the action data retrieved by the action past operation retrieval unit 305 on the CRT display device 130, and the action retrieved by the action past operation retrieval unit 305.
- the data it may be a form in which only the data whose evaluation result in the similar operation evaluation unit 306 is “good” is displayed and notified to the worker 200.
- the data of “reduction position” is acquired as the process data for similar operation search, and the data of “plate bending” and “plate flatness” are acquired as the process data for evaluation.
- the similar operation search target process data and the evaluation target process data are different from each other.
- the present invention is not limited to this form.
- the similar operation search target process data and the evaluation target A form in which process data is acquired as the same data can also be applied.
- the “plate flatness” data shown in FIGS. 6A and 6B may be acquired as evaluation target process data and acquired as similar operation search target process data.
- the similar operation search unit 303 takes a form of searching past operation process data similar to the current operation process data from the past operation process data based on the data of “plate flatness”.
- the action data searched in the action past operation search unit 305 is notified to the worker 200 together with the evaluation result in the similar operation evaluation unit 306. It is possible to determine how the worker 200 should perform an operation related to the operation in the future.
- FIG. 13 showing the operation support method by the operation support apparatus 120 according to the present embodiment described above can be realized by the CPU 121 executing the control program 1251.
- This program and a computer-readable storage medium storing the program are included in the present invention.
- the program is recorded on a storage medium such as a CD-ROM, or provided to a computer via various transmission media.
- a storage medium for recording the program a flexible disk, a hard disk, a magnetic tape, a magneto-optical disk, a nonvolatile memory card, or the like can be used in addition to the CD-ROM.
- a transmission medium of the program a communication medium in a computer network (LAN, WAN such as the Internet, wireless communication network, etc.) system for propagating and supplying program information as a carrier wave can be used.
- examples of the communication medium at this time include a wired line such as an optical fiber, a wireless line, and the like.
- the present invention is not limited to a mode in which the function of the operation support apparatus 120 according to the present embodiment is realized by executing a program supplied by a computer.
- the program is also included in the present invention even when the function of the operation support apparatus 120 according to the present embodiment is realized in cooperation with an OS (operating system) or other application software running on the computer. .
- OS operating system
- the program is not limited to this program. Included in the invention.
- the present invention it is possible to provide a technique for assisting a worker so that an operator can easily and accurately determine how to perform an operation related to the operation in the future in the operation of the manufacturing facility. As a result, for example, it can be expected that even an unskilled worker can appropriately deal with the situation when an operational problem occurs.
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Abstract
Description
以下に示す本発明の実施形態の説明では、鉄鋼業の圧延ラインにおいて、複数の仕様の鋼板を連続して製造する場合に、本発明に係る操業支援装置等を適用する一例を示す。また、下記の説明において、被圧延材である鋼板のそれぞれを圧延(加工)する操業について、“鋼板のロット”、または、単に“操業”もしくは“ロット”とも記す。そして、ロットそれぞれに名称として「操業ID」を付す。
図1に示すように、操業支援システム100は、上位コンピュータ110と、操業支援装置120と、CRTディスプレイ装置130と、製造設備140(140-1、140-2、・・・)と、ネットワーク150(150-1、150-2)を有して構成されている。
図2は、本発明の実施形態に係る操業支援装置120の内部のハードウエア構成の一例を示す模式図である。
図3は、本発明の実施形態に係る操業支援装置120の処理に係る機能構成の一例を示す模式図である。
図4に示す例では、製造条件データ1261として、鋼板の仕上りサイズ(厚み、幅、長さ)、鋼板の仕上り温度、鋼板の製品種別を含む各種のデータが、製造設備140における操業(即ち、鋼板のロット)を識別する識別情報である操業IDと関連付けられて記憶されている。また、製造条件データ記憶領域126Aには、図4に示すように、製造設備140における過去の製造条件データ(操業IDが1~40の製造条件データ)、及び、現在の製造条件データ(操業IDが41の製造条件データ)が記憶されている。具体的に、図4に示す例では、操業IDが41の現在の製造条件データとして、鋼板の厚みの仕上りサイズが10mm、鋼板の幅の仕上りサイズが2700mm、鋼板の長さの仕上りサイズが30m、鋼板の仕上り温度が735℃、鋼板の製品種別(硬さ等)がAAAA、・・・が示されている。
この類似操業判定テーブル1262は、図4に示す製造条件データ1261における操業と類似の操業を判定するための基準となる判定条件が示されている。より詳細に、図5に示す例では、類似操業判定テーブル1262は、ある製造条件データに対して、鋼板の厚みの仕上りサイズが±αmm以内、鋼板の幅の仕上りサイズが±βmm以内、鋼板の長さの仕上りサイズが±γm以内、鋼板の仕上り温度が±δ℃以内、鋼板の製品種別(硬さ)がAA--(-は任意)等である場合に、当該製造条件データにおける操業と類似の操業と判定する判定条件を示している。なお、図5に示す例では、説明を簡単にするために、1つの判定条件のみを示しているが、複数の判定条件を設けるようにして、その中から1つの判定条件を選択する形態であっても良い。
操業プロセスデータ取得部302は、製造設備140の設備管理装置141から、製造設備140の操業に係るプロセスデータ(操業プロセスデータ1263)を、各ロットにおける鋼板の圧延中又は圧延の前後に取得する。この際、操業プロセスデータ取得部302は、製造条件データ取得部301から当該操業プロセスデータにおける操業IDを入手し、当該操業IDと紐付けて操業プロセスデータ1263を入力して取得する。この場合、操業IDは、図4に示すように、製造条件データ1261と紐付けられているため、その結果、操業プロセスデータ取得部302は、製造条件データ1261と関連付けて操業プロセスデータ1263を取得することができる。そして、操業プロセスデータ取得部302は、設備管理装置141から取得した操業プロセスデータ1263を、製造条件データ取得部301から入手した操業IDと関連付けて情報記憶媒体126の操業プロセスデータ記憶領域126Cに記憶する。
具体的に、類似操業検索対象プロセスデータとしては、製造設備140に配設されたセンサ1421による測定値及び製造設備140の状態に関する実績値のうちの少なくともいずれか一方を含むものを適用可能である。
また、操作可能プロセスデータとしては、製造設備140において作業者200による操作に基づき設定された実績値のデータを適用可能である。
また、評価対象プロセスデータとしては、製品の良否(例えば圧延処理した鋼板の性状等の良否)又は操業の良否に係るデータを適用可能である。
ここで、図7Aには、現在の操業プロセスデータ1263bにおける類似操業検索対象プロセスデータ710である「圧延力」のデータが経過時間と共に示されている。
アクション判定部304は、操業プロセスデータ記憶領域126Cに記憶されている操業プロセスデータ1263の操作可能プロセスデータ(図6A及び図6Bに示す「圧下位置」のデータ等)に基づいて、当該操作可能プロセスデータにおける操業において、作業者200による操作のアクションがあったか否かを判定する処理を行う。この際、アクション判定部304は、アクション判定テーブル記憶領域126Dに記憶されているアクション判定テーブル1264を用いて、作業者200による操作のアクションがあったか否かを判定する。
アクションデータ1における操作可能プロセスデータ(「圧下位置」のデータ)の現在時刻t0のデータ値をd0とし、変化評価時間前の時刻(t0-st1)のデータ値をdst1とすると、図8Bに示す変化開始検出量Δs0は、以下に示す(1)式で表せる。
Δs0=d0-dst1 ・・・(1)
なお、図8Bでは、データ値dst1が瞬時値とした場合の例を示しているが、例えば、変化評価時間前の時刻を中心とする、ある時間幅での平均値であってもかまわない。
Δs0≧s1 ・・・(2)
ここで、(2)式のs1は、図8Aに示すアクション判定テーブル1264で規定されている有意変化量の値に相当するものである。
アクション判定部304は、[1]の処理で変化開始を検出した場合、以下に示す方法で基準値を計算する。
具体的に、(t0-st1-t11)時刻~(t0-st1-t12)時刻の範囲を基準値計測時間範囲とし、当該基準値計測時間範囲における当該操作可能プロセスデータの平均値を基準値dkとして計算する。
(i)変化継続の監視
(2)式の条件を満たしている状態が続いていれば、ts=ts+T1(初回はts=T1)とし、変化継続時間をカウントアップする。
(2)式の条件を満たさなくなった時点で変化終了とし、その時刻における当該操作可能プロセスデータのデータ値をdeとする。
なお、データ値deは変化終了時点の瞬時値とする他、例えば、変化終了時点を中心とする、ある時間幅での平均値であってもかまわない。
(i)変化継続時間の有意性判定
アクション判定部304は、[3]の処理で変化終了を判定した場合、変化継続時間tsが以下に示す(3)式を満たす場合に、有意性ありと判定する。
ts1n≦ts≦ts1x ・・・(3)
[4](i)で変化継続時間の有意性がありと判定された場合、アクション判定部304は、当該操作可能プロセスデータにおける作業者200の操作アクションの有意性を以下の方法で判定する。
まず、操作可能プロセスデータのアクション変化量ΔSを、以下の(4)式により算出する。
ΔS=de-dk ・・・(4)
続いて、操作可能プロセスデータの変化係数(傾き)Aを、以下の(5)式により算出する。
A=ΔS/ts ・・・(5)
そして、アクション判定部304は、以下に示す(6)式を満たす場合に、当該操作可能プロセスデータにおける作業者200の操作アクションがありと判定を行う。
A≧a1 ・・・(6)
図9に示すように、アクションデータ1265は、図6A及び図6Bに示す操業プロセスデータに基づく操業IDと、アクションの発生時刻を示すアクション発生時刻の情報と、図8Aに示すアクションID及びアクション種別の情報と、アクション変化量(ΔS)の情報とが関連付けられて記憶されている。この際、アクション発生時刻情報としては、図8Aに示す例では、例えば、現在時刻t0となる。
アクション過去操業検索部305は、アクションデータ記憶領域126Eに記憶されるアクションデータ1265の中から、類似操業検索部303で検索された過去の操業プロセスデータ1263aにおけるアクションデータを、操業IDに基づき検索する。
図10に示すように、アクション検索期間定義テーブル1266には、図9に示すアクションデータ1265の種別を示す情報であるアクションID及びアクション種別の情報と、当該各アクションデータのアクション検索期間を示す検索開始時間及び検索終了時間が示されている。ここで、検索開始時間及び検索終了時間は、過去の類似操業における現在相当時刻からの相対時間を表している。したがって、検索開始時刻及び検索開始時刻は、それぞれ、以下のようになる。
検索開始時刻=現在相当時刻+検索開始時間
検索終了時刻=現在相当時刻+検索終了時間
そして、この場合、アクション過去操業検索部305によるアクション検索期間は、検索開始時刻から検索終了時刻までとなる。なお、図7A~図7Cに示す例では、アクション検索期間定義テーブル1266における検索開始時間が負の値であって検索終了時間が正の値である場合の例を示しているが、この形態に限定されずに、必要に応じて、検索開始時間及び検索終了時間を任意の値に設定することが可能となっている。
即ち、アクション評価テーブル1267は、図11Aに示すアクション評価ロジックテーブル12671と、図11Bに示すアクション評価重み付けテーブル12672と、図11Cに示すアクション総合評価判定テーブル12673が示されている。ここで、図11A~図11Cに示すテーブルには、アクションデータ1265の種別を示すアクションID及びアクション種別の情報ごとに、それぞれ、各種の情報が規定されている。
過去操業ガイダンス報知制御部307は、アクション過去操業検索部305で検索されたアクションデータを、CRTディスプレイ装置130に表示する制御を行って、これを作業者200に報知する制御を行う。この際、過去操業ガイダンス報知制御部307は、アクション過去操業検索部305で検索されたアクションデータを、類似操業評価部306における評価結果と共にCRTディスプレイ装置130に表示して、作業者200に報知する制御を行う。なお、この場合、過去操業ガイダンス報知制御部307は、CRTディスプレイ装置130への表示に加えて或いは表示に替えて、アクションデータ及びその評価結果を音声により作業者200に報知する形態であっても良い。また、過去操業ガイダンス報知制御部307は、アクション過去操業検索部305で検索されたアクションデータをCRTディスプレイ装置130に表示する際に、アクション過去操業検索部305で検索されたアクションデータのうち、類似操業評価部306における評価結果が「良」であるもののみ表示して、作業者200に報知する制御を行う形態であってもよい。
図13は、本発明の実施形態に係る操業支援装置120による操業支援方法の処理手順の一例を示すフローチャートである。この図13に示すフローチャートは、CPU121が制御プログラム1251を実行することによって行われる。なお、以下に示す図13のフローチャートの説明においては、図3に示す機能構成と対応させて説明を行う。
Claims (20)
- 製品を製造する製造設備の操業を支援する操業支援装置において、
前記製造設備の操業に係るプロセスデータであって、前記製造設備において作業者による操作に基づき設定された実績値である第1のプロセスデータと、前記製品の良否又は前記操業の良否に係るデータを含む第2のプロセスデータとを有する操業プロセスデータを取得する操業プロセスデータ取得手段と、
前記操業プロセスデータ取得手段で取得された操業プロセスデータであって、過去に記憶され、前記製造設備の過去の操業における過去の操業プロセスデータと、前記製造設備の現在の操業における現在の操業プロセスデータとを記憶する操業プロセスデータ記憶手段と、
前記現在の操業プロセスデータにおける前記第1のプロセスデータ又は前記第2のプロセスデータに基づいて、前記過去の操業プロセスデータの中から、前記現在の操業プロセスデータと類似する過去の操業プロセスデータを検索する類似操業検索手段と、
前記第1のプロセスデータに基づいて、当該第1のプロセスデータにおける操業において、作業者による操作のアクションがあったか否かを判定するアクション判定手段と、
前記アクション判定手段で判定された前記アクションに係るアクションデータを記憶するアクションデータ記憶手段と、
前記アクションデータ記憶手段に記憶されているアクションデータの中から、前記類似操業検索手段で検索された過去の操業プロセスデータに係るアクションデータを検索するアクション過去操業検索手段と、
前記第2のプロセスデータを用いて、前記アクション過去操業検索手段で検索されたアクションデータの評価を行う評価手段と
を有することを特徴とする操業支援装置。 - 前記アクション過去操業検索手段で検索されたアクションデータを、前記評価手段における評価結果と共に報知する制御を行う報知制御手段を更に有することを特徴とする請求項1に記載の操業支援装置。
- 前記操業プロセスデータ取得手段は、前記第2のプロセスデータとして、前記製品の良否又は前記操業の良否に係るデータである評価対象プロセスデータに加えて、類似操業検索対象プロセスデータを取得するものであり、
前記類似操業検索手段は、前記類似操業検索対象プロセスデータに基づいて、前記過去の操業プロセスデータの中から、前記現在の操業プロセスデータと類似する過去の操業プロセスデータを検索するものであり、
前記評価手段は、前記評価対象プロセスデータを用いて、前記アクション過去操業検索手段で検索されたアクションデータの評価を行うことを特徴とする請求項1に記載の操業支援装置。 - 前記類似操業検索対象プロセスデータは、前記製造設備に配設されたセンサによる測定値及び前記製造設備の状態に関する実績値のうちの少なくともいずれか一方を含むものであることを特徴とする請求項3に記載の操業支援装置。
- 前記操業プロセスデータ取得手段は、1つの前記操業プロセスデータにおいて、前記評価対象プロセスデータを複数取得するものであり、
前記評価手段は、前記評価対象プロセスデータごとに、前記アクション過去操業検索手段で検索されたアクションデータに対する評価値を算出し、算出した各評価値に基づいて当該アクションデータの評価を行うことを特徴とする請求項3に記載の操業支援装置。 - 前記製造設備の製造条件に係る製造条件データを取得する製造条件データ取得手段と、
前記製造条件データ取得手段で取得された製造条件データであって、前記製造設備における過去の製造条件データ及び現在の製造条件データを記憶する製造条件データ記憶手段とを更に有し、
前記操業プロセスデータ取得手段は、前記製造条件データと関連付けて前記操業プロセスデータを取得するものであり、
前記操業プロセスデータ記憶手段には、前記過去の製造条件データと関連付けられて前記過去の操業プロセスデータが記憶され、前記現在の製造条件データと関連付けられて前記現在の操業プロセスデータが記憶されており、
前記類似操業検索手段は、前記過去の製造条件データの中から、前記現在の操業プロセスデータにおける前記現在の製造条件データと類似する過去の製造条件データを検索し、当該検索された過去の製造条件データと関連付けられた過去の操業プロセスデータを検索範囲として、前記現在の操業プロセスデータと類似する前記過去の操業プロセスデータの検索を行うことを特徴とする請求項1に記載の操業支援装置。 - 前記アクション判定手段は、前記第1のプロセスデータの所定時間に対する変化量が所定の閾値以上である場合に、前記アクションがあったと判定を行うことを特徴とする請求項1に記載の操業支援装置。
- 前記アクションデータ記憶手段には、前記アクションデータが時刻情報と共に記憶されており、
前記アクション過去操業検索手段は、前記類似操業検索手段で検索された過去の操業プロセスデータに係るアクションデータを検索する際に、前記現在の操業プロセスデータの現在時刻に相当する前記過去の操業プロセスデータの相当時刻における前後の所定期間の範囲内で、前記アクションデータの検索を行うことを特徴とする請求項1に記載の操業支援装置。 - 前記報知制御手段は、表示装置に、前記アクションデータを前記評価手段における評価結果ごとにクラス分けして表示する制御を行って、前記アクションデータの報知を行うことを特徴とする請求項2に記載の操業支援装置。
- 製品を製造する製造設備の操業を支援する操業支援装置による操業支援方法において、
前記製造設備の操業に係るプロセスデータであって、前記製造設備において作業者による操作に基づき設定された実績値である第1のプロセスデータと、前記製品の良否又は前記操業の良否に係るデータを含む第2のプロセスデータとを有する操業プロセスデータを取得する操業プロセスデータ取得ステップと、
前記操業プロセスデータ取得ステップで取得された操業プロセスデータであって、過去に記憶され、前記製造設備の過去の操業における過去の操業プロセスデータと、前記製造設備の現在の操業における現在の操業プロセスデータとを前記操業支援装置の操業プロセスデータ記憶手段に記憶する操業プロセスデータ記憶ステップと、
前記現在の操業プロセスデータにおける前記第1のプロセスデータ又は前記第2のプロセスデータに基づいて、前記過去の操業プロセスデータの中から、前記現在の操業プロセスデータと類似する過去の操業プロセスデータを検索する類似操業検索ステップと、
前記第1のプロセスデータに基づいて、当該第1のプロセスデータにおける操業において、作業者による操作のアクションがあったか否かを判定するアクション判定ステップと、
前記アクション判定ステップで判定された前記アクションに係るアクションデータを前記操業支援装置のアクションデータ記憶手段に記憶するアクションデータ記憶ステップと、
前記アクションデータ記憶手段に記憶されているアクションデータの中から、前記類似操業検索ステップで検索された過去の操業プロセスデータに係るアクションデータを検索するアクション過去操業検索ステップと、
前記第2のプロセスデータを用いて、前記アクション過去操業検索ステップで検索されたアクションデータの評価を行う評価ステップと
を有することを特徴とする操業支援方法。 - 前記アクション過去操業検索ステップで検索されたアクションデータを、前記評価ステップにおける評価結果と共に報知する制御を行う報知制御ステップを更に有することを特徴とする請求項10に記載の操業支援方法。
- 前記操業プロセスデータ取得ステップでは、前記第2のプロセスデータとして、前記製品の良否又は前記操業の良否に係るデータである評価対象プロセスデータに加えて、類似操業検索対象プロセスデータを取得するものであり、
前記類似操業検索ステップでは、前記類似操業検索対象プロセスデータに基づいて、前記過去の操業プロセスデータの中から、前記現在の操業プロセスデータと類似する過去の操業プロセスデータを検索するものであり、
前記評価ステップでは、前記評価対象プロセスデータを用いて、前記アクション過去操業検索ステップで検索されたアクションデータの評価を行うことを特徴とする請求項10に記載の操業支援方法。 - 前記類似操業検索対象プロセスデータは、前記製造設備に配設されたセンサによる測定値及び前記製造設備の状態に関する実績値のうちの少なくともいずれか一方を含むものであることを特徴とする請求項12に記載の操業支援方法。
- 前記操業プロセスデータ取得ステップでは、1つの前記操業プロセスデータにおいて、前記評価対象プロセスデータを複数取得するものであり、
前記評価ステップでは、前記評価対象プロセスデータごとに、前記アクション過去操業検索ステップで検索されたアクションデータに対する評価値を算出し、算出した各評価値に基づいて当該アクションデータの評価を行うことを特徴とする請求項12に記載の操業支援方法。 - 前記製造設備の製造条件に係る製造条件データを取得する製造条件データ取得ステップと、
前記製造条件データ取得ステップで取得された製造条件データであって、前記製造設備における過去の製造条件データ及び現在の製造条件データを前記操業支援装置の製造条件データ記憶手段に記憶する製造条件データ記憶ステップとを更に有し、
前記操業プロセスデータ取得ステップでは、前記製造条件データと関連付けて前記操業プロセスデータを取得するものであり、
前記操業プロセスデータ記憶手段には、前記過去の製造条件データと関連付けられて前記過去の操業プロセスデータが記憶され、前記現在の製造条件データと関連付けられて前記現在の操業プロセスデータが記憶されており、
前記類似操業検索ステップでは、前記過去の製造条件データの中から、前記現在の操業プロセスデータにおける前記現在の製造条件データと類似する過去の製造条件データを検索し、当該検索された過去の製造条件データと関連付けられた過去の操業プロセスデータを検索範囲として、前記現在の操業プロセスデータと類似する前記過去の操業プロセスデータの検索を行うことを特徴とする請求項10に記載の操業支援方法。 - 前記アクション判定ステップでは、前記第1のプロセスデータの所定時間に対する変化量が所定の閾値以上である場合に、前記アクションがあったと判定を行うことを特徴とする請求項10に記載の操業支援方法。
- 前記アクションデータ記憶手段には、前記アクションデータが時刻情報と共に記憶されており、
前記アクション過去操業検索ステップでは、前記類似操業検索ステップで検索された過去の操業プロセスデータに係るアクションデータを検索する際に、前記現在の操業プロセスデータの現在時刻に相当する前記過去の操業プロセスデータの相当時刻における前後の所定期間の範囲内で、前記アクションデータの検索を行うことを特徴とする請求項10に記載の操業支援方法。 - 前記報知制御ステップでは、表示装置に、前記アクションデータを前記評価ステップにおける評価結果ごとにクラス分けして表示する制御を行って、前記アクションデータの報知を行うことを特徴とする請求項11に記載の操業支援方法。
- 製品を製造する製造設備の操業を支援する操業支援装置による操業支援方法をコンピュータに実行させるためのプログラムにおいて、
前記製造設備の操業に係るプロセスデータであって、前記製造設備において作業者による操作に基づき設定された実績値である第1のプロセスデータと、前記製品の良否又は前記操業の良否に係るデータを含む第2のプロセスデータとを有する操業プロセスデータを取得する操業プロセスデータ取得ステップと、
前記操業プロセスデータ取得ステップで取得された操業プロセスデータであって、過去に記憶され、前記製造設備の過去の操業における過去の操業プロセスデータと、前記製造設備の現在の操業における現在の操業プロセスデータとを前記操業支援装置の操業プロセスデータ記憶手段に記憶する操業プロセスデータ記憶ステップと、
前記現在の操業プロセスデータにおける前記第1のプロセスデータ又は前記第2のプロセスデータに基づいて、前記過去の操業プロセスデータの中から、前記現在の操業プロセスデータと類似する過去の操業プロセスデータを検索する類似操業検索ステップと、
前記第1のプロセスデータに基づいて、当該第1のプロセスデータにおける操業において、作業者による操作のアクションがあったか否かを判定するアクション判定ステップと、
前記アクション判定ステップで判定された前記アクションに係るアクションデータを前記操業支援装置のアクションデータ記憶手段に記憶するアクションデータ記憶ステップと、
前記アクションデータ記憶手段に記憶されているアクションデータの中から、前記類似操業検索ステップで検索された過去の操業プロセスデータに係るアクションデータを検索するアクション過去操業検索ステップと、
前記第2のプロセスデータを用いて、前記アクション過去操業検索ステップで検索されたアクションデータの評価を行う評価ステップと
をコンピュータに実行させるためのプログラム。 - 前記アクション過去操業検索ステップで検索されたアクションデータを、前記評価ステップにおける評価結果と共に報知する制御を行う報知制御ステップを更にコンピュータに実行させることを特徴とする請求項19に記載のプログラム。
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US13/261,015 US20120059834A1 (en) | 2009-07-07 | 2009-07-07 | Operation supporting apparatus, operation supporting method, and program |
CN200980160146.XA CN102473275B (zh) | 2009-07-07 | 2009-07-07 | 操作支援装置、操作支援方法及程序 |
KR1020117031104A KR101344635B1 (ko) | 2009-07-07 | 2009-07-07 | 조업 지원 장치, 조업 지원 방법 및 프로그램이 기록된 컴퓨터 판독 가능 기록 매체 |
BR112012000470A BR112012000470A2 (pt) | 2009-07-07 | 2009-07-07 | aparelho de suporte à operação, método de suporte à operação e programa |
JP2011521724A JPWO2011004454A1 (ja) | 2009-07-07 | 2009-07-07 | 操業支援装置、操業支援方法及びプログラム |
EP09847059.4A EP2453403A4 (en) | 2009-07-07 | 2009-07-07 | OPERATING SUPPORT DEVICE, OPERATIONAL SUPPORT PROCESS AND PROGRAM |
PCT/JP2009/062351 WO2011004454A1 (ja) | 2009-07-07 | 2009-07-07 | 操業支援装置、操業支援方法及びプログラム |
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PCT/JP2009/062351 WO2011004454A1 (ja) | 2009-07-07 | 2009-07-07 | 操業支援装置、操業支援方法及びプログラム |
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US (1) | US20120059834A1 (ja) |
EP (1) | EP2453403A4 (ja) |
JP (1) | JPWO2011004454A1 (ja) |
KR (1) | KR101344635B1 (ja) |
CN (1) | CN102473275B (ja) |
BR (1) | BR112012000470A2 (ja) |
WO (1) | WO2011004454A1 (ja) |
Cited By (1)
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WO2024033970A1 (ja) * | 2022-08-08 | 2024-02-15 | 東芝三菱電機産業システム株式会社 | 圧延ラインの操業支援方法、操業支援装置及び操業支援プログラム |
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WO2016151744A1 (ja) * | 2015-03-24 | 2016-09-29 | 三菱電機株式会社 | プラント監視制御装置 |
CN107969143B (zh) * | 2015-07-28 | 2021-05-11 | 三菱电机株式会社 | 判定支援装置、判定支援方法以及记录介质 |
JP7206066B2 (ja) * | 2018-07-30 | 2023-01-17 | 三菱重工業株式会社 | 運転支援方法及び運転支援システム |
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- 2009-07-07 EP EP09847059.4A patent/EP2453403A4/en not_active Withdrawn
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Also Published As
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US20120059834A1 (en) | 2012-03-08 |
EP2453403A4 (en) | 2014-02-26 |
CN102473275A (zh) | 2012-05-23 |
JPWO2011004454A1 (ja) | 2012-12-13 |
EP2453403A1 (en) | 2012-05-16 |
BR112012000470A2 (pt) | 2016-02-16 |
CN102473275B (zh) | 2015-09-30 |
KR20120014057A (ko) | 2012-02-15 |
KR101344635B1 (ko) | 2013-12-26 |
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