Plant operating state analysis system

A plant operating state analysis system includes a data collector which is connected to both a control network and a monitoring network and which collects both control network data and monitoring screen video data. The data collector includes a synchronization processing unit and a data display processing unit. The synchronization processing unit synchronizes the control network data and the monitoring screen video data by adding a delay time due to transmission through the monitoring network, which includes an encoding time spent by a video capturer, to the time at which the control network data has been collected. The data display processing unit reproduces and displays, on a screen, the control network data and monitoring screen video data that are synchronized by the synchronization processing unit.

FIELD

The present invention relates to a plant operating state analysis system.

BACKGROUND

A plant includes a field device (including an actuator and a sensor) constituting the plant and a control PLC (Programmable Logic Controller) for controlling the field device. The control PLC receives input of a feedback signal from the field device and outputs a control signal for controlling the field device. The field device operates according to the control signal. An input/output signal (control network data) of the control PLC is collected by a data collector.

The operating condition of the field device and the operating condition of a mechanical facility including the field device are photographed by cameras in some cases. For example, in PTL 1, a plant monitoring system that includes monitor camera for photographing the operating condition of a mechanical facility and can store video information obtained from the monitor camera is disclosed.

Monitoring of the entire plant facility is performed by a monitor. A plant operating state, which includes the positional information of materials, the operation state of an operator, and mechanical information such as a mechanical speed and position, is displayed in summary on a monitoring screen of the monitor. The operator performs operation according to both screen information on the monitor and visual confirmation.

CITATION LIST

Patent Literature

SUMMARY

Technical Problem

A monitoring network to which the monitor is connected and a control network to which the field device, control PLC, and data collector are connected are different networks. Therefore, a conventional data collector can collect control network data but cannot collect screen information on the monitor. Thus, when an abnormality factor is analyzed in the data collector, it is necessary to determine the plant operating state, which includes the positional information of materials, the operation state of an operator, and mechanical information such as a mechanical speed and position, from the control network data. Every time an abnormality occurs, a person checks necessary control network data in detail, and this has a possibility of failing to obtain correct information. Further, it requires a long time to perform an operation of analyzing an abnormality factor.

In addition, in the conventional data collector, even when video data captured by photographing the operating condition of a mechanical facility by a camera is collected, the mechanical operation in a range which is not photographed by the camera cannot be checked. Therefore, it cannot be said that it is sufficient as a recording state of information at the time of abnormality occurrence and mechanical adjustment.

The present invention has been made so as to solve the above-described problems, and it is an object of the present invention to provide a plant operating state analysis system that can support analysis of the plant operating state in a data collector by synchronously displaying both control network data and screen information on a monitor.

Solution to Problem

To achieve the above object, a plant operating state analysis system according to the embodiment of the present disclosure is configured as follows.

The plant operating state analysis system includes, at least, a controller, a control network, a monitor, a video capturer, a monitoring network, and a data collector.

The controller controls a field device constituting a plant. The field device includes an actuator and a sensor. The controller is, for example, a control PLC.

The control network is connected to the controller and transmits control network data which is input/output to/from the controller. The control network data includes a feedback signal output by the field device and a control signal output by the controller.

The monitor has a monitoring screen and displays operating information for the entire plant facility other than the control network data, on the monitoring screen. The operating information includes plant operating-related information including: the operation state of an operator; and mechanical information such as a mechanical speed and position.

The video capturer is connected to the monitor and outputs monitoring screen video data obtained by encoding video displayed on the monitoring screen.

The monitoring network is connected to the video capturer and transmits the monitoring screen video data.

The data collector is connected to both the control network and monitoring network and collects both the control network data and monitoring screen video data. The data collector includes a synchronization processing unit and a data display processing unit.

The synchronization processing unit synchronizes the control network data and monitoring screen video data by adding a delay time due to transmission through the monitoring network, which includes an encoding time spent by the video capturer, to a time at which the control network data has been collected.

The data display processing unit reproduces and displays, on a screen, the control network data and monitoring screen video data that are synchronized by the synchronization processing unit.

Preferably, the plant operating state analysis system further includes a network camera. The network camera is connected to the monitoring network and photographs the appearance of the field device and outputs field device video data. The synchronization processing unit synchronizes the control network data, monitoring screen video data, and field device video data. The data display processing unit reproduces and displays, on a screen, the control network data, monitoring screen video data, and field device video data that are synchronized by the synchronization processing unit.

In addition, the plant operating state analysis system according to another embodiment of the present disclosure includes, instead of the video capturer described above, a vide capturer that outputs monitoring screen video data, which is obtained by encoding video displayed on a monitoring screen, with the input time at which the video has been input added. Further, the plant operating state analysis system includes, instead of the synchronization processing unit described above, a synchronization processing unit that synchronizes the control network data and the monitoring screen video data by associating both the data pieces with each other so as to match the time at which the control network data has been collected and the input time which has been added to the monitoring screen video data.

Advantageous Effects of Invention

According to an embodiment of the present disclosure, in the data collector, the control network data relating to control of the field device constituting the plant and the monitoring screen video data including operating information for the entire plant facility other than the control network data can be synchronously reproduced. This data collector allows analysis of the operating state of the plant to be supported. In the data collector, the operating state of the plant can be easily grasped and accordingly, the speed of analyzing an abnormality factor is improved; thereby, a recovery time at the time of abnormality occurrence can be reduced. Due to a reduction in the recovery time, a reduction in labor costs relating to trouble settlement and an increase in production volume can be expected.

DESCRIPTION OF EMBODIMENTS

Hereinafter, the embodiments of the present disclosure will be described in detail with reference to drawings. It is noted that common elements in the drawings are denoted by the same reference signs, thereby omitting redundant descriptions thereof.

First Embodiment

System Configuration

FIG. 1is a system configuration diagram of a plant operating state analysis system according to the first embodiment of the present disclosure.

The plant operating state analysis system includes a data collector1, a control PLC2, a network camera3, a video capturer4, a monitor5, a control network10, and a monitoring network20.

The data collector1is connected to both the control network10and the monitoring network20. The data collector1is connected to the control PLC2via the control network10. The data collector1is connected to the network camera3and video capturer4via the monitoring network20. The video capturer4is connected to the monitor5.

The control network10is constituted of a plurality of network devices. In the example inFIG. 1, the control network cables12and13are connected to the control network line concentration device11. The control network cable12is connected to the data collector1. The control network cable13is connected to the control PLC2. That is, in the example inFIG. 1, the data collector1is connected to the control PLC2via the control network cable12, the control network line concentration device11, and the control network cable13.

The monitoring network20is constituted of a plurality of network devices. In the example inFIG. 1, the monitoring network cables22to24are connected to the monitoring network line concentration device21. The monitoring network cable22is connected to the data collector1. The monitoring network cable23is connected to the network camera3. The monitoring network cable24is connected to the video capturer4. That is, in the example inFIG. 1, the data collector1is connected to the network camera3via the monitoring network cable22, the monitoring network line concentration device21, and the monitoring network cable23. In addition, the data collector1is connected to the video capturer4via the monitoring network cable22, the monitoring network line concentration device21, and the monitoring network cable24. The video capturer4is connected to the monitor5by a video cable6(for example, HDMI® cable).

The control PLC2is a controller that controls a field device (not shown) constituting a plant. The field device is connected to the control network10. The field device includes an actuator and a sensor. The control PLC2receives input of a feedback signal which is output to the control network10by the field device; and outputs a control signal for controlling the field device to the control network10. The field device operates based on the control signal.

The control network10transmits control network data which is input/output to/from the control PLC2. The control network data includes a feedback signal that is output by the field device and a control signal that is output by the controller.

The network camera3photographs the appearance of the field device that is a control object of the control PLC2. The network camera3sequentially outputs the video data of the photographed field device (field device video data) to the monitoring network20(for example, in units of one frame).

The monitoring network20transmits the field device video data which is output from the network camera3, to the data collector1.

The monitor5has a monitoring screen and displays operating information for the entire plant facility other than the control network data, on the monitoring screen. The operating information includes plant operating-related information (the positional information of materials, the operation state of an operator, the mechanical speed and position, operating schedule, etc.) which cannot be obtained from the control network10. Part or summarized information of the control network data can also be displayed.

The video capturer4sequentially outputs monitoring screen video data which is obtained by encoding video displayed on the monitoring screen of the monitor5to the monitoring network20(for example, in units of one frame).

The monitoring network20transmits the monitoring screen video data which is output from the video capturer4, to the data collector1. The transmission speed of the monitoring network20is lower than the transmission speed of the control network10.

Data Collector

The data collector1is connected to both the control network and monitoring network and sequentially collects the control network data from the control network10, and the field device video data and monitoring screen video data from the monitoring network20. The data collector1synchronously displays the data pieces collected from the different networks on a data confirmation screen. Therefore, in a case where, for example, an abnormality occurs, analysis of the plant operating state can be supported in the data collector that is closer to a worksite than the monitor.

Configuration of Data Confirmation Screen

FIG. 2is a configuration diagram of a data confirmation screen30in the data collector1. The data confirmation screen30of the data collector1includes an image display part31, a PLC input/output data display part32, a data reproduction operation part33, and a still image display part34.

The image display part31includes a monitoring screen video display area35and a camera video display area36. In the monitoring screen video display area35, the monitoring screen video data collected from the video capturer4is displayed. In the camera video display area36, the field device video data collected from the network camera3is displayed. Through these displays, operating information and field device appearance information can be checked.

In the PLC input/output data display part32, the control network data collected from the control network10is displayed in a time-series graph. In addition, in the PLC input/output data display part32, a reproduction position indicator37indicating a current reproduction position on the time axis of the time-series graph is displayed. The reproduction position indicator37indicates the reproduction position of: the monitoring screen video data displayed in the monitoring screen video display area35; and the field device video data displayed in the camera video display area36. The reproduction position indicator37also indicates a current reproduction position when each button on the data reproduction operation part33functions.

The data reproduction operation part33includes a reproduction button38, a stop button39, a slow reproduction button40, a reverse reproduction button41, a fast forward button42, a fast reverse button43, a frame feed button44, a frame return button45, an end display button46, a head display button47, a continuous reproduction button48, and a still image capture button49.

The reproduction button38is a button for starting both the movement of the reproduction position indicator37and the reproduction of video data in the image display part31, from a position indicated by the reproduction position indicator37.

The stop button39is a button for stopping the reproduction of the image display part31when video data is being reproduced in the image display part31by the reproduction button38, slow reproduction button40, reverse reproduction button41, fast forward button42, or fast reverse button43.

The slow reproduction button40is a button for starting both the movement of the reproduction position indicator37and the slow reproduction of video data in the image display part31, from a position indicated by the reproduction position indicator37.

The reverse reproduction button41is a button for starting both the movement of the reproduction position indicator37and the reverse reproduction of video data in the image display part31, from a position indicated by the reproduction position indicator37.

The fast forward button42is a button for starting both the movement of the reproduction position indicator37and the fast forward reproduction of video data in the image display part31, from a position indicated by the reproduction position indicator37.

The fast reverse button43is a button for starting both the movement of the reproduction position indicator37and the fast reverse reproduction of video data in the image display part31, from a position indicated by the reproduction position indicator37.

The frame feed button44is a button for performing both the movement of the reproduction position indicator37and the frame feeding of video data in the image display part31, from a position indicated by the reproduction position indicator37. In frame feeding, one frame time, which depends on the frame rate of a camera, is, for example, 33.33 msec with a camera having a frame rate of 30 fps and data being displayed can be changed at every 33.33 msec.

The frame return button45is a button for performing both the movement of the reproduction position indicator37and the frame return of video data in the image display part31, from a position indicated by the reproduction position indicator37. Description of the frame rate is omitted since it is the same as the description of the frame feed button44.

The end display button46is a button for moving the reproduction position indicator37from the current reproduction position to the reproduction position for the end of the control network data and displaying the end of video data in the image display part31.

The head display button47is a button for moving the reproduction position indicator37from the current reproduction position to the reproduction position for the head of the control network data and displaying the head of video data in the image display part31.

The continuous reproduction button48is a button for: automatically moving, when the reproduction position indicator37has moved to the end of data, the reproduction position indicator37to the head of the control network data; and restarting the movement of the reproduction position indicator37and the reproduction of video data in the image display part31from the head of the control network data.

The still image capture button49is a button for creating a still image from video data being displayed in the image display part31at a current reproduction position indicated by the reproduction position indicator37.

The still image display part34displays a still image which is created when the still image capture button49is pressed. The still image display part34includes a redisplay button50for a still image creation position. The redisplay button50for a still image creation position is a button for: moving the reproduction position indicator37to a reproduction position at the time of creating a still image; and displaying, in the image display part31, video data at the time of creating the still image.

Hardware Configuration of Data Collector

FIG. 3is a block diagram showing a hardware configuration example of a processing circuit included in the data collector1. Each unit shown inFIGS. 4 to 6, which is described later, represents part of functions included in the data collector1and each of the functions is implemented by a processing circuit. For example, the processing circuit is a computer including a processor101, a memory102, an input/output interface103, a system bus104, an input device105, an output device106, a display107, a storage108, and a communication device109.

The processor101is a processing device that performs arithmetic processing for implementing each function by using programs and data which are stored in the memory102. The memory102stores programs executed by the processor101and data necessary for executing each of the programs. The input/output interface103is a device for interfacing between various kinds of hardware and a system bus104. The system bus104is an information transmission path shared by the processor101, the memory102, and the input/output interface103.

To the input/output interface103, hardware such as the input device105, the output device106, the display107, the storage108, and the communication device109is connected. The input device105is a keyboard, a mouse, or the like operated by an operator. The output device106is an external storage terminal. The display107displays the data confirmation screen shown inFIG. 2. The storage108is a large-capacity auxiliary storage device that stores programs and data: for example, a hard disk device and a nonvolatile semiconductor memory. The communication device109includes a connector for connecting to the control network10and a connector for connecting to the monitoring network20and can communicate with devices which are connected to the networks.

Function Block Diagram of Data Collector

FIG. 4is a function block diagram of the data collector1. The data collector1includes a monitoring network I/F51, a control network I/F52, a first data storage unit53, a control network data monitoring unit54, a second data storage unit55, an image data processing unit56, a graphing processing unit57, a reproduction position indication unit58, a synchronization processing unit59, a data display processing unit60, a data reproduction processing unit70, and a still image processing unit90.

The monitoring network I/F51obtains field device video data and monitoring screen video data from the monitoring network20via the communication device109shown inFIG. 3.

The control network I/F52obtains control network data from the control network10via the communication device109shown inFIG. 3.

The first data storage unit53stores, in the memory102or storage108shown inFIG. 3, the field device video data, monitoring screen video data, and control network data which are obtained by the monitoring network I/F51and control network I/F52. A collection time is associated with each piece of the data.

The control network data monitoring unit54monitors a state change of the control network data obtained by the control network I/F52. For example, when a predetermined parameter value included in the control network data exceeds a set value, or when the change rate of the predetermined parameter value exceeds the set change rate, it can be determined that a state change has occurred.

The second data storage unit55stores, when it is determined that a state change has occurred, the field device video data, monitoring screen video data, and control network data in a predetermined period before or after a timing of the occurrence of the state change. For example, the data is stored in the memory102or storage108shown inFIG. 3. A collection time is associated with each piece of the data.

The image data processing unit56performs processing for reproducing as video each of the field device video data and monitoring screen video data which are stored in the second data storage unit55, in the image display part31shown inFIG. 2.

The graphing processing unit57performs processing for displaying as a time-series graph the control network data stored in the second data storage unit55, in the PLC input/output data display part32shown inFIG. 2.

The reproduction position indication unit58sets the reproduction position indicator37that is displayed in the PLC input/output data display part32shown inFIG. 2. The reproduction position indicator37is controlled by the data reproduction processing unit70described later. The reproduction position indicator37indicates the current reproduction position of the control network data and also indicates the current reproduction position of the field device video data and monitoring screen video data which are displayed as video in the image display part31.

The synchronization processing unit59synchronizes the control network data and monitoring screen video data by adding a delay time due to transmission through the monitoring network20, which includes an encoding time spent by the video capturer4, to the time at which the control network data has been collected. Concretely, after a delay time has passed since the time at which the control network data has been collected, monitoring screen video data corresponding to the control network data at the collection time is collected. Accordingly, the monitoring screen video data which is collected behind the time at which the control network data has been collected, by the delay time, is associated to the control network data, thereby allowing these pieces of data to be synchronized.

Similarly, the synchronization processing unit59synchronizes the control network data and field device video data by adding a delay time due to transmission through the monitoring network20to the time at which the control network data has been collected.

The data display processing unit60reproduces and displays, on the data confirmation screen30, the control network data, monitoring screen video data, and field device video data that are synchronized by the synchronization processing unit59. Concretely, in the PLC input/output data display part32shown inFIG. 2, the control network data is displayed as a time-series graph (graphing processing unit57). The data display processing unit60sequentially obtains the reproduction position indicator37from the reproduction position indication unit58and displays the reproduction position indicator37indicating the current reproduction position, on the time-series graph. In addition, in the image display part31shown inFIG. 2, the monitoring screen video data and field device video data which correspond to the current reproduction position are displayed as video (image data processing unit56). At this time, the control network data, monitoring screen video data, and field device video data are synchronously displayed by the synchronization processing unit59. That is, each piece of the video data displayed in the image display part31shown inFIG. 2is video data at the collection time which is obtained by adding the above-described delay time to the time at which the control network data indicated by the reproduction position indicator37has been collected.

Further, since the data display processing unit60displays, on the data confirmation screen30, each kind of data corresponding to the reproduction position indicator37, the display contents on the data confirmation screen30are also updated every time the reproduction position indicator37is updated by the reproduction position indication unit58.

FIG. 5is a function block diagram of the data reproduction processing unit70of the data collector1. The data reproduction processing unit70includes a reproduction processing unit71, a stop processing unit72, a slow reproduction processing unit73, a reverse reproduction processing unit74, a fast forward processing unit75, a fast reverse processing unit76, a frame feed processing unit77, a frame return processing unit78, a head display processing unit79, an end display processing unit80, and a continuous reproduction processing unit81. By these processing units, the reproduction position indicator37in the reproduction position indication unit58is controlled.

The reproduction processing unit71advances, in response to pressing of the reproduction button38shown inFIG. 2, the reproduction position indicator37in the reproduction direction with time.

The stop processing unit72stops, in response to pressing the stop button39shown inFIG. 2, the reproduction position indicator37during reproduction.

The slow reproduction processing unit73advances, in response to pressing of the slow reproduction button40shown inFIG. 2, the reproduction position indicator37in the reproduction direction at a slower speed than in the reproduction processing unit71.

The reverse reproduction processing unit74advances, in response to pressing the reverse reproduction button41shown inFIG. 2, the reproduction position indicator37in the reverse reproduction direction.

The fast forward processing unit75advances, in response to pressing of the fast forward button42shown inFIG. 2, the reproduction position indicator37in the reproduction direction at a higher speed than in the reproduction processing unit71.

The fast reverse processing unit76advances, in response to pressing of the fast reverse button43shown inFIG. 2, the reproduction position indicator37in the reverse reproduction direction at a higher speed than in the reverse reproduction processing unit74.

The frame feed processing unit77advances, in response to pressing of the frame feed button44shown inFIG. 2, the reproduction position indicator37in the reproduction direction frame by frame.

The frame return processing unit78advances, in response to pressing of the frame return button45shown inFIG. 2, the reproduction position indicator37in the reverse reproduction direction frame by frame.

The head display processing unit79moves, in response to pressing the head display button47shown inFIG. 2, the reproduction position indicator37to the head of data.

The end display processing unit80moves, in response to pressing of the end display button46shown inFIG. 2, the reproduction position indicator37to the end of data.

The continuous reproduction processing unit81automatically moves, in response to pressing the continuous reproduction button48shown inFIG. 2, the reproduction position indicator37to the head of the data when the reproduction position indicator37has moved to the end of data, and advances it from the head of the data toward the reproduction direction.

FIG. 6is a function block diagram of the still image processing unit90of the data collector1. The still image processing unit90includes a still image capture processing unit91, a still image export processing unit92, and an image format conversion unit93.

The still image capture processing unit91captures video currently being reproduced on the data confirmation screen30and creates a still image.

The still image export processing unit92exports the still image created by the still image capture processing unit91to an external storage terminal (output device106).

The image format conversion unit93converts, in exporting the still image to the external storage terminal by the still image export processing unit92, the image format of the still image into a predetermined format (e.g. JPEG).

Effects

As described above, the data collector according to the present embodiment allows the control network data relating to control of the field device constituting the plant and the monitoring screen video data including operating information for the entire plant facility other than the control network data to be synchronously reproduced. In addition, it also includes the functions of “stop,” “slow reproduction,” “reverse reproduction,” “repetitive reproduction,” “frame feed,” “frame return,” “fast reverse,” “fast forward,” “head display,” and “end display.” Therefore, when an abnormality occurs or a mechanical adjustment is performed, analysis of the plant operating state can be supported by using the data collector that is closer to a worksite than the monitor. Facilitation of grasping the operating state of the plant improves the speed of analyzing an abnormality factor, thereby allowing a recovery time at the time of abnormality occurrence to be reduced. Due to a reduction in the recovery time, a reduction in labor costs relating to trouble settlement and an increase in production volume can be expected.

In addition, the data collector according to the present embodiment allows screen information (monitoring screen video data) of the monitor to be stored as a still image. The still image can be used as an evidence of an analysis result. Further, also when a similar trouble occurs or a mechanical adjustment is performed, improvement in productivity and quality can be expected by referencing these evidences.

The plant operating state analysis system according to the present embodiment allows a relationship between operation and control to be grasped in a data collector on a worksite and therefore, can improve efficiency in troubleshooting and mechanical adjustment procedures when an abnormality occurs or a mechanical adjustment is performed; thereby allowing improvement in quality and improvement in productivity to be expected.

Modified Example

The system of the first embodiment described above has a configuration that includes the network camera3; however, the system may have a configuration that does not include the network camera3. In addition, the control network10is not limited to the concrete example shown inFIG. 1and may be a network to which other line concentration devices and cables are further connected. The same applies to the monitoring network20. In addition, the data collector1may have a configuration that does not include the still image processing unit90. In this regard, the same applies to the second embodiment.

Second Embodiment

Next, with reference toFIG. 7toFIG. 8, the second embodiment of the present disclosure will be described.

According to the first embodiment described above, in the data collector1, a delay time due to transmission through the monitoring network20, which includes an encoding time spent by the video capturer4, is added to the time at which the control network data has been collected, thereby synchronizing the control network data and monitoring screen video data. However, a method for synchronizing the control network data and monitoring screen video data is not limited to this. Thus, in the second embodiment, the control network data and monitoring screen video data are synchronized by using another method.

FIG. 7is a system configuration diagram of a plant operating state analysis system according to the second embodiment of the present disclosure.FIG. 8is a function block diagram of a data collector according to the second embodiment of the present disclosure. The system configuration shown inFIG. 7is the same as the system configuration shown inFIG. 1except that the video capturer4is replaced with a video capturer4a. In addition, the configuration shown inFIG. 8is the same as the configuration shown inFIG. 4except that the synchronization processing unit59is replaced with a synchronization processing unit59a. Therefore, the same reference sign is used for the same configurations, and description thereof is omitted.

Video Capturer

The video capturer4ais connected to the monitor5by a video cable6(for example, HDMI (R) cable) and has a function of obtaining an input time at which video has been input from the monitor5. The video capturer4asequentially outputs monitoring screen video data, which is obtained by encoding video displayed on the monitoring screen of the monitor5, with the input time at which the video has been input being added (for example, in units of one frame), to the monitoring network20.

When TCP/IP is used as a communication protocol of the monitoring network20, the input time may be included in a data part of a packet together with monitoring screen video data, or the input time may be included in an option part of a packet IP header. The same applies to field device video data which is output by the network camera3.

Data Collector

The synchronization processing unit59aof the data collector1synchronizes the control network data and monitoring screen video data by associating both the data pieces with each other so as to match the time at which the control network data10has been collected and the input time which has been added to the monitoring screen video data. The input time which has been added to the monitoring screen video data represents the time at which video has been displayed on the monitoring screen of the monitor5; and is a time which has not been affected by a delay due to encoding and transmission through the monitoring network20. Thus, control network data and monitoring screen video data can be synchronized by associating these data pieces with each other so as to match this input time and the time at which the control network data10has been collected.

As described above, in the plant operating state analysis system according to the second embodiment, effects similar to those in the system according to the first embodiment can be obtained. That is, in the data collector1on a worksite, the control network data relating to control of the field device constituting the plant and the monitoring screen video data including operating information for the entire plant facility other than the control network data can be synchronously reproduced. Thus, analysis of the operating state of the plant can be supported on the worksite.

REFERENCE SIGNS LIST