DATA COLLECTION SYSTEM, PROCESSING SYSTEM, AND STORAGE MEDIUM

• US 20180129173A1
• Filed: 11/09/2017
• Published: 05/10/2018
• Est. Priority Date: 11/09/2016
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Original Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Inventors: KUSAKA, Tsubasa
• Granted Patent: US 10,613,487 B2
• Time in Patent Office: Days
• CPC Class Codes: G05B 13/0265 the criterion being a learning criterion
• CPC Class Codes: G05B 13/042 in which a parameter or coefficient is automatically adjusted to optimise the performance
• CPC Class Codes: G05B 19/045 using logic state machines, consisting only of a memory or a programmable logic device containing the logic for the controlled machine and in which the state of its outputs is dependent on the state of its inputs or part of its own output states, e.g. binary decision controllers, finite state controllers
• CPC Class Codes: G05B 19/418 Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
• CPC Class Codes: G05B 2219/13009 State machine instructions
• CPC Class Codes: G05B 2219/31078 Several machines and several buffers, storages, conveyors, robots
• CPC Class Codes: G05B 2219/31274 Convey products, move equipment according to production plan in memory
• CPC Class Codes: G05B 2219/37555 Camera detects orientation, position workpiece, points of workpiece
• CPC Class Codes: G06F 16/13 File access structures, e.g. distributed indices arrangements of input from, or output to, record carriers G06F3/06
• CPC Class Codes: G06F 9/542 Event management; Broadcasting; Multicasting; Notifications
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

According to one embodiment, a data collection system includes an event data collector, a state machine generator, a state machine list, and a state machine driver. The event data collector collects sense signals respectively as a plurality of event data. The state machine generator generates a state machine as a model corresponding to the workpiece. One of the sense signals is acquired when the workpiece is fed into the processing system. The state machine generator generates the state machine and generates an ID for the state machine when the event data collector collects one of the plurality of event data corresponding to the one of the sense signals. The state machine driver drives the state machine retained in the state machine list by sending, to the state machine retained in the state machine list, an event corresponding to another one of the sense signals.

Claims

1. A data collection system, comprising:

an event data collector collecting a plurality of sense signals respectively as a plurality of event data, the plurality of sense signals each being acquired when a passage of a workpiece in a processing system is sensed;

a state machine generator generating a state machine as a model corresponding to the workpiece, the state machine including a plurality of states, a transition between the plurality of states, and an action, one of the plurality of sense signals being acquired when the workpiece is fed into the processing system, the state machine generator generating the state machine and generating an ID for the state machine when the event data collector collects one of the plurality of event data corresponding to the one of the plurality of sense signals;

a state machine list retaining the generated state machine; and

a state machine driver driving the state machine retained in the state machine list by sending, to the state machine retained in the state machine list, an event corresponding to another one of the plurality of sense signals.

2. The system according to claim 1, further comprising:

a process data collector collecting process data when the workpiece is processed;

an associator; and

a process data outputter,

the state machine including a secondary event send action,

the secondary event send action sending a secondary event for performing an extraction of the process data when an entry to or an exit from a prescribed state is performed by being driven by the state machine driver,

the secondary event being accompanied by the ID,

the associator providing, to the process data, the ID accompanying the secondary event when the secondary event is received,

the process data outputter performing at least one of file storage or data transmission of the process data provided with the ID.

3. The system according to claim 2, wherein

the state machine sends the secondary event when the workpiece is processed,

the associator extracts a portion of the process data according to the received secondary event and provides, to the portion of the process data, the ID accompanying the secondary event, and

the process data outputter performs at least one of file storage or data transmission of the portion of the process data provided with the ID.

4. The system according to claim 2, wherein the process data is waveform data of at least one of a pressure or a temperature when the workpiece is processed.

5. The system according to claim 1, further comprising:

a state machine model file defining a state list and an incoming event list, the state list including possible states of the generated state machine;

a state machine model editing tool configured to allow a user to edit the state machine model file on a GUI screen, and to be able to select, from a plurality of the state machine model files, one of the state machine model files corresponding to a processing system used as an object of data collection; and

a state machine generation timing definition file defining an event generated by the state machine.

6. The system according to claim 1, further comprising a phantom eraser searching for a phantom state machine retained in the state machine list and terminating the phantom state machine, the phantom state machine corresponding to the workpiece not having a passage sensed in the processing system.

7. The system according to claim 6,

further comprising:

a correspondence master storing a plurality of the states, a plurality of locations of the processing system, and a correspondence between the plurality of states and the plurality of locations; and

a dwelling number upper limit master storing a first dwelling number upper limit and a second dwelling number upper limit, the first dwelling number upper limit being the upper limit of the state machines that can dwell in each of the plurality of states, the second dwelling number upper limit being the upper limit of the state machines that can dwell at each of the plurality of locations,

the phantom eraser performing, when the state machine transitions;

referring to the correspondence master and acquiring a first location corresponding to a first state after the transition;

calculating a first scheduled dwelling number and a second scheduled dwelling number, the first scheduled dwelling number being of the state machines in the first state, the second scheduled dwelling number being of the state machines at the first location,

referring to the dwelling number upper limit master and acquiring the first dwelling number upper limit of the first state and the second dwelling number upper limit of the first location;

calculating a first excess dwelling number from the first scheduled dwelling number and the first dwelling number upper limit;

terminating, as the phantom state machine, the first excess dwelling number of state machines in the first state;

calculating a second excess dwelling number from the second scheduled dwelling number and the second dwelling number upper limit; and

terminating, as the phantom state machine, the second excess dwelling number of state machines at the first location.

8. A processing system, comprising:

the data collection system according to claim 2;

a first sensor sensing a feeding of a workpiece into the processing system; and

a second sensor sensing a passage of the workpiece in the processing system,

the state machine generator generating the state machine and generating the ID when a sense signal transmitted from the first sensor is collected as the event data by the event data collector,

the state machine driver driving the state machine by sending, to the state machine, an event corresponding to a sense signal transmitted from the second sensor.

9. The processing system according to claim 8, further comprising:

a third sensor sensing the process data and transmitting the process data to the process data collector; and

a fourth sensor sensing information accompanying the workpiece,

the state machine generator performing an association between the ID and the information.

10. A storage medium storing a program for causing a computer to function as:

an event data collector collecting, as event data, a sense signal when a passage of a workpiece in a processing system is sensed;

a state machine generator generating a state machine and generating an ID for the state machine when the event data collector collects event data indicating a feeding of the workpiece into the processing system, the state machine including a plurality of states, a transition between the plurality of states, and an action, the state machine being generated as a model corresponding to each of the workpieces;

a state machine list retaining the generated state machine; and

a state machine driver driving the state machine retained in the state machine list by sending, to the state machine retained in the state machine list, an event corresponding to the sense signal.

11. The storage medium according to claim 10, wherein the program further causes the computer to function as:

a process data collector collecting process data when the workpiece is processed;

an associator; and

a process data outputter,

the state machine including a secondary event send action,

the secondary event send action sending a secondary event for performing an extraction of the process data when an entry to or an exit from a prescribed state is performed by being driven by the state machine driver,

the secondary event being accompanied by the ID,

the associator providing, to the process data, the ID accompanying the secondary event when the secondary event is received,

the process data outputter performing at least one of file storage or data transmission of the process data provided with the ID.

12. The storage medium according to claim 10, wherein the program further causes the computer to function as a phantom eraser searching for a phantom state machine retained in the state machine list and terminating the phantom state machine, the phantom state machine corresponding to the workpiece not having a passage sensed in the processing system.

13. The storage medium according to claim 12, wherein

the phantom eraser in the program performs, when the state machine transitions:

acquiring a first location corresponding to a first state after the transition;

calculating a first scheduled dwelling number and a second scheduled dwelling number, the first scheduled dwelling number being of the state machines in the first state, the second scheduled dwelling number being of the state machines at the first location;

acquiring the first dwelling number upper limit of the first state and the second dwelling number upper limit of the first location;

calculating a first excess dwelling number from the first scheduled dwelling number and the first dwelling number upper limit;

terminating, as the phantom state machine, the first excess dwelling number of state machines in the first state;

calculating a second excess dwelling number from the second scheduled dwelling number and the second dwelling number upper limit; and

terminating, as the phantom state machine, the second excess dwelling number of state machines at the first location.