초록 ▼

SILS(Software-in-the-Loop Simulator)를 이용하여 제조공정의
특성을 다각적으로 반영한 데이터들의 패턴과 공정전문가의 지식을 지속적으로 수집, 분석, 패턴화하여 특정 공정에 대한 분석, 설계, 운영개선과 고장 진단·예방 기능을 점진적으로 개선하는 범용적인 소프트웨어를 목표로 개발함. 이러한 개발성과를
기반으로 현대기아자동차 및 LG디스플레이, LS산전 등 제조현장의 자동화 라인의 설계로부터 운영, 유지보수에 이르는 다양한
영역에서 I/O 표준화 및 시뮬레이션, 설비상태의 진단/분석, 제어로직

SILS(Software-in-the-Loop Simulator)를 이용하여 제조공정의
특성을 다각적으로 반영한 데이터들의 패턴과 공정전문가의 지식을 지속적으로 수집, 분석, 패턴화하여 특정 공정에 대한 분석, 설계, 운영개선과 고장 진단·예방 기능을 점진적으로 개선하는 범용적인 소프트웨어를 목표로 개발함. 이러한 개발성과를
기반으로 현대기아자동차 및 LG디스플레이, LS산전 등 제조현장의 자동화 라인의 설계로부터 운영, 유지보수에 이르는 다양한
영역에서 I/O 표준화 및 시뮬레이션, 설비상태의 진단/분석, 제어로직 기반의 설비 효율화 분야에 솔루션 및 엔지니어링 서비스로 적용하여 성과를 창출함. 특히 자동화 생산라인의 가동정보 표현을 위한 HMI 표준화 및 가상공장 구축을 통하여 국내 대표자동차 제조사의 HMI 국산화 및 글로벌 생산교육센터의 표준
솔루션으로 채택되었고 산업부 스마트공장 거점 클러스터 사업의 대표/데모 스마트공장 구축에 본 기술이 채택되어 활용 됨.

Abstract ▼

Results
○ Developed state model to commonly express operating and diagnosis
knowledge of actual model.
∙ Development of the user interface that can express equipment state model
for understanding the state flow of the concerned equipments following the
manufacturing process.
∙ Supp

Results
○ Developed state model to commonly express operating and diagnosis
knowledge of actual model.
∙ Development of the user interface that can express equipment state model
for understanding the state flow of the concerned equipments following the
manufacturing process.
∙ Supporting symbol recommendation for having similar forms to related
equipments by analyzing the text of symbols contacts.
∙ Improved user accessibility by developing of diagrammatic modeling
methods and supporting faster modeling.
∙ Developed a repository that can be used in future process operations by
intellectualizing the analysis results and improving user's comprehension.
∙ Developed an efficient technology for visualizing operational results of the
equipments and processes through graphs and tables by analyzing the logs
collected based on typed and grouped primary work-site equipment
knowledge model.
∙ Developed supporting technology for support decision making to improve
efficiencies of the processes and work-sites by expressing primary elements
of the processes(times of operating, waiting, moving, disorder).
∙ Achieving high-efficiency and optimization through improvement of the
process operating by calculating of key performance Indicator and also by
utilizing the analysis major elements of the processes.
○ Developed a methodology of extracting operating times of each devices
consumed by SILS and actual device.
∙ Developed reduction technology for synchronization error between the
actual log data and the results of the SILS.
∙ Extracted accurate operating times of the devices from actual log data and
developed standard sequence generating technology.
∙ Developed an analyzing module of analysis controllers resulting for defining
motions and registering related log data.
∙ Developed an algorithm to analyze the program that extracts and controls
the operating times of the devices using actual log data.
∙ Selecting function for motion related log data through collected data filter.
○ Developed a common file format to secure the static design data.
∙ Design and develop a file format that can save as common file and load
the main controller data mostly used in auto mobile, LCD/semiconductor
industries.
∙ Developed a XML file structure that can convert the different types for
each controller maker to the common type file(I/O, Internal, Latch, Link
relay), and save that.
∙ Developed a tool to easily and fastly connect between the design
information of work-site control and the SILS prototypical model.
○ Built a library for automatically generate manufacturing standard models.
∙ Developed a DB system which is capable of reading variables of the
work-site controller and transform that to manageable standard words.
∙ Developed library environment separates words for plants, lines and
stations(processes) since the controller variables are different for each work
site so .
∙ Built a standard words dictionary through analyzing current words from the
work-site PLC variables.
∙ Cut down the analyzing time of the PLC processes at existing lines by
using the standard design tool.
∙ Enabling automatically generate the standard model for devices.
○ Developed the basic COM interface environment to binding with SILS for
users to develop.
∙ Core elements modularizing for flexible respond to development additional
functions in future.
∙ Developed the structure that user can make set of new functions by
composing the existing basic functions.
∙ Developed the Interface binding which is enabling user can create the
environment of new functions and conveniently use.
○ Developed a filtering method for processing the log of big data.
∙ Developed a filtering algorithm reflecting characteristics of the log data.
∙ Setting clear area of analysis and target based on collected log
∙ Selecting the data analyzing methods and technology suited for a work site
considering type and format of data.
○ Technology to support design and data standardization.
∙ Standardization technology even low-skilled engineers can easily use.
∙ Reduction of work time through data compatibility and effective access.
∙ Improving work efficiencies by changing the work processes at work-site.
∙ Developed program based on the needs of work-site supports develop
control programs and standardization in the design process.
∙ Developed support technology for reduce data writing time and errors from
creation to completion process.
∙ Easily data analysis, support check data redundancy and error.
∙ Support data conversion between different data and increasing
interoperability between data.
∙ Developed import and export technology to possible directly collect data
from the controller since many cases in line remodeling use active data from
the controller.
∙ Developed domain manage technology to efficiently manage tag addresses
when create data making possible to visualizing and editable entire address
structure.
∙ Developed coherency keeping technology that is capable to keep data
coherency by forms and rules through making standard library of data
writing by administrator.
○ Developed a module that can connect PLC to SILS environment.
∙ Developed a module can interface with diverse commercial
controllers(Siemens, AB, Mitsubishi, LS, Fuji etc) which is most used in
manufacturing processes for guaranteeing the collecting of diverse data.
∙ The data collecting module manage data from commercial controller after
standardizing it.
∙ Developed data getting technology collect data through direct interface
with controllers without commercial OPC(GX-Developer(Mitsubishi),
STEP-7(Siemens), Rs-logix(Rockwell), SX-D300(Fuji)).
∙ Developed functions can save massive collected data to DB server and
manage it.
○ Developed a data collecting environment for sending primary information
from work-site operating system to SILS.
∙ Developed a data convert technology that can reproduce the management
state by editing and sampling the numerous information from log which is
raw source data.
∙ Supporting functions that can reduce amount of data through recording
events as data changes.
∙ Desiged data structure for high speed collecting of data less than 100ms.
∙ Supporting diversity of channel collecting and protocols like electric
current, temperature, vibration etc.
○ Developed expressible extended static model.
∙ Setting final goal to develop data management program which supports
making design data from process to plant level using SILS as systematically
classifying and grouping design data, in early stage building stereotyped
template of graphic data according to the equipment type which forms the
process.
∙ Completing the SILS component model as classifying each data according to
similarity type.
∙ Improving arranging speed of worker as building the library.
∙ Transforming the equipment graphic data of the manufacturing process to
stereotyped SILS static data.
∙ Understanding basic characteristic about process like radius of motion,
approach path, weld etc of the equipment which you need when processing
products through analyzing the process operating scenario after that
expressing necessary documents and 3D data that is needed for performing
each stages as hierarchy structure.
○ Technology for design supporting and data standardization supporting.
∙ Developed evaluation technology that can evaluate terms by forming each
stages by starting from form analysis later departmentalizing data structure.
∙ Developed a technology that can evaluation data and automatically edit or
manually edit by user's confirm as visualizing it according to user's type.
∙ Major feature of the manufacturing process, automatic extraction of I/O
contacts and variable standardization, control logic modeling.
∙ Changing operating sequence by time and mapping on space of SILS I/O
control devices.
∙ Developed technology of equipment modeling for extracting meaningful
data by lapse of time out of numerous process control signals.
∙ Developed synchronization technology that can update and edit standard
protocol as standard libraries usable in DB.
∙ Developed method for easily visualize data which completed checking
standard to attribute definition of work-site data in order from user's point
of view.
○ Development of control program analyze by commonly express operating
diagnosis knowledge of the prototype model.
∙ Removing repetitive tasks by analyzing on/off line for improved processes.
∙ Visualizing entire structure from I/O's perspective in order to remove
difficulties of program interpretation to analyze the program.
∙ Developed a function to automatically analyze commercial control
programs.
∙ Developed a user's screen which is even non-technical users can quickly
trace the association and the conditions of each signal.
∙ Developed highlight function to provide information on the various
conditions base on the collected data and the control program logic.
○ Developed comprehensive platform of analyzing the cause of the error by
interworking between process control program and operation log.
∙ Supporting to facilitate identifying the sequence and overall structure on
the basis of a structured analysis of the control program (LD).
∙ Support visualize the time information and the preceding input condition
which is problem according to signal output related to the equipment
operation.
∙ Developed a function that can provide information on the cause by
tracking the conditions for the output.
∙ Developed an efficient way easier to identify than expression of the
two-dimensional context of input and output from the user's point of view.
○ Extracting device operating sequence which is needed for detailed operating
times of devices and SILS expression time.
∙ Developed a technology to generate sequences based on device state.
∙ Developed algorithm that analyze the relationship of condition based on
the collected data and express diagrams by the relationship between output
and condition of analyzed logic.
○ Developed technology of set the sequence in order to automatically
generate the standard model based on control devices.
∙ Developed a technology for estimating operating times of the entire
processes.
∙ Developed a technology that make the rule models which is basic of
analyzing flow of the processes based on actual control contacts of control
equipments in the processes.
∙ Models about work order of the equipments in the processes and interlock
which will set the standard of sequence validity decision.
∙ Developed a technology that can interlock with state models which can
show current state of the equipments precisely in order to define the
sequence models.
∙ Making precise sequence rules of the major concerned equipments through
state models.
∙ In specific concerned section of the processes, Setting simultaneous action,
serial action, delayable time of the main signal among the equipment
sequences.
∙ Making precise sequence judgment rules about forward direction, reverse
direction, correlation of the equipments work order through support for
setting.
○ Developed a technology for acquire suitable data for the SILS environment
from work-site operating system.
∙ A method to replay the situation that reflects the characteristic of
work-site systems of the industries.
∙ Developed how to get physical data considering of factory specific situation
∙ Gathering data with optical fibers and ethernet cables and reducing noise
from gathered data.
∙ Developed gathering algorithms in consideration PLC scan time for
preventing data loss when gathering data from PLC.
○ Framework for managing operation and diagnosis knowledges on running
time.
∙ Framework for real-time diagnosis and analysis on the manufacturing
process, equipment.
∙ Design of the I/O symbols for various state analysis(Key, General, Alarm)
∙ Design of the standard operation pattern options for reflecting various
manufacturing environment.
∙ Error detecting technology with no alarm and analysis on the
manufacturing process state.
∙ Processing state analysis technology with alarm types.
∙ Processing state changes analysis technology and symbol time-series data
analysis for trend diagnosis.
∙ Design of alarm systems with category of processing state(running,
stopping, checking, repairing)
∙ Developed repository for fault repair results and causes with PLC logic
information.
∙ Generating alarms when detecting symptoms of fault with manufacturing
machines using the standard operation patterns and fault histories.
∙ Managing the history of faults and repairs with the operation environment.
○ Support script for binding other program languages.
∙ Support script for reflecting various situation in manufacturing
environment.
∙ Support interfaces for applying other systems.
∙ Support COM(Component Object Model) interface for binding other
languages like Java, VBScript, C#.
∙ Modularized design for flexible integration with other systems.
○ Technology for converting 3D graphic data.
∙ Designed to extend compatible PLC models using common xml format.
∙ Registering command symbols which are mapped with actuators
automatically.
○ General expression of the primitive model on operation & diagnosis
knowledges.
∙ PLC program analysis to express the primitive operation & diagnosis
knowledges.
∙ Supporting the primitive models to apply in various industries.
∙ Technology for applying contents with base templates and mapping the PLC
I/O with template I/O points.
∙ Design of Ladder logic representation: a coil has two parts with COM
conditions and OPT conditions; the COM describes common contacts, OPT is
for option path contacts.
∙ Supporting function block analysis.
∙ Automatic analysis PLC IL with importing common format.
∙ Technology for tracing delay I/O point and optimizing with the PLC logic
diagram.
∙ Optimizing not necessary point with tracing plc logic using the logic
diagram.
○ The expression time error with physical I/O operation time and SILS
operation time.
∙ To reduce time error, Monitoring packets which are composite of PLC step
tags.
∙ Tracing machine stop causes with monitoring PLC step tags.
∙ Developed to trace to final input tags with PLC step from a error coil tag.
∙ Reliability of monitoring I/Os and sensing changes fast and stable.
○ Compatible data format and devices.
∙ Importing each developer(maker) IL formation and Standardization IL
formation and Analysing IL steps, tags, relations.
∙ Supporting PLC steps, tags, relations information with converting and
analysing technology.
○ Transmitting major data and replaying from running systems.
∙ Analysis technology using monitoring device data(logs) and PLC control
logics for machine operation state detection.
∙ Optimizing technology for manufacturing machines and processes using PLC
control logics and monitoring device data.
∙ Tracing technology to final input tags for finding and analysis faults and
causes.
∙ Knowledge acquisition technical for recovering machine faults.
∙ Supporting Gantt Chart for express the machine and production flow states
to trace causes.
○ Runtime extension abilities on manufacturing operation and diagnosis
knowledge.
∙ Functional extension to trace faults and causes while processing.
∙ Framework to update master operation patterns and fault patterns
constantly which are used for faults and causes analysis.
∙ Framework to evaluate manufacturing operation states.
∙ Framework to build up operation master patterns and fault patterns
continually with real time monitoring data.
○ Study on relation with next generation smart factory.
∙ Smart Factory will interconnect and better harmonize individual stages of
manufacturing production to advance plant-wide efficiency for corresponding
with market changes.
∙ SILS simulation is necessary to verify operation control logic cause of
frequent changes for corresponding with market.
∙ SILS simulation is necessary to verify operation control logic with physical
PLC controllers and logics.
∙ SILS simulation is necessary to test various operation scenarios.
∙ SILS analysis technologies are necessary to diagnose manufacturing process
state and find causes when fault detecting with raw data.
∙ Multi-channel and multi-devices monitoring base on IoT(Internet of things) is
necessary for various analysis.
∙ Supporting AML(Automation Markup Language) formations.
∙ Supporting libraries for manufacturing operation sequences, mechanical and
electronical models.
∙ The platform of primitive models for applying smart factory systems.

목차 Contents

• 표지 ... 1
• 제 출 문 ... 2
• 보고서 요약서 ... 3
• 연구개발사업 주요 연구성과 ... 4
• 국문 요약문 ... 5
• 영문 요약문 ... 15
• 목차 ... 26
• 제1장. 연구개발과제의 개요 ... 27
• 1. 연구개발 목적 ... 27
• 2. 연구개발의 필요성 ... 27
• 3. 연구개발 범위 ... 28
• 제2장. 국내외 기술 개발 현황 ... 32
• 1. 국외 기술 동향 및 수준 ... 32
• 2. 국내 기술 동향 및 수준 ... 36
• 제3장. 연구 수행 내용 및 성과 ... 40
• 1. 최종 목표 ... 40
• 2. 연차별 세부 내용 ... 40
• 3. 연구성과 ... 89
• 제4장. 목표 달성도 및 관련 분야 기여도 ... 99
• 1. 목표 달성도 ... 99
• 2. 관련 분야 기여도 ... 105
• 제5장. 연구개발성과의 활용계획 ... 108
• 1. 시장환경 ... 108
• 2. 경쟁력 확보 ... 108
• 3. 활용 계획 ... 109
• 제6장. 연구 과정에서 수집한 해외 과학기술 정보 ... 113
• 1. AML(Automation Markup Language) ... 113
• 2. OPC UA(Unified Architecture) ... 113
• 제7장. 연구개발성과의 보안등급 ... 115
• 제8장. 국가과학기술종합정보시스템에 등록한 연구시설·장비 현황 ... 116
• 제9장. 연구개발과제 수행에 따른 연구실 등의 안전 조치 이행 실적 ... 117
• 제10장. 연구개발과제의 대표적 연구 실적(대표적 성과 10건) ... 118
• 제11장. 기타 사항 ... 119
• 제12장. 참고 문헌 ... 120
• 붙임1. 자체 보안관리 진단표 ... 121
• 붙임2. 연구실 안전조치 이행표 ... 122
• 끝페이지 ... 123