System for predicting abnormality occurrence using PLC log data

A system for predicting abnormality occurrence using Programmable Logic Controller (PLC) log data, the system comprising:

• a controller configured to receive the PLC log data from a lower-level device connected to a PLC data log module to determine the PLC log data, and to store the determined data when the determined data is related to abnormality occurrence;
• an analyzer configured to generate and store an abnormality analysis result by analyzing the determined data related to the abnormality occurrence;
• and
• an alarm unit configured to receive an abnormality occurrence prediction signal from the controller and generate an alarm for a user indicating that the abnormality occurrence is predicted,
• wherein the controller is further configured to:
• compare the PLC log data received from the lower-level device with the stored abnormality analysis result;
• generate the abnormality occurrence prediction signal when it is determined that the PLC log data received from the lower-level device is similar to the stored abnormality analysis result;
• and
• determine whether the received PLC log data is related to the abnormality occurrence,
• wherein the analyzer is further configured to:
• generate the abnormality analysis result by analyzing a pattern of the determined data based on a time change;
• calculate an average of the analyzed data and an inclination, and store the calculated average and inclination along with the abnormality analysis result when a change trend has linearity within a predetermined scope of the analyzed pattern as a result of the analysis of the pattern of the determined data based on the time change;
• store a predetermined data value along with the abnormality analysis result when it is determined that the analyzed pattern has a converging physical property where a data change is converged to the predetermined data value as the result of the analysis of the pattern of the determined data based on the time change;
• and
• calculate a time for which the analyzed data is constantly maintained and store the calculated time along with the abnormality analysis result when the analyzed pattern has a circulating physical property as the result of the analysis of the pattern of the determined data based on the time change, wherein at least one of the average of the analyzed data, the inclination, the predetermined data value, and the time is sent to the alarm unit along with the abnormality occurrence prediction signal to alert the user.