JPH0370005A - Sequence control method - Google Patents

Abstract

PURPOSE:To easily perform the recombination of a process and the addition of a brand etc., by performing the operation of a facility with the combination of unit sequence that is sequence generated in the minimum function unit. CONSTITUTION:The unit sequence 30-1 to 30-4 that are a series of operating programs from the start and the completion of the operation of a unit that is the minimum function unit proper to the facility and are the programs used commonly for each unit are provided on each unit. At such a case, a series of programs in the unit sequence can be automatically run by judging flags and also, reading parameters in the unit sequence 30-1 to 30-4. Therefore, sequence control for the manufacturing of a product with a brand to be manufactured can be performed by selecting such unit sequence corresponding to the brand to be manufactured, and executing it sequentially. Thereby, the sequence control not depending on the brand or the process can be performed.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application This invention is applicable to the production of articles, etc., in which various units, such as a unit for charging raw materials, a temperature raising unit for heating the charged raw materials, etc., are sequentially driven under predetermined conditions. The present invention relates to a method of performing so-called sequence control for stopping, etc.

Prior Art This type of sequence control method is disclosed in, for example, Japanese Unexamined Patent Publication No. 59-1.
It is disclosed in Japanese Patent Application Laid-open No. 25403, Japanese Patent Application Laid-open No. 100806/1983, and the like.

The former is a batch process sequence control method in which each device is provided with an equipment operation sequence that corresponds to 1 to 1, and a process sequence that is a combination of multiple equipment operation sequences for each process, making it possible to combine multiple process sequences. It attempts to process process sequences created for each process using a batch sequence in chronological order, and is characterized by initializing the state of the equipment controlled by the process sequence at the beginning of each process sequence. , the batch sequence is characterized in that a numerical value specifying the operating state or operating condition of the device is created using a temporary variable, and the temporary variable is replaced with a specific numerical value during actual operation.

The latter is specified based on a set of equipment information specified by the designation organization, as well as equipment constituting general-purpose equipment for batch data production stored in the first storage machine and piping connection information between the equipment. By associating the at least one type of equipment located between the set of equipment with the specific equipment constituting the general-purpose equipment for batch production, the plurality of similar processes stored in the second storage mechanism A program for sequence control of a specific process among the plurality of similar processes is generated from a non-generating general-purpose module for sequence control, and a specified mechanism generates a program for sequence control of a specific process among the plurality of similar processes, and the - set of equipment for each of the plurality of similar processes is By specifying the type of general-purpose module to be generated through a specification mechanism and, if necessary (if there are multiple types of general-purpose modules to be generated), the type of general-purpose module to be generated can be specified easily and without the risk of error even when general-purpose production equipment is complex. At the very least, a sequence control program for a batch production process can be generated.

Problems that the invention aims to solve The conventional method is to create a process sequence for each process for all brands to be manufactured, and for each brand, manage the brand using operating conditions such as temperature and pressure as parameters for combination information of the process sequence, and then start production. By downloading the data to the control combinator and processing the process sequence in series, brand-name operation is realized. Therefore, it is necessary to design a sequence that takes into account the processes of all brands, and when new brands and new processes increase, there are problems such as the need to create a process sequence.

In any of the conventional techniques, complicated preliminary work and the like are required during actual operation in a production process of a wide variety of products in small quantities.

This invention does not take into account the processes of all brands to be manufactured and does not create a sequence for each process. A process is composed of a combination of unit sequences, and the combination information is parameterized. The unit sequence is a sequence created for each minimum functional operation, and is intended to provide a control method that can perform sequence control that depends on the equipment but does not depend on the brand or process.

Means for Solving the Problems The present invention provides a series of operating programs from the start of operation to the completion of operation of a unit, which is the minimum functional unit unique to equipment, independent of brand or process, and can be commonly used for each unit. In addition to providing a unit sequence for each unit, each unit sequence is assigned a flag for cooperating with programs such as other unit sequences, and the necessary flags are determined for each unit sequence and executed within the unit sequence. This sequence control method is characterized in that, while program control is progressing, the operating conditions of each brand are incorporated into the unit sequence as parameters, and sequence control is performed according to the judgment of the flag and the incorporated parameters.

By determining the flags and reading the parameters within the action unit sequence, the series of programs within the unit sequence progresses automatically. Therefore, by selecting such a unit sequence according to the brand to be manufactured and sequentially executing it, it is possible to control the sequence of manufacturing the product of the brand.

According to the above sequence control method, the operation schedule data includes step conditions for each process, name of each process, unit sequence for starting/stopping each process as instrument parameters, operating conditions such as temperature and pressure as parameters, brand name, etc. Brand-name operation is achieved by managing the data, downloading it to the control computer at the start of production, and processing the unit sequence in parallel.

Sequence control is possible once the equipment is determined without having to be aware of the processes for all brands.Even if new brands and new processes increase, there is no need to create sequences, and unit sequences can be combined to control operation schedule data and instrument parameters. This can be done simply by creating parameters such as.

Example An embodiment of the present invention will be described below with reference to the drawings.

FIG. 2 shows an example of a manufacturing apparatus to which the present invention is applied, where 1 is an A raw material charging unit, 2 is a B raw material charging unit, 3 is a temperature raising unit, 4 is a circulation unit, and 5 is a stirring unit. , 6 is a vacuum unit, and 7 is a timer unit.

Valves 11.12 are connected to the charging unit 1.2, and raw material A or raw material B is introduced into the processing tank 10 by opening these valves 11.12.

The temperature raising unit 3 is provided with a heating jacket 13 surrounding the processing tank 10, for example, and controls the supply of steam to the heating jacket 13 by opening and closing the control pulp 17, thereby controlling the temperature of the processing tank 10. Let's do it.

The amount of raw material A charged is detected by the flow meter 15, and the amount of raw material B
The amount of raw material charged is detected by a flow rate integrator 16, and the temperature of the processing tank 10 is detected by a temperature sensor 14.

The rotation speed of the stirring unit 5 is detected by a tachometer 18.

The degree of vacuum in the vacuum unit 6 is detected by a vacuum sensor 19.

Data from each sensor is input to the control device shown in FIG. 1(A).

The sequence control device of the present invention, as shown in FIG.
Sensors 21 such as limit switches and level switches that regulate the position. A relay module 23 serves as an input/output interface for transmitting and receiving signals between an operating device 22 such as a valve, pump heater, or motor and the control computer 20, and a keyboard 2 for inputting data from an operator.
4, an operator console 26 including a CRT 25 for displaying input/output data, a keyboard 27 for inputting various parameters (details will be described later) associated with the brand to be produced, and a brand management computer 29 including a CRT 28 for displaying parameters, etc. We are prepared.

The control computer 20 stores a unit sequence (described in detail later) 30 that controls the sequential operation of each unit described above, an operation scheduler 31 that controls which unit sequence is used, and a flag that is a control signal when the unit sequence is activated. It has a flag area 32 and the like.

The unit referred to here is the above-mentioned A raw material preparation unit 1.
B raw material charging unit 2, temperature raising unit 3, circulation unit 4, stirring unit 5, vacuum unit 6, timer unit 7, etc. As mentioned above, the operation of the equipment is considered as a collection of minimum functional operation units, A sequence created for each minimum functional operation unit is a unit sequence. therefore,
The unit sequence is constructed depending on the equipment and not on the variety.

The unit sequence is a block that executes a series of programs as shown in FIG. 3, and FIG. 3 shows the unit sequence for a temperature increasing unit as an example.

The unit sequence has the following functions assigned to it: start flag/stop flag/interruption flag/running flag/completion flag.

The start flag is on and the unit sequence starts.

The assignment of flags may be different depending on whether it is automatic or manual.

The stop flag is on and the unit sequence stops.

The interrupt flag is on and the unit sequence is interrupted.

The execution flag is on and the unit sequence is being executed.

The completion flag is on and the unit sequence satisfies the completion conditions.

In particular, start/stop flag/completion flag: These are closely related to the operation scheduler, and the start flag and stop flag are used for starting and stopping a unit sequence, and the completion flag is used for step conditions.

To explain FIG. 3 in detail, the completion flag is reset in step S1, and the completion flag is reset in step S2.
It is determined whether the stop flag is on or not, and if it is on, step S
If the interrupt flag is off, it is determined in step S3 whether the interrupt flag is on. If it is off, it is determined in step S4 whether the start flag is on. If the start flag is on, the running flag is turned on in the unit sequence in step S5, and a check is made to see if the liquid level is LS-1 or higher in step S6. Next, in step S7, it is determined whether the liquid level is greater than t, s-1. If the liquid level is less than LS-1, the process returns to step S2; if it is above, the process proceeds to step S8, and the valve V-1 opening TlC-1 setting value is set. Set from the data buffer (85℃) Perform operations such as switching to TIC-I AUTO mode, then in step S9 TIC-177)
Check if PV is above 85°C-a. Then, in step S1O, it is determined whether the PV is 85°C or higher, and if it is, the completion flag is turned on in step S1l, and step S2
Return to The process also returns to step S2 in the following cases.

In step S12, valve V-1 is closed and TIC-IMAN is closed.
mode, and TIC-IMV=0 control pulp is fully closed.

In step S13, valve V-1 is closed and TIC-IMAN is closed.
, mode is switched to TIC-IMV=O,: 1 control valve is fully closed, and in step S14, start flag reset, stop flag reset, interruption flag reset,
The execution flag is reset, the completion flag is turned on, and the series of sequences ends.

According to the invention, a unit sequence similar to the program described above is provided in the control computer 20 for each unit 1-7. A flowchart generally representing the unit sequence as used by all units is shown in FIG.

As can be easily seen from the comparison between FIG. 3 and FIG. 4, all steps are common to each unit, and step S6.
S7. S8. S9. S 10. S l 2. S
13 can be arbitrarily rewritten from the outside using its contents as parameters.

Note that step S2 of the unit sequence. Each flag in S3 and S4 is a signal obtained from other programs that cooperate with these unit sequences, such as the operation of a push button switch, a sensor, a limit switch, etc., and these signals are sent to the flag area 32 by the other programs mentioned above. will be written to. This flag area 32 is then read by the unit sequence.

Next, each parameter will be explained.

In the unit sequence, all the elements that depend on the product type are parameterized, and when activated by an operation scheduler or manual operation, execution is performed by referring to instrument parameters. An example of the instrument parameters is shown in Table 1 below.

Table 1 The instrument parameters for each type are input as brand data together with operation schedule data by the brand management computer 29 from a prescription 34 in which an operator has written various data regarding the brand to be produced, as shown in FIG. When a product type is selected at the start of operation, the product data is downloaded from the brand management computer 29 to the control computer 20 as brand data.

Next, the driving schedule data will be explained.

The operation schedule data is a data file that controls which unit sequences are started and stopped in what order. For example, as shown in Figure 6, the operation schedule data is a data file that controls which unit sequences are started and stopped in what order. Whether to start or stop is downloaded from the stock management computer and written in the schedule data buffer 33Y, which is a RAM, in a table format. In FIG. 5, . is a start flag, X is a stop flag, and O is a completion flag, indicating the step condition. Each flag and process number are stored in the memory area Ml as shown in FIG.

M2. M3. Written to M4.

For example, in the example shown in FIG. 5, the process with step number l is started first, unit sequence A is operated, the start flag Fl of unit sequence A is turned on, and then the predetermined process in the unit of unit sequence A is completed. When the stop flag F2 of the unit A is turned on, the next step moves to step number 2, and the unit sequence B, C, E is set to the start flag F3. F4. P5 is read and activated, and when the predetermined steps of each unit B and C are completed, the process moves to step 3 and unit sequence D is activated.

The process step condition is constantly monitored for each process by referring to the operation schedule data, and if the conditions are met, the start flag of the unit sequence to be started in that process is turned on, and the stop flag of the unit sequence to be stopped is turned on. All the signals in the control computer can be used as step conditions, and the algorithm is not limited by the combination of AND conditions and OR conditions. In addition, the operation scheduler manages step No. 1 and operation step No. 9 for each process and utilizes it for operation monitoring, process display, etc.

In a batch plant, an operation scheduler is provided for each tank, but it can basically be used in a continuous plant as well, and is a general-purpose program.

The operation mode of the operation scheduler is automatic operation and process operation. In automatic operation, the process is transferred only according to the step condition of the process, and in process operation, even if the step condition of the process is met, the step flag is not turned on. The process will not be transferred until the process is completed. Therefore, a process operation flag and a step flag are provided as flags specific to the operation scheduler.

At the bottom of the groove, the units 30 in the control computer 20 are configured as shown in FIG. is provided. A program corresponding to the flowchart shown in FIG. 4 is written in each unit sequence.

Now, for example, a control method for performing sequence control for manufacturing a product of type A using a preparation unit and a temperature raising unit will be described.

First, regarding the preparation unit, raw material A (A in type A)
It has nothing to do with it. ) is inputted from the brand management computer 29, this amount is automatically entered at the start of operation, when the product name is entered manually from the operator's console 26, the RA
It is written in the area provided corresponding to the preparation unit of the data buffer 33X in M33.

Regarding the temperature increasing unit, when the temperature increasing limit "85° C." is inputted from the brand management computer 29 in the same manner as above, this temperature increasing limit is written in the area provided corresponding to the temperature increasing unit of the data buffer 33X.

Other necessary conditions, such as the number of the sensor, the number of the valve to be opened and closed, the number of the pump or motor to be started/stopped, etc., are written into the data buffer 33X.

On the other hand, as shown in FIG. 7, the step conditions, step numbers, process numbers, and start/stop flag numbers necessary for manufacturing type A are entered into the operation scheduler 31 from the brand management computer 29, and these data are input into the operation scheduler 31. At the start, R according to the product name entered from the operator's console 26.
The data is written into the data buffer 33Y using AM33 by process number, for example, as shown in FIG.

During actual operation, the sequence of each unit is step S8 in FIG. S9. S12. In S13, the corresponding area of the data buffer 33X is read and, for example, in the temperature raising unit, sequence control is executed while importing the data into the program shown in FIG.

When the control system is started after performing the above settings, the preparation unit sequence 30-1 whose step number is set to rN is selected first. Then, when the process progresses to step 3, the temperature raising unit sequence is started, and 914 is started from the step number shown in FIG.
When the program up to this point is executed and the flag reset in step S14 is completed, the operation scheduler 31 selects and starts the timer unit sequence 7.

Note that by setting start flags for multiple unit sequences at the same time, multiple unit sequences can be operated in parallel at the same time.

Furthermore, without using an operation scheduler, the operator can start and control a required unit sequence by independent operation while observing the operating state of each unit.

In summary, the sequence control method of the present invention described above is realized by considering the operation of equipment as a set of minimum functional operation units, and by combining unit sequences, which are sequences created for the minimum functional units, so that the unit sequences can be processed in parallel. Brand operation is performed by the following, and the operating conditions that depend on the type of product to be manufactured, that is, the brand, can be managed for each brand as instrument parameters for each unit sequence.

A start flag (automatic/manual), stop flag, interruption flag, running flag, and completion flag are provided for each unit sequence, and are used for communication with the operation scheduler and push button sequence, interlock between units, process display, etc.

A single operation push button sequence can be created for each unit sequence and started/stopped individually.

There is an operation scheduler that turns on the start flag and stop flag of the unit sequence that starts and stops each process.

The flag is reset on the unit sequence side.

The parameters of the operation scheduler include step conditions for the next process, unit sequence information for starting/stopping each process, and the name of each process, which is called operation schedule data.

Operation process N for each step (process) of the operation scheduler
The process is displayed by referring to the master (FIG. 9) that manages the Ol and associates numbers and names.

The operation mode of the operation scheduler is automatic operation and process operation, and if you turn on the process step manual flag specific to the operation scheduler from the push button sequence, it will become process operation mode.
Even if the conditions for proceeding to the next process are met, the process does not proceed to the next process.

Furthermore, if a process forced step flag specific to the operation scheduler is turned on during process operation, the process will proceed to the next process even if the step condition for the next process is not satisfied. If the process step manual flag is turned off during process operation, process operation is switched to automatic operation.

As stock data Driving schedule data Instrument parameters There is.

Effects of the Invention As described above, according to this invention, equipment operation is considered to be a set of minimum functional operation units, and is realized by combining unit sequences, which are sequences created for the minimum functional units, and unit sequences are processed in parallel. 1) If you create a -degree no-ken program, you can easily rearrange processes, add types, etc. by registering and changing parameters, as long as there are no changes to the process.

2) Therefore, even people who do not understand sequence programming can easily rearrange processes, add products, etc.

3) Even when changing equipment, only the related unit sequences need to be changed, making debugging work more efficient.

4) Quick response to prototypes.

5) It is easy to conduct various trials related to production, and it is effective in shortening cycle time and improving quality.

6) At the design stage of the control system, it is not necessary to design with product types in mind, which is effective for multi-product production equipment.

7) The concept is simple and sequence program maintenance is easy.

[Brief explanation of drawings]

Figure 1 is a block diagram of the device used in the control method of the present invention, Figure 1 (B) is a detailed block diagram of the main part of Figure 1 (AI), and Figure 2 is a diagram of the equipment to which the present invention is applied. A block diagram showing an example, FIG. 3 is a flow chart showing the unit sequence of the temperature increasing unit,
Figure 4 is a flowchart of a general unit sequence, Figures 5 and 6 are diagrams showing an example of the operation scheduler, Figure 7 is a diagram showing an example of the storage area of the operation scheduler, and Figure 8 is a diagram showing the unit sequence. FIG. 9 is a diagram showing the storage area of the parameters used, and FIG. 9 is a diagram showing the contents of the operating process name master. l... A raw material preparation unit, 2... B raw material preparation unit, 3... Temperature raising unit, 4... Circulation unit, 5...
... Stirring unit, 6... Vacuum unit, 7... Timer unit 10... Processing tank, 11.12... Valve,! 3...
- Heating jacket, 14... Temperature sensor, 15.
16...Flow rate totalizer, 7...Control valve, 18...Tachometer,
9... Vacuum sensor, 20... Control computer, l.
...sensor, 22...operator, 3...relay module, 24...keyboard, 5...CRT, 2
6...Operator console, 7...Keyboard,
28...CRT. 9...Brand management computer, 0...Unit sequence, ■...Operation scheduler, 2...Flag area. 3...RAM 4...Prescription data 1st! ! I (Japanese)

Claims (4)

[Claims] (1) A unit sequence, which is a series of operation programs from the start of operation to the completion of operation of the unit, which is the minimum functional unit unique to equipment that does not depend on the brand or process, is provided for each unit, and each of the above unit sequences has a unit sequence other than the other unit sequences. Alternatively, flags can be assigned to work in conjunction with other programs, and the program control within the unit sequence can proceed while determining the required flags for each unit sequence, while the operating conditions of each brand can be used as parameters for the unit sequence. A sequence control method characterized in that sequence control is performed according to the determination of the above-mentioned flag and the imported parameters. (2) The control method according to claim (1), wherein brand operation is realized by simultaneously processing a plurality of unit sequences in parallel. (3) Claim (1) using an operation scheduler that has step conditions, start/stop unit sequences, or operation process names as parameters for each process and performs process management.
) Control method described. (4) The control method according to claim (1), wherein the unit sequence and the operation scheduler are combined to realize brand operation.