JPH10149215A - Device and method for monitoring abnormality of equipment - Google Patents

Abstract

PROBLEM TO BE SOLVED: To quickly identify an abnormal source even in the case of any abnormality in various equipments. SOLUTION: Operation waiting time from the output of an operation command for specifying an actuator in turn of operation up to the output of a start signal for the actuator is counted (S1 to S3). Whether the operation waiting time has exceeded previously determined operation waiting allowable time or not is judged (S4), and when the time has exceeded the allowable time, the actuator is judged as operation unstarted abnormality (S5). On the other hand, real operation time from the output of the start signal to the actuator up to the completion of operation of the actuator is counted (S2, S7, S8). Whether the real operation time has exceeded previously determined real operation allowable time or not is judged (S9), and when the counted time has exceeded the allowable time, the actuator is judged as operation unfinished abnormality (S10).

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an abnormality of a facility including one or more actuators for performing a predetermined operation in response to a start signal and one or more sensors for detecting the operation of the one or more actuators. The present invention relates to a monitoring device and an abnormality monitoring method thereof.

[0002]

2. Description of the Related Art Examples of conventional equipment abnormality monitoring devices include, for example, JP-A-60-222328 and JP-A-5-3.
There is one described in Japanese Patent No. 33414.

[0003] Each of these abnormality monitoring devices is adapted only to a predetermined device such as a transmission or a camera, and monitors only the actual operation time during which a specific actuator is actually operating. When the actual operation time exceeds the specified time, the cause of the abnormality expected in advance in relation to the specific actuator is dealt with or the cause of the abnormality is displayed.

[0004]

However, in such a conventional technique, a predetermined device such as a transmission or a camera targets only a specific actuator. By monitoring only the actual operation time, the cause of the abnormality can be predicted from the causal relationship between the actual operation time abnormality and the cause of the abnormality.However, if this conventional abnormality monitoring device is applied to various facilities, the actuator Even if only the actual operation time is monitored, it is not possible to grasp whether the actuator itself is abnormal or whether an external factor such as a device that triggers the operation of the actuator is abnormal. That is, in the related art, when the abnormality monitoring device is applied to various facilities, there is a problem that it takes time to identify an abnormality source.

The present invention has been made in view of such conventional problems, and provides an equipment abnormality monitoring apparatus capable of shortening the time required for identifying an abnormality source for any equipment. The purpose is to do.

[0006]

In order to achieve the above object, an apparatus for monitoring abnormality of equipment comprises at least one actuator (81, 81,...) Which performs a predetermined operation in response to an input of a start signal.
And one or more sensors (82, 82,...) For detecting the operation of one or more actuators (81, 81,...), Respectively.
(8) comprising: an actuator operation sequence management for outputting an operation command for designating an actuator (81) that has reached an operation order among one or more actuators (81, 81,...) When the starting condition for the means (31) and the actuator (81) specified by the operation command is satisfied, the actuator (8)
In an abnormality monitoring device for equipment controlled by a control device having a start control means (32) for outputting a start signal to 1), one or more actuators (81, 8) are provided.
1,...), The operation waiting time from when the operation command is output to when the activation signal is output to the actuator (81) designated by the operation command is a predetermined operation. The operation waiting time monitoring means (33) for monitoring whether or not it is within the allowable waiting time, and the actuator (81) to which the activation signal is output among the one or more actuators (81, 81,...). , After the activation signal is output, the actuator (81)
Actual operation time monitoring for monitoring whether or not the actual operation time until the operation end signal of the actuator (81) is output from the sensor (82) for detecting the operation of the actuator is within a predetermined actual operation allowable time. Means (33), when the operation waiting time exceeds the operation waiting allowable time, outputting a notification that the operation of the actuator (81) is not started abnormally; If exceeded,
Abnormality output means (10) for outputting an operation incomplete abnormality of the actuator (81).

Here, the abnormality output means may display the contents of the abnormality in an image or output the sound.

The activation control means (32) of the control device includes a plurality of external signals from the sensors (82, 82,...) Or switches (83, 83,...) And a plurality of external signals. A start condition and / or an interlock condition, which are one or more of an internal signal determined by a combination and an internal signal determined by a combination of the internal signal and the external signal or the internal signal. Is established, the abnormality monitoring device includes a signal storage unit (34) that stores states of the plurality of external signals and the plurality of internal signals, and the activation control when the operation is not started abnormally. A signal indicating that the means (32) is in a state in which the output of the start signal among the signals constituting the start condition and / or the interlock condition is hindered for the actuator (81) whose operation has not started abnormally. Is selected from the signal storage unit (34), and when the selected signal is the internal signal, the internal signal is decomposed, and the output of the activation signal is output from a plurality of signals obtained by decomposing. A signal that is obstructing is selected, and the decomposition of the signal and the selection of a signal that is obstructing the output of the activation signal are repeated to find the external signal that is obstructing the output of the activation signal. Abnormality source searching means (4), and the abnormality output means (10).
May output the name of the external signal obtained by the abnormality source searching means (4), or the name of the sensor (82) or the switch (83) that has output the external signal.

The abnormality output means (10) is predetermined based on the relationship between the external signal obtained by the abnormality source searching means (4) and the start signal whose output has been prevented by the external signal. It may output a comment that has been entered.

The activation control means (32) includes:
An activation control procedure is defined for each of the actuators (81, 81,...), And each activation control procedure includes the operation command name, the activation signal name, the operation end signal name, the operation wait allowable time, or the When the reference time and the actual operation allowable time or the reference time are set, the abnormality monitoring device executes the execution procedure of the operation waiting time monitoring means (33) and the actual operation Time monitoring means (3
A monitoring procedure model relating to the execution procedure of 3) is prepared in advance, and the operation command name, the activation signal name, the operation end signal name, and the operation command name are obtained from the activation control procedure for each of one or more actuators (81, 81,...). The operation waiting allowable time or the reference time and the actual operation allowable time or the reference time are extracted and set in the monitoring procedure model for each of the actuators (81, 81,...). A monitoring procedure generation means (2) for determining an execution procedure of the operation waiting time monitoring means (33) and an execution procedure of the actual operation time monitoring means (33) for each of one or more actuators (81, 81, ...). May be.

Further, in each of the activation control procedures of the activation control means (32), the actuators (81, 81,
..), The monitoring procedure generating means (2) multiplies the standard actual operation time by a predetermined magnification to obtain the operation wait allowable time and the actual operation time. The operation allowable time may be determined, and the operation wait allowable time and the actual operation allowable time may be set in the monitoring procedure model.

In order to achieve the above-mentioned object, the method for monitoring abnormality of equipment is characterized in that one or more actuators (81, 81,...) Which perform a predetermined operation in response to a start signal and one or more actuators (81, 81,...). 81,...) For detecting the operation of each of the actuators (81, 81,...). An inter-actuator operation order management means (31) for outputting an operation command designating the actuator (81) in the order to be operated; and, when the activation condition for the actuator (81) specified by the operation command is satisfied, the actuator (81) 81)
In a method for monitoring abnormality of equipment controlled by a control device having a start control means (32) for outputting a start signal to the actuator, one or more of the actuators (81, 81,
...), The operation waiting time from when the operation command is output to when the activation signal is output to the actuator (81) designated by the operation command is a predetermined operation waiting time. It is monitored whether it is within the time (steps 1, 2, 3, 4). If the operation waiting time exceeds the operation waiting allowable time, the actuator (81)
Is an operation unstart abnormality (step 5), the activation signal is output to the actuator (81) to which the activation signal is output, among the one or more actuators (81, 81,...). After that, the actual operation time from when the sensor (82) for detecting the operation of the actuator (81) outputs an operation end signal of the actuator (81) is within a predetermined actual operation allowable time. Is monitored (steps 2, 7, 8, 9), and when the actual operation time exceeds the actual operation allowable time, it is determined that the actuator (81) is in an operation incompletion abnormal state (step 10). It is characterized by the following.

In the above description, the symbols in parentheses are as follows:
9 shows a corresponding part or target processing in the following embodiment.

[0014]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing an apparatus for monitoring abnormality of equipment according to an embodiment of the present invention.

As shown in FIG. 1 and FIG. 2, a facility 8 which is an object of the abnormality monitoring apparatus according to the present embodiment controls a plurality of actuators 81, 81,. , And various switches 83, 83,... The abnormality monitoring device includes a program development and abnormality confirmation device 9 and a program execution device (programmable controller) 3.

As shown in FIG. 1, the program development / abnormality check device 9 develops a program for developing an actuator activation control program and an inter-actuator operation sequence program, which will be described later, according to a predetermined procedure. Unit 1, an actuator activation control program storage unit 5 for storing an actuator activation control program developed by the program development unit 1, and an inter-actuator operation sequence for storing an inter-actuator operation sequence program developed by the program development unit 1. A program storage unit 6, a monitoring program generation unit 2 that generates a monitoring program for each actuator using a monitoring model and an actuator activation control program stored in advance, and a monitoring program generation unit 2 for each actuator generated by the monitoring program generation unit 2. of A monitoring program storage unit 7 for storing a viewing program; an abnormality source searching unit 4 for searching for a signal output by an abnormality source based on information obtained by executing the monitoring program by the program execution device 3; A display unit 10 for displaying an abnormality source or the like found by the unit 4. Also, the program execution device 3 executes the operation sequence program in software and designates the actuator 81 that has reached the operation order among the plurality of actuators 81, 81,. Operation sequence program execution unit 3 that outputs a command
1 and a signal (external signal) from a sensor 82 or a switch 83 in the equipment 8, and outputs a start signal to an actuator 81 in the equipment 8 according to a start control program to control the start control program execution unit 32. And a monitoring program execution unit 33 that executes a monitoring program to monitor an abnormality of the equipment, and a data storage unit 34 that temporarily stores various signals and the like. The function of the equipment 8 as a control device is performed by the operation sequence program 31 and the activation control program execution unit 32.

As shown in FIG. 2, the program development and abnormality check device 9 includes a CPU 91 for executing various calculations, a memory 92 for storing various programs and the like, and a calculation result of the CPU 91. CRT displaying
95, a keyboard 96 for inputting various data and the like,
An I / O controller 93 for controlling the RT 95 and the keyboard 96 and a communication controller 94 for controlling data transmission and reception with the programmable controller 3 are provided. In the program development and abnormality check device 9, the above-described program development unit 1, monitoring program creation unit 2, and abnormality source search unit 4 are stored in a memory 92 in which various programs are stored, and in the memory 92. And a CPU 91 for executing a program. Each of the program storage units 5, 6, and 7 is configured by a memory 92. The display unit 10 is a CRT.
95.

In terms of hardware, the programmable controller 3 includes a CPU 311 for executing various operations,
Program memory 31 in which various programs are stored
2, a data memory 314 for storing various data,
A sequence control processor 313 for executing a program stored in a program memory 312, a communication controller 315 for controlling data reception and transmission between the program development and abnormality check device 9, and input / output between the equipment 8 An I / O controller 316 for controlling signals. In the programmable controller 3, each of the program execution units 31, 32, and 33 includes a program memory 312 in which various programs are stored.
And a CPU 311 for executing various programs stored in the program memory 312 and a sequence control processor 313. Further, the data storage unit 34 includes a data memory 314. Under the control of the CPU 311, the sequence control processor 313 controls the programmer controller 3 via the I / O controller 316 in accordance with the sequence control program (actuator activation control program, operation sequence program) written in the program memory 312. Actuator).

Data and the like can be transmitted and received between the program development and abnormality check device 9 and the programmable controller system 3 via the communication controllers 94 and 315. Be executed.

The inter-actuator operation sequence program stored in the inter-actuator operation sequence program storage unit 6 includes a plurality of actuators 81,
Among the programs 81,..., The program is for designating the actuator 81 that has reached the order of operation, and has a transition condition and a process (operation command to the actuator). In this program, the operation order of each actuator 81, 81,... In the equipment 8 is determined by describing an instruction for giving an operation command to the activation control program of the actuator to be controlled at the processing step. This program is, for example, IEC (International Electrotechnique)
inical Commition) SFC (Sequential Function)
Chart). A specific example of the inter-actuator operation order program will be described later with reference to FIG.

The operation sequence program executing section 31 for executing the inter-actuator operation sequence program executes this program, and when a certain processing step is reached, the actuator 81 described in this processing step is executed.
Outputs the operation command related to

The actuator start control program stored in the start control program storage unit 5 is a program library in which conditions relating to the start and stop of each actuator are described, and the names of the actuators and the actuators are stored. Name, the name of the start signal for starting the operation, the start condition (including the operation command), the interlock condition, the standard operation time until the operation is completed, and the operation end signal for confirming the completion of the operation. It is configured. A specific example of the actuator activation control program will be described later with reference to FIGS.

The activation control program executing section 32 for executing the actuator activation control program, when a start condition specified by the program is satisfied for a certain actuator 81 among the plurality of actuators 81, 81, 81, the actuator 81 Outputs a start signal to the controller.

The monitoring program execution unit 33 measures the operation waiting time and actual operation time of each actuator, and monitors whether or not these times of each actuator are within the allowable time. Here, the operation waiting time of the actuator 81 refers to an operation command for the actuator 81 that has reached the operation order from the operation order program execution unit 31 among the plurality of actuators 81, 81,. This is the time until the activation signal is output from the activation control program execution unit 32 assuming that the activation condition is satisfied. The actual operation time of the actuator is the time from when the activation signal of the actuator 81 is output to when the operation end signal is output from the sensor 82 that detects the operation of the actuator 81.

The monitoring program execution unit 33 operates as shown in the flowchart in FIG. This flowchart is a flowchart of the monitoring model. Since the processing procedure is substantially the same for the monitoring program and the monitoring model, the operation of the monitoring program execution unit 33 will be described using the flowchart. The monitoring program execution unit 33
Executes the operation in parallel with the operation of the inter-actuator operation order program execution unit 31 and the operation of the activation control program execution unit 32, and sequentially stores the execution results of the monitoring program in the data storage unit 34.

When the monitoring program execution unit 33 receives an operation command of the actuator from the operation sequence program execution unit 31 (step 1), the activation control program execution unit 32
The operation waiting time from the start until the start signal is output is measured (steps 2 and 3). Next, it is determined whether or not the operation waiting time has exceeded the operation waiting allowable time (step 4). If the operation waiting time has exceeded the operation waiting time, it is determined that the actuator has not started operation. The activation signal name of the actuator and the abnormality identification data indicating the operation unstart abnormality are stored in the data storage unit 34 (Step 5). Then, the abnormality detection number stored in the data storage unit 34 is increased by one (step 6). If it is determined in step 4 that the operation waiting time does not exceed the allowable operation waiting time, in other words, if the operation waiting time is within the allowable operation waiting time, the process returns to steps 2 and 3;
The measurement of the operation waiting time is continued until the activation signal is output from the activation control program execution unit 32. In this embodiment, a time obtained by multiplying the standard operation time of the actuator by 0.2 (0.2 × the standard operation time) is used as the operation wait allowable time.

In step 2, when the output of the activation signal from the activation control program execution section 32 is detected, the actual operation time until the operation end signal is input from the sensor is measured (steps 7, 8). Next, it is determined whether or not the actual operation time exceeds the actual operation allowable time (step 9). If the actual operation time exceeds the actual operation allowable time, it is determined that the actuator is in an operation incomplete end abnormality. The activation signal name of the actuator and the abnormality identification data indicating the operation incompletion abnormality are stored in the data storage unit 34 (step 1).
0). Then, the abnormality detection number stored in the data storage unit 34 is increased by one (step 11). Step 7
In the above, if it is determined that the actual operation time does not exceed the actual operation allowable time, in other words, if it is determined that the actual operation time is within the actual operation allowable time, the process returns to steps 7 and 8, and the operation end signal is output from the sensor. Measurement of the actual operation time is continued until the operation is completed. In this embodiment, a time obtained by multiplying the standard operation time of the actuator by 1.2 (1.2 × standard operation time) is adopted as the actual operation allowable time.

The data storage section 34 is provided with a monitoring result table for storing data in the above steps 5, 6, 10, and 11. As shown in FIG. 4, the monitoring program execution unit 3
The activation signal name column 34c for storing the activation signal name for the actuator determined to be abnormal in 3 and operation abnormality identification data for identifying whether the actuator determined to be abnormal is an operation unstart abnormality or an operation unfinished abnormality. There is an operation abnormality identification data column 34b in which data is stored, and an abnormality detection number column 34a in which the number of detected equipment abnormalities is stored. The data storage unit 3
4 is determined by a start signal (Y) as an output signal, an external signal (X) as an input signal from the sensor 82 and the switch 83 of the facility 8, and a combination of a plurality of external signals, in addition to the above data. The state of the internal signal (R) is also stored. The internal signal is created in the program execution device 3 and, in order to facilitate programming work, speed up program execution, and the like, combine signals meant by a combination of a plurality of external signals into one signal. It is a thing. It should be noted that, as the internal signal, in addition to a signal obtained by combining a plurality of external signals, a signal obtained by combining an external signal and an internal signal, and a signal obtained by combining internal signals are used.

As shown in FIG. 3, the monitoring program generation section 2 has a monitoring model storage section 21 in which an actuator monitoring model is stored. The actuator monitoring model includes four parameters of an operation command name 51, a start signal name 52, an operation end signal name 53, and a standard operation time 54 of the parameters constituting the monitoring program described above with reference to FIG. 3. One parameter is not specified. That is, in the actuator monitoring model, parameters necessary for monitoring a specific actuator are not defined in order to ensure versatility as a model. Therefore, the monitoring program generation unit 2
The operation command name 51, the start signal name 52, the operation end signal name 53, and the standard operation time 54 for each actuator stored in the start control program storage unit 5 are extracted. Then, for each actuator, these extracted parameters are substituted into the actuator monitoring model, and an actual operation time monitoring program 70 and an operation start waiting time monitoring program 71 are created for each actuator, and these are stored in the actuator monitoring program storage. Register in section 7.

The abnormality source searching unit 4 refers to the description contents of the actuator activation control program, and inputs / outputs the actuator which has caused the operation abnormality to the actuator determined to be abnormal by the monitoring program execution unit 33. Find out the signal. As shown in the flowchart of FIG. 5, the abnormality source searching unit 4 first starts the monitoring program executing unit 33.
With reference to the monitoring result table (FIG. 4) of the data storage unit 34 in which the execution results of
a, a start signal (Y) name 34c for the actuator determined to be abnormal by the monitoring program execution unit 33, and an actuator operated by the start signal (Y) of the start signal name 34c has an operation non-start abnormality or an operation incomplete error Then, operation abnormality identification data (LN) 34b for identifying whether the operation is abnormal is collected (step 41). Next, referring to the abnormality detection number 34a of the equipment, the following loop is performed for the number of times (steps 43 to 52).
Is determined (step 42). The following loop (step 43) is performed for the number of detected equipment abnormalities 34a.
To 52), the operation abnormality identification data
With reference to (LN) 34b, this operation abnormality identification data (L
N) It is determined whether the meaning of 34b is an operation not started abnormality or an operation not completed abnormality (step 43). If the meaning of the operation abnormality identification data (LN) 34b is an operation incompletion abnormality, the signal causing the operation abnormality is the sensor 8
This is an operation end signal which is an input signal (external signal) from No. 2. Therefore, the start signal (Y) is supplied from the actuator start control program using the start signal (Y) name 34c as a key.
(X) is extracted (Step 4).
4). The name of the actuator, the name of the activation signal (Y) of the actuator, and the input signal (X) that caused the abnormality
The name and the mode of the operation abnormality of the actuator are displayed on the display unit 10 (step 52).

In step 43, operation abnormality identification data
If the meaning of the data (LN) 34b is that the operation has not been started yet, the start condition and the interlock condition are extracted from the actuator start control program using the start signal (Y) as a key (step 45). Next, the state of each signal constituting the extracted start condition and interlock condition is stored in the data storage unit 34.
(Step 46), and extract the non-logic signal that is preventing the output of the activation signal (Step 4).
7). Then, it is determined whether the extracted signal is an internal signal (R) or an external signal (input signal (X)) based on the signal name (step 48).
The processing of step 52 described above is performed. If the extracted signal is an internal signal (R), a condition for establishing the internal signal (R) is extracted from the activation control program (step 49), and the state of each signal constituting the extracted condition is stored in data. A signal that prevents the output of the activation signal is extracted from the plurality of signals (step 51). Thereafter, the processing of steps 48 to 51 is repeated, and when the extraction signal becomes an external signal (X) in step 51, the processing of step 52 described above, that is, the name of the actuator, the name of the activation signal (Y) of the actuator , The input signal that caused the error (external signal X)
The display unit 10 displays the name and the mode of operation abnormality of the actuator.

As described above, the processing loop of steps 42 to 52 is repeatedly executed. In step 42, when the number of executions reaches the abnormality detection number 34a of the equipment, it is determined that the abnormality source search has been completed for all abnormalities, The abnormality detection number 34a of 34 is cleared.

Next, using the conveyor equipment shown in FIG.
The operation of the abnormality monitoring device described above will be specifically described. As shown in FIG. 6, the conveyor equipment includes a conveyor, various sensors 102, 103, 104, and various switches 105, 106, 107. The conveyor includes a driving pulley 109, a driven pulley (not shown), and a belt 110 wound around these pulleys.
A work table 108 attached to the belt 110;
And a motor 101 for rotating the drive pulley 109. The motor 101 rotates forward in response to the start signal (Y112) and reversely rotates in response to the start signal (Y113). Work table 108
Performs reciprocation by repeating forward and reverse rotations of the motor 101. The work table sensor 1 is provided at one reversing position of the work table 108 and outputs a normal rotation operation end signal (X102) when the work table 108 is detected.
02 and the other inverted position of the work table 108,
When the work table 108 is detected, the reverse rotation operation end signal (X1
03) and the work table sensor 103,
There is a foreign object sensor 104 which outputs a foreign object detection signal (X104) when detecting a foreign object in the movement route 08. The switches include stop pushbutton switches 105 and 106 that output stop signals (X105 and X106) by operation of an operator, and a speed adjustment switch 107 that changes the rotation speed of the motor 101. Work table 108
Is detected by the work table sensor 102 during normal rotation of the motor 101, the motor 101 rotates in the reverse direction and moves in the direction of the work table sensor 103, and is detected by the work table sensor 103 during the reverse rotation of the motor 101. Then, the motor 101 rotates forward and moves in the direction of the work table sensor 102. The standard time required for the one-way movement of the work table 108 is 10 seconds. That is, the standard operation time of the motor 101 is 10 seconds. When a foreign object is detected by the foreign object sensor 104 or when the stop push button switches 105 and 106 are pressed, the motor 101 stops in any case.

The operation sequence program between actuators applied to the above conveyor equipment will be described with reference to FIG. The above-mentioned conveyor equipment has only one motor 101 as an actuator, but since this motor 101 rotates forward and reverse, here, assuming that there are two motors, a forward rotation motor and a reverse rotation motor,
An actuator operation sequence program is created.

In FIG. 7, 32a is an initial step, 3
2b is a branch source to the sub-route of the selective branch, 32c, 32
h is the transition (transition condition) at the time of selective branch, 32 g
Is the junction from the sub-route of the selective branch, 32d, 32
f, 32i, and 32k indicate processing steps, and 32e and 32j indicate transitions. This inter-actuator operation order program is executed in order from the initial step 32a downward, but at the branch source 32b to the sub-route of the selective branch, the transition 3 at the time of the selective branch is performed.
Routes A and B in which the condition is satisfied first among 2c (reverse operation end signal X103) and 32h (forward operation end signal X102) are executed. For example, when the work table 108 reaches the work table sensor 103, the route A is selected.
In the route A, next, in processing step 32d, the motor 1
A normal rotation operation command (R112) of 01 is output. In other words, a start control program for normal rotation of the motor 101 (the upper part of FIG. 8 and FIG. 14) to be described later is called. Next, the normal rotation operation end signal (X102) from the work table sensor 102
Waits at transition 32e until is output, and transitions to the next processing step 32f. In the processing step 32f, the operation command to the start control program for normal rotation of the motor 101, which has been performed earlier, is canceled, and the motor 101 is stopped. Then, after returning to the initial step 32a again,
It reaches branch source 32b. After the route A is selected, the work table 108 has reached the work table sensor 102, so that the route B is selected at the branch source 32b.
In route B, next, in processing step 32i, motor 1
01 is output, in other words, a start-up control program for the reverse rotation of the motor 101 (lower part in FIG. 8 and FIG. 15) to be described later is called. And
A reverse rotation operation end signal (X10
Wait at transition 32j until 3) is output,
Transition is made to the next processing step 32k. Processing step 32
At k, the operation command to the start control program for reverse rotation of the motor 101 performed earlier is canceled, and the motor 101 is stopped. Thereafter, the process returns to the initial step 32a again, and the same processing is repeated.

The above-described inter-actuator operation sequence program is stored in the operation sequence program storage section 6 shown in FIG.

Next, an actuator activation control program called by the execution of the above-described inter-actuator operation sequence program will be described with reference to FIGS.

The upper part of FIG. 8 shows a start control program for normal rotation, and the lower part of FIG. 8 shows a start control program for reverse rotation. Each start control program, respectively,
Actuator name, operation name, operation command (start condition) name, start signal name, operation end signal name for confirming completion of operation, standard operation until operation completion Time and interlock conditions are described. By the way, in FIG. 8, the signal with the sign of R is the above-mentioned internal signal. FIG. 9 defines this internal signal.
In FIG. 9, (+) means that a logical sum operation is performed on the extracted conditions, and when there is no (+), a logical product operation is performed. In FIG.
The internal signal (R000) indicating the interlock condition is a signal that is satisfied when a foreign object detection signal (X104), which is an external signal, is input, or a stop instruction (R001), which is an internal signal, is satisfied. Also, a stop instruction (R001) which is an internal signal
Is a signal that is established by inputting a stop signal (X105) that is an external signal or inputting a stop signal (X106) that is also an external signal.

FIG. 10 shows a program obtained by converting the start control program shown in FIGS. 8 and 9 into a ladder program. In this conversion procedure, first, an activation signal is extracted from the activation control program, and subsequently, an activation condition and / or an interlock condition corresponding to the extracted activation signal are extracted. Next, the extracted conditions are combined by a logical product or a logical sum, and a logical expression for substituting the result into a start signal is generated.
This is repeated for the number of times the activation signal is registered. Then, these logical expressions are converted into a ladder format. Similarly,
An internal signal is extracted from the activation control program, and subsequently, an activation condition and / or an interlock condition corresponding to the extracted internal signal are extracted. Next, the extracted conditions are combined by a logical product or a logical sum, and a logical expression for substituting the result into an internal signal is generated. This is repeated for the number of registered internal signals. Then, these logical expressions are converted into a ladder format.

The above startup control program is stored in the startup control program storage section 5 shown in FIG.

As shown in FIG. 11, the monitoring program generator 2 includes a program template 21a for monitoring the actual operation time of the actuator, and as shown in FIG.
A template 21b of a program for monitoring the operation waiting time of the actuator is stored. The template 21a shown in FIG.
This is a program template for the processing of 7, 8,..., 11. The template 21a starts the timer after the actuator start signal 52 is output, and the operation end signal 53 for confirming the end of the operation is the actual operation allowable time (the standard operation time 54 of the actuator).
It consists of a process for detecting whether or not an input has been made within the extra (steps 2, 7, 8, 9 in FIG. 3) and a process for storing the result when an operation abnormality is detected (steps 10, 11 in FIG. 3). The template 21a includes an activation signal (Y) 52,
The parameters of the operation end signal (X) 53 and the standard operation time (t) 54 are blank. Therefore, the monitoring program generation unit 2 calls the above parameters for each actuator (for normal rotation and for reverse rotation) from the activation control program stored in the activation control program storage unit 5 and fills this blank space. Then, a program 71 for monitoring the actual operation time of each actuator (for normal rotation and for reverse rotation) is completed. The completed actual operation time monitoring program 70 is stored in the actuator monitoring program storage unit 7.

The template 21b shown in FIG.
Is a template for a program for monitoring the operation waiting time of the actuator, which is for the program of the processing of steps 1 to 6 in FIG. The template 21b starts the timer after the actuator start control program receives the operation command 51, and the start signal 52
Is the allowable operation waiting time (standard operation time of actuator 5
(See FIG. 3).
Steps 1 to 4) and processing for storing the result when an operation abnormality is detected (Steps 5 and 6 in FIG. 3).
In the template 21b, the parameters of the operation command (R) 51, the activation signal (Y) 52, and the standard operation time (t) 54 are blank. The monitoring program generation unit 2 calls the above parameters for each actuator (for normal rotation and for reverse rotation) from the activation control program stored in the activation control program storage unit 5 and fills this blank space, The operation waiting time monitoring program 72 for each actuator is completed. The completed operation waiting time monitoring program 71 is stored in the actuator monitoring program storage unit 7.

The program shown in FIGS. 14 and 15 has been completed as a conveyor facility monitoring program as described above. FIG. 14 is a monitoring program for forward rotation of the motor 101 of the conveyor equipment, and FIG. 15 is a monitoring program for reverse rotation of the motor 101 of the conveyor equipment. In these figures, the upper programs 702 and 703 are actual operation time monitoring programs, and the lower programs 71 and 703 are programs.
Reference numeral 2713 denotes an operation waiting time monitoring program. Actual operation time monitoring programs 702, 7 for forward rotation and reverse rotation
03, the start signal (Y112) and the start signal (Y113) are set as blank start signal names in the template 21a of the actual operation time monitoring program shown in FIG. As a name,
Reverse operation end signal (X102), forward operation end signal (X
103) is set. Further, a time (12 seconds) obtained by multiplying the standard operation time (10 seconds) by 1.2 is set as the actual operation allowable time. The operation waiting time monitoring programs 712 and 713 for forward rotation and reverse rotation include the operation instruction (R112) and the operation instruction as blank operation instruction names in the template 21b of the operation waiting time monitoring program shown in FIG. (R113) is set,
The start signal (Y1
12), a start signal (Y113) is set. Further, as the allowable operation waiting time, the standard operation time (10
(Second) is set to 0.2 times (2 seconds).

The data output by the execution of the above monitoring program is stored in the monitoring result table of the data storage unit 34, as described above with reference to FIG. Here, the result monitoring table will be described in detail with reference to FIG. By the way, as described above with reference to FIG. 3, the data output during execution of the monitoring program includes the start signal name, the operation abnormality identification data, and the abnormality signal output in steps 5, 6, 10, and 11 in FIG. There is the number of detection. The storage column (counter) 34a for the number of detected abnormalities is 16 bits from RFF0 to RFFF, and can be expressed as a word variable RWFF0. Further, the operation abnormality identification data column 34b and the activation signal name column 34c
Is 16 bits in both columns, the most significant 1 bit is the operation abnormality identification data column 34b,
Five bits are the activation signal name column 34c. The column combining the operation abnormality identification data column 34b and the activation signal name column 34c is
There are four records from word variables RWFE0 to RWFB0. When 0 is set here, the operation abnormality identification data column 34b indicates an operation incomplete abnormality, and when 1 is set here,
Indicates that the operation has not started yet. In addition, the counter 3 for the number of detected abnormalities
When 4a reaches 4 (RFFD is established), the monitoring operation of all actuator monitoring programs is interrupted.

Next, the operation of the abnormality monitoring device when the conveyor equipment actually causes various abnormalities will be described.

First, the case where the moving time of the work table 108 is delayed due to the wear of the pulley 109 will be described. In the case of this abnormality, during the normal rotation of the motor 101, the monitoring program execution unit 33 executes the normal rotation actual operation time monitoring program 702 (FIG. 14), and the normal rotation actual operation time exceeds the actual operation allowable time. Is recognized (steps 7, 8, 9). As a result, the monitoring program execution unit 33 stores in the monitoring result table of the data storage unit 34
It is described as shown in FIG. 16 (steps 10 and 11). That is, in the monitoring result table, the number of detected abnormalities is 1,
It describes what means an operation incompletion abnormality of the actuator activated by the activation signal (Y112). The abnormality source searching unit 4 refers to the monitoring result table (step 4).
1) It is grasped that the content of the abnormality is an operation unfinished abnormality (step 43). Then, since the content of the abnormality is the operation unfinished abnormality, the activation control program of FIG. 8 is searched using the activation signal (Y112) as a key, and an operation termination signal (X102) is obtained (step 44). Then, as shown in FIG. 17, the display unit 10 displays “Start signal (Y
112) was output, but the operation was not completed. Check the output circuit of the motor 101 and the status of the operation end signal (X102). Is displayed (step 5
2). At this time, instead of the operation end signal (X102), the name of the sensor 102 that outputs the signal may be displayed. Finally, the monitoring program execution unit 33
Clears the abnormality detection counter 34a in the monitoring result table.

Next, when the motor 101 rotates in the reverse direction, foreign matter enters the conveyor, and the foreign matter sensor 104 detects this.
A case where the conveyor has stopped will be described. In the case of this abnormality, the monitoring program execution unit 33 recognizes that the reverse operation waiting time exceeds the allowable operation waiting time by executing the reverse operation waiting time monitoring program 713 (FIG. 15) (steps 1, 2, and 2). 3, 4). As a result, the monitoring program execution unit 33 describes the monitoring result table in the data storage unit 34 as shown in FIG. 18 (steps 5 and 6). That is, the monitoring result table describes that the number of detected abnormalities is 1, which means that the operation of the actuator activated by the activation signal (Y113) has not been started. The abnormality source searching unit 4 refers to the monitoring result table (step 41) and grasps that the content of the abnormality is an operation unstarted abnormality (step 43). Then, since the content of the abnormality is the operation not started abnormality, the start signal (Y113) is used as a key,
The start control program shown in FIG. 8 is searched, and the corresponding start conditions and interlock conditions are extracted (step 45). Here, an operation command (R113) is extracted as a start condition, and a motor stop (R000) is extracted as an interlock condition. Then, the abnormality source searching unit 4 stores the data storage unit 3
4, the operation command (R113) and the motor stop (R
000) is checked (step 46), and the motor stop (R000) which is obstructing the output of the start signal, in other words, becomes unlogical, is extracted (step 4).
7). However, since the motor stop (R000) is not an external signal directly input from a sensor or a switch but an internal signal, the source of the abnormality is not specified. Therefore, the foreign object detection signal (X104) and the stop instruction (R001) constituting the motor stop (R000) are extracted again with reference to the start control program of FIG. 9 (steps 48 and 49). Then, the data storage unit 34
, A foreign object detection signal (X104) and a stop instruction (R
001) is checked (step 50), and an illogical foreign matter detection signal (X104) is extracted (step 51). Since the foreign matter detection signal (X104) is an external signal from the foreign matter sensor 104, it is determined that the abnormality source has been grasped, and the abnormality source search ends. And the display unit 1
0, as shown in FIG. 19, “Start signal (Y113) for reverse rotation operation of motor 101 for detecting interlock signal.
Cannot be output. Check the status of the foreign object detection signal (X104). Is displayed (step 52). In this case, as in the case of the above abnormality,
Instead of the foreign object detection signal (X104), the name of the foreign object sensor 104 that has output this signal may be displayed. Finally, the monitoring program execution unit 33 clears the abnormality detection counter 34a in the monitoring result table.

Next, the case where the stop button switch 105 is pressed during the reverse rotation of the motor 101 to stop the conveyor will be described. In this case, the monitoring program execution unit 33 executes the reverse operation waiting time monitoring program 71.
3 (FIG. 15) to recognize that the reverse operation waiting time exceeds the allowable operation waiting time (steps 1 and 2).
2, 3, 4). As a result, the monitoring program execution unit 33
Is described in the monitoring result table of the data storage unit 34 as in FIG.
6). The abnormality source searching unit 4 searches the activation control program of FIG. 8 by using the activation signal (Y113) as a key because the abnormality content is the operation not started abnormality, and the operation command (R1
13) is extracted, and motor stop (R000) is extracted as an interlock condition (steps 41, 43, 4).
5). Then, the abnormality source searching unit 4 refers to the data storage unit 34 and sends an operation command (R113) and a motor stop (R00
The signal state of 0) is checked (step 46), and the motor stop (R000) which is preventing the output of the start signal is extracted (step 47). This motor stop (R000)
Since the signal is an internal signal, not an external signal directly input from a sensor or a switch, the foreign object detection signal (X104) and stop which constitute the motor stop (R000) are referred to again with reference to the start control program in FIG. Instruction (R00
1) are extracted (steps 48 and 49). The abnormality source searching unit 4 refers to the data storage unit 34, checks the signal states of the foreign object detection signal (X104) and the stop instruction (R001) (step 50), and determines the non-logic stop instruction (R0).
01) is extracted (step 51). This stop instruction (R
001) is also an internal signal, so that the stop signal (X105) and the stop signal (X10) constituting the stop instruction (R001) are further referred to with reference to the start control program in FIG.
6) is extracted (steps 48 and 49). Subsequently, the signal states of the stop signal (X105) and the stop signal (X106) are checked with reference to the data storage unit 34 (step 50).
The stop signal (X105) which is in the non-logic state is extracted (step 51). Since the stop signal (X105) is an external signal from the stop push button switch 105,
Assuming that the source of the abnormality has been grasped, the search for the source of the abnormality ends. Then, as shown in FIG. 20, the display unit 10 outputs “The start signal (Y113) for the reverse rotation operation of the motor 101 cannot be output because the stop signal 105 is detected. The stop signal (X105)
Check the status of. Is displayed (step 52). In this case, as in the case of each abnormality described above, instead of the stop signal (X105), the name of the stop pushbutton switch 105 that has output this signal may be displayed. Finally, the monitoring program execution unit 33 clears the abnormality detection counter 34a.

As described above, according to the present embodiment, the monitoring program for detecting the abnormality of the equipment 2 to be controlled by the programmable controller 3 is automatically generated, so that the development man-hour and the development period of the monitoring program are substantially eliminated. And eliminate errors in the monitoring program. Further, in this embodiment, in addition to the actual operation time of the actuator, the operation waiting time is also monitored.
Not only for the actuator itself, but also for the abnormality caused by external factors such as equipment that causes the operation of this actuator, the signal that causes the abnormality is searched for, so the time required to identify the source of the abnormality Can be greatly reduced.

[0050]

According to the present invention, since the operation waiting time is monitored in addition to the actual operation time of the actuator, not only the abnormality of the actuator itself, but also the equipment causing the operation of the actuator, etc. An abnormality caused by an external factor can be grasped, and the time required for identifying an abnormality source can be reduced. In particular, in the case of having an abnormality source searching means, even in the case of an abnormality due to an external factor, a signal causing the abnormality is searched for and the signal name or the name of the device outputting this signal Is output, the time required to identify the abnormality source can be greatly reduced.

[Brief description of the drawings]

FIG. 1 is a functional block diagram of an equipment abnormality monitoring device as one embodiment according to the present invention.

FIG. 2 is a circuit block diagram of the equipment abnormality monitoring device as one embodiment according to the present invention.

FIG. 3 is an explanatory diagram showing a method of generating a monitoring program as one embodiment according to the present invention.

FIG. 4 is an explanatory diagram showing a configuration of a monitoring result table of a data storage unit as one embodiment according to the present invention.

FIG. 5 is a flowchart illustrating an operation of an abnormality source searching unit as one embodiment according to the present invention.

FIG. 6 is a configuration diagram of a conveyor facility to be monitored by an abnormality monitoring device as one embodiment according to the present invention.

FIG. 7 is an explanatory diagram showing a description example of an inter-actuator operation sequence program as one embodiment according to the present invention.

FIG. 8 is an explanatory diagram showing a description example of an actuator activation control program as one embodiment according to the present invention.

9 is a description example of an actuator activation control program as one embodiment of the present invention, and is an explanatory diagram showing definitions of internal signals shown in FIG. 8;

FIG. 10 is an explanatory diagram showing a ladder format program of the actuator activation control program shown in FIGS. 8 and 9;

FIG. 11 is an explanatory diagram showing a method of generating a ladder format program of an actual operation time monitoring program as one embodiment according to the present invention.

FIG. 12 is an explanatory diagram showing a method of generating a ladder format program of an operation waiting time monitoring program as one embodiment according to the present invention.

FIG. 13 is an explanatory diagram showing a specific configuration inside a monitoring result table shown in FIG. 4;

FIG. 14 is an explanatory diagram showing a motor forward rotation monitoring program automatically generated by the monitoring program generating method shown in FIGS. 11 and 12.

FIG. 15 is an explanatory diagram showing a motor reversal operation monitoring program automatically generated by the monitoring program generation method shown in FIGS. 11 and 12;

FIG. 16 is an explanatory diagram showing an example of description in a monitoring result table shown in FIG. 13;

FIG. 17 is an explanatory diagram showing a display example by a display unit as one embodiment according to the present invention.

FIG. 18 is an explanatory diagram showing another example of description in the monitoring result table shown in FIG. 13;

FIG. 19 is an explanatory diagram showing another display example by the display unit as one embodiment according to the present invention.

FIG. 20 is an explanatory diagram showing still another display example by the display unit as one embodiment according to the present invention.

[Explanation of symbols]

1: Program development unit, 2: Monitoring program generation unit, 3
... Program execution device (programmable controller), 4 ... Abnormality source search unit, 5 ... Actuator control program storage unit, 6 ... Actuator operation sequence program storage unit, 7 ... Actuator monitoring program, 8 ... Equipment, 9 ... Program development and abnormality Confirmation device, 10 ... Display unit, 21 ... Actuator monitoring model storage unit, 21a ...
Template of actual operation time monitoring program, 21b: template of operation waiting time monitoring program, 31: operation sequence program execution unit, 32: activation control program execution unit, 33: monitoring program execution unit, 34: data storage unit, 34a: abnormality Detection number column, 34b: operation abnormality identification data column, 34c: activation signal name column.

Continued on the front page (72) Inventor Sachiko Yoshida 292, Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa Prefecture Inside the Hitachi, Ltd. Production Technology Research Institute (72) Inventor Tadashi Okamoto 5-2-1 Omika-cho, Hitachi, Ibaraki, Japan Inside the Omika Plant of Hitachi, Ltd. (72) Inventor Takao Kokubu 3-1, Ogawa Higashi-cho, Kodaira-shi, Tokyo Inside Bridgestone Corporation (72) Inventor Masaharu Oku 3-1-1, Ogawa Higashi-cho, Kodaira, Tokyo Inside Bridgestone

Claims (6)

[Claims] A predetermined operation is performed by inputting a start signal.
An installation comprising the above-mentioned actuator and one or more sensors for respectively detecting the operation of one or more of the actuators, wherein an operation command for designating an actuator which has come to the order of operation among the one or more actuators Is controlled by a control device including: an inter-actuator operation order management unit that outputs a start signal; and a start control unit that outputs a start signal to the actuator when a start condition for the actuator specified by the operation command is satisfied. In the abnormality monitoring device, among the one or more actuators, an operation waiting time from when the operation command is output to when the activation signal is output to the actuator designated by the operation command is set in advance. Operation wait time monitor that monitors whether it is within the prescribed operation wait allowable time Means, for the actuator to which the activation signal has been output, among the one or more actuators, after the activation signal is output, an operation end signal of the actuator is output from the sensor that detects the operation of the actuator. An actual operation time monitoring means for monitoring whether or not the actual operation time until output is within a predetermined actual operation allowable time; and, when the operation waiting time exceeds the operation waiting allowable time, Abnormality output means for outputting an operation unstart abnormality of the actuator, and outputting an operation unfinished abnormality of the actuator when the actual operation time exceeds the actual operation allowable time. An equipment abnormality monitoring device characterized by the following. 2. The equipment abnormality monitoring device according to claim 1, wherein said activation control means of said control device is an internal signal determined by a combination of a plurality of external signals from said sensor or switch and a plurality of said external signals. And an internal signal determined by a combination of the internal signal and the external signal or the internal signal, a start condition and / or an interlock condition are defined by any one signal or any plurality of signals. A signal storage unit that stores states of the plurality of external signals and the plurality of internal signals; and, in the case of the operation unstart abnormality, the activation control unit activates an activation condition and / or an interlock with respect to the actuator that has not started operation. Of the signals constituting the condition, a signal in a state where the output of the start signal is obstructed is selected from the signal storage unit, and the selected signal is the internal signal. When the internal signal is decomposed, the internal signal is decomposed, and a signal obstructing the output of the activation signal is selected from a plurality of signals obtained by decomposing, and the decomposition of the signal and the activation signal are performed. An abnormality source searching means for repeating the selection of a signal obstructing the output of the abnormal signal, and searching for the external signal obstructing the output of the activation signal. An equipment abnormality monitoring device, which outputs the name of the external signal obtained by the search means or the name of the sensor or the switch that has output the external signal. 3. The equipment abnormality monitoring device according to claim 2, wherein the abnormality output means includes: the external signal obtained by the abnormality source searching means; and the start signal whose output has been prevented by the external signal. An equipment abnormality monitoring device, which outputs a predetermined comment in relation to the above. 4. The equipment abnormality monitoring device according to claim 1, wherein the start control means has a start control procedure for each of one or more of the actuators. An operation command name, the start signal name, the operation end signal name, the operation wait allowable time or a reference time thereof, and the actual operation allowable time or a reference time thereof are set, and the operation wait time monitoring means is set. And a monitoring procedure model relating to the execution procedure of the actual operation time monitoring means are prepared in advance, and the operation command name, the activation signal name, and the operation end signal are obtained from the activation control procedure for each of one or more actuators. A name, the allowable operation waiting time or a reference time thereof, and the actual allowable operation time or a reference time thereof are extracted, and these are extracted for each of the actuators by the monitoring means. Equipment abnormality monitoring, characterized by comprising a monitoring procedure generation means for setting an execution procedure of the operation waiting time monitoring means and an execution procedure of the actual operation time monitoring means for each of one or more actuators set in a model. apparatus. 5. The equipment abnormality monitoring device according to claim 4, wherein each of the activation control procedures of the activation control means includes a reference time of the allowable operation waiting time and a reference of the actual allowable operation time. A standard actual operation time of the actuator is set as the time, and the monitoring procedure generation unit multiplies the standard actual operation time by a predetermined magnification, and calculates the operation wait allowable time and the actual operation allowable time. And determining the operation waiting time and the actual operation time in the monitoring procedure model. 6. A predetermined operation is performed by inputting a start signal.
An installation comprising the above-mentioned actuator and one or more sensors for respectively detecting the operation of one or more of the actuators, wherein an operation command for designating an actuator which has come to the order of operation among the one or more actuators Is controlled by a control device including: an inter-actuator operation order management unit that outputs a start signal; and a start control unit that outputs a start signal to the actuator when a start condition for the actuator specified by the operation command is satisfied. In the abnormality monitoring method, among the one or more actuators, an operation waiting time from when the operation command is output to when the activation signal is output to the actuator designated by the operation command is set in advance. It monitors whether it is within the specified allowable operation waiting time and checks the operation waiting time. If the operation wait allowable time is exceeded, it is determined that the actuator is in an operation unstart abnormality, and the activation signal is output to one of the one or more actuators to which the activation signal has been output. After that, it is monitored whether or not the actual operation time until the operation end signal of the actuator is output from the sensor that detects the operation of the actuator is within a predetermined actual operation allowable time, and the actual operation time is monitored. If the time exceeds the permissible actual operation time, it is determined that the actuator is in an operation incompletion abnormality.