CA2032048C - Diagnosis system for a digital control apparatus - Google Patents

Abstract

In a diagnosis system for a digital control apparatus of a printing press, at least one processor is provided, with a program for the testing of subassemblies of the control apparatus and for the monitoring of parameters during the operation of the printing press. Results of the tests and of the monitoring of the parameters are displayed and/or stored.

Description

2 ~ 8 Heidelberger Druckmaschinen AG, 6900 Heidelberg Diagnosis system for a digital control apparatus The invention relates to a diagnosis system for a digital control apparatus of a printing press.

The control of printing presses with the aid of digital control apparatuses frequently also includes functions in which faults may lead to considerable material damage or even to the endangering of persons.
Particularly in the case of complex structures of control apparatuses, there~ore, very high demands are placed also on the reliability of individual system components.

Nevertheless, faults may occur within the control apparatus, among the sensors and actuators that connect the control apparatus to the printing press or in the printing press itself. Furthermore, it is important in thP case of printing presses to rectify faults as quickly as possible and using the personnel present at the site of the printing press.

The object of the present invention, ther2fore, is to indicate a diagnosis system for a digital control apparatus of a printing press, said diagnosis system permitting the reliable detection and displaying of faults. Furthermore, faults are, if possible, also to he detectable even in the event of the failure of one ~ ~ ,?, ~ 8 of the processors performing the actual monitoring.
Finally, a subsequent diagnosis is necessary in the case of faults that occur merely sporadically or in the case of faults that lead to the failure of the control apparatus.

The diagnosis system according to the invention is characterized in that at least one processor is provided, with a program for the testing of the subassemblies of the control apparatus and for the monitoring of parameters during the operation of the printing press and in that results of the tests and of the monitoring of the parameters are displayed and/or stored. Preferably, the processor also performs control tasks.
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In order further to increase the safety, according to a further development of the invention, two processors are provided for testing and monitoring, said processors each testing and monitoring, in addition to subassemblies assigned to them, also the other processor and means for communication between the processors.

Since, in the case of printing presses, the control tasks are frequently distributed between two processors anyway, according to another further development of the invention, economical and safe monitoring is possible in that two processors are provided in the control apparatus for various control tasks, said processors each also testing and monitoring subassemblies assigned to them and the other proce~sor and means for c uniCatiOn between the processors.

2~3~,2~8 In the diagnosis system according to the invention, it is possible, firstly, to evaluate data that exist anyway during the operation of the printing press, for example output signals from sensors, such as rotational-speed sensors or paper sensors. Such data are referred to in the following as operating parameters. The diagnosis system according to the invention also evaluates data generated in test programs, such as in known programs for the testing of memories or processors. It is also possible for operating parameters to be included in such tests, for example in the form of comparisons of setpoint and actual values or in the form of so-called validity checks. The results of such tests - referred to in the following as t2st results - are designated below as fault messages in the case of faults.

In order to permit the reliable display of fault messages, it is provided according to another further development of the invention that at lPast one of the processors comprises an output for fault messages, with a bus system being bypassed. It is of advantage in this connection that each of the processors is disposed on its own system board and that the processors are each connected independently of one another to at least one display apparatus.

Other further developments of the invention relate to the storing of information that is of importance with regard to repair and maintenance operations.
Essentially provided in this connection is a non-volatile memory in order to be able to evaluate important data also after the printing press or the control apparatus has been switched of~. For this purpose, depending on the embodiment of the invention, ~3~8 it is possible to store fault messages, test results or operating parameters. Preferably, the data can be stored in such a manner that the latest data are in a non-volatile memory.

The measures enumerated in the subclaims permit advantageous further developments of and improvements to the invention indicated in the main claim.

A specimen embodiment of the invention is explained in greater detail in the following description and is represented in the drawing with reference to several Figures, in which:

Fig. 1 shows a block diagram of a digital control apparatus for a printing press with a diagnosis system according to the invention; and ~ig. 2 shows a flow diagram of a program used in the specimen embodiment.

Provided in the control apparatus shown in Fig. 1 are two processors (computers) 1, 2, each of which is disposed on a system board. The computer 1 serves for ' the central control of the printing press, while the computer 2 serves essentially for the control of the main d-ive. In known manner, each cl ~ter 1, 2 has a microprocessor 3, 4 and further subassemblies, such as working memory, program memory and internal bus system, an explanation of which, however, is not necessary for an understanding of the present invention.

Provided in addition to these subassemblies, however, on the computer boards are non-volatile memories 5, 6, which store test results, operating data and fault ~ g messages - necessary for subsequent evaluation - beyond switching-off or a defect in the control apparatus. In the case of fault messages that do not lead to the failure of the control apparatus or of the computer concerned, it is possible for a plurality of fault messages to be stored, if necessary, with other valid test results and operating parameters.

owing to the fact that a non-volatile memory 5, 6 is provided in each of the computers 1, 2, it is possible for fault messages to be evaluated even if the corresponding board has been removed from the control apparatus and has, for example, been sent to the manufacturer or to a maintenance company for repair.

The computers 1, 2 are connected to a system bus 7, which, furthermore, is connected to an input/output unit 8 and to a communication memory 9. The communication memory 9 is used for the exchange of data between the computers 1, 2 such that the receiving computer calls from the communication memory 9 those data that the sending computer has previously written there. Furthermore, it i~ also possible to store test results and fault messages in the communication memory 9, which, in this case, is in the form of a non-~olatile memory. Such test results and fault messages can then be read out by both computers 1, 2.

Sensors and actuators are connected to the input/output unit 8 ~ia inputs and outputs 10, as is describad, for example, in patent application P 36 42 500.1 of the Applicant.

In order to display the data occurring during the operation of the printing press, a central display unit 2~32~8 11 is connected to the computer 1 via a serial interface 12. In the diagnosis system according to the invention, the interface 12 and the display unit 11 are used additionally to display fault messages. Further display units 13, 14 are connected via serial interfaces 15, 16 to the input/output unit 8 and serve likewise, in addition to the displaying of operating data, for the displaying of fault messages.

The computer 2 for controlling the main drive is connected to a control board 17 for the main drive, to which control board 17 the motor 19 o~ the main drive is connected via a power stage 18. Furthermore, the control board 17 comprises a connection to the system bus 7, with the result that, for example, the computer 1 is able to check the status of the power control board 17. Provided for the supply of power to the digital control apparatus are a plurality of power-supply units, of which merely two power-supply units are represented by way of example in Fig. 1. For reasons of safety, it is provided that the ~omputer l and the central display unit 11 are connected to a first power-supply unit 20 and tha~ the computer 2, the input/output unit 8 and the further display units 13, 14 are connected to a second power-supply unit 21.

The use of a connection independent of the system bus 7 between the computer 1 and the central display unit 11, together with the use of a separate power-supply unit 20 for these subassemblies, means that it is possible also to display those faults that prevent streams of data to one of the display units or on the system bus.
Provided for the microprocessors 3, 4 are programs that permit extensive testing and monitoring. Among other things, each microprocessor monitors the other 2 ~, -.>; ~

microprocessor as well as the communication memory 9.
In this connection, the test and monitoring programs can be designed with such flexibility that more or fewer tests are performed, depending on the respective test results. Thus, for example, it may be provided in normal operation that each of the microprocessors 3, 4 tests the other microprocessor in addition to some of the subassemblies of the control apparatus. If, however, the other microprocessor fails, the microprocessor that is still capable of operation also tests those subassemblies that were previously tested by the other microprocessor.

Advantageously, after the control apparatus has been switched on or as long as the printing press itself is not yet in operation, thorough tests of the individual components are performed within the framework of an initialization. In addition, the operating parametQrS
are then monitored while the printing press is in operation. This makes it possible also to detect faults that are ascertainable only when the printing press is in operation.

The continuous testing of plug-in connections is possible by means of suitable line loops or by the monitoring of signals that are constantly present on the respective boards (for example clock signals).

The flow diagram in the Fig. 2 shows essential parts of a test program, which is executed in the microprocessors 3, 4 after the control apparatus has been switched on. After a start at 31, there is first of all a self-test 32, which is performed by the respective microprocessor and relates to the respecti~e computer 1, 2. In the case of a fault, a corresponding 8 2~2~8 fault message is stored at 33 and is supplied at 34 via the serial interface 12 to the central display unit 11 (Fig. 1).

If, however, the self-test did not yield any faults, the communication memory 9 is tested in the program part 35. The latter is conducted in known manner by the writing-in and reading out-again of information.
If there is a fault, the information is stored again and there is a display, whereas, if the communication memory 9 is ~ault-free, there is a test of the other microprocessor in the program part 36.

In the specimen embodiment shown, it is assumed that it is generally sufficient to test the other microprocessor and not the entirety of the othex computer, since the latter has already been tested before by the other microprocessor.

After a successful test of the other microprocessor, the tests of the other subassemblies are performed at 37. If these, too, are fault-free, the test program is terminated at 38, whereafter programs for the control of the printing press are activated. This may also be done after the program parts Store 33 and Display 34, if no faults were previously detected that prevent the correct operation of the printing press.

Claims (30)

1. A device for monitoring an electronic control device for a printing machine having modules (1, 2) connected by means of a bus system (7), at least one memory (5, 6), at least one input and output unit (8), and at least one display device (11, 13, 14), characterized - in that it has at least two modules (1, 2), one module (1) serving for the central control of the printing machine and another module (2) serving to control the main drive (17, 18, 19), - in that the modules (1, 2) have at least one processor (3, 4) in each case and a non-volatile memory (5, 6) in each case, - in that the modules (1, 2) have at least one separate interface (12) connected to a central display unit (11), - and in that each module (1, 2) has a separate power supply unit (20, 21).

2. A device according to Claim 1, characterized in that each processor (3, 4) is arranged on a separate system card, and in that the processors (3, 4) are connected independently of one another to at least one display means (11, 13, 14) in each case.

3. A device according to at least one of Claims 1 or 2, characterized in that the system cards with the respective associated display devices (11, 13, 14) are connected to different voltage supply devices (20, 21).

4. A device according to at least one of the preceding claims, characterized in that the device for indicating error states has the display means(11, 13, 14) indicating the normal sequence.

5. A method for monitoring an electronic control device of a printing machine according to at least one of Claims 1 to 4, characterized in that first of all a self-testing of the processors (3, 4) is carried out after switching on, in that after that a read/write memory (9 serving for communication between the processors is successively tested by one of the processors (3, 4) in each case, and in that a testing of the processors (3, 4) among one another is carried out after the read/write memory (9) has been tested.

6. A method according to Claim 5, characterized in that dynamic test runs are executed during operation of the printing machine.

7. A method according to at least one of Claims 5 or 6, characterized in that if a processor (3, 4) fails, the tests, analyses and displays normally to be carried out by the failed processor (3, 4) are carried out by the processor (4, 3) that has not failed.

8. A method according to at least one of Claims 5, 6 or 7, characterized in that the test results are stored in non-volatile memories (5, 6) on the system cards to which the test results related in each case.

9. A method according to at least one of Claims 5 to 8, characterized in that error messages and/or test results are stored in a non-volatile memory, the latter additionally serving for the communication between the processors (3, 4).

10. A method according to at least one of Claims 5 to 9, characterized in that the error messages are stored in a non-volatile memory and if a further error message occurs, the error message(s) that previously occurred is (are) moved on one position in a non-volatile memory (5, 6).

11. A method according to at least one of Claims 5 to 10, characterized in that the oldest error message from the non-volatile memory (5, 6) is transferred into an additional memory and is stored together with even older error messages.

12. A method according to at least one of Claims 5 to 11, characterized in that operating parameters are stored in non-volatile memory before and during the occurrence of errors.

13. A method according to one of preceding Claims 5 to 12, characterized in that operating parameters present during operation are continuously written into a non-volatile memory, in that operating parameters that have aged more than a predetermined time are lost, and in that the state of the non-volatile memory is retained if an error occurs.

14. A control device for monitoring a printing machine, said device comprising at least first and second modules, said first module for monitoring control of said printing machine and said second module for controlling the main drive of said printing machine, at least one data input/output unit, at least one display device, and a communications bus arrangement connecting said modules to said data input/output unit and to said display device;

each module having at least one processor, non-volatile memory and a separate power supply; at least one of said first and second modules having a connection independent of said communications bus arrangement to said at least one display device.

15. A control device according to Claim 14, wherein each processor is arranged on a separate system card and at least one of said processors includes an independent connection to said at least one display device.

16. A control device according to Claim 14, wherein each processor is arranged on a separate system card and in said first module said at least one processor includes an independent connection to said at least one display device.

17. A control device as claimed in Claims 15 and 16, wherein each module is associated with a separate display device powered by said separate power supply of said module.

18. A control device as claimed in Claims 14, 15, 16 and 17, wherein said at least one of said first and second modules detects both normal sequence states and error states of said printing machine and displays said normal sequence states and error states on said at least one display device.

19. A control device according to claim 14 wherein said at least one display device comprises two display devices.

20. A control device according to claim 14 wherein said modules communicate with each other to detect a malfunctioning module and upon detection thereof, at least one of said modules provides an operational backup for said malfunctioning module.

21. A control device as claimed in claim 14 further comprising non-volatile memory accessible by each module and connected to said communications bus arrangement.

22. A method for testing and configuring a control device of a printing machine having a display device, at least two modules and shared memory accessible by each module; each module having at least one processor and other sub-assembly elements; said method comprising each processor sequentially performing a series of tests and upon failure of an individual test therein, storing results of said failure, displaying said results on said display device and terminating said series of tests; said series of tests comprising a first test for self-evaluation of functionality by each processor, a second test for evaluation of said shared memory by each processor, and a third test for evaluation of functionality of other processors.

23. A method as claimed in Claim 22, wherein said series of tests is performed while said printing machine is operating.

24. A method as claimed in Claim 22, wherein said series of tests is performed while said printing machine is operating or not operating.

25. A method as claimed in Claims 22, 23 and 24, wherein upon said failure of an individual test by a failing processor, functionality of said failing processor is transferred to a non-failing processor.

26. A method as claimed in Claims 22, 23, 24 and 25, said method further comprising storing results of said series of tests in said shared memory.

27. A method as claimed in Claims 22, 23, 24, 25 and 26, wherein upon said failure of an individual test, an error message is generated and is stored in said shared memory, and upon generation of a later error message, said later error message is stored in said shared memory and is marked as the latest error message generated.

28. A method as claimed in Claim 27, wherein the earliest error message stored in said shared memory is transferred to an additional memory unit.

29. A method as claimed in Claims 22, 23, 24, 25, 26, 27 and 28, wherein during operation of said printing machine said method further comprises periodically storing results of said series of tests in said shared memory; said results which have been stored for longer than a predetermined time are removed from said shared memory;
upon said failure of an individual test, contents of said shared memory are stored for analysis.

30. A method as claimed in Claim 22 wherein said series of tests further comprises testing said other sub-assembly elements.

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