CA2082919C - Method for diagnosing an electrically controlled mechanical device - Google Patents
Method for diagnosing an electrically controlled mechanical deviceInfo
- Publication number
- CA2082919C CA2082919C CA 2082919 CA2082919A CA2082919C CA 2082919 C CA2082919 C CA 2082919C CA 2082919 CA2082919 CA 2082919 CA 2082919 A CA2082919 A CA 2082919A CA 2082919 C CA2082919 C CA 2082919C
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Classifications
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- G—PHYSICS
- G07—CHECKING-DEVICES
- G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
- G07B17/00—Franking apparatus
- G07B17/00185—Details internally of apparatus in a franking system, e.g. franking machine at customer or apparatus at post office
- G07B17/00362—Calculation or computing within apparatus, e.g. calculation of postage value
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0224—Process history based detection method, e.g. whereby history implies the availability of large amounts of data
- G05B23/0227—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
- G05B23/0235—Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F11/00—Error detection; Error correction; Monitoring
- G06F11/22—Detection or location of defective computer hardware by testing during standby operation or during idle time, e.g. start-up testing
- G06F11/2205—Detection or location of defective computer hardware by testing during standby operation or during idle time, e.g. start-up testing using arrangements specific to the hardware being tested
- G06F11/2221—Detection or location of defective computer hardware by testing during standby operation or during idle time, e.g. start-up testing using arrangements specific to the hardware being tested to test input/output devices or peripheral units
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2201/00—Indexing scheme relating to error detection, to error correction, and to monitoring
- G06F2201/805—Real-time
-
- G—PHYSICS
- G07—CHECKING-DEVICES
- G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
- G07B17/00—Franking apparatus
- G07B17/00185—Details internally of apparatus in a franking system, e.g. franking machine at customer or apparatus at post office
- G07B17/00314—Communication within apparatus, personal computer [PC] system, or server, e.g. between printhead and central unit in a franking machine
- G07B2017/00322—Communication between components/modules/parts, e.g. printer, printhead, keyboard, conveyor or central unit
-
- G—PHYSICS
- G07—CHECKING-DEVICES
- G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
- G07B17/00—Franking apparatus
- G07B17/00185—Details internally of apparatus in a franking system, e.g. franking machine at customer or apparatus at post office
- G07B17/00314—Communication within apparatus, personal computer [PC] system, or server, e.g. between printhead and central unit in a franking machine
- G07B2017/00338—Error detection or handling
-
- G—PHYSICS
- G07—CHECKING-DEVICES
- G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
- G07B17/00—Franking apparatus
- G07B17/00185—Details internally of apparatus in a franking system, e.g. franking machine at customer or apparatus at post office
- G07B17/00362—Calculation or computing within apparatus, e.g. calculation of postage value
- G07B2017/00395—Memory organization
Abstract
A method for analyzing in real time the performance of an electrically controlled mechanical device is provided. It includes a method for monitoring control parameters which are important to know on a microprocessor clock-cycle-by-clock-cycle basis so that the various components of the system can be synchronized with each other if needed, and their performance analyzed. A method is also provided for monitoring control parameters over a plurality of microprocessor clock cycles so that histograms can be obtained for analyzing the performance of the device.
Description
-20829 1 9 c-842 METHOD FOR DIAGNOSING AN
ELECTRICALLY CONTROLLED MECHANICAL DEVICE
Background Of The Invention The present invention relates to a method for diagnosing an electrically controlled mechanical device. More particularly, the present invention relates to a method for analyzing and debugging an article processing system in real time.
Article processing systems, as well as other electrically controlled mechanical devices, generally include a plurality of apparatus or components for carrying out the various functions of the system. For mail processing systems, these components perform a variety of tasks and include, for example, envelope feeders, envelope sealers, weighers, postage meters, motion control components and various types of sensors.
These components are generally controlled by a central microprocessor operating at a predetermined clock cycle. In order to achieve high mail processing speeds, the components are generally operated under what is referred to as "distributed" control. Under distributed control, in contrast to serial or individual control, the states of the various components of the system are changed independent of whether other components in the system are functioning properly. In other words, one component does not generally wait for another component to complete its '~C
20829 1 ~
assigned function prior to performing its own, as would be the case if the system were operated under serial control. The control system assumes that all components are functioning properly and at their correct speed. This feature of a distributed control system allows high mail processing speeds to be achieved since time is inherently saved in the component instruction process.
A disadvantage of complex article processing systems as well as other electrically controlled mechanical devices, especially if operated under distributed control, is that it is sometimes difficult to analyze the performance of the overall system by simply inspecting the individual components of the system while the system is at rest. If the system is not functioning properly, the malfunction may be due to the malfunction of one or more individual components of the system. Determining which of the many components in the system are malfunctioning can be time consuming and laborious. In order to locate a particular malfunction in a component, it may be necessary to monitor the performance of the various components of the system while the system is in actual operation, or in other words, in "real time."
Similarly, the performance of the system can be dependent upon the interaction of the various individual components making up the system. For example, a particular component, although functioning properly when externally tested on its own, may not function properly when incorporated into the overall system. The need to replace such a component may not be detectable unless the system is monitored and analyzed in real time. Furthermore, even after insertion of a replacement component into the system, the replacement component may cause other system 2û829 1 9 components that previously operated normally to malfunction. In order to locate this particular type of malfunction, it may be similarly necessary to monitor the interaction of the various components of the system in real time.
As discussed above, although there are a variety of situations where it is desirable to monitor and analyze the performance of an electrically controlled mechanical device in real time, diagnosing such a device can be difficult. First, since the diagnosis must be performed in real time, there are time limitations which must be taken into account. The diagnosing method must be able to track the performance of the system at typical operating speeds. For example, for high-speed article processing systems which operate at speeds in excess of four articles per second, the diagnosing method should be able to monitor the system at such speeds. Furthermore, for article processing systems which operate under "distributed"
microprocessor control, as discussed above, where typical clock cycle times are on the order of 1 to 2 milliseconds, the diagnosing method should also be able to monitor the system at these clock cycle rates.
Second, in analyzing an electrically controlled mechanical device in real time, there can be a very large number of features of the device to monitor. As a result, in order to avoid slowing down the speed of the device and to avoid collecting prohibitively large amounts of data, only a select number of features can be monitored at a given time.
The particular method of monitoring and analyzing the selected features of the system can influence the overall number of features which can be monitored. For example, if the method for monitoring and analyzing the selected features of the system is too slow, then only 20829 1 ~
a small number of features can be monitored at once, and the system would have to be operated repeatedly in order to collect data on all the various features of the system which must be monitored in order analyze the performance of the device.
Because electrically controlled mechanical devices have so many potential reasons for faulty operation, a method for analyzing the performance of the device should be flexible enough so that the user can select which features of the device are monitored in addition to the time when the monitoring is initiated or triggered. Otherwise, if the method does not have great flexibility, then it may be more difficult, and take longer than necessary to identify a faulty component in the device.
In addition, the method for analyzing the performance of the device should be able to give detailed information about the performance of the device without overburdening the control system of the device.
It would be desirable to be able to provide a method for analyzing the performance of an electrically controlled mechanical device while the device is in actual operation.
It would also be desirable to provide such a method that does not require slowing down the device.
It would be further desirable to provide a method for analyzing the performance of an electrically controlled mechanical device that is flexible enough so that the user can select which features of the device to monitor, as well as the time when the monitoring is initiated.
It would still further be desirable to provide a method for analyzing the performance of an electrically controlled mechanical device that is able _ - 5 -to give detailed information about the performance of the device without overburdening the control system of the device.
Summary Of The Invention It is an object of an aspect of this invention to provide a method for analyzing the performance of an electrically controlled mechanical device while the device is in actual operation.
It is an object of an aspect of this invention to provide such a method that does not require slowing down the device.
It is an object of an aspect of this invention to provide a method for analyzing the performance of an electrically controlled mechanical device that is flexible enough so that the user can select which features of the device to monitor, as well as the time when the monitoring is initiated.
It is an object of an aspect of this invention to provide a method for analyzing the performance of an electrically controlled mechanical device that is able to give detailed information about the performance of the device without overburdening the control system of the device.
Other aspects of this invention are as follows:
A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device .~
A~
functions during normal mechanical device operations, said method comprising the steps of:
(a) initiating normal device operation (b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components;
(d) after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and (e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of ~ - 6a -log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operation, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its on state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components; and (d) repeatedly, for a predetermined period:
after setting said memory to its one state, and for each clock cycle until substantially all cf said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters, and storing, in said pointer address, the address of said first log address.
A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last ,,.~
20829 1 ~
~ - 6b -log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operation, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said system components;
(c) setting said memory to its on state;
(d) storing the address of said first log address in said pointer address;
(e) selecting a triggering event for initiating the monitoring of said control parameter in real time, and, for a predetermined time period;
(f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the net log address and if said address is equal to said last log address, storing said first log address in said pointer addresses.
A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
- 208291q - 6c -(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor;
(d) after setting said memory to its one state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameter; and;
(e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
A ~
A
- 6d -(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real timei (c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor; and (d) repeatedly, for a predetermined period;
after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and storing, in said pointer address, the address of said first log address.
A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said sensors and motors;
(c) setting said memory to its on state;
_ - 6e -(d) storing the address of said first log address in said pointer address;
(e) selecting a trigger event for initiating the monitoring of said control parameter in real time, and, for a predetermined time periodi (f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the next log address and if said address is equal to said last log address, storing said first log address in said pointer address;
Brief Description Of The Drawinqs The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
A.~
2082q 1 9 FIG. 1 is a schematic view of apparatus with which the present invention can be used;
FIG. 2 is a flow diagram of a first method according to the present invention; and FIG. 3 is a flow diagram of a second method according to the present invention.
Detailed Description Of The Invention In accordance with the present invention, a method for analyzing the performance of an electrically controlled mechanical device is presented. The method can be employed in electrically controlled mechanical devices, such as article processing systems, which employ a microprocessor in conjunction with a memory for controlling the operation of the system.
A representative electrically controlled mechanical device with which the present invention can be used is shown in FIG. 1. Apparatus 10, shown schematically in FIG. 1, includes a microprocessor/
controller 11, a memory 12, a user interface device 13 and a plurality of system components 14 which carry out the functions of apparatus 10. For example, if apparatus 10 is a mail processing system, then system components 14 can include an envelope feeder, an envelope sealer, a weigher, a postage meter, motion control devices, various types of sensors and other components necessary for carrying out the functions of a mail processing system.
Microprocessor 11, in FIG. 1, is used to control system components 14. In accordance with the present invention, it is also used to analyze and debug the performance of the apparatus in real time and to diagnose any faulty condition in the apparatus.
Microprocessor 11 stores in memory 12 pre-selected data relating to the status of a predetermined number of control parameters of the apparatus. In accordance with the present invention, "control parameters" are used to characterize the status of the system components. After being stored in memory 12 during the real-time operation of apparatus 10, the control parameters are read from memory 12 under the control of user interface device 14 to produce a human-readable report or record of the control parameter data. User interface device 14 can include, for example, a display terminal, a keyboard, a printer, or any other type of device which can be used to communicate with microprocessor 11 so as to produce a human-readable report or record of the control parameter data. The report or record containing the control parameter data is then used for analyzing and debugging the performance of the apparatus. As will be discussed below, the report or record of control parameter data can be used by a technician or operator to monitor the change in device performance while the device is being repaired or modified. In addition, the report or record of control parameter data can be compared to an analogous report or record obtained under ideal device performance in order to diagnose any faulty condition in the device.
In accordance with a preferred embodiment the present invention, and particularly if apparatus 10 is a mail processing system, the control parameters which are used for analyzing and debugging the performance of the system can be classified into two general categories. A first category includes those parameters which it is important to monitor on a clock-cycle-by-clock-cycle basis so that the various components of the system can be analyzed and synchronized with each other if needed. These parameters include, for example, motor positions, motor velocities, motor power - 20~329 1 9 g dissipation, sensor currents (i.e., whether or not an item is being detected), motor inter-relationships (i.e., the position or velocity of one motor relative another), sensor inter-relationships, etc. A second category of control parameters includes those parameters which are histograms of the first category of control parameters over a plurality of clock cycles.
These parameters include, for example, envelope flap profiles, mailpiece length, distance between mailpieces, postage meter print-to-print cycle time, time from start of a postage meter print cycle to the start of the next mailpiece feed, time from a mailpiece stop for a postage meter print to the start of the print, weighing scale parameters, system component to microprocessor communication error codes, motion control processor to interface processor message headers and various other indicators of mail processing system performance.
As stated above, apparatus 10 operates at a clock cycle determined by microprocessor 11. Typical clock cycles can vary from application to application.
However, for real-time control systems used in conjunction with high-speed mail processing systems, for example, clock cycles are typically on the order of 1-2 milliseconds. Generally, for each clock cycle microprocessor 11 alters the status of apparatus 10 in order for the system to perform the function which it is intended to carry out. As each clock cycle passes, the system progresses from one state to another state as the various system components 14 change state (e.g., motors advance, etc.). It is desirable to log the status of system components 14, as their states are changed by microprocessor 11, so that the performance of the system can be analyzed and debugged.
A first method for analyzing the performance of an electrically controlled mechanical device in accordance with the present invention is diagrammed in FIG. 2. The method starts at test 20 where it is determined whether the memory log is in its ON state.
If not, the process proceeds to test 21 where it determines whether the triggering event is true. This test determines if the monitoring of control parameters should be initiated. As used herein, a triggering event is an event or state of the mechanical device which represents a particular point in time during the operation of the mechanical device (e.g., a position or velocity of a motor, or the state of a sensor, etc.).
At step 27, if the triggering event is not true, the process waits for the next clock cycle to begin the process all over again, starting at test 20. If at test 21 the triggering event is true, then at step 22, the process sets the memory log to its ON state and the pointer address of the memory log is cleared. Next, at test 23, the system determines whether the control parameter list has been initialized. If so, the process proceeds directly to step 26. Otherwise, the process proceeds to steps 24 and 25, where the list of control parameters to be monitored is made and the number of control parameters is counted, for future reference, respectively, and then on to step 26. At step 26, the pointer is assigned the address of the first log address of the memory log, and at step 27, the process waits for the next clock cycle so that it can return to the beginning of the process.
If at test 20 the memory log is in its ON
state, such as when the process returns to test 20 the second time, the process proceeds to step 31. At step 31, the address in the pointer address is read so that the process will know the next place in memory for 20829 I q storing control parameter data. The process then proceeds to where test 32 determines whether there are any control parameters left on the control parameter list to be monitored. Next, at step 33, each control parameter on the control parameter list is monitored and corresponding data is stored in memory. Test 32 and step 33 are performed for each control parameter on the control parameter list. After the last control parameter has been monitored and its corresponding data has been stored in memory, the process advances to step 34, where the pointer address is updated so that it points to the next available memory address where control parameter data can be stored.
Next, at test 35, the process determines whether the memory is full, or substantially full, so that another complete set of control parameter data can not fit into the unused space of the memory. If an additional complete set of control parameter data will fit into the memory, then the process proceeds directly to step 36 where it waits for the next clock cycle to return to the beginning of the process. If a complete set of additional control parameter data will not fit into the memory, then the process advances to test 37 where it is determined whether the logging mode is NORMAL. If so, then for NORMAL logging, the memory is set at step 38 to its OFF state before the process proceeds to step 36 where it waits for the next clock cycle to return to the beginning of the process. At this point, since the memory is in its OFF state, the process will wait until the triggering event is true, in accordance with test 21, until additional control parameter data is monitored and stored in memory.
Under NORMAL logging, every time the memory is full, the process waits until the triggering event is true - 20829 1 ~ ~
before it proceeds to writing over previously-acquired control parameter data that is stored in memory.
If at test 37 the logging mode is not NORMAL, then the process proceeds to test 39 where it is determined whether the logging mode is CONTINUOUS. If so, then for CONTINUOUS logging the process at step 40 stores the first memory log address in the pointer address before the process proceeds to step 36 where it waits for the next clock cycle to return to the beginning of the process. Because the pointer address contains the first memory log address and the memory is in its ON state, on the next clock cycle the process will continue to monitor the control parameters and store data in the memory, writing over previously-acquired stored data. This procedure will continue"continuously," thus called CONTINUOUS logging, until a user interrupts the process by pressing a key or button on the apparatus whose components are being monitored.
Such a user could be a technician, for example, who is making a mechanical adjustment on the apparatus, while the apparatus is simultaneously operated in real time, so as to observe how the performance of the system changes in response to the mechanical adjustment.
If at test 39 the logging mode is not CONTINUOUS, then the process goes directly to step 36 where on the next clock cycle it returns to the beginning of the process without altering the pointer address or the state of the memory. At the beginning of the process, since the memory is already in its ON
state and since the memory is full (i.e., the pointer address points to the end of the memory), no new control parameter data will be written at step 33.
Therefore, if the logging mode is not CONTINUOUS or NORMAL, control parameter data will be monitored and stored only until the memory is full. Accordingly, - 2082q 1 q this type of logging mode can be referred to as ONE-SHOT logging. After ONE-SHOT logging, the user would read the control parameter data stored in the memory log, through a user interface device, and thereafter analyze it for determining the performance of the mechanical device and for diagnosing any faulty condition in it.
The method diagrammed in FIG. 2 is used to analyze and debug the performance of an electrically controlled mechanical device with respect to the first category of control parameters discussed above -- i.e., those which it is important to monitor on a clock-cycle-by-clock-cycle basis. As discussed above, the method includes three different data logging modes --NORMAL, CONTINUOUS, and ONE-SHOT. In general, the decision of which type of logging mode to use to analyze the performance of the mechanical device is mainly a matter of user preference. However, ONE-SHOT
logging is generally more useful since this particular logging mode terminates when the memory log is full.
In contrast, for NORMAL and CONllNUOUS logging the memory will eventually be written over. Thus, for ONE-SHOT logging control parameter data will be gathered for a fixed period of time beginning at the first occurrence of the triggering event. It is for this reason that ONE-SHOT logging is generally more useful.
For example, whenever mailing machines come off the assembly line, it may be desirable for quality control purpose~ to compare how each machine performs on the first in a sequence of many mailpieces. Under this condition, the triggering event would be chosen to be the time when a mailpiece passes a particular sensor. With ONE-SHOT logging, control parameter data will be saved for a fixed period of time after the first mailpiece passes the sensor. If NORMAL logging 20~29 1 9 were used instead, then each time the memory becomes full previously-acquired control parameter data will be written over as soon as the next mailpiece passes the sensor. Accordingly, control parameter data from the first mailpiece may be lost if many mailpieces pass the triggering sensor. For CONTINUOUS logging, the process would not even wait for the next triggering event to take place before it writes over previously-acquired control parameter data. Thus, to compare the performance of a particular machine to a group of other machines, ONE-SHOT logging can be more useful than either CONTINUOUS or NORMAL logging.
There are some situations, however, where CONTINUOUS and NORMAL logging are more useful than ONE-SHOT logging. For example, if a particular mailingmachine has a problem and a mechanical adjustment has to be made in order to identify or fix the problem, then it may be desirable to simultaneously monitor particular control parameters while a technician is making the adjustment. Under these conditions, one would want to continuously monitor the machine while the adjustment is being made. Accordingly, ONE-SHOT
logging would not be as convenient as either CONTINUOUS
or NORMAL logging for this particular purpose.
The method diagrammed in FIG. 2 is employed to monitor and analyze the first type of control parameters discussed above. If it is desired to monitor and analyze the second type of control parameters (i.e., those which represent histograms of the first category of control parameters over a plurality of clock cycles), then the preferred method for such analysis is that diagrammed in FIG. 3.
In accordance with the present invention, a second method for analyzing the performance of an electrically controlled mechanical device is shown in 2082~ 1 9 FIG. 3. The method starts at test 50 where it is determined whether the memory log is in its ON state.
If not, at step 51 the memory log is set to its ON
state. At step 52, the pointer is assigned the address of the first log address of the memory log. At step 53, the process waits for the next clock cycle so that it can return to the beginning of the process.
If at test 50, the memory is in its ON state, such as when the process returns to test 50 the second time, since the process proceeds to step 54. At step 54 it is determined whether the triggering event is true. If not, the process returns to the beginning.
If the triggering event is true, then the process proceeds to step 55 where the system components are monitored until the control parameter data is gathered.
For example, in a mail processing system, if the control parameter is the mailpiece length then the appropriate sensor is monitored until the microprocessor or controller can establish the length of the mailpiece. After the control parameter data is gathered, step 56 stores the data in memory. At step 57, the pointer is moved to the next available memory address. For this step, if the memory is full, then the pointer is moved back to the first log address where control parameter data will be written over previously-acquired data. Thus, for this embodiment of the present invention, the memory is used as a "ring buffer" since data is written to the memory without regard to whether previously-acquired data is written over.
At step 58, the process returns to the beginning where whenever the triggering event becomes true (in accordance with test 54), the above-described process is repeated. Thus, as the mechanical device being analyzed continues to operate in real time, and ~0~2q 1 q many triggering events occur, a histogram will be generated since control parameter data will be stored in the ring buffer for each occurrence of the triggering event. For example, if it is desired to monitor the postage meter print-to-print cycle time in a mailing machine (i.e., the time it takes to process a mailpiece through a postage meter), then for each mailpiece, a "print-to-print cycle time" will be stored in the print-to-print-cycle-time ring buffer. Thus, for example, if this buffer can store up to 128 words of information, and it takes one word of memory to store the data generated during each cycle, then a histogram containing 128 cycles can be generated by the process diagrammed in FIG. 3. In accordance with the present invention, the histogram data would then be read out of the ring buffer by way of a user interface device, such as a printer or display terminal, and the data would then be used for analyzing the performance of the mailing machine. By way of further example, if a technician or operator were to make modifications to the postage meter, then the process diagrammed in FIG. 3 could then be repeated and used to determine if the modifications were successful or unsuccessful by comparing histograms obtained before and after the modifications.
In contrast to the process of FIG. 2, the process diagrammed in FIG. 3 is independently repeated for each control parameter desired to be monitored and analyzed. Accordingly, the number of control parameters which can be monitored and analyzed is limited by the number of dedicated memory ring buffers that the system has available. For example, if there are nine such memories, then nine control parameters can be monitored simultaneously in real time. In the method of FIG. 2, on the other hand, the method is not -~ 20829 1 9 dedicated to a particular number of control parameters.
As shown in FIG. 2, step 24 of that process generates a control parameter list. This list can contain any number of control parameters which it is desired to monitor. The only constraint on the number that can be accommodated is the burden that the process imposes on the microprocessor which is simultaneously used to carry out the functions of the device. Accordingly, as long as the microprocessor can process the control parameter data without overburdening and slowing down the mechanical device, then the number of monitored control parameters can be increased, if desired. Of course, the physical size of the memory may also place a limit on the number of control parameters that can be monitored.
Thus, a method for analyzing the performance of an electrically controlled mechanical device in real time has been presented. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.
ELECTRICALLY CONTROLLED MECHANICAL DEVICE
Background Of The Invention The present invention relates to a method for diagnosing an electrically controlled mechanical device. More particularly, the present invention relates to a method for analyzing and debugging an article processing system in real time.
Article processing systems, as well as other electrically controlled mechanical devices, generally include a plurality of apparatus or components for carrying out the various functions of the system. For mail processing systems, these components perform a variety of tasks and include, for example, envelope feeders, envelope sealers, weighers, postage meters, motion control components and various types of sensors.
These components are generally controlled by a central microprocessor operating at a predetermined clock cycle. In order to achieve high mail processing speeds, the components are generally operated under what is referred to as "distributed" control. Under distributed control, in contrast to serial or individual control, the states of the various components of the system are changed independent of whether other components in the system are functioning properly. In other words, one component does not generally wait for another component to complete its '~C
20829 1 ~
assigned function prior to performing its own, as would be the case if the system were operated under serial control. The control system assumes that all components are functioning properly and at their correct speed. This feature of a distributed control system allows high mail processing speeds to be achieved since time is inherently saved in the component instruction process.
A disadvantage of complex article processing systems as well as other electrically controlled mechanical devices, especially if operated under distributed control, is that it is sometimes difficult to analyze the performance of the overall system by simply inspecting the individual components of the system while the system is at rest. If the system is not functioning properly, the malfunction may be due to the malfunction of one or more individual components of the system. Determining which of the many components in the system are malfunctioning can be time consuming and laborious. In order to locate a particular malfunction in a component, it may be necessary to monitor the performance of the various components of the system while the system is in actual operation, or in other words, in "real time."
Similarly, the performance of the system can be dependent upon the interaction of the various individual components making up the system. For example, a particular component, although functioning properly when externally tested on its own, may not function properly when incorporated into the overall system. The need to replace such a component may not be detectable unless the system is monitored and analyzed in real time. Furthermore, even after insertion of a replacement component into the system, the replacement component may cause other system 2û829 1 9 components that previously operated normally to malfunction. In order to locate this particular type of malfunction, it may be similarly necessary to monitor the interaction of the various components of the system in real time.
As discussed above, although there are a variety of situations where it is desirable to monitor and analyze the performance of an electrically controlled mechanical device in real time, diagnosing such a device can be difficult. First, since the diagnosis must be performed in real time, there are time limitations which must be taken into account. The diagnosing method must be able to track the performance of the system at typical operating speeds. For example, for high-speed article processing systems which operate at speeds in excess of four articles per second, the diagnosing method should be able to monitor the system at such speeds. Furthermore, for article processing systems which operate under "distributed"
microprocessor control, as discussed above, where typical clock cycle times are on the order of 1 to 2 milliseconds, the diagnosing method should also be able to monitor the system at these clock cycle rates.
Second, in analyzing an electrically controlled mechanical device in real time, there can be a very large number of features of the device to monitor. As a result, in order to avoid slowing down the speed of the device and to avoid collecting prohibitively large amounts of data, only a select number of features can be monitored at a given time.
The particular method of monitoring and analyzing the selected features of the system can influence the overall number of features which can be monitored. For example, if the method for monitoring and analyzing the selected features of the system is too slow, then only 20829 1 ~
a small number of features can be monitored at once, and the system would have to be operated repeatedly in order to collect data on all the various features of the system which must be monitored in order analyze the performance of the device.
Because electrically controlled mechanical devices have so many potential reasons for faulty operation, a method for analyzing the performance of the device should be flexible enough so that the user can select which features of the device are monitored in addition to the time when the monitoring is initiated or triggered. Otherwise, if the method does not have great flexibility, then it may be more difficult, and take longer than necessary to identify a faulty component in the device.
In addition, the method for analyzing the performance of the device should be able to give detailed information about the performance of the device without overburdening the control system of the device.
It would be desirable to be able to provide a method for analyzing the performance of an electrically controlled mechanical device while the device is in actual operation.
It would also be desirable to provide such a method that does not require slowing down the device.
It would be further desirable to provide a method for analyzing the performance of an electrically controlled mechanical device that is flexible enough so that the user can select which features of the device to monitor, as well as the time when the monitoring is initiated.
It would still further be desirable to provide a method for analyzing the performance of an electrically controlled mechanical device that is able _ - 5 -to give detailed information about the performance of the device without overburdening the control system of the device.
Summary Of The Invention It is an object of an aspect of this invention to provide a method for analyzing the performance of an electrically controlled mechanical device while the device is in actual operation.
It is an object of an aspect of this invention to provide such a method that does not require slowing down the device.
It is an object of an aspect of this invention to provide a method for analyzing the performance of an electrically controlled mechanical device that is flexible enough so that the user can select which features of the device to monitor, as well as the time when the monitoring is initiated.
It is an object of an aspect of this invention to provide a method for analyzing the performance of an electrically controlled mechanical device that is able to give detailed information about the performance of the device without overburdening the control system of the device.
Other aspects of this invention are as follows:
A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device .~
A~
functions during normal mechanical device operations, said method comprising the steps of:
(a) initiating normal device operation (b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components;
(d) after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and (e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of ~ - 6a -log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operation, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its on state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components; and (d) repeatedly, for a predetermined period:
after setting said memory to its one state, and for each clock cycle until substantially all cf said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters, and storing, in said pointer address, the address of said first log address.
A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last ,,.~
20829 1 ~
~ - 6b -log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operation, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said system components;
(c) setting said memory to its on state;
(d) storing the address of said first log address in said pointer address;
(e) selecting a triggering event for initiating the monitoring of said control parameter in real time, and, for a predetermined time period;
(f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the net log address and if said address is equal to said last log address, storing said first log address in said pointer addresses.
A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
- 208291q - 6c -(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor;
(d) after setting said memory to its one state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameter; and;
(e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
A ~
A
- 6d -(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real timei (c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor; and (d) repeatedly, for a predetermined period;
after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and storing, in said pointer address, the address of said first log address.
A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said sensors and motors;
(c) setting said memory to its on state;
_ - 6e -(d) storing the address of said first log address in said pointer address;
(e) selecting a trigger event for initiating the monitoring of said control parameter in real time, and, for a predetermined time periodi (f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the next log address and if said address is equal to said last log address, storing said first log address in said pointer address;
Brief Description Of The Drawinqs The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
A.~
2082q 1 9 FIG. 1 is a schematic view of apparatus with which the present invention can be used;
FIG. 2 is a flow diagram of a first method according to the present invention; and FIG. 3 is a flow diagram of a second method according to the present invention.
Detailed Description Of The Invention In accordance with the present invention, a method for analyzing the performance of an electrically controlled mechanical device is presented. The method can be employed in electrically controlled mechanical devices, such as article processing systems, which employ a microprocessor in conjunction with a memory for controlling the operation of the system.
A representative electrically controlled mechanical device with which the present invention can be used is shown in FIG. 1. Apparatus 10, shown schematically in FIG. 1, includes a microprocessor/
controller 11, a memory 12, a user interface device 13 and a plurality of system components 14 which carry out the functions of apparatus 10. For example, if apparatus 10 is a mail processing system, then system components 14 can include an envelope feeder, an envelope sealer, a weigher, a postage meter, motion control devices, various types of sensors and other components necessary for carrying out the functions of a mail processing system.
Microprocessor 11, in FIG. 1, is used to control system components 14. In accordance with the present invention, it is also used to analyze and debug the performance of the apparatus in real time and to diagnose any faulty condition in the apparatus.
Microprocessor 11 stores in memory 12 pre-selected data relating to the status of a predetermined number of control parameters of the apparatus. In accordance with the present invention, "control parameters" are used to characterize the status of the system components. After being stored in memory 12 during the real-time operation of apparatus 10, the control parameters are read from memory 12 under the control of user interface device 14 to produce a human-readable report or record of the control parameter data. User interface device 14 can include, for example, a display terminal, a keyboard, a printer, or any other type of device which can be used to communicate with microprocessor 11 so as to produce a human-readable report or record of the control parameter data. The report or record containing the control parameter data is then used for analyzing and debugging the performance of the apparatus. As will be discussed below, the report or record of control parameter data can be used by a technician or operator to monitor the change in device performance while the device is being repaired or modified. In addition, the report or record of control parameter data can be compared to an analogous report or record obtained under ideal device performance in order to diagnose any faulty condition in the device.
In accordance with a preferred embodiment the present invention, and particularly if apparatus 10 is a mail processing system, the control parameters which are used for analyzing and debugging the performance of the system can be classified into two general categories. A first category includes those parameters which it is important to monitor on a clock-cycle-by-clock-cycle basis so that the various components of the system can be analyzed and synchronized with each other if needed. These parameters include, for example, motor positions, motor velocities, motor power - 20~329 1 9 g dissipation, sensor currents (i.e., whether or not an item is being detected), motor inter-relationships (i.e., the position or velocity of one motor relative another), sensor inter-relationships, etc. A second category of control parameters includes those parameters which are histograms of the first category of control parameters over a plurality of clock cycles.
These parameters include, for example, envelope flap profiles, mailpiece length, distance between mailpieces, postage meter print-to-print cycle time, time from start of a postage meter print cycle to the start of the next mailpiece feed, time from a mailpiece stop for a postage meter print to the start of the print, weighing scale parameters, system component to microprocessor communication error codes, motion control processor to interface processor message headers and various other indicators of mail processing system performance.
As stated above, apparatus 10 operates at a clock cycle determined by microprocessor 11. Typical clock cycles can vary from application to application.
However, for real-time control systems used in conjunction with high-speed mail processing systems, for example, clock cycles are typically on the order of 1-2 milliseconds. Generally, for each clock cycle microprocessor 11 alters the status of apparatus 10 in order for the system to perform the function which it is intended to carry out. As each clock cycle passes, the system progresses from one state to another state as the various system components 14 change state (e.g., motors advance, etc.). It is desirable to log the status of system components 14, as their states are changed by microprocessor 11, so that the performance of the system can be analyzed and debugged.
A first method for analyzing the performance of an electrically controlled mechanical device in accordance with the present invention is diagrammed in FIG. 2. The method starts at test 20 where it is determined whether the memory log is in its ON state.
If not, the process proceeds to test 21 where it determines whether the triggering event is true. This test determines if the monitoring of control parameters should be initiated. As used herein, a triggering event is an event or state of the mechanical device which represents a particular point in time during the operation of the mechanical device (e.g., a position or velocity of a motor, or the state of a sensor, etc.).
At step 27, if the triggering event is not true, the process waits for the next clock cycle to begin the process all over again, starting at test 20. If at test 21 the triggering event is true, then at step 22, the process sets the memory log to its ON state and the pointer address of the memory log is cleared. Next, at test 23, the system determines whether the control parameter list has been initialized. If so, the process proceeds directly to step 26. Otherwise, the process proceeds to steps 24 and 25, where the list of control parameters to be monitored is made and the number of control parameters is counted, for future reference, respectively, and then on to step 26. At step 26, the pointer is assigned the address of the first log address of the memory log, and at step 27, the process waits for the next clock cycle so that it can return to the beginning of the process.
If at test 20 the memory log is in its ON
state, such as when the process returns to test 20 the second time, the process proceeds to step 31. At step 31, the address in the pointer address is read so that the process will know the next place in memory for 20829 I q storing control parameter data. The process then proceeds to where test 32 determines whether there are any control parameters left on the control parameter list to be monitored. Next, at step 33, each control parameter on the control parameter list is monitored and corresponding data is stored in memory. Test 32 and step 33 are performed for each control parameter on the control parameter list. After the last control parameter has been monitored and its corresponding data has been stored in memory, the process advances to step 34, where the pointer address is updated so that it points to the next available memory address where control parameter data can be stored.
Next, at test 35, the process determines whether the memory is full, or substantially full, so that another complete set of control parameter data can not fit into the unused space of the memory. If an additional complete set of control parameter data will fit into the memory, then the process proceeds directly to step 36 where it waits for the next clock cycle to return to the beginning of the process. If a complete set of additional control parameter data will not fit into the memory, then the process advances to test 37 where it is determined whether the logging mode is NORMAL. If so, then for NORMAL logging, the memory is set at step 38 to its OFF state before the process proceeds to step 36 where it waits for the next clock cycle to return to the beginning of the process. At this point, since the memory is in its OFF state, the process will wait until the triggering event is true, in accordance with test 21, until additional control parameter data is monitored and stored in memory.
Under NORMAL logging, every time the memory is full, the process waits until the triggering event is true - 20829 1 ~ ~
before it proceeds to writing over previously-acquired control parameter data that is stored in memory.
If at test 37 the logging mode is not NORMAL, then the process proceeds to test 39 where it is determined whether the logging mode is CONTINUOUS. If so, then for CONTINUOUS logging the process at step 40 stores the first memory log address in the pointer address before the process proceeds to step 36 where it waits for the next clock cycle to return to the beginning of the process. Because the pointer address contains the first memory log address and the memory is in its ON state, on the next clock cycle the process will continue to monitor the control parameters and store data in the memory, writing over previously-acquired stored data. This procedure will continue"continuously," thus called CONTINUOUS logging, until a user interrupts the process by pressing a key or button on the apparatus whose components are being monitored.
Such a user could be a technician, for example, who is making a mechanical adjustment on the apparatus, while the apparatus is simultaneously operated in real time, so as to observe how the performance of the system changes in response to the mechanical adjustment.
If at test 39 the logging mode is not CONTINUOUS, then the process goes directly to step 36 where on the next clock cycle it returns to the beginning of the process without altering the pointer address or the state of the memory. At the beginning of the process, since the memory is already in its ON
state and since the memory is full (i.e., the pointer address points to the end of the memory), no new control parameter data will be written at step 33.
Therefore, if the logging mode is not CONTINUOUS or NORMAL, control parameter data will be monitored and stored only until the memory is full. Accordingly, - 2082q 1 q this type of logging mode can be referred to as ONE-SHOT logging. After ONE-SHOT logging, the user would read the control parameter data stored in the memory log, through a user interface device, and thereafter analyze it for determining the performance of the mechanical device and for diagnosing any faulty condition in it.
The method diagrammed in FIG. 2 is used to analyze and debug the performance of an electrically controlled mechanical device with respect to the first category of control parameters discussed above -- i.e., those which it is important to monitor on a clock-cycle-by-clock-cycle basis. As discussed above, the method includes three different data logging modes --NORMAL, CONTINUOUS, and ONE-SHOT. In general, the decision of which type of logging mode to use to analyze the performance of the mechanical device is mainly a matter of user preference. However, ONE-SHOT
logging is generally more useful since this particular logging mode terminates when the memory log is full.
In contrast, for NORMAL and CONllNUOUS logging the memory will eventually be written over. Thus, for ONE-SHOT logging control parameter data will be gathered for a fixed period of time beginning at the first occurrence of the triggering event. It is for this reason that ONE-SHOT logging is generally more useful.
For example, whenever mailing machines come off the assembly line, it may be desirable for quality control purpose~ to compare how each machine performs on the first in a sequence of many mailpieces. Under this condition, the triggering event would be chosen to be the time when a mailpiece passes a particular sensor. With ONE-SHOT logging, control parameter data will be saved for a fixed period of time after the first mailpiece passes the sensor. If NORMAL logging 20~29 1 9 were used instead, then each time the memory becomes full previously-acquired control parameter data will be written over as soon as the next mailpiece passes the sensor. Accordingly, control parameter data from the first mailpiece may be lost if many mailpieces pass the triggering sensor. For CONTINUOUS logging, the process would not even wait for the next triggering event to take place before it writes over previously-acquired control parameter data. Thus, to compare the performance of a particular machine to a group of other machines, ONE-SHOT logging can be more useful than either CONTINUOUS or NORMAL logging.
There are some situations, however, where CONTINUOUS and NORMAL logging are more useful than ONE-SHOT logging. For example, if a particular mailingmachine has a problem and a mechanical adjustment has to be made in order to identify or fix the problem, then it may be desirable to simultaneously monitor particular control parameters while a technician is making the adjustment. Under these conditions, one would want to continuously monitor the machine while the adjustment is being made. Accordingly, ONE-SHOT
logging would not be as convenient as either CONTINUOUS
or NORMAL logging for this particular purpose.
The method diagrammed in FIG. 2 is employed to monitor and analyze the first type of control parameters discussed above. If it is desired to monitor and analyze the second type of control parameters (i.e., those which represent histograms of the first category of control parameters over a plurality of clock cycles), then the preferred method for such analysis is that diagrammed in FIG. 3.
In accordance with the present invention, a second method for analyzing the performance of an electrically controlled mechanical device is shown in 2082~ 1 9 FIG. 3. The method starts at test 50 where it is determined whether the memory log is in its ON state.
If not, at step 51 the memory log is set to its ON
state. At step 52, the pointer is assigned the address of the first log address of the memory log. At step 53, the process waits for the next clock cycle so that it can return to the beginning of the process.
If at test 50, the memory is in its ON state, such as when the process returns to test 50 the second time, since the process proceeds to step 54. At step 54 it is determined whether the triggering event is true. If not, the process returns to the beginning.
If the triggering event is true, then the process proceeds to step 55 where the system components are monitored until the control parameter data is gathered.
For example, in a mail processing system, if the control parameter is the mailpiece length then the appropriate sensor is monitored until the microprocessor or controller can establish the length of the mailpiece. After the control parameter data is gathered, step 56 stores the data in memory. At step 57, the pointer is moved to the next available memory address. For this step, if the memory is full, then the pointer is moved back to the first log address where control parameter data will be written over previously-acquired data. Thus, for this embodiment of the present invention, the memory is used as a "ring buffer" since data is written to the memory without regard to whether previously-acquired data is written over.
At step 58, the process returns to the beginning where whenever the triggering event becomes true (in accordance with test 54), the above-described process is repeated. Thus, as the mechanical device being analyzed continues to operate in real time, and ~0~2q 1 q many triggering events occur, a histogram will be generated since control parameter data will be stored in the ring buffer for each occurrence of the triggering event. For example, if it is desired to monitor the postage meter print-to-print cycle time in a mailing machine (i.e., the time it takes to process a mailpiece through a postage meter), then for each mailpiece, a "print-to-print cycle time" will be stored in the print-to-print-cycle-time ring buffer. Thus, for example, if this buffer can store up to 128 words of information, and it takes one word of memory to store the data generated during each cycle, then a histogram containing 128 cycles can be generated by the process diagrammed in FIG. 3. In accordance with the present invention, the histogram data would then be read out of the ring buffer by way of a user interface device, such as a printer or display terminal, and the data would then be used for analyzing the performance of the mailing machine. By way of further example, if a technician or operator were to make modifications to the postage meter, then the process diagrammed in FIG. 3 could then be repeated and used to determine if the modifications were successful or unsuccessful by comparing histograms obtained before and after the modifications.
In contrast to the process of FIG. 2, the process diagrammed in FIG. 3 is independently repeated for each control parameter desired to be monitored and analyzed. Accordingly, the number of control parameters which can be monitored and analyzed is limited by the number of dedicated memory ring buffers that the system has available. For example, if there are nine such memories, then nine control parameters can be monitored simultaneously in real time. In the method of FIG. 2, on the other hand, the method is not -~ 20829 1 9 dedicated to a particular number of control parameters.
As shown in FIG. 2, step 24 of that process generates a control parameter list. This list can contain any number of control parameters which it is desired to monitor. The only constraint on the number that can be accommodated is the burden that the process imposes on the microprocessor which is simultaneously used to carry out the functions of the device. Accordingly, as long as the microprocessor can process the control parameter data without overburdening and slowing down the mechanical device, then the number of monitored control parameters can be increased, if desired. Of course, the physical size of the memory may also place a limit on the number of control parameters that can be monitored.
Thus, a method for analyzing the performance of an electrically controlled mechanical device in real time has been presented. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.
Claims (22)
1. A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operations, said method comprising the steps of:
(a) initiating normal device operation (b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components;
(d) after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and (e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
(a) initiating normal device operation (b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components;
(d) after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and (e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
2. The method of Claim 1 further comprising the step of:
(f) after termination of the sequential storing step and prior to the next clock cycle, storing in said pointer address, the address of said first log address and setting said memory to its off state.
(f) after termination of the sequential storing step and prior to the next clock cycle, storing in said pointer address, the address of said first log address and setting said memory to its off state.
3. The method of Claim 1 wherein the step of producing said report further comprises using said user interface device to produce said report.
4. A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operation, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its on state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components; and (d) repeatedly, for a predetermined period:
after setting said memory to its one state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters, and storing, in said pointer address, the address of said first log address.
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its on state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said system components, each control parameter corresponding to the status of one of said system components; and (d) repeatedly, for a predetermined period:
after setting said memory to its one state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters, and storing, in said pointer address, the address of said first log address.
5. The method of Claim 4 further comprising the step of manually indicating to said mechanical device the end of said predetermined time period.
6. The method of Claim 4 further comprising the step of:
(e) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
(e) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
7. The method of Claim 6 wherein the step of producing said report further comprises using said user interface device to produce said report.
8. A method for analyzing the performance of an electrically controlled mechanical device in real time, said electrically controlled device including a plurality of system components for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said programmable microprocessor being programmed to control said mechanical device functions during normal mechanical device operation, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said system components;
(c) setting said memory to its on state;
(d) storing the address of said first log address in said pointer address;
(e) selecting a triggering event for initiating the monitoring of said control parameter in real time, and, for a predetermined time period;
(f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the net log address and if said address is equal to said last log address, storing said first log address in said pointer addresses.
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said system components;
(c) setting said memory to its on state;
(d) storing the address of said first log address in said pointer address;
(e) selecting a triggering event for initiating the monitoring of said control parameter in real time, and, for a predetermined time period;
(f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the net log address and if said address is equal to said last log address, storing said first log address in said pointer addresses.
9. The method of Claim 8 further comprising the step of manually indicating to said mechanical device the end of said predetermined time period.
10. The method of Claim 8 further comprising the step of:
(h) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
(h) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the mechanical device.
11. The method of Claim 10 wherein the step of producing said report further comprises using said user interface device to produce said report.
12. A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor;
(d) after setting said memory to its one state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameter; and;
(e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor;
(d) after setting said memory to its one state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time and sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameter; and;
(e) after termination of the sequential storing step and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
13. The method of Claim 12 further comprising the step of:
(f) after termination of the sequential storing step and prior to the next clock cycle, storing, in said pointer address, the address of said first log address and setting said memory to its off state.
(f) after termination of the sequential storing step and prior to the next clock cycle, storing, in said pointer address, the address of said first log address and setting said memory to its off state.
14. The method of Claim 12 wherein the step of producing said report further comprises using said user interface device to produce said report.
15. A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor; and (d) repeatedly, for a predetermined period;
after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and storing, in said pointer address, the address of said first log address.
(a) initiating normal device operation;
(b) selecting a triggering event for initiating the monitoring of a plurality of control parameters in real time;
(c) after the occurrence of said triggering event, setting said memory to its one state, storing the address of said first log address in said pointer address, and selecting a plurality of control parameters for characterizing status of said sensors and motors, each control parameter corresponding to the status of either a sensor or a motor; and (d) repeatedly, for a predetermined period;
after setting said memory to its on state, and for each clock cycle until substantially all of said plurality of log addresses are in use to store data representing said control parameters, monitoring said plurality of control parameters in real time, sequentially storing, beginning at the address stored in said pointer address and continuing to said last log address, said data representing said control parameters; and storing, in said pointer address, the address of said first log address.
16. The method of Claim 15 further comprising the step of manually indicating to said mechanical device the end of said predetermined time period.
17. The method of Claim 15 further comprising the step of:
(e) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
(e) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
18. The method of Claim 17 wherein the step producing said report further comprises using said user interface device to produce said report.
19. A method for analyzing the performance of an article processing device in real time, said article processing device including one or more sensors and one or more motors for carrying out the functions of the device, a programmable microprocessor having a predetermined clock cycle, a user interface device, and a memory having an on state and an off state, a pointer address, a first log address, a last log address, and a plurality of log addresses positioned in between said first and last log addresses, said method comprising the steps of:
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said sensors and motors;
(c) setting said memory to its on state;
(d) storing the address of said first log address in said pointer address;
(e) selecting a trigger event for initiating the monitoring of said control parameter in real time, and, for a predetermined time period;
(f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the next log address and if said address is equal to said last log address, storing said first log address in said pointer address;
(a) initiating normal device operation;
(b) selecting a control parameter for characterizing status of said sensors and motors;
(c) setting said memory to its on state;
(d) storing the address of said first log address in said pointer address;
(e) selecting a trigger event for initiating the monitoring of said control parameter in real time, and, for a predetermined time period;
(f) after occurrence of said triggering event, monitoring said control parameter in real time and storing control parameter data after said data is obtained in the address stored in said pointer address; and (g) after termination of the storing step, incrementing said address stored in said pointer address to the next log address and if said address is equal to said last log address, storing said first log address in said pointer address;
20. The method of Claim 19 further comprising the step of manually indicating to said mechanical device the end of said predetermined time period.
21. The method of Claim 19 further comprising the step of:
(h) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
(h) after said predetermined time period and for each of said monitored plurality of control parameters, producing a report for analysis, which contains said stored data representing said control parameters, for determining real time performance of the article processing device.
22. The method of Claim 21 wherein the step of producing said report further comprises using said user interface device to produce said report.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US79650291A | 1991-11-22 | 1991-11-22 | |
| US796,502 | 1991-11-22 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2082919A1 CA2082919A1 (en) | 1993-05-23 |
| CA2082919C true CA2082919C (en) | 1997-03-18 |
Family
ID=25168341
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2082919 Expired - Fee Related CA2082919C (en) | 1991-11-22 | 1992-11-13 | Method for diagnosing an electrically controlled mechanical device |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2082919C (en) |
| GB (1) | GB2261748B (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4446667C2 (en) * | 1994-12-15 | 1998-09-17 | Francotyp Postalia Gmbh | Process for improving the security of franking machines when transferring credit |
| JP4490714B2 (en) * | 2004-03-25 | 2010-06-30 | 株式会社アドバンテスト | Switch control device, semiconductor test device, and generation program |
| DE102007015762A1 (en) * | 2007-03-30 | 2008-10-02 | It-Designers Gmbh | Data recording system and method for collecting data by means of a data recording system |
| EP2746952B1 (en) | 2012-12-18 | 2017-02-08 | Neopost Technologies | Secured management of traces in a mail processing device |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5827250A (en) * | 1981-08-10 | 1983-02-17 | Fuji Xerox Co Ltd | Protecting device at the time of self-diagnosis |
| US4851985A (en) * | 1985-04-15 | 1989-07-25 | Logitek, Inc. | Fault diagnosis system for comparing counts of commanded operating state changes to counts of actual resultant changes |
| US4908746A (en) * | 1986-10-15 | 1990-03-13 | United States Data Corporation | Industrial control system |
| US4942514A (en) * | 1987-11-17 | 1990-07-17 | Hitachi, Ltd. | Process monitoring and control system and method of process monitoring and control |
| US4977394A (en) * | 1989-11-06 | 1990-12-11 | Whirlpool Corporation | Diagnostic system for an automatic appliance |
-
1992
- 1992-11-13 CA CA 2082919 patent/CA2082919C/en not_active Expired - Fee Related
- 1992-11-13 GB GB9223808A patent/GB2261748B/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| GB2261748B (en) | 1995-07-19 |
| GB9223808D0 (en) | 1993-01-06 |
| GB2261748A (en) | 1993-05-26 |
| CA2082919A1 (en) | 1993-05-23 |
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