JP2002163020A - Method and device for detecting abnormality in programmable controller - Google Patents

Abstract

PROBLEM TO BE SOLVED: To extract a cause of abnormality in a programmable controller by simple processing. SOLUTION: A program reading means 11 reads a sequence program PR1, and in input and output data reading means 12 reads input and output data IO1 as a required specification. A data table 14 wherein combinations of the input and output data IO1 in every hour are served as data groups is prepared in an input and output operation decoding means 13. A following operation determining means 15 determines the presence of a logical inconsistency when the data group in the every hour is applied to the sequence program PR1, ratiocinates a cause of the logical inconsistency, when the logical inconsistency exists, by tracing an input and an output concerned, going upstream from the group of the input and the output in which the inconsistency is generated out of the sequence program PR1, and outputs a ratiocinated result from a result output means 16.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for detecting an abnormality in a programmable controller. More specifically, the present invention relates to an error in a sequence program under development in a programmable controller and an error in a control target after completion of the sequence program. Alignment,
The present invention relates to a technique for detecting an abnormality in a programmable controller such as an abnormality occurring in a control target during operation.

[0002]

2. Description of the Related Art Conventionally, as a technique for diagnosing a failure of a control target, which is a kind of abnormality in a programmable controller, as disclosed in Japanese Patent Application Laid-Open No. Hei 10-97318, a reference pattern and an abnormal state are disclosed. A device that performs an abnormality diagnosis by comparing with a pattern has been proposed.

[0003]

However, in the technique described in the above-mentioned publication, the reference pattern and the pattern at the time of abnormality are compared, so that two-dimensional patterns are compared with each other. There is a problem that complicated processing is required.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and has as its object to provide a method and apparatus for detecting an abnormality in a programmable controller which can extract the cause of the abnormality in the programmable controller by relatively simple processing. To provide.

[0005]

According to a first aspect of the present invention, a sequence program for operating a programmable controller and input / output data of the programmable controller associated with the sequence program are input through a reading unit, and a predetermined time is determined by a next operation determining unit. Is used to determine the presence or absence of a logical inconsistency based on the consistency between the sequence program and the combination of input and output data when the combination of input and output data is applied to the sequence program. Infer the cause of logical inconsistency by tracking related I / Os retroactively from the resulting I / O combinations,
The inference result is output from the result output means.

According to a second aspect of the present invention, in the first aspect of the present invention, the input / output data is used as input / output data representing a required specification of operation timing of a control target, and input / output operation decoding means is used from the input / output data. A data table which is a time series of the data set is created by extracting a combination for each time as a data set, and the next operation determining means determines whether there is a logical inconsistency based on the consistency between each data set of the data table and the sequence program. By determining, the cause of the logical contradiction in the sequence program is inferred.

According to a third aspect of the present invention, in the second aspect of the present invention, the result output means visualizes and outputs a time chart of a part including a data set in which a logical inconsistency occurs in the required specifications, and outputs the time chart. The timing at which a logical inconsistency occurs is shown in, and a message indicating the cause and content of the inconsistency inferred by the next operation determining means is visualized and output together with a time chart.

According to a fourth aspect of the present invention, in the second or third aspect, a correction plan is created and created for a cause of a logical inconsistency in the sequence program inferred by the next operation determining means. Among the amendments, the amendment for resolving the logical contradiction is visualized and output by the result output means.

According to a fifth aspect of the present invention, in the first aspect of the present invention, the input / output data is used as input / output data at the time of occurrence of an abnormality in a control target in an actual operation, and the next operation determining means outputs the input / output data. By determining the presence or absence of a logical inconsistency based on the consistency between the data set and the sequence program, a cause of the logical inconsistency is inferred for the control target.

According to a sixth aspect of the present invention, in the first aspect of the present invention, the input / output data is input / output data in a predetermined time range including a time of occurrence of an abnormality of a control target, and the input / output operation is decoded from the input / output data. A data table which is a time series of the data set is created by extracting a combination for each time as a data set by using the means, and the next operation determining means determines a logical table based on the consistency between each data set of the data table and the sequence program. By determining the presence or absence of a contradiction, a cause of the logical contradiction is inferred for the control target.

According to a seventh aspect of the present invention, in the fifth or sixth aspect of the present invention, a message representing a cause and a content of the contradiction inferred by the next operation determining means is visualized and output by a result output means. It is characterized by.

According to an eighth aspect of the present invention, in the invention of the fifth to seventh aspects, the sequence program is a sequence program already mounted on a programmable controller for actually operating a controlled object, and Transferred from the programmable controller,
Further, the input / output data is transferred from the programmable controller via communication means.

According to a ninth aspect of the present invention, a sequence program for operating the programmable controller and input data of the programmable controller associated with the sequence program are input through the reading means, and the input data is given to the simulation control means equivalent to the programmable controller. And executing the simulation model displayed on the display device by the result output means by simulating the control target in accordance with the execution of the sequence program by the simulation control means.

According to a tenth aspect of the present invention, in the ninth aspect of the present invention, the timing control is performed such that the minimum unit of the ON / OFF time interval of the input data supplied to the simulation control means is the cycle of the reference timing generated by the timing generation means. And the timing generation means makes the period of the reference timing variable.

According to an eleventh aspect of the present invention, the sequence program for operating the programmable controller and the input data of the programmable controller associated with the sequence program are input through the reading means, and the minimum unit of the ON / OFF time interval of the input data is determined by the timing generating means. The timing control means regulates the cycle of the reference timing to be the same as the cycle of the reference timing generated, and the cycle of the reference timing is variable in the timing generation means. The input data is given to the simulation control means equivalent to a programmable controller, and the sequence program is executed. And generating a time chart by the result output means from output data accompanying execution of the sequence program by the simulation control means and input data given to the simulation control means. And butterflies.

In a twelfth aspect of the present invention based on the eleventh aspect, the result output means includes a simulation model simulating a control target and displayed on a display device.
The operation is performed at the timing of input / output data represented by the time chart.

According to a thirteenth aspect, in the eleventh aspect, the result output means compares a time chart of input / output data given as a required specification of an operation timing of a control target with the time chart. , The differences are extracted, and a message of the extraction result is visualized and output.

According to a fourteenth aspect, in the ninth to thirteenth aspects, the controlled object is a set of a plurality of blocks each of which completes one process, and the simulation model corresponds to each block. It is characterized by being configured as a combination of sub-models.

According to a fifteenth aspect of the present invention, in the ninth to fourteenth aspects of the present invention, the sequence program is a sequence program already mounted on a programmable controller for actually operating a controlled object, and It is characterized by being transferred from a programmable controller.

According to a sixteenth aspect of the present invention, a sequence program for operating a programmable controller, reading means for inputting input / output data of the programmable controller associated with the sequence program, and a combination of input / output data at a predetermined time are included in the sequence program. Determine whether there is a logical inconsistency based on the consistency between the sequence program and the combination of input / output data when applied, and if there is a logical inconsistency, go back to the sequence program from the combination of I / O that caused the logical inconsistency. The next operation determining means for inferring the cause of the logical inconsistency by tracing the input / output performed, and the result output means for outputting the inference result.

According to a seventeenth aspect, in the sixteenth aspect, the input / output data is input / output data representing a required specification of an operation timing of a control target, and a combination for each time is defined as a data set from the input / output data. An input / output operation decoding means for creating a data table which is a time series of a data set by extraction is added, and the next operation determination means determines whether there is a logical inconsistency based on the consistency between each data set of the data table and the sequence program. By determining, the cause of the logical contradiction in the sequence program is inferred.

According to an eighteenth aspect of the present invention, in the invention of the sixteenth aspect, the input / output data is used as input / output data at the time of occurrence of an abnormality in a controlled object during actual operation, and the next operation determining means outputs the input / output data. By determining the presence / absence of a logical inconsistency based on the consistency between the data set and the sequence program, the cause of the logical inconsistency is inferred for the control target.

According to a nineteenth aspect, in the sixteenth aspect, the input / output data is input / output data in a predetermined time range including the time of occurrence of an abnormality in the control target, and the input / output data is combined for each time. Is extracted as a data set, an input / output operation decoding means for creating a data table which is a time series of the data set is added, and the next operation determination means determines the logic based on the consistency between each data set of the data table and the sequence program. By determining the presence or absence of inconsistency, the cause of the logical inconsistency is inferred for the control target.

According to a twentieth aspect of the present invention, the sequence program according to the eighteenth or nineteenth aspect, wherein the sequence program is already mounted on a programmable controller for causing a controlled object to actually operate,
A communication means for transferring a sequence program and the input / output data from the programmable controller is added.

According to a twenty-first aspect of the present invention, a sequence program for operating a programmable controller and read means for inputting input data of the programmable controller associated with the sequence program are provided, and the input data is equivalent to the programmable controller and provided with the input data. Simulation program means for executing a sequence program, and a result output means for displaying a simulation model simulating an object to be controlled on a display device, wherein the result output means executes the simulation model in accordance with the execution of the sequence program by the simulation control means. To make it work.

According to a twenty-second aspect of the present invention, in the twenty-first aspect of the present invention, the timing generation means for generating the reference timing at a predetermined cycle, and the minimum unit of the on / off time interval of the input data to be supplied to the simulation control means is set to the reference value. A timing regulating means for regulating the cycle of the timing is added, and the cycle of the reference timing is made variable in the timing generating means.

According to a twenty-third aspect of the present invention, a sequence program for operating a programmable controller, reading means for inputting input data of the programmable controller associated with the sequence program, and timing generating means for generating a reference timing at a predetermined cycle are provided. A timing control means for restricting a minimum unit of an on / off time interval of input data to be supplied to the simulation control means to be a cycle of the reference timing; and a sequence program provided with the input data being equivalent to a programmable controller. And a result output means for displaying a simulation model simulating the control target on a display device. The timing generation means has a variable reference timing cycle. And it generates a time chart by result output unit from the input data supplied to the output data and the simulated control means associated with the execution of Nsu program.

According to a twenty-fourth aspect of the present invention, in the invention of the twenty-first to twenty-third aspects, the sequence program is a sequence program already mounted on a programmable controller for actually operating a controlled object,
A communication means for transferring a sequence program from the programmable controller is added.

[0029]

DESCRIPTION OF THE PREFERRED EMBODIMENTS As an embodiment of the present invention described below, in a first embodiment, a programmable controller (hereinafter abbreviated as PLC) detects and debugs an error in a sequence program under development. A device having a function of supporting the creation of a sequence program by improving work efficiency is exemplified. In the second embodiment, when an abnormality occurs in a control target during operation, the location of the abnormality can be easily detected. An example of a device having a function of supporting failure diagnosis will be described. Further, in the third embodiment, a phenomenon (operation) in which consistency between the sequence program and the control target occurs in the control target after the completion of the sequence program
An example of a device having a function of extracting the necessity of correcting a program and the necessity of adjusting a control target before starting the operation of an actual system by verifying through an example. In each of the devices described in the embodiments, the sequence program for operating the PLC and the P associated with the sequence program
The above-described functions are realized by using the input / output data of the LC as input information. However, since each function is independent of each other, each device is usually used individually according to the purpose. However, after detecting the presence / absence of abnormality in the operation of the PLC using the device of the first embodiment or the device of the second embodiment, the abnormality is set as a control target by using the device of the third embodiment. It is verified as a phenomenon that occurs, and conversely, the cause of the abnormal phenomenon that has occurred in the control target using the apparatus of the third embodiment is caused by the apparatus of the first embodiment or the apparatus of the second embodiment. For example, the apparatus of the first embodiment, the apparatus of the second embodiment, and the apparatus of the third embodiment can be used in cooperation with each other. Therefore,
A program that implements the apparatus of the first embodiment or the apparatus of the second embodiment and a program that implements the apparatus of the third embodiment are mounted on a single computer, and the program to be executed is It is possible to switch and use. Therefore, the device according to the third embodiment is exemplified as a configuration obtained by adding a function to the device according to the first embodiment or the device according to the second embodiment. Also, the device of the first embodiment and the device of the second embodiment are different in the information to be input and the information to be output, but the main processing contents are common. The same block diagram shows the configuration. However, the device of the first embodiment and the device of the second embodiment have some differences in the function of each means described as a block diagram.

(First Embodiment) In this embodiment, a programmable controller (hereinafter abbreviated as PLC) will be described.
A device used for the purpose of verifying whether or not the sequence program satisfies the required specifications during the development of the sequence program for operating the device will be exemplified. The present embodiment is realized by mounting a program on a computer such as a personal computer, and includes a keyboard and a mouse as an input device, and at least a display device as an output device. Further, a printer may be provided as an output device as needed.

In the present embodiment, as shown in FIG. 1, a sequence program PR1 under development and a PL given as a required specification for the sequence program PR1 are provided.
The input / output data IO1 of C is input information. The sequence program PR1 and the input / output data IO1 are read by a program reading unit 11 and an input / output data reading unit 12, respectively, as reading units. As the sequence program PR1 and the input / output data IO1, those recorded on an appropriate storage medium can be used.
Is input from the outside through.

In this embodiment, the sequence program P
It is assumed that R1 has the content shown in FIG. 3, and the illustrated sequence program PR1 is a part of the sequence program PR1 for operating the PLC.
It represents a part that performs a series of controls for completing one process. In the illustrated example, the sequence program PR1 is expressed in the form of a ladder diagram, and five inputs X0, X1, X
2, X3, X7 and three outputs Y10, Y20, Y21.

The input / output data IO1 read by the input / output data reading means 12 is input to the input / output operation decoding means 13. The input / output data IO1 given as a required specification of the operation timing of the controlled object is generally associated with the sequence program PR1 and has inputs X0, X1, X2, X3, X7 and outputs Y10, Y2 as shown in FIG.
It is given in the form of a time chart showing ON / OFF of 0, Y21. The input / output operation decoding means 13 extracts a combination of inputs X0, X1, X2, X3, X7 and outputs Y10, Y20, Y21 at each time at an appropriate timing determined by the timing determining means 13a (the extraction time is shown in FIG. 4). (In (a), it is shown by the number of 0-9.) That is, as shown in FIG. 4B, the data table 14 is created by extracting the combination of input and output at each time as a data set (one vertical column in FIG. 4B becomes a data set). In FIG. 4B, “0” indicates off and “1” indicates on. The timing determining means 13a may extract the data set at a fixed time interval, or may extract the data set immediately after the change point at each input / output change point (rise and fall). The data set obtained in this way is used as inputs X0, X1, X2,
It shows the states of X3, X7 and outputs Y10, Y20, Y21.

The sequence program PR1 read by the program reading means 11 and the input / output data IO1
And a data table 14 created based on the input / output data I and the input sequence program PR1 given as a required specification.
It is verified whether O1 is satisfied. Next operation determination means 15
Then, the data sets obtained from the required specifications are sequentially applied to the sequence program PR1, and the sequence program P1
When a data set is applied to inputs X0, X1, X2, X3, and X7 of R1, outputs Y10, Y20,
Sequence program PR1 when Y21 occurs
Is determined not to satisfy the required specifications. That is, the next operation determining means 15 determines whether the output Y10, Y20, Y21 obtained by the sequence program PR1 when the data set is applied to the sequence program PR1 is different from the output Y10, Y20, Y21 of the data set. In the sequence program PR1, inputs X0, X1, X2, X3, X7 and outputs Y10, Y20,
It is determined that there is an inconsistency (hereinafter, referred to as "logical inconsistency") in the logical connection relationship (logical OR, AND, and negation) with Y21.

For example, for the sequence program PR1 shown in FIG. 3, a data set DT1 shown in FIG.
Is applied, the output Y10 is determined by the logical product of the inputs X1 and X2 in the sequence program PR1, whereas the output Y10 is on when the input X1 is off and the input X2 is on in the data set DT1. There is a logical contradiction. In the present embodiment, the input / output data IO1 is given by the required specification, and since the data set DT1 is based on the required specification, it may be assumed that there is no error.
1 can be considered to have occurred. Although the sequence program PR1 is shown in a ladder diagram in FIG. 3, the same processing can be performed when the sequence program PR1 is described using, for example, a mnemonic.

In short, the next operation determining means 15 sequentially applies input data of each data set included in the data table 14 to the sequence program PR1, and obtains the output of the data set at that time and the sequence program PR1. The output and the output are compared, and if they do not match, it is determined that a logical contradiction has occurred. If there is no logical inconsistency in all data sets in the data table 14, it is determined that the sequence program PR1 satisfies the required specifications. In short, it is determined whether there is a logical inconsistency between the sequence program PR1 and the required specification based on the consistency between the sequence program PR1 and the required specification.

When the next operation judging means 15 detects the above logical inconsistency, the sequence program P
R1 is traced back from the output where the logical contradiction occurred, and the input and output related to this output (that is, the input and output required to determine this output) are tracked and extracted (this processing is referred to as “ladder coverage” in this embodiment). ). Since the ladder coverage extracts the input and output related to the output causing the logical inconsistency and its logical connection, it is possible to infer the cause of the logical inconsistency by collating with the data table 14. Will be possible.

In the above-described example, a logical contradiction occurs in the output Y10, and if ladder coverage is performed, the logical product (association relation) of the inputs X1 and X2 (inputs) becomes the output Y10.
Therefore, the cause of the logical contradiction is inferred for these. First, when the data set DT1 of FIG. 4 (b) is applied to the sequence program PR1, a logical contradiction occurs. Therefore, although the output Y10 should be on, the sequence program PR1 has An inference result that “the output Y10 is not output” is obtained in the sense that the output Y10 is not on. The output Y10 is determined by two inputs X
1, X2 and the connection relationship between the inputs X1, X2,
An inference result is obtained for the cause of "the inputs X1 and X2 are incorrect" and "the connection relationship between the inputs X1 and X2 is incorrect". These inference result messages are displayed in a list on the screen of the display device together with a time chart of the required specifications. In the time chart, the position at which the logical contradiction occurred is indicated by a cursor line (vertical line). Therefore, the creator of the sequence program PR1 only needs to modify the sequence program PR1 for the places listed on the screen while referring to the time chart, so that the sequence program PR1 can be easily debugged. it can. In short, by performing ladder coverage, the range of the cause of the logical inconsistency can be narrowed down.

In order to further facilitate the debugging work of the sequence program PR1, not only the inference of the cause of the logical inconsistency as described above, but also a sequence program for eliminating the logical inconsistency for the cause of the logical inconsistency A correction plan for PR1 is prepared, and the prepared correction plan is shown on a display device as an output device included in the result output means 16. The amendment for resolving the logical inconsistency is inferred by checking the connection relationship between the input and the output at the location where the logical inconsistency has occurred with the rule base provided in the next operation determining means 15. The inference result is given in the form of inversion (negation) of on / off with respect to the input or change of the connection relation of the input.

In the example described above, two inputs X
Since one output Y10 is obtained by a logical operation of X1 and X2, in such a format, as a correction plan when a logical contradiction occurs, one of the inputs X1 and X2 is inverted (that is, normally open). If it is a contact, change it to a normally closed contact,
If it is a normally closed contact, change it to a normally open contact.)
The conjunction of 1, X2 is taken as a logical product, or two inputs X
1, or X2 is a logical sum or two inputs X
A correction plan for deleting one of X1 and X2 is considered. Normally, a plurality of types of correction plans are extracted. Therefore, after each correction plan is inserted into the sequence program PR1, the presence / absence of the occurrence of the logical inconsistency is verified again using the data set in which the logical inconsistency has occurred. Here, all the correction plans are verified, and if the logical contradiction is resolved, the correction plans are output to the display device through the result output unit 16. Although the actual modification of the sequence program PR1 is performed manually, the modification of the sequence program PR1 can be easily performed because the modification location and the modification content are narrowed down.

FIG. 2 summarizes the above-described processing procedure. That is, during the development of the sequence program PR1, the data set created from the input / output data IO1 given as the required specification is stored in the sequence program P1.
By applying to R1, it is verified whether there is a logical contradiction (S1). If even one of the data sets causes a logical inconsistency, ladder coverage is performed to extract the input related to the output that caused the logical inconsistency (S2), and the result is sent to the display device through the result output means 16. indicate. As described above, when the cause of the logical inconsistency is narrowed down, the relationship between the input and output of that part is determined by the next operation determining means 1.
Then, a correction plan of the sequence program PR1 is extracted by collating with the rule base provided in S5 (S3). Next, the extracted correction plan is embedded in the sequence program PR1 (S4), and the data set having the logical contradiction is applied again to the sequence program PR1 (S5). Is verified again (S6). If the logical inconsistency is resolved by the verification in step S6, the correction plan extracted in step S3 is output for presentation. Here, when there are a plurality of correction plans extracted in step S3, there may be a plurality of correction plans for resolving the logical contradiction caused by the data set in which the logical contradiction has occurred. In this case, all the amendments whose logical contradiction is eliminated by the data set are displayed on the display device, and it is left to the creator of the sequence program PR1 to select which amendment is to be selected. After the sequence program PR1 is modified,
The process of FIG. 2 is repeated again to verify whether or not there is a logical inconsistency with the sequence program PR1 for all data sets in the data table 14.

In the above example, when a logical inconsistency occurs in one data set, a correction plan is set so as to eliminate the logical inconsistency in that data set. However, if the correction plan is set so as not to cause inconsistency in at least one data set before and after the data set, the reliability of the correction plan can be further improved, and as a result, the sequence program P
The efficiency of the debugging work of R1 is further improved.

(Second Embodiment) In the first embodiment, there is no error in the input / output data IO1 given as the required specification, and there is a possibility that the sequence program PR1 under development contains bugs. When there is a logical contradiction when a data set is applied to the sequence program PR1, the cause of the logical contradiction is determined in the sequence program PR1. On the other hand, in the present embodiment, the data set obtained from the input / output data IO2 obtained by the actual operation of the control target is applied to the sequence program PR2 which has already controlled the control target, and logical contradiction occurs. When it occurs, its cause is sought from the control target. Therefore, the configuration of this embodiment is the same as that of the first embodiment shown in FIG.

In this embodiment, basically, one set of data at the time when an abnormality (failure) occurs in the control target is used as one-dimensional data in the input / output data IO2, but before and after the time when the abnormality occurs. The data table 14 created from the time chart in the same manner as in the first embodiment may be used as the two-dimensional data for the input / output data IO2. That is, the input / output data IO2 is read by the input / output data reading means 12 when an abnormality occurs in the control target.
Regardless of whether the data is one-dimensional data or two-dimensional data, if it is applied to the sequence program PR2, it is possible to verify whether there is a logical contradiction. In this embodiment, since the sequence program PR2 is a completed product, if a logical contradiction occurs, it can be considered that the control target is abnormal.

In this embodiment, as in the first embodiment, the sequence program PR2 shown in FIG.
Is assumed. This sequence program is described using mnemonics as shown in FIG. Here, it is assumed that two-dimensional data is used as the input / output data IO2, and inputs X0, X1, X2, X3, and X10 and outputs Y20, Y21 obtained before and after the occurrence of an abnormality in the control target.
ON / OFF state of the internal relay R0 and the input / output data I
It is assumed that it has been obtained as O2. That is, similarly to the first embodiment, the data table 14 as shown in FIG. 7B is created for the input / output data IO2 having the time chart as shown in FIG. 7A. Here, when performing a failure diagnosis, a data set is generated for each change point of each input and each output of the input / output data IO2. FIG.
FIG. 7A shows an example in which the input / output data IO2 indicated by a solid line indicates that the control target is normal, and FIG. 7A indicates an example in which the input / output data IO2 indicated by a broken line indicates that the control target has a failure. I have. Also, the data table of FIG.
7A corresponds to the state indicated by the broken line, and the numbers 0 to 9 in the column of “No.” correspond to the numbers 0 to 9 indicating the respective changing points in FIG. No. for normal and abnormal cases. 4, no. 5, no. 7, the data set changes, and the sequence program PR2 and the data set match in the normal state, so that in the event of a failure, logical inconsistency occurs in these data sets.

In the present embodiment, based on the occurrence of such a logical contradiction, the location where the abnormality occurs in the control target and the input that causes the abnormality are tracked. Depending on the cause of the abnormality, it may not be possible to identify the location of the abnormality using only the one-dimensional data. However, since the process of applying the one-dimensional data is completed in a short time, first, the location of the occurrence of the abnormality using the one-dimensional data is simply simplified. May be detected, and two-dimensional data may be used when no abnormal location is detected in the one-dimensional data. Since the two-dimensional data includes information before and after the time of occurrence of the abnormality, it is possible to reliably extract the location of the occurrence of the abnormality. When the location of the occurrence of the abnormality is extracted in this way, by collating with the rule base, it is possible to extract the candidate of the cause of the abnormality. The rule base stores a rule in which each input (cause signal) is associated with an abnormality cause in a form as shown in FIG. 8, for example, and when an input is given as an abnormality occurrence location, the abnormality occurrence cause is extracted. can do.

FIG. 5 summarizes the processing procedure for detecting the presence / absence of a failure in the control target. That is, when an abnormality occurs in the control target, a data table is created using one-dimensional data or two-dimensional data as input / output data (or a data set at the time of occurrence of the abnormality is extracted), and the sequence program mounted on the PLC is executed. Apply the data set to. In this way, it is verified whether or not there is a logical inconsistency when the data set is applied to the sequence program (S1). If there is a logical inconsistency, the input and output having the logical inconsistency are extracted (S2). Is determined (S
3). If it is an output (including an internal relay), the ladder coverage is performed by the next operation determination means 15 to track the location (input) of the failure (S4). The input which is the location where the abnormality has occurred is extracted by the ladder coverage, or if the input is determined in step S3, the input as the location where the abnormality is caused is extracted (S5) and collated with the rule base for the abnormality. A candidate for the cause of the occurrence is extracted (S6). In short, the input which is the location of the abnormality in the sequence program PR2 is detected by the processing basically similar to that of the first embodiment, and the input causes the location of the abnormality and the cause of the abnormality in the control target. Is specified by the rule base. Other configurations and operations are the same as those of the first embodiment.

(Third Embodiment) This embodiment is intended to verify the consistency with the control target by executing the sequence program after the completion of the sequence program. That is, even if the sequence program is created so as to satisfy the required specifications, there is a deviation in the operation timing between the PLC and the control target, the operation timing between the components to be controlled, and the control when the control target is operated. Interference may occur between components of interest. Such a phenomenon occurs when the input / output data given as the required specification contains an error, or when the controlled object changes over time during operation of the controlled object, there is a deviation from the input / output data originally given as the required specification. It may occur when it occurs.

Therefore, in this embodiment, instead of actually controlling the controlled object, as shown in FIG. 9, a simulation model 23 simulating the controlled object is output to the result output means 16.
Display on the display device provided in the
Is executed by the simulation control means 22 for simulating the above operation, and the simulation model 23 is operated on the screen of the display device. The function of this embodiment is added to the device of the first embodiment or the device of the second embodiment, and the program reading means 11 and the data reading means 12 are used in common with those of the above-described embodiment. I have. However, in the present embodiment, only input data is used among input / output data provided through the data reading unit 12. For example, of the input / output data given as required specifications, only input data is extracted and used, or only input data generated by a sensor or the like provided in an operating control target is used. Also,
The output data is generated by providing the simulation control means 22 with input data.

The input data obtained through the data reading means 12 is input to the timing control means 21. The timing control means 21 sets the rise and fall of the input data to the reference timing generated as a clock signal by the timing generation means 21a. Synchronize. That is, the timing control unit 21 sets the minimum interval between the ON and OFF of the input data as the cycle of the reference timing. The timing generation means 21a can change the cycle of the reference timing and change the cycle of the reference timing to verify the consistency between the PLC and the control target when the tact time of the control target is changed. Has become. The input data output from the timing control means 21 is PL
C is provided to the simulation control means 22 for simulating C, and output data corresponding to the input data is generated.
The simulation model 23 provided in 6 is controlled.
Therefore, by checking the operation of the simulation model 23 on the screen of the display device, it can be easily known whether or not the control target operates normally.

For example, when the input data in the required specification is as shown in FIG. 11 (a), the reference timing from the timing generation means 21a is given in a cycle as shown in FIG. 11 (b) and input at the rise of the reference timing. If data is latched, input data as shown in FIG. 11C can be given to the simulation control means 22. When the reference timing is given in a cycle as shown in FIG. 11D, the result becomes as shown in FIG. That is, since the reference timing is variable, it is possible to generate input data having different rising and falling timings from one input data. FIGS. 12 and 13 show examples of input / output data and the data table 14 when the simulation control unit 22 is operated by changing the reference timing in this way. 12 and 13, each figure (a) is a time chart of input / output data, and each figure (b) is a data table 14 corresponding to each figure (a). FIG. 12 shows that the cycle of the reference timing is 10 msec.
FIG. 13 shows an example in the case of 5 msec. Thus, the cycle of the reference timing is 10 m
If the operation of the sequence program is confirmed by changing the speed to 20 msec, 25 msec, or the like, it becomes possible to know the operation speed of the control target that can be handled by the sequence program. That is, it is possible to verify the consistency between the sequence program and the control target when the tact time of the control target is changed.

By the way, controlled objects such as factory equipment are:
As shown in FIG. 14, it is often configured as a set of a plurality of blocks BL1 to BL3 each completing one process. In the illustrated example, a block BL1 as an input unit for supplying a component, a block BL2 as an adjustment unit for monitoring the position of the component and adjusting it to a fixed position, and a block BL3 as a base machine unit for mounting the component are combined. Are configured as controlled objects. That is, the blocks BL1 to BL3 are associated so that the block BL2 operates in response to the result of the block BL1 and the block BL3 operates in response to the result of the block BL2. Therefore, the simulation model 23 is configured as a combination of sub-models corresponding to the blocks BL1 to BL3. By configuring the simulation model 23 as a combination of sub-models, it is possible to narrow down the range of the part for verifying the consistency between the control target and the sequence program, and to perform the operation quickly. In addition, if a program to be a sub model is stored in a library, each sub model can be incorporated as another component to be controlled, and a simulation model can be efficiently created.

On the other hand, a sequence program corresponding to such an object to be controlled is created as a combination of modules for each part corresponding to each of the blocks BL1 to BL3. That is, the modules are associated with each other such that the module corresponding to the block BL2 is executed in response to the result of the module corresponding to the block BL1, and the module corresponding to the block BL3 is executed in response to the result of the module corresponding to the block BL2. Will be done. If the sequence program is modularized based on the above-described standard, the range in which ladder coverage is performed in the first and second embodiments can be set as the range of the module. It is easy to specify the adjustment point. If a module is configured for each of the blocks BL1 to BL3 and is made into a library, the module can be reused when the same block BL1 to BL3 is used in another control target, and the efficiency of creating a sequence program is improved. be able to.

As a technique for dividing a sequence program into modules, blocks BL1 to BL1 constituting a control target are used.
Instead of using BL3 as a unit, it is also possible to modularize based on the structure of the sequence program itself. Now, if the sequence program is represented by a ladder diagram, it becomes as shown in FIG.
(B). 1 in the ladder diagram
Since the line connected to one output is the input that determines this output, the sequence program is divided as a module for each output, and becomes an input when the output in each module is used as an input of another module It is possible to create a hierarchy in which the module on the side is lower than the module on the output side. Here, if the input / output relations in the illustrated example are represented in a table format so that they can be listed, FIG.
It looks like 6. In FIG. 16, the left column is an input, and the right column is an output. Such an input / output relationship is applied to each output by employing the ladder coverage technique used in the first and second embodiments. The relevant input can be easily known by going back. In the illustrated example, the output Y10 is an input to the internal relay (not an input / output to the control target but a flag on a memory) R0, and the internal relay R0
Is an input of the output Y21, and the output Y21 is not an input for determining another output. Further, the output Y20 is not an input at any other part of the sequence program. Therefore, the outputs Y20, Y20, and Y21 can be hierarchized, with the output Y20 and the output Y21 being the same level, and the output Y10 being the lower level of the output Y21.
That is, in FIG. 16, each output Y10, Y20, Y2
If the modules M1 to M3 corresponding to 1 are set, the hierarchical relationship as shown in FIG. 17 can be obtained from the sequence program. If the sequence programs are modularized and hierarchized in this way, the range of the ladder coverage for specifying the location where the inconsistency occurs and the adjustment location when the inconsistency occurs can be limited.

An example of the processing procedure for verifying the consistency between the completed sequence program and the control target using this embodiment will be described below. In the present embodiment, as shown in FIG. 10, before performing the simulation, it is verified whether or not there is a logical inconsistency between the sequence program and the required specification (S
1). For this purpose, the data table 14 is created from the input / output data obtained by the simulation control means 22, and the same technique as in the first embodiment is applied. That is, each data set is applied to a sequence program to verify whether there is a logical inconsistency. If there is a logical inconsistency, ladder coverage is performed to extract a related input retroactively from the output, thereby narrowing down the part of the logical inconsistency (S2). If the location of the logical contradiction is narrowed down, it is possible to know which sub-model the location corresponds to. Therefore, the sub-model is selected (S3), and the part for operating the sub-model in the sequence program is controlled by the simulation control means 22. Execute (S4). The result of executing the sequence program by the simulation control means 22 is displayed on the screen of the display device as the operation of the simulation model 23 (S5). Here, the location of occurrence of an abnormality can be known from the movement of the simulation model. If there is an abnormality in the movement of the simulation model (S6), the input data corresponding to the part where the logical contradiction occurs is corrected (S7), and the sub model is operated again (S8). The correction of the input data is a correction for inverting the on / off of the input data which is considered to have caused the logical contradiction.
The result of operating the sub-model in step S8 is displayed on the screen of the display device (S9). If there is no abnormality in the operation, it is assumed that the cause of the logical inconsistency is the corrected input data location. The cause of the inconsistency is output (S10). It is possible to know which input value should be inverted to resolve the logic inconsistency. This makes it easy to adjust the actual control target. Here, there is a case where the abnormal operation can be eliminated by changing the reference timing. Therefore, the same operation may be performed by changing the reference timing as needed.

By the way, as described above, the simulation control means 2
In 2, the output data is generated based on the input data. Therefore, a time chart corresponding to the input / output data can be generated by combining the output data with the input data. The time chart generated in this way is displayed on the screen of the display device through the result output means 16. In addition, if the time chart and the simulation model 23 are displayed together on the screen of the display device, and the movement of the simulation model 23 is displayed in association with the time chart, when there is an abnormality in the operation of the simulation model 23, any input In addition, it is possible to easily know whether an abnormality has occurred in relation to the output. Alternatively, the time chart generated by the simulation control means 22 is displayed on the screen of the display device together with the time chart of the required specification, the difference is extracted by comparing the two, the message of the extraction result is visualized and output. Is also good.

As described above, if the sequence program and the input / output data are received through the communication means 17, even if the PLC or the control target is installed at a remote place, the description has been given in the second embodiment. By using the fault diagnosis technique and the simulation control means 22 described in the third embodiment, it is possible to easily detect an abnormality in the PLC or the control target, and to use a PL installed in a remote place.
Even for C or the control target, the sequence program can be corrected or the control target can be adjusted.

For example, when an unknown error occurs in the controlled object, the sequence program and the input / output data of the actual operation are transferred to the developer of the sequence program. By simulating or verifying the consistency by the next operation determination unit 15, it is possible to track the location and cause of the abnormality.

The above-described embodiment shows an example in which the apparatus shown in FIGS. 1 to 9 is realized by a computer.
You may make it incorporate in LC. In this case, since a PLC can be used as the simulation control means 22, more accurate simulation can be performed.

[0060]

According to a first aspect of the present invention, a sequence program for operating a programmable controller and input / output data of the programmable controller associated with the sequence program are input through a read unit,
The next operation determining means determines whether or not there is a logical inconsistency based on the consistency between the sequence program and the combination of the input and output data when the combination of the input and output data at the predetermined time is applied to the sequence program. The sequence program is characterized by inferring the cause of the logic inconsistency by tracing the related inputs and outputs retroactively from the combination of the inputs and outputs that caused the logic inconsistency, and outputting the inference result from the result output means. The presence / absence of a logical inconsistency is determined based on the consistency between the combination of the sequence program and the input / output data. Therefore, the consistency between the sequence program and the input / output data can be verified by a simple process using only the logical operation. In addition, when there is a logical inconsistency, the cause of the logical inconsistency can be inferred by tracing back and forth the input / output, so that it is possible to easily cope with the abnormality by correcting the cause of the logical inconsistency. be able to. Furthermore, since the cause of the logical contradiction is inferred only from the part related to the part where the logical contradiction occurs, the cause can be found in a relatively short time.

According to a second aspect of the present invention, in the first aspect of the present invention, the input / output data is used as input / output data representing a required specification of operation timing of a control target, and input / output operation decoding means is used from the input / output data. A data table which is a time series of the data set is created by extracting a combination for each time as a data set, and the next operation determining means determines whether there is a logical inconsistency based on the consistency between each data set of the data table and the sequence program. It is characterized by inferring the cause of the logical inconsistency in the sequence program by making a judgment, creating a data table from the input / output data, and applying the data set to the sequence program to detect the presence or absence of the logical inconsistency. Data sets in the data table without executing the sequence program. Can be relatively easily found the error location in the sequence program in a simple process that only apply to.

According to a third aspect of the present invention, in the second aspect of the present invention, the result output means visualizes and outputs a time chart of a part including a data set having a logical inconsistency in the required specifications, and outputs the time chart. Indicates the timing at which a logical inconsistency has occurred, and outputs a message indicating the cause and content of the inconsistency inferred by the next operation determination means together with a time chart, and outputs the cause and content. Since the displayed message is visualized and output together with the time chart, the location of the logical contradiction can be easily specified by the time chart, and the cause of the logical contradiction can be easily specified by the message.

According to a fourth aspect of the present invention, in the second or third aspect, a correction plan is created and created for a cause of a logical inconsistency in the sequence program inferred by the next operation determining means. It is characterized in that the amendment that resolves the logical inconsistency is visualized and output by the result output means, and the amendment that resolves the logical inconsistency is indicated, so that it is easy to deal with the cause of the inconsistency. Become.

According to a fifth aspect of the present invention, in the first aspect of the present invention, the input / output data is used as input / output data at the time of occurrence of an abnormality in a control target during actual operation, and the next operation determining means uses the input / output data of the input / output data. By determining whether there is a logical inconsistency based on the consistency between the data set and the sequence program, it is possible to infer the cause of the logical inconsistency for the controlled object. It can be easily extracted by simple processing.

According to a sixth aspect of the present invention, in the first aspect of the invention, the input / output data is input / output data in a predetermined time range including a time of occurrence of an abnormality of a control target, and the input / output operation is decoded from the input / output data. A data table which is a time series of the data set is created by extracting a combination for each time as a data set by using the means, and the next operation determining means determines a logical table based on the consistency between each data set of the data table and the sequence program. It is characterized by inferring the cause of the logical inconsistency for the controlled object by determining the presence or absence of the inconsistency, and the presence or absence of the abnormality in the controlled object can be easily extracted by simple processing based on the presence or absence of the logical inconsistency.

According to a seventh aspect of the present invention, in the fifth or sixth aspect of the present invention, a message indicating a cause and a content of the contradiction inferred by the next operation determining means is visualized and output by a result output means. The message makes it easy to identify the cause and content of the logical inconsistency.

The invention according to claim 8 is the invention according to claims 5 to 7, wherein the sequence program is a sequence program already mounted on a programmable controller for actually operating a controlled object, and Transferred from the programmable controller,
Further, the input / output data is transferred from the programmable controller via a communication unit, and by including the communication unit, the failure diagnosis can be easily performed even when the programmable controller and the control target are installed at a remote place. be able to.

According to a ninth aspect of the present invention, a sequence program for operating the programmable controller and input data of the programmable controller associated with the sequence program are input through the reading means, and the input data is given to the simulation control means equivalent to the programmable controller. Executing the sequence program, simulating the control target, and causing the simulation model displayed on the display device by the result output means to operate in accordance with the execution of the sequence program by the simulation control means. By operating the simulation model by the sequence program using the program, the sequence program can be adjusted for the control target without actually operating the control target by the sequence program. It is possible to verify the sex in advance.

According to a tenth aspect of the present invention, in the ninth aspect of the present invention, the timing control is performed such that the minimum unit of the ON / OFF time interval of the input data given to the simulation control means is the cycle of the reference timing generated by the timing generation means. Means, and the timing generation means is characterized in that the cycle of the reference timing is variable. By adjusting the reference timing, the time interval of input data when operating the simulation control means can be adjusted. In addition, the tact time of the control target can be variously changed to verify the consistency with the sequence program.

According to an eleventh aspect of the present invention, the sequence program for operating the programmable controller and the input data of the programmable controller associated with the sequence program are input through the reading means, and the minimum unit of the ON / OFF time interval of the input data is determined by the timing generating means. The timing control means regulates the cycle of the reference timing to be the same as the cycle of the reference timing generated, and the cycle of the reference timing is variable in the timing generation means. The input data is given to the simulation control means equivalent to a programmable controller, and the sequence program is executed. And generating a time chart by the result output means from output data accompanying execution of the sequence program by the simulation control means and input data given to the simulation control means. By adjusting the reference timing, the time interval of input data when operating the simulation control means can be adjusted, so that the tact time of the control target is variously changed and the consistency with the sequence program is verified. can do. In addition, by generating a time chart, it is possible to visually extract the presence or absence of an abnormality.

According to a twelfth aspect of the present invention, in the invention of the eleventh aspect, the result output means includes a simulation model that simulates a control target and displays the simulation model on a display device.
The operation is performed at the timing of the input / output data represented by the time chart, and the consistency between the sequence program and the control target can be easily verified by using the simulation model and the time chart together.

According to a thirteenth aspect, in the eleventh aspect, the result output means compares a time chart of input / output data given as a required specification of an operation timing of a control target with the time chart. The difference between the sequence program and the control target is obtained by comparing the time chart according to the required specifications with the time chart generated by the simulation control means. Can be easily verified.

According to a fourteenth aspect, in the ninth to thirteenth aspects, the control object is a set of a plurality of blocks each of which completes one process, and the simulation model corresponds to each block. The feature is that it is configured as a combination of sub-models that can be verified, and the consistency between the sequence program and the control target can be verified for each sub-model. And can be processed in a short time.

According to a fifteenth aspect of the present invention, in the ninth to fourteenth aspects of the present invention, the sequence program is a sequence program already mounted on a programmable controller for actually operating a controlled object, and The feature is that the sequence program is transferred from the programmable controller, and the sequence program can be captured by the communication means. Therefore, even if the programmable controller is installed in a remote place, the consistency between the sequence program and the control target can be easily verified. Can be.

The invention according to claim 16 is a reading program for inputting a sequence program for operating a programmable controller, input / output data of the programmable controller associated with the sequence program, and a combination of the input / output data at a predetermined time into the sequence program. Determine whether there is a logical inconsistency based on the consistency between the sequence program and the combination of input / output data when applied, and if there is a logical inconsistency, go back to the sequence program from the combination of I / O that caused the logical inconsistency. And a result output unit for inferring the cause of the logical inconsistency by tracing the input / output to be performed and a result output unit for outputting an inference result. Determine if there is any inconsistency Et al, it is possible to verify the integrity of the sequence program and the input data by a simple process of only the logical operation. In addition, when there is a logical inconsistency, the cause of the logical inconsistency can be inferred by tracing back and forth the input / output, so that it is possible to easily cope with the abnormality by correcting the cause of the logical inconsistency. be able to.

According to a seventeenth aspect, in the sixteenth aspect, the input / output data is input / output data representing a required specification of an operation timing of a control object, and a combination for each time is defined as a data set from the input / output data. An input / output operation decoding means for creating a data table which is a time series of a data set by extraction is added, and the next operation determination means determines whether there is a logical inconsistency based on the consistency between each data set of the data table and the sequence program. By determining, the cause of the logical inconsistency in the sequence program is inferred, and a data table is created from the input / output data, and the data set is applied to the sequence program to detect the presence or absence of the logical inconsistency. , The data set in the data table can be converted to a sequence program without executing the sequence program Can be relatively easily found the error location in the sequence program in a simple process that only use.

According to an eighteenth aspect of the present invention, in the invention of the sixteenth aspect, the input / output data is input / output data at the time of occurrence of an abnormality in a control target in an actual operation, and the next operation determining means outputs the input / output data. By judging the presence or absence of a logical inconsistency from the consistency between the data set and the sequence program, the cause of the logical inconsistency is inferred for the controlled object. And can be easily extracted.

A nineteenth aspect of the present invention is the invention according to the sixteenth aspect, wherein the input / output data is input / output data in a predetermined time range including a time of occurrence of an abnormality of a control object, and the input / output data is combined for each time. Is extracted as a data set, an input / output operation decoding means for creating a data table which is a time series of the data set is added, and the next operation determination means determines the logic based on the consistency between each data set of the data table and the sequence program. By determining the presence or absence of the contradiction, the cause of the logical contradiction is inferred for the control target, and the presence or absence of the abnormality in the control target can be easily extracted by the simple processing based on the presence or absence of the logical contradiction.

According to a twentieth aspect of the present invention, in accordance with the eighteenth or nineteenth aspect, the sequence program is a sequence program already mounted on a programmable controller for causing a controlled object to actually operate,
A communication means for transferring a sequence program and the input / output data from the programmable controller is added. By providing the communication means, even when the programmable controller and the control target are installed at a remote place, failure diagnosis can be easily performed. It can be carried out.

According to a twenty-first aspect of the present invention, there is provided a sequence program for operating a programmable controller and reading means for inputting input data of the programmable controller associated with the sequence program. Simulation program means for executing a sequence program, and a result output means for displaying a simulation model simulating an object to be controlled on a display device, wherein the result output means executes the simulation model in accordance with the execution of the sequence program by the simulation control means. By operating the simulation model by the sequence program using the simulation control means,
The consistency of the sequence program with respect to the control target can be verified in advance without actually operating the control target by the sequence program.

According to a twenty-second aspect of the present invention, in the twenty-first aspect, a timing generating means for generating a reference timing at a predetermined cycle, and a minimum unit of an on / off time interval of input data to be given to the simulation control means is set to the reference value. A timing regulating means for regulating the cycle of the timing is added, and the timing generating means makes the cycle of the reference timing variable, and the input data when the simulation control means is operated by adjusting the reference timing. Can be adjusted, so that the tact time of the controlled object can be variously changed and the consistency with the sequence program can be verified.

According to a twenty-third aspect of the present invention, there is provided a reading means for inputting a sequence program for operating a programmable controller and input data of the programmable controller associated with the sequence program, and a timing generating means for generating a reference timing at a predetermined cycle. A timing control means for restricting a minimum unit of an on / off time interval of input data to be supplied to the simulation control means to be a cycle of the reference timing; and a sequence program provided with the input data being equivalent to a programmable controller. And a result output means for displaying a simulation model simulating the control target on a display device. The timing generation means has a variable reference timing cycle. A time chart is generated by the result output means from output data accompanying the execution of the sense program and input data given to the simulation control means, and input data for operating the simulation control means by adjusting the reference timing. Can be adjusted, so that the tact time of the controlled object can be variously changed and the consistency with the sequence program can be verified. In addition, by generating a time chart, it is possible to visually extract the presence or absence of an abnormality.

According to a twenty-fourth aspect of the present invention, in the invention of the twenty-first to twenty-third aspects, the sequence program is a sequence program which is already mounted on a programmable controller for actually operating a controlled object,
Communication means for transferring the sequence program from the programmable controller is added, and the sequence program can be captured by the communication means. Therefore, even when the programmable controller is installed at a remote location, matching between the sequence program and the control target is possible. Can be easily verified.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a first embodiment of the present invention.

FIG. 2 is an operation explanatory view of the above.

FIG. 3 is an explanatory diagram showing an example of a sequence program in the above.

FIG. 4 is an operation explanatory view of the above.

FIG. 5 is an operation explanatory view showing a second embodiment of the present invention.

FIG. 6 is an explanatory diagram showing an example of a sequence program in the above.

FIG. 7 is an operation explanatory diagram of the above.

FIG. 8 is a diagram showing an example of a rule used in the embodiment.

FIG. 9 is a block diagram of a main part showing a third embodiment of the present invention.

FIG. 10 is an operation explanatory view of the above.

FIG. 11 is an operation explanatory diagram of the above.

FIG. 12 is an operation explanatory view of the above.

FIG. 13 is an explanatory diagram of the operation of the above.

FIG. 14 is a diagram illustrating a configuration example of a control target in the above energy management system;

FIG. 15 is an explanatory diagram showing an example of a sequence program in the above.

FIG. 16 is an explanatory diagram showing an example of a sequence program in the above.

FIG. 17 is a diagram showing an example of hierarchization of a simulation model in the above.

[Explanation of symbols]

 Reference Signs List 11 program reading means 12 input / output data reading means 13 input / output operation decoding means 13a timing determination means 14 data table 15 next operation determination means 16 result output means 21 timing regulation means 21a timing generation means 22 simulation control means 23 simulation model PR1, PR2 Sequence program IO1, IO2 I / O data

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 5H220 BB10 BB12 CC07 CX01 DD04 JJ28 JJ42 JJ48 KK01 KK08 LL03 LL04 LL06 LL07 5H223 CC03 EE19 FF05 FF06

Claims (24)

[Claims] 1. A sequence program for operating a programmable controller and input / output data of the programmable controller associated with the sequence program are input through a reading unit, and a combination of input / output data at a predetermined time is applied to the sequence program by a next operation determining unit. The presence / absence of a logical inconsistency is determined from the consistency between the sequence program and the combination of the input / output data at the time of the execution, and if a logical inconsistency occurs, the sequence program is related to the input / output combination that caused the logical inconsistency retroactively. An abnormality detection method in a programmable controller, characterized by inferring a cause of a logical contradiction by tracing an input / output and outputting an inference result from a result output means. 2. The method according to claim 1, wherein the input / output data is input / output data representing a required specification of an operation timing of a control target, and a combination for each time is extracted as a data set from the input / output data using input / output operation decoding means. By creating a data table that is a time series of the data set, the next operation determining means determines whether there is a logical inconsistency from the consistency between each data set of the data table and the sequence program,
2. The method according to claim 1, wherein a cause of the logical contradiction in the sequence program is inferred. 3. The result output means visualizes and outputs a time chart of a part including the data set in which the logical contradiction occurs in the required specification, and indicates a timing in which the logical contradiction occurs in the time chart. 3. The method according to claim 2, wherein a message indicating a cause and a content of the contradiction inferred by the next operation determining means is visualized and output together with a time chart. 4. A correction plan is created for a cause of the logical inconsistency in the sequence program inferred by the next operation determining unit, and a correction plan for eliminating the logical inconsistency among the generated correction plans is output by a result output unit. 4. The method for detecting an abnormality in a programmable controller according to claim 2, wherein the abnormality is visualized and output. 5. The input / output data is used as input / output data at the time of occurrence of an abnormality in a control target during actual operation, and the next operation determining means determines a logical contradiction based on consistency between a data set of the input / output data and a sequence program. 2. The method according to claim 1, wherein a cause of the logical inconsistency is inferred for the control target by determining the presence or absence of the abnormality. 6. The input / output data is input / output data in a predetermined time range including a time of occurrence of an abnormality of a control object, and a combination for each time is converted from the input / output data using an input / output operation decoding unit into a data set. By creating a data table which is a time series of the data set by extracting, the next operation determining means determines whether there is a logical inconsistency from the consistency between each data set of the data table and the sequence program, and 2. The method according to claim 1, wherein a cause of the logical contradiction is inferred. 7. A result output unit visualizes and outputs a message indicating a cause and a content of a contradiction inferred by the next operation determination unit.
7. A method for detecting an abnormality in a programmable controller according to claim 6. 8. The sequence program is a sequence program already mounted on a programmable controller for actually operating a controlled object, wherein the sequence program is transferred from the programmable controller via communication means, and the input / output data is transmitted via communication means. 6. The data is transferred from a programmable controller in a predetermined manner.
An abnormality detection method in the programmable controller according to claim 7. 9. A sequence program for operating a programmable controller and input data of the programmable controller associated with the sequence program are inputted through a reading means, and the sequence data is executed by giving the input data to simulation control means equivalent to the programmable controller. A method of simulating a control target and causing a simulation model displayed on a display device by a result output means to be operated in conjunction with execution of a sequence program by the simulated control means. 10. The timing control means controls the minimum unit of the ON / OFF time interval of input data to be supplied to the simulation control means to be the cycle of the reference timing generated by the timing generation means. 10. The method for detecting an abnormality in a programmable controller according to claim 9, wherein the period is variable. 11. A reference timing in which a sequence program for operating a programmable controller and input data of the programmable controller associated with the sequence program are input through a read unit, and a minimum unit of an on / off time interval of the input data is generated by a timing generation unit. While regulating by the timing regulating means so as to make the cycle of, the cycle of the reference timing is variable in the timing generation means, and furthermore, the input data is given to the simulation control means equivalent to a programmable controller to execute the sequence program, A time chart is generated by a result output means from output data accompanying execution of a sequence program in the simulation control means and input data given to the simulation control means. Abnormality detection method in the mable controller. 12. The system according to claim 1, wherein the result output means operates a simulation model simulating a control target and displayed on a display device at timing of input / output data represented by the time chart.
2. An abnormality detection method in the programmable controller according to 1. 13. The result output means extracts a difference by comparing a time chart of input / output data given as a required specification of an operation timing of a control object with the time chart, and outputs a message of the extraction result. 12. The abnormality detection method in a programmable controller according to claim 11, wherein the abnormality is visualized and output. 14. The control object is a set of a plurality of blocks each completing one process, and the simulation model is configured as a combination of sub-models corresponding to each block. An abnormality detection method in the programmable controller according to any one of claims 9 to 13. 15. The sequence program according to claim 9, wherein the sequence program is a sequence program already mounted on a programmable controller that actually operates a control target, and is transferred from the programmable controller via communication means. Any one of item 14
Item 14. The abnormality detection method in the programmable controller according to the paragraph. 16. A sequence program for operating a programmable controller, reading means for inputting input / output data of the programmable controller associated with the sequence program, and a sequence when a combination of input / output data at a predetermined time is applied to the sequence program. Determines whether there is a logical inconsistency based on the consistency between the program and the combination of input and output data, and if there is a logical inconsistency, traces the related input and output of the sequence program from the combination of the I / O that caused the logical inconsistency An abnormality detection device for a programmable controller, comprising: a next operation determination unit that infers a cause of a logical contradiction by performing the operation; and a result output unit that outputs an inference result. 17. The data which is a time series of a data set by extracting the input / output data as input / output data representing a required specification of operation timing of a control object and extracting a combination for each time from the input / output data as a data set. An input / output operation decoding unit for creating a table is added, and the next operation determination unit determines whether there is a logical inconsistency based on the consistency between each data set of the data table and the sequence program. 17. The abnormality detection device for a programmable controller according to claim 16, wherein a cause of the inconsistency is inferred. 18. The input / output data is used as input / output data at the time of occurrence of an abnormality in a control target during actual operation. 17. The abnormality detection device for a programmable controller according to claim 16, wherein a cause of the logical inconsistency is inferred for the control target by determining the presence or absence of the error. 19. The method according to claim 1, wherein said input / output data is input / output data in a predetermined time range including a time of occurrence of an abnormality of a control target, and a combination for each time is extracted as a data set from said input / output data. An input / output operation decoding unit for creating a data table as a series is added, and the next operation determination unit determines whether there is a logical inconsistency based on the consistency between each data set of the data table and the sequence program. 17. The abnormality detection device for a programmable controller according to claim 16, wherein a cause of the logical contradiction is inferred. 20. The sequence program is a sequence program already mounted on a programmable controller for actually operating a control target, and communication means for transferring the sequence program and the input / output data from the programmable controller is added. 20. The abnormality detecting device in the programmable controller according to claim 18 or 19, wherein 21. A sequence program for operating a programmable controller and reading means for inputting input data of the programmable controller associated with the sequence program, and the sequence program is executed by being provided with the input data and equivalent to the programmable controller. And a result output means for displaying a simulation model simulating a control target on a display device, wherein the result output means operates the simulation model in accordance with execution of the sequence program by the simulation control means. Abnormality detection device in a programmable controller. 22. Timing generating means for generating a reference timing at a predetermined cycle, and timing regulating means for regulating a minimum unit of an on / off time interval of input data to be supplied to the simulation control means to be the cycle of the reference timing. 22. The abnormality detection device for a programmable controller according to claim 21, wherein a period of the reference timing is variable in the timing generation means. 23. A reading means for inputting a sequence program for operating a programmable controller and input data of the programmable controller associated with the sequence program, a timing generating means for generating a reference timing at a predetermined cycle, and the simulation control means Timing control means for restricting the minimum unit of the ON / OFF time interval of the input data to be given to the cycle of the reference timing; and a simulated control equivalent to a programmable controller and executing the sequence program given the input data. Means, and a result output means for displaying a simulation model simulating the controlled object on a display device, wherein the timing generation means has a variable reference timing period, and the simulation control means An abnormality detection device for a programmable controller, wherein a time chart is generated by a result output unit from output data accompanying execution and input data given to a simulation control unit. 24. The sequence program, wherein the sequence program is already mounted on a programmable controller for actually operating a control target, and communication means for transferring the sequence program from the programmable controller is added. Item 2
An abnormality detection device in the programmable controller according to any one of claims 1 to 23.