JP2002196816A - Automatic simulation device for control program for plc and its method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To confirm the control program of a PLC by operating a real machine without previously verifying it. SOLUTION: Data constituting a time chart T prepared by a computer 3 are converted into data which can be communicated between a computer 3 and a PLC 2, edited, and stored, and an automatic simulation program is executed based on the storage data. Then, only input signal data to the PLC 2 in the storage data can be used, and the input signal is automatically transmitted from the computer 3 to the PLC 2 successively at a set lapsed time, and an output signal from the PLC is transmitted to the computer 3. Thus, the transmission of the input and output signal between the computer 3 and the PLC 2 can be automatically performed. Then, the control program of the PLC 2 is executed, and the situation is displayed on a screen.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention utilizes an operation diagram and a time chart created on a computer, which are the basis for constructing and designing an automatic control program using a PLC (programmable logic controller). Further, the present invention relates to an automatic simulation method and an automatic simulation program for a control program for a PLC, which can automatically execute a control program stored in a memory in the PLC.

[0002]

2. Description of the Related Art Conventionally, in a PLC control program, a time chart is first created and a program is constructed based on the time chart. Then, when verifying whether or not the created control program is logically configured as planned, a method of inputting the input conditions to the PLC and confirming the output of the PLC in response to the input signal, or There is a method of creating a so-called PLC input scenario in which input conditions for an output are created in advance.

[0003]

However, in the former method, one input is not one output, but one input is one output for a plurality of inputs, or one output is a plurality of outputs for one input. It is necessary to perform more than twice the number of steps or steps in the sequence on the PLC, and
It is also necessary to monitor the change in the output from, and if the operation is incorrect or a logical mistake occurs in the program, it is necessary to start over. Further, in the latter method, it takes time to determine whether there is a mistake in the control program on the PLC side or a mistake in the scenario as an adverse effect associated with an increase in the program amount or the number of steps. There is a risk that you may not be able to understand. Therefore,
Either the method of inputting the conditions while inputting them into the PLC or the method of creating a scenario requires a lot of time and effort. It is the fact that actual equipment is operated and checked without prior verification.

[0004]

SUMMARY OF THE INVENTION According to the present invention, there is provided a time chart created by a computer in consideration of the problem that a control program of a PLC is checked by operating an actual machine without prior verification. Is converted, edited, and stored into data that can be communicated between the computer and the PLC, and by executing the automatic simulation program based on the stored data, only the input signal data to the PLC in the stored data is used. The computer and the PLC so that the input signal is automatically transmitted from the computer to the PLC sequentially at the set elapsed time, and the output signal from the PLC is transmitted to the computer.
The above-described problem is solved by automatically transmitting an input / output signal between the C and executing the control program of the PLC and displaying the status on a screen.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings. As shown in FIG. 1, a system 1 required for performing an automatic simulation of a sequence program of the present invention includes a PLC 2 having a CPU (central processing unit) and a memory (storage device for data and instructions).
And a computer 3 composed of a personal computer (personal computer), and a connection device 4 between the PLC 2 and the computer 3.

The computer 3 includes an output device 5
A CRT display device 5a and a printer 5b, a storage device 6, a keyboard 7a or a mouse 7b as an input device 7, these output devices 5 and an input device 7 are controlled and executed, and a CPU and a memory are mounted. And PLC2
The connection device 4 for connecting the computer 3 to the computer 3 includes, for example, an I / O port (input / output port), an RS-23
2C, connection cable, interface, etc.

Next, the automatic simulation according to the present invention will be described for each stage. [First Stage] Time Chart Creation A time chart creation program is selected and activated on the computer 3 in the activated state, and a time chart T as shown in FIG. 1 is created. As for the ON / OFF state of the input / output signal, only the ON state is indicated by a ruled line after the row number 5 and after the column number H for easy understanding. The time display is a number automatically entered after the row number 4 and the column number I in FIG. In addition, ON / OFF of the input / output signal means PLC
ON / OFF of internal relay, link relay, step relay, latch relay, etc., in addition to the input / output relay in 2
Shall be included. Further, the time chart creation program can be easily performed by using a commercially available spreadsheet program. Specifically, creation of a dedicated sheet as shown in FIG. 2, for example, setting the time allocated to one row, that is, the unit time, automatic writing, and setting the ruled lines to “1”, “0”
It is necessary to create an auxiliary program, such as automatic conversion to a program. The device number actually used,
Enter the type of signal (input or output), comment, etc.
The input of the device number and the input / output signal is automatically input by setting the range of the device used for input and output. [Second stage] Data conversion The time chart is converted into designated data, and for example, as shown in FIG.
After replacing F with "0" and leaving the rest blank (blank) and storing it in the memory of the computer 3, the time chart creation program is terminated. [Third stage] Program start and initial setting An automatic simulation program of the sequence program is selected and started, and stored in the FD (floppy disk), HD (hard disk) or the like during the sequence program from the PLC 2 or when the sequence program is created. The read various data is read and stored in the memory of the computer 3. At this time, an input / output comment table as shown in FIGS. Next, initial settings such as selection of the model of the PLC 2 and setting of a range of used device numbers are performed. For example, in the case of the present embodiment, the input range is “000000”
0000000 ”to“ 000100 to 000103 ”, and the output range is“ 000200 to 200001 ”,“ 0 ”.
The range is automatically set when the automatic simulation program is started. [Fourth Step] Execution The storage data in the second step is read. It is meaningless to use all “1” in
Only the portion where F → ON has been recognized, and automatic editing is performed assuming that "1" exists between "1" at the start end and "0" at the end end. In order to perform such automatic editing, first, a plurality of "1" s arranged at the start end, that is, an input / output signal changed from "OFF to ON" and an end end thereof "0", that is, the input / output signal Recognize only the signal changed from “ON → OFF” (for example, “1” of column number K and “0” of column number O in row number 6 in FIG. 3), and the corresponding transmission time and device number , Comment and "1" or "0" are automatically edited. And FIG.
The time chart divided into upper and lower two stages as shown in FIG. Specifically, in the check history Ta on the upper screen, the PLC 3
Device number, comment, O
The N / OFF state is displayed, and the device number, comment, and the like of the changed output signal from the PLC 2 to the computer 3 corresponding to the set input signal are displayed on the lower right side.
The ON / OFF state is displayed. On the other hand, in the time chart Tb on the lower screen, [First stage]
Is displayed as substantially the same as the time chart T created in the step (a). Also, the color of the ruled line differs between input and output, and specifically,
The input is blue and the output is red. [Fifth stage] Start of simulation When the simulation is executed, P
A condition setting signal, an automatic operation signal, and the like are output to the LC2, the signal is input, and the sequence program is started.
From C2, various start command signals based on the sequence sequential control of the sequence program are output to the computer 3 corresponding to the input / output device of the actual machine. ON
/ OFF state, etc., and a check history Ta and a time chart Tb based on these input / output and transfer are created.
As shown in FIG. 7, the image is displayed on the CRT display device 5a of the computer 3. On the display screen, the check history Ta of the upper screen
In the time chart Tb on the lower screen, the ruled lines are sequentially extended by sequentially changing the color of the square cells displayed in a column at the left end while keeping the display state. "● (ON)" or "○ (OF)
F) is switched to display the progress of the program respectively. [Sixth step] Start of repetition test After setting the repetition start position and the number of repetitions, the display is displayed in the fifth step. A check history Ta and a time chart Tb similar to those on the screen are continuously formed, and the number of executions is displayed at the lower right of the screen. In the lower screen, each ruled line is erased and displayed on a new screen each time it is completed. It is also possible to set the operation time longer than usual to make the transition time of the simulation longer so that the operation can be easily confirmed.The simulation log (history) It is desirable to store all of them, but in consideration of the memory capacity of the computer 3, a plurality of storage times are selected in advance, and only those numbers are stored, and such a log is printed. Then, as shown in FIGS. 8 and 9, the date, time, number of times, and magnification are displayed at the top, and a chart is displayed below them.

It is desirable to provide the following functions as options. Specifically, during the simulation, the user clicks a button displayed on the screen as shown in FIG. 10 or presses a function key on a keyboard 7a (not shown), which is assigned in advance.
An arbitrary input signal is transmitted to the PLC 2, and thereafter, it is confirmed how the operation is performed, so that it can be verified whether or not the sequence program proceeds without any support. In addition, it is possible to verify whether or not all situations can be dealt with by dividing one process into equal time by another setting in advance and inputting an arbitrary input signal automatically and sequentially with time. Is desirable. Specifically, enter numbers such as “0”, “1”, and “2” in the entry fields in the setting box shown in FIG. 10, and click the buttons displayed on the left of each entry field during the simulation. It is made to execute by doing. Incidentally, in the present embodiment, “0” is the device number “00”.
“0000”, “start PB”, “1” is device number “0”
“00001” is “emergency stop PB”, and “2” is device number “000002” is “emergency release PB”.
When the button (button o in the drawing) to which "emergency stop PB" is assigned is clicked, the device number "000001 emergency stop PB" is interrupted and displayed as "★ 1" during the simulation as shown in FIG. .

Here, as an example of a real machine for connecting a PLC 2 loaded with a sequence program and performing sequence control, as shown in FIG. 11, a two-way front and rear up-and-down controlled object will be described in detail as an embodiment. . Solenoid valve 1 for air supply port of two air cylinders 11 and 11a
2, 12a, 13 and 13a (SOL1, 2, 3 and 4) are respectively connected to supply pipes, and a pusher 15 and a lifter 15a are attached to the tip of the rod of the air cylinders 11 and 11a. A sensor for detecting the forward end and the backward end of the pusher 15, such as the descending end and the rising end of the lifter 15a, and an auxiliary device 16,
16a, 17, 17a (PX1, 2, AS1, 2) are provided respectively. The solenoid valve 13a (SOL4) is related to the activation of the air cylinder 11a, and the solenoid valve 13 (S
OL3) shall be related to the deactivation and the sensor
17a (AS2) relates to the detection of the falling edge, and the sensor 17
(AS1) relates to detection of the rising end. Then, when a start button (not shown) is pressed, the lifter 15a first rises, and the pusher 15 moves forward after the lifting is completed,
After the forward movement is completed, the pusher 15 retreats and the lifter 15a
Descends.

A relay circuit in the sequence control circuit relating to the vertical movement of the pusher 15 and the lifter 15a is not shown, and an example of a relay number and its ON / OFF command will be described. Regarding the controlled object “pusher”, SOL3,
The output relay numbers of No. 4 are Y302 and Y303, respectively.
The circuit is designed so that when one is output, the other stops output, and the input relay number of AS1, 2 is X1
02 and X103, and in the check of the sequence program of the present application, the respective input / output numbers are “000”.
0302 "," 000303 "," 000102 ",
"000103". Regarding the controlled object “lifter”, SOL1, PX2 and PX1 and PX2 are also Y300 and YPX.
301, X100, X101, “000300”, “0”
00301 ”,“ 000100 ”, and“ 000101 ”.

Here, description will return to the automatic simulation (see FIG. 6). (1) Item number

[0000] As initial conditions, “000101 to ON” “00010
3 to “ON” input signal to the PLC 2,
The output signal of “000200 to ON” is transferred to the computer 3. That is, the “lifter lower end” and the “retractor pusher end” change from “OFF” to “ON”,
Sent to LC2, the virtual real machine returns to the home position. (2) Item number [0001] An input signal of “000000 to ON” is transmitted to the PLC 2, and “000201 to ON” and “00” are transmitted from the PLC 2.
The output signal of “0300 to ON” is transferred to the computer 3. That is, the “start PB” is turned “ON”, and
Sent to LC2, automatic operation of the virtual real machine starts, and lifter 15a starts to rise. (3) Item No. [0002] The input signal of “000000 to OFF” and the input signal of “000101 to OFF” due to the rise of the lifter 15a are PL
C2, and "000200-OF" from the PLC2.
The output signal of F ″ is transferred to the computer 3. That is,
The “lifter lower end” changes from “ON” to “OFF”, which is transmitted to the PLC 2 so that the virtual real machine is not at the original position. (4) Item No. [0003] An input signal of “000100 to ON” is transmitted to the PLC 2, and an output signal of “000302 to ON” is transferred from the PLC 2 to the computer 3. That is, the “lifter rising end” changes from “OFF” to “ON”, and this is
And the pusher 15 starts moving forward. But,
Lifter 15a is still rising. (5) No. [0004] An input signal of “000103 to OFF” is transmitted to the PLC 2 when the pusher 15 advances. That is, the “pushing backward end” becomes “OFF”, which is transmitted to the PLC 2. (6) Item No. [0005] An input signal of “000102 to ON” is transmitted to the PLC 2, and “000300 to OFF”, “00”
The output signals of “0302 to OFF” and “000301 to ON” are transferred to the computer 3. That is, the “pusher advance end” changes from “OFF” to “ON”, which is the PL.
Sent to C2, the lifter 15a stops moving up and the pusher 15 moves forward, while the lifter 15a moves down and pusher 15a.
15 retreat begins. (7) Item No. [0006] An input signal of “000102 to OFF” accompanying the retreat of the pusher 15 is transmitted to the PLC 2. That is, the “pusher forward end” is turned “OFF” and transmitted to the PLC 2. (8) No. [0007] “000100 to OFF” accompanying the lowering of the lifter 15a,
The input signal “000103 to ON” is transmitted to the PLC 2. That is, the “lifter rising end” is turned “OFF” and the “pushing-back retreat end” is turned “ON”, which is transmitted to the PLC 2 and the retraction of the pusher 15 is stopped. But lifter 15
a is still descending. (9) Item No. [0008] An input signal of “000101 to ON” is transmitted to the PLC 2, and “000200 to ON”, “000”
The output signals of "201-OFF" and "000301-OFF" are transferred to the computer 3. That is, the "lifter lower end" is turned "ON", transmitted to the PLC 2, and the lowering of the lifter 15a is stopped. At the same time, the virtual machine returns to the original position and the automatic operation ends.

[0012]

In short, the present invention provides a program for creating a time chart T for displaying the ON / OFF states of a plurality of relays in the PLC 2 with time, and a computer 3 and a PLC for creating the data constituting the time chart T.
A program for converting the data into data communicable between the two,
A PL that transmits an input signal in the converted data to the PLC 2 at every set elapsed time, extracts necessary data based on an output signal changed by the input signal, and displays the data on a screen.
Since it is composed of a computer 3 in which an automatic simulation program of C2 is stored and a PLC 2 which is connected online to the computer 3 and in which a control program is stored and which is to be connected to a real machine, in short, control for PLC has been conventionally performed Since the data for the automatic simulation can be created using the time chart T created when the program is created, a reliable simulation can be executed.

Further, by setting an input signal at the repetition return position and an input signal at the repetition end position, the PLC 2 automatic simulation program can be used.
2 is continuously simulated, so that it is not necessary to perform a long-time test operation using an actual machine, and the operation can be easily performed only by communication between the computer 3 and the PLC 2.

Since the automatic simulation program of the PLC 2 transmits an arbitrary input signal during the simulation, it is verified whether or not it is possible to cope with an emergency during the operation of the actual machine without using the actual machine. That is, the practical effect is extremely large.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of an automatic simulation device for a PLC control program according to the present invention.

FIG. 2 is a diagram illustrating an example of a display screen of a time chart.

FIG. 3 is a diagram showing an example of a display screen of a time chart after conversion.

FIG. 4 is a diagram showing a list of input comments.

FIG. 5 is a diagram showing a list of output comments.

FIG. 6 is a diagram showing a simulation screen in a state where stored data is opened.

FIG. 7 is a diagram showing a display screen of an execution state of an automatic simulation.

8 is a diagram showing a state in which the result of FIG. 7 is printed out.

FIG. 9 is a view showing another embodiment of FIG. 8;

FIG. 10 is a diagram showing a state in which an interrupt key is displayed on an automatic simulation screen and an interrupt is executed.

FIG. 11 is a schematic view of a lifter according to an embodiment.

[Explanation of symbols]

 2 PLC 3 Computer T Time chart

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Tomio Hayashi 1 Toyota Town, Toyota City, Aichi Prefecture Toyota Motor Corporation F-term (reference) 5H220 BB12 CX06 CX08 HH01 JJ12 JJ31 JJ53 KK08 LL06 5H223 AA15 CC03 CC08 DD03 EE19 FF05

Claims (4)

[Claims] 1. ON / O of a plurality of relays in a PLC
A program for creating a time chart for displaying the FF status over time, a program for converting the data constituting the created time chart into data communicable between a computer and a PLC, and an input signal in the converted data are set. A computer which stores a PLC automatic simulation program for transmitting necessary data to the PLC at every elapsed time, extracting necessary data based on the output signal changed by the input signal and transmitted to the computer, and displaying the data on a screen; An automatic simulation device for a PLC control program, comprising a PLC connected online to a computer, storing a control program, and connected to an actual machine. 2. The PLC according to claim 1, wherein an automatic simulation program for the PLC sets an input signal at a repetition return position and an input signal at a repetition end position to continuously simulate the PLC. Automatic simulation device for control program for the computer. 3. The PLC according to claim 1, wherein the PLC automatic simulation program transmits an arbitrary input signal during the simulation.
Automatic simulation device for control program for the computer. 4. ON / O of a plurality of relays in a PLC
A step of creating a time chart for displaying the FF state over time; a step of converting data constituting the created time chart into data that can be communicated between the computer and the PLC; and setting an input signal in the converted data. Transmitting the necessary data based on the output signal changed by the input signal and transmitted to the computer, and displaying the screen on the screen. Simulation method.