JP2023173619A - Control program testing device - Google Patents

Abstract

To perform labor saving in testing a control program that operates a facility.SOLUTION: A testing device 1 for testing a sequence program 30 of a programmable controller 3 that operates a facility by inputting and outputting a signal comprises: reception means 11 for receiving information on a cycle diagram for indicating an operation sequence of the facility; test pattern generation means 12 for generating a test pattern for the sequence program 30 based on the information of the cycle diagram; and evaluation means 13 for evaluating the sequence program 30 by executing the test pattern.SELECTED DRAWING: Figure 1

Description

The present invention relates to a testing device for a control program for controlling equipment.

Conventionally, a programmable controller that controls equipment such as a machine tool controls the equipment to be controlled by executing a sequence program written in a ladder diagram language defined by IEC61131-3, for example. A programmer who creates a sequence program often creates a cycle diagram showing the operating order of equipment and then writes the sequence program along this cycle diagram.

Such sequence programs include interlocks to prevent collisions between moving parts of the equipment, and this prevents damage to the equipment even if a worker performs an inappropriate operation when handling an abnormality. However, it cannot be guaranteed that there will be no programming errors when creating a sequence program. Therefore, as described in Patent Documents 1 and 2, for example, methods and systems have been proposed for testing (debugging) sequence programs through operation simulation using a computer.

Japanese Patent Application Publication No. 2003-248504 JP2008-203947A

When testing a sequence program as described above, the more moving parts there are in the equipment, the more test items there are and the longer the time required for the test. Furthermore, the work of extracting test items also requires a long time. Therefore, if even part of the work of extracting test items and conducting tests can be automated, the burden on personnel such as programmers and test workers can be reduced.

The present inventors developed the present invention based on the idea that by using a cycle diagram showing the operating sequence of equipment, it is possible to automate the extraction of test items and the implementation of tests for control programs for controlling equipment. It's arrived. That is, an object of the present invention is to save labor in testing a control program for operating equipment.

In order to achieve the above object, the present invention provides a test device that tests a control program of a control device that operates equipment by inputting and outputting signals, and which accepts information on a cycle diagram indicating the operating order of the equipment. a control program comprising: a test pattern generating means for generating a test pattern of the control program based on information of the cycle diagram; and an evaluation means for executing the test pattern and evaluating the control program. We provide testing equipment for

According to the control program testing device according to the present invention, it is possible to save labor when testing a control program for operating equipment.

FIG. 2 is a block diagram showing a test configuration of a sequence program using a test device according to an embodiment of the present invention. FIG. 2 is an explanatory diagram schematically showing a part of a grinding machine to be controlled. It is a part of a cycle diagram showing the operating order of the grinding machine in automatic operation mode. FIG. 3 is a diagram showing an example of a test pattern generated by a test pattern generation means. FIG. 3 is a diagram showing an example of a sequence program.

[Embodiment]
Embodiments of the present invention will be described with reference to the drawings. The embodiments described below are shown as preferred specific examples for carrying out the present invention, and some portions specifically illustrate various technical matters that are technically preferable. However, the technical scope of the present invention is not limited to this specific embodiment.

FIG. 1 is a block diagram showing a test configuration of a control program using a test device according to an embodiment of the present invention. Testing of the control program in this embodiment is performed by connecting a display 2 and a programmable controller 3 as an example of a control device to a test device 1 configured by a computer, and connecting an operation panel 4 to the programmable controller 3.

The test apparatus 1 functions as a reception means 11, a test pattern generation means 12, an evaluation means 13, and an evaluation result presentation means 14 by a microprocessor executing a program 101 stored in a storage unit 100. The storage unit 100 is capable of adding, changing, and deleting stored contents, and is, for example, an HDD (hard disk drive) or an SSD (solid state drive). The display 2 displays image information indicating the evaluation results generated by the evaluation result presentation means 14 on the display screen 20.

The programmable controller 3 stores a sequence program 30, which is a control program created by a user, and operates the equipment by inputting and outputting signals. The sequence program 30 is written, for example, in the ladder diagram language specified by IEC61131-3, and mainly controls the operation of the equipment to be controlled using the A contact (normally open) and B contact (normally closed) of the relay, and the coil. It is expressed in the form of a relay circuit that simulates

The operation panel 4 is for an operator to operate the equipment, and includes a touch panel display 40 and a select switch 41 for selecting whether to operate the equipment in automatic operation mode or in individual operation mode. , an operation preparation switch 42 that operates the servo power source that is the power source of the servo motor and a hydraulic pump that generates oil pressure, a start switch 43 that instructs the start of automatic operation of the equipment in the automatic operation mode, and It has an execution switch 44 for executing the operation, and an emergency stop switch 45 for immediately stopping the operation of the equipment.

FIG. 1 shows a state in which each individual operation mode is selected by the select switch 41. The individual operation mode is a mode in which the operator can individually operate the movable parts of the equipment, for example, for abnormality processing or operation confirmation. In the individual operation mode, a plurality of buttons are displayed on the touch panel display 40 of the operation panel 4 to indicate the names of the movable parts and the contents of the operations. By touching any of these buttons, the operator can cause the corresponding movable part to operate. In FIG. 1, among a plurality of buttons, a first button 401 indicating "center forward", a second button 402 indicating "center backward", a third button 403 indicating "steady rest forward", and a "steady rest A fourth button 404 indicating "reverse", a fifth button 405 indicating "drive fitting included", and a sixth button 406 indicating "drive fitting removed" are shown.

The receiving means 11 receives information on a cycle diagram indicating the operating order of the equipment. The cycle diagram is created, for example, by a programmer of the sequence program 30, and is a diagram that describes the operating order of the equipment in the automatic operation mode together with the signal names or addresses of the input/output signals of the programmable controller 3. The receiving means 11 may receive cycle diagram information through communication, for example, or may receive cycle diagram information through a portable storage medium. The receiving means 11 stores the received cycle diagram information in the storage unit 100 as cycle diagram information 102.

The test pattern generation means 12 generates a test pattern for the sequence program 30 based on the cycle diagram information stored as the cycle diagram information 102. More specifically, a test pattern for normal operation is generated when the equipment is operated in accordance with the normal operation order of the equipment shown in the information on the cycle diagram, and is stored in the storage unit 100 as a normal operation test pattern 103. At the same time, a test pattern for abnormal operation is generated when the equipment is operated in a different order of operation from the normal operation order of the equipment shown in the information on the cycle diagram, and is stored in the storage unit 100 as an abnormal operation test pattern 104. do.

The evaluation means 13 evaluates the sequence program 30 by executing the test pattern created by the test pattern generation means 12. More specifically, when the test pattern for normal operation is executed, it is confirmed that the programmable controller 3 outputs a signal that causes the equipment to operate in the normal operation order shown in the information on the cycle diagram, and the test pattern for abnormal operation is confirmed. It is confirmed that the programmable controller 3 does not output a signal that causes the equipment to operate in an operation order different from the normal operation order when the test pattern is executed.

The evaluation means 13 stores the evaluation results in the storage unit 100 as evaluation result information 105. The evaluation means 13 determines whether the programmable controller 3 outputs a signal to operate the equipment in the normal operation order when a test pattern for normal operation is executed, and when the programmable controller 3 outputs a signal to operate the equipment in the normal operation order when a test pattern for abnormal operation is executed. A case where a signal to operate the equipment in an operation order different from the operation order is not outputted is determined to be OK. In addition, the evaluation means 13 determines whether the programmable controller 3 does not output a signal to operate the equipment in the normal operation order when the test pattern for normal operation is executed, or when the programmable controller 3 does not output a signal for operating the equipment in the normal operation order when the test pattern for abnormal operation is executed. A case where the controller 3 outputs a signal to operate the equipment in an operation order different from the normal operation order is determined to be NG. The evaluation results of these OK determinations and NG determinations are stored in the storage unit 100 as evaluation result information 105.

(Specific example of operation of test device 1)
Next, a specific example of the operation of the test apparatus 1 will be described in detail with reference to FIGS. 2 to 5. FIG. 2 is an explanatory diagram schematically showing a part of the grinding machine 5 that is controlled by the programmable controller 3. As shown in FIG. This grinding machine 5 grinds a cylindrical workpiece 50 using a grindstone 500, and includes a headstock 51, a tailstock 52, and a steady rest device 53. Center holes 50a and 50b are formed in both longitudinal end faces of the workpiece 50, respectively. A disk-shaped drive fitting 501 is attached to the end of the workpiece 50 on the headstock 51 side so as to be non-rotatable. The workpiece 50 is set on the grinding machine 5 while being placed on a temporary stand (not shown).

The headstock 51 includes a rotating face plate 512 that is rotationally driven by a motor (not shown) via a shaft 511, a headstock center 513 provided on the rotating face plate 512, a hydraulic cylinder 514 that rotates integrally with the rotating face plate 512, and a hydraulic cylinder 514 that rotates integrally with the rotating face plate 512. It includes a piston 515 disposed within a cylinder 514 and a drive pin 516 that moves forward and backward together with the piston 515. The tip of the headstock center 513 fits into one center hole 50a of the workpiece 50. The drive pins 516 are moved forward by the pressure of the hydraulic oil supplied to the hydraulic cylinder 514, and fit into the fitting holes 501a formed in the drive metal fittings 501, respectively.

The tailstock 52 includes a tailstock center 521, a hydraulic cylinder 522, a piston 523 disposed within the hydraulic cylinder 522, and a dog portion 524 that is disposed outside the hydraulic cylinder 522 and moves forward and backward together with the piston 523. and a proximity switch 525 disposed at a position facing the dog portion 524 when the tailstock center 521 is at the forward end.

The tailstock center 521 moves forward together with the piston 523 by the pressure of the hydraulic oil supplied to the hydraulic cylinder 522, and its tip fits into the other center hole 50b of the workpiece 50. The workpiece 50 is supported by being sandwiched between the tailstock center 521 and the headstock center 513 when hydraulic oil for advancing the piston 523 is supplied to the hydraulic cylinder 522 . Confirmation that the tailstock center 521 has moved to the forward end is performed by the proximity switch 525. The output signal of the proximity switch 525 is input to the programmable controller 3.

The steady rest device 53 includes a hydraulic cylinder 531, a piston 532 disposed in the hydraulic cylinder 531, and a rod 533 that moves forward and backward together with the piston 532, and the tip of the rod 533 contacts the outer peripheral surface 50c of the workpiece 50. The shoe 533a is a shoe 533a. The steady rest device 53 is configured such that the rod 533 presses the workpiece 50 by the pressure of the hydraulic oil supplied to the hydraulic cylinder 531, and the grindstone 500 is pressed against the outer circumferential surface 50c of the workpiece 50. Suppresses deflection.

Hydraulic oil is supplied from a hydraulic pump 57 to hydraulic cylinders 514, 522, 531 of the headstock 51, tailstock 52, and steady rest device 53, respectively, via electromagnetic control valves 54, 55, 56. The hydraulic pump 57 sucks hydraulic oil from the drain tank 58 and discharges it. The electromagnetic control valves 54, 55, and 56 are operated by signals output from the programmable controller 3 to switch the flow path of the hydraulic oil.

Although not shown, the drive pin 516 of the headstock 51 and the rod 533 of the steady rest device 53 are also equipped with position sensors (such as limit switches or (proximity switches, etc.) are provided, and signals from these position sensors are input to the programmable controller 3. Further, in FIG. 2, illustration of auxiliary hydraulic circuit elements such as a check valve and a fixed throttle valve is omitted.

FIG. 3 is a part of a cycle diagram showing the operation sequence of the grinding machine 5 in the automatic operation mode. Here, among the movable parts of the grinding machine 5, the operating order of the drive pin 516 of the headstock 51, the tailstock center 521 of the tailstock 52, and the rod 533 of the steady rest device 53 is shown. The cycle diagram shows the operating order of the movable parts as well as addresses of output signals output by the programmable controller 3 to operate the movable parts.

In the example shown in FIG. 3, the address of the output signal for moving the tailstock center 521 forward is D1, and when this output signal is turned on, hydraulic oil is supplied to the forward side of the hydraulic cylinder 522 of the tailstock 52. is supplied, and the tailstock center 521 moves forward. The address of the output signal for advancing the rod 533 of the steady rest device 53 is D2, and when this output signal is turned on, hydraulic oil is supplied to the forward side of the hydraulic cylinder 531 of the steady rest device 53, and the rod 533 is moved forward. 533 moves forward. Further, the address of the output signal for advancing the drive pin 516 of the headstock 51 is D3, and when this output signal is turned on, hydraulic oil is supplied to the forward side of the hydraulic cylinder 514 of the headstock 51. Drive pin 516 moves forward.

In the sequence program 30, in the automatic operation mode, when the tailstock center 521 is moved forward, the output signal of D1 is turned on, and when the tailstock center 521 moves to the forward end, the output signal of D2 is turned on. , the output signal of D3 is described as being in the ON state when the rod 533 of the steady rest device 53 moves to the forward end.

Furthermore, in each individual operation mode, the sequence program 30 is such that when the first button 401 indicating "center forward" on the touch panel display 40 of the operation panel 4 is pressed, the output signal of D1 is turned on, ” is pressed, the output signal of D2 is turned on, and when the fifth button 405, which shows “driver fitting included” is pressed, the output signal of D3 is turned on. However, if these buttons 401, 403, and 405 are touched to operate in an operation order different from that shown in the cycle diagram, the operation will not be performed. is desirable. For example, even if the third button 403 indicating "steady rest forward" or the fifth button 405 indicating "driver bracket included" is pressed before the tailstock center 521 moves forward, the operation will not be performed. is desirable.

FIG. 4 is a diagram showing an example of a test pattern generated by the test pattern generation means 12 in a table format. This test pattern shows that the state of the grinding machine 5 is such that the first button 401, the third button 403, and the fifth button 405 are pressed at each position P ₁ , P ₂ , P ₃ on the cycle diagram shown in FIG. It shows how the programmable controller 3 that executes the sequence program 30 should operate when a touch operation is performed. In the table shown in FIG. 4, the "operating" cell is a test pattern of normal operation when the equipment is operated according to the normal operating order of the equipment shown in the cycle diagram, and the cell "not operating" This cell is a test pattern for abnormal operation when equipment is operated in an operation order different from the normal operation order.

The test device 1 reads the signal output from the programmable controller 3 to confirm the operation of the sequence program 30 so that the sequence program 30 can be tested on a desk without operating the actual grinding machine 5. Further, the test device 1 simulates signals from position sensors arranged in each part of the grinding machine 5 and transmits the simulated signals to the programmable controller 3.

For example, when checking the operation of the sequence program 30 when the state of the grinding machine 5 is at position _P1 on the cycle diagram, the tailstock center 521 of the tailstock 52, the rod of the steady rest device 53, 533 and the drive pin 516 of the headstock 51 are at the backward end, the test apparatus 1 transmits a signal to the programmable controller 3. In this state, the operator touches the first button 401, the third button 403, and the fifth button 405 on the touch panel display 40 of the operation panel 4, and the evaluation means 13 detects the output signal of the programmable controller 3. Check whether it is on or off.

The evaluation means 13 determines OK if the on/off state of the output signal of the programmable controller 3 is as shown in the table of FIG. 4, and determines NG if they are different. In other words, when the state of the grinding machine 5 is at position _P1 on the cycle diagram, if the "center forward" operation is performed in response to the touch operation of the first button 401, it will be determined as OK, but the third If the "steady rest forward" action is performed in response to a touch operation on the fifth button 403, or the "drive bracket entered" action is performed in response to a touch operation on the fifth button 405, the order of operations will differ from the normal order. Since the equipment will be operated in the operating order, the judgment will be NG.

Also, when checking the operation of the sequence program 30 when the grinding machine 5 is at position _P2 on the cycle diagram, the tailstock center 521 of the tailstock 52 is at the forward end, and the runout is The test apparatus 1 sends a signal to the programmable controller 3 indicating that the rod 533 of the stopper 53 and the drive pin 516 of the headstock 51 are at the retreat end. Then, the operator touches the first button 401, the third button 403, and the fifth button 405 on the touch panel display 40, and the evaluation means 13 checks the on/off state of the output signal of the programmable controller 3. do. Note that when the first button 401 indicating "center advance" is pressed, the output signal of D1 for advancing the tailstock center 521 remains in the on state, resulting in an OK determination.

In addition, when checking the operation of the sequence program 30 when the state of the grinding machine 5 is at position _P3 on the cycle diagram, the tailstock center 521 of the tailstock 52 and the rod of the steady rest device 53 are The test apparatus 1 sends a signal to the programmable controller 3 indicating that the drive pin 533 is at the forward end and the drive pin 516 of the headstock 51 is at the backward end. Then, the operator touches the first button 401, the third button 403, and the fifth button 405 on the touch panel display 40, and the evaluation means 13 checks the on/off state of the output signal of the programmable controller 3. do. When the first button 401 indicating "center forward" is pressed, the output signal of D1 for advancing the tailstock center 521 remains on, and the third button indicating "steady rest forward" is pressed. When 403 is pressed, the output signal of D2 for moving the rod 533 forward remains in the on state, resulting in an OK determination.

In this way, the test pattern generation means 12 automatically generates test patterns for all the operations of each movable part of the grinding machine 5 at each position in the cycle diagram, and the evaluation means 13 OK/NG is determined based on the output signal of the programmable controller 3 when each generated test pattern is executed.

Note that the test pattern generated by the test pattern generation means 12 may be changed by, for example, a programmer of the sequence program 30. In this case, for example, a test pattern generated by the test pattern generation means 12 is displayed on the display screen 20 of the display 2, and a programmer changes the test pattern using a pointing device such as a keyboard or a mouse connected to the test apparatus 1. This change is intended to increase the degree of freedom in each individual operation so that on-site operators can easily handle abnormalities and check the operation of the grinder 5, regardless of the operation order in the cycle diagram. It is possible to move the tailstock center 521 forward or backward with the door 5 open, or to rotate the rotating face plate 512 of the headstock 51 with the rod 533 of the steady rest device 53 at the backward end. It is something.

FIG. 5 is a diagram showing an example of a sequence program for turning on the D1 (center forward) output signal when the first button 401 of the touch panel display 40 is touched in the individual operation mode. In the sequence program shown in FIG. 5, the "start condition" A contact (EX101) is a contact that indicates that the conditions for starting the automatic operation of the grinding machine 5 are satisfied. The A contact (M1D2G) "in automatic operation" is a contact indicating that the vehicle is in automatic operation mode. The "operating condition" contact A (EL201) is a contact indicating that the conditions for moving the tailstock center 521 forward in the automatic operation mode are satisfied. The "power supply" A contact (M1R2M) is a contact that indicates that power is being supplied to operate the grinding machine 5. The “command” coil (D1 (EL301)) is an output signal for operating the electromagnetic control valve 56 and supplying hydraulic oil to the hydraulic cylinder 522 to advance the piston 523.

In the sequence program shown in FIG. 5, the A contact (EX601) of the "push button" is a contact that indicates that the first button 401 of the touch panel display 40 has been touched. The A contact (X60) of the "execution button" is a contact that indicates that the execution switch 44 of the operation panel 4 has been pressed. The "individual" A contact (M1D1H) is a contact that indicates that the execution switch 44 of the operation panel 4 has been pressed. The "operating end" contact A (D2P (EL001)) is a contact that indicates that the proximity switch 525 is in the on state, that is, that the tailstock center 521 is at the forward end. Further, the B contact (D11) for "opposite command" is a contact that indicates that the operation opposite to advancing the tailstock center 521, that is, the command to move the tailstock center 521 backward has not been made.

In this sequence program, for example, when the first button 401 of the touch panel display 40 is touched (EX601: on) and the execution switch 44 is pressed (X60: on) in the individual operation mode (M1D1H: on), the operating conditions is satisfied (EL201: ON) and power is being supplied (M1R2M: ON), the "command" coil (D1 (EL301)) is turned on, and the tailstock center 521 moves forward. If the tailstock center 521 moves to the forward end and the "operating end" A contact (D2P (EL001)) turns on, even if the execution switch 44 turns off (X60: off), The "command" coil (D1 (EL301)) is maintained in the on state. This series of operations is an example of normal operation when the state of the grinding machine 5 is at position _P1 on the cycle diagram.

Here, the A contact (EL201) of "operating condition" is an interlock for the operation of advancing the tailstock center 521, and includes, for example, the condition that the workpiece 50 is placed on the temporary table. Therefore, even though the A contact (EL201) of the "operating condition" is in the OFF state, due to a programming error, when the first button 401 on the touch panel display 40 is touched and the execution switch 44 is pressed, the "command" If the coil (D1 (EL301)) is in the on state, the determination is NG. If such a programming error occurs, the evaluation result presenting means 14 presents the result of the NG determination, prompting the programmer to modify the sequence program 30.

(Effects of embodiment)
As explained above, according to the present embodiment, the test pattern generation means 12 generates the test pattern of the sequence program 30 based on the information of the cycle diagram, and the evaluation means 13 generates the sequence program 30 based on this test pattern. Since 30 evaluations are performed, it is possible to save labor in testing the sequence program 30, and the burden on programmers, operators, etc. can be reduced.

(Additional note)
Although the present invention has been described above based on the embodiments, the embodiments do not limit the invention according to the claims. Furthermore, it should be noted that not all combinations of features described in the embodiments are essential for solving the problems of the invention. Moreover, the present invention can be implemented with appropriate modifications by omitting some configurations, or adding or replacing configurations, without departing from the spirit thereof. Further, it is also possible to combine some of the configurations of the plurality of embodiments described above, and it is also possible to modify, for example, as described below.

In the above embodiment, the case where the sequence program 30 is tested using the actual operation panel 4 has been described, but the present invention is not limited to this. 3 to test the sequence program 30. Further, in the above embodiment, a case has been described in which the sequence program 30 is tested using the actual programmable controller 3. The program 30 may also be tested.

Further, in the above embodiment, a case has been described in which the sequence program 30 is tested by transmitting and receiving signals between the programmable controller 3 and the test device 1 without operating the actual grinding machine 5, but the present invention is not limited to this. The sequence program 30 may be tested by monitoring the input/output signals of the programmable controller 3 using the testing device 1 while operating the actual grinding machine 5 using the programmable controller 3. Alternatively, the sequence program 30 may be tested by simulating the 3D model of the grinding machine 5 in the test apparatus 1.

Furthermore, in the above embodiment, the case where the equipment to be controlled is the grinding machine 5 has been explained as an example, but the equipment to be controlled is not limited to the grinding machine, but may also be a machine tool such as a cutting machine or an assembly machine. Alternatively, as long as the equipment is controlled by a programmable controller, it is possible to target various types of equipment such as conveyors, elevators, and vending machines.

1...Testing device 11...Reception means 12...Test pattern generation means 13...Evaluation means 103...Normal operation test pattern 104...Abnormal operation test pattern 3...Programmable controller (control device)
30...Sequence program (control program)
5...Grinding machine (equipment)

Claims (3)

A test device that tests a control program of a control device that operates equipment by inputting and outputting signals,
reception means for receiving information on a cycle diagram indicating the operating order of the equipment;
test pattern generation means for generating a test pattern for the control program based on information on the cycle diagram;
evaluation means for evaluating the control program by executing the test pattern;
Control program testing equipment equipped with The test pattern generating means generates a test pattern of normal operation when the equipment is operated in accordance with the normal operation order of the equipment shown in the information of the cycle diagram, and a test pattern of an operation different from the normal operation order. generating a test pattern for abnormal operation when operating the equipment in sequence;
The evaluation means verifies that the control device outputs a signal for operating the equipment in the normal operation order when the normal operation test pattern is executed, and when the abnormal operation test pattern is executed. confirming that the control device does not output a signal that causes the equipment to operate in an operation order different from the normal operation order;
The control program testing device according to claim 1. The test pattern generation means generates the test pattern for all operations of each movable part of the equipment at each position of the cycle diagram.
A control program testing device according to claim 1 or 2.

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