JP2607620B2 - Grouping method of sequence program control system monitor - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for grouping sequence program control monitors.

(Prior Art) For example, a so-called sequence program control in which a sequence program designating an operation sequence of equipment to be controlled is set and each step of a control sequence is sequentially advanced according to the program is generally well known. The sequence control is often used in an assembly line of machine tools or a machine tool in a factory to automatically and continuously perform the next operation in accordance with the operation of the previous operation. I have.

By the way, in the sequence program control as described above, whether or not the control is performed normally is monitored, that is, another program for monitoring is additionally incorporated, and monitoring is performed for each control step, and an alarm is issued when an abnormality occurs. There is something of the idea. However, in this case, each time the contents of the equipment are changed, it is necessary to change both the operation control program and the monitoring program of the equipment accordingly. There is a drawback in that the total program capacity eventually increases due to the need for one program.

On the other hand, the reference operation patterns (I / O transition patterns) of the respective constituent control elements of the sequence control circuit when the equipment is normally operated are sequentially stored, and the actual operation is performed when the equipment is actually operated. A so-called playback-type sequence monitor device in which whether or not the pattern matches the stored reference operation pattern is sequentially checked for each step, and if the pattern does not match, it is pointed out that the pattern is abnormal. Is known (for example, see Japanese Patent Application Laid-Open No. 60-238906). In the case of this playback type sequence monitor system, regardless of whether or not the above equipment is operating normally, if both operation patterns do not match, an abnormality is always pointed out.

However, in actual equipment, there are a plurality of groups in the equipment in which the transition order of the operation of each control element is constant, and these groups are simultaneously operated independently in parallel (hereinafter referred to as simultaneous and parallel operation). ). In this case, the types of transition of the actual operation pattern of each control element constituting the sequence control system of the facility become extremely large under the influence of the shift of the operation timing of each of the independent operation groups.

Therefore, when the status of the sequence control of such equipment is monitored by the above-mentioned playback type sequence monitor device, despite the fact that the equipment is operating normally, due to the above-mentioned operation timing shift, each control element has There is a problem that the actual operation pattern does not match the reference operation pattern stored in the monitor device, and an abnormality is pointed out, that is, so-called monitor device malfunctions increase.

As a countermeasure against this problem, the equipment is divided into a plurality of independent operation groups in which the transition order (operation timing) of each operation is considered to be the same, and the operation of each control element included in each independent operation group is determined for each independent operation group. By monitoring the pattern, it is conceivable to eliminate the influence of the deviation of the operation timing of each independent operation group performing the simultaneous / parallel operation and eliminate the malfunction of the monitor device.

For example, although it has not been directly conscious of the problem of malfunction due to simultaneous and parallel operation of such a monitor device in the past,
In JP-A-61-177505, one batch is divided into a plurality of processes, and a normal sequence procedure and an abnormal processing process are ruled for each process unit, thereby flexibly preventing abnormal occurrence. An abnormality handling method of a sequence control system that can deal with the problem has been proposed.

Further, in the playback type sequence monitor, when an actual operation pattern different from the stored pattern is obtained, the operation state of the subsequent equipment is actually confirmed, and if there is no abnormality in the operation, the actual operation pattern is used. A monitor device having a so-called learning function has been proposed, in which each time a plurality of operation patterns recognized as normal are obtained by newly storing them as normal patterns, these are automatically and sequentially learned and stored.

By the way, the grouping work of dividing each control element constituting the control system of the equipment to be controlled into each independent operation group is extremely important since it directly affects the reliability of the monitoring device, and therefore, it is very carefully performed. It is.

However, actual equipment, especially equipment having a large scale and a complicated mechanism, has an extremely large number of constituent control elements, and no matter how careful grouping work is performed, it is actually difficult to group all of these control elements in character. Difficult and accidental mistakes can occur. In general, the rules for grouping the above-described concurrent operations have not been clearly established, and must be artificially trial-and-error inevitably, resulting in an enormous number of preparation steps. If there is a mistake in the grouping, the monitor device malfunctions.

(Means for Solving the Problems) The method of the present invention has been made for the purpose of solving the above-described problems, and is intended to solve the above-mentioned problems. Detect changes,
By comparing the detected pattern with a previously stored reference change pattern in a normal operation state of each control element, a normal or abnormal control state of the control system is diagnosed in a predetermined control element group. In the monitoring system of the sequence program control system, the signals representing the operating states of the plurality of control elements are related to each other and affect only other specific signals, or are included in the signals. On the basis of whether or not there is a relationship affecting other plural signals, each of the signals representing the operating state of each of the plural control elements is first or second.
The second dependent influence degree is determined, and the signal representing the operating state of each of the control elements affected by the signal representing the operating state of the control element determined to be the first dependent influence degree from the determination result is the same. The signal indicating the operating state of each of the control elements which influences the group is determined by the signal indicating the operating state of the control element determined to have the second subordinate degree of influence. Are grouped into a new group.

(Operation) In the configuration of the method of the present invention, first, the signal representing the operation state of each of the plurality of control elements is in a relationship affecting only other specific signals among them, or other Each of the signals representing the operating state of each of the plurality of control elements on the basis of whether or not there is a relationship affecting the signal,
1, judge the second dependent influence degree, and based on the judgment result,
The signals representing the operating states of the control elements affected by the signal representing the operating state of the control element determined to have the first dependent influence are determined to belong to the same group and the second dependent influence is determined. The signal representing the operation state of each of the control elements affected by the signal representing the operation state of the selected control element groups one of the signals into the same group and the other signal into a new group according to predetermined rules. In this way, control elements that are dependent on a plurality of control elements are placed in the same group, while control elements that are not dependent on each other are placed in a separate group, eliminating human judgment elements. Are grouped into groups.

As a result, control elements having the same operation timing are always in different groups, and the number of groups after grouping can be reduced to the minimum state in combination.

(Effect of the Invention) Therefore, according to the configuration of the method of the present invention, the grouping itself, which is a premise of monitoring, does not involve trial and error elements due to human work, so that the grouping accuracy is improved and the number of preparation steps is significantly reduced. it can. As a result, malfunction of the monitor device is eliminated, and the reliability of the monitor device is improved.

(Embodiment) FIGS. 1 to 5 show a grouping method of a sequence program control system monitor according to an embodiment of the present invention and a system for implementing the method.

First, FIG. 1 shows an overall configuration of an example of a playback type sequence monitor system of a sequence program control system to which the above-described grouping method of the present invention is applied.

As shown in FIG. 1, the sequence monitor device according to the present embodiment system receives an input signal (IN / OUT) indicating an operation state of each control element constituting a control system of the equipment 1 to be controlled. An O-state input unit 2, a signal from the input unit 2, and a change detection unit 3 for detecting a change in the I / O state, that is, a change in an operation state of each element constituting the control system; And a normal pattern storage unit 4 for storing the operation pattern of each of the above-described elements during normal operation for each step in which the pattern changes.

The equipment 1 is divided into, for example, a plurality of independent operation groups in which the transition order of each operation is fixed, and at least some of these independent operation groups perform concurrent operations at the time of starting the equipment. And the above equipment 1
The control system includes various output elements (for example, a cylinder device) related to processing and transport of a work or the like, and a detection element (for example, a limit switch) that detects an operation state of the facility 1 such as an operation state of the output element and a position of the work. And the output element and the detection element are divided corresponding to the respective independent operation groups.

The normal pattern storage unit 4 causes the equipment 1 to perform a normal operation in advance, and stores the operation pattern of each element in each of the independent operation groups at that time for each step in which the pattern changes. It is a thing.

By the way, the sequence monitor device according to the present embodiment system stores the actual operation pattern obtained by the detection operation of the change detection unit 3 for each element constituting the control system of the equipment 1 and the normal pattern storage unit 4. The control state of the equipment 1 is diagnosed by comparing the stored operation pattern with the storage pattern of the step in the independent operation group corresponding to the operation pattern. The diagnostic processing unit 10 automatically corrects the grouping according to the conditions.

The diagnostic processing unit 10 stores a step in an independent operation group corresponding to the operation pattern stored in the normal pattern storage unit 4 with an actual operation pattern obtained by the detection of the operation state change detection unit 3. A determination unit 11 for determining whether or not the pattern matches the pattern, and, when the determination result is a mismatch, receiving a mismatch determination signal from the determination unit 11 to determine whether or not the element indicating the mismatch is abnormal. A judgment unit 12 for judging by a learning function, and in the case where the mismatched element is not a true abnormality in the judgment result, receiving a diagnosis signal from the judgment unit 12 that the mismatched element is not a true abnormality, and The monitoring target control unit 13 for once removing the unmatched elements from the monitoring target, and the equipment 1
In each of the independent operation groups, a step storage unit 14 for storing a change step in which the operation state of the mismatched element changes, and an independent operation group in which the change step is not continuously the same (not synchronized) is deleted. The extraction unit 15 extracts the only independent operation group in which the change step is continuously the same (synchronous), and outputs it to the normal pattern storage unit 4 to store the contents of the operation state of the inconsistent element. And a storage change control unit 16 for changing the storage contents from the independent operation group in which the storage contents were initially stored to the independent operation group extracted by the extraction unit 15.

The monitoring operation of the sequence monitor device having the above configuration will be briefly described with reference to the flowchart of FIG.

First, when the monitoring control is started, the operation states of the respective control elements constituting the sequence program control system of the equipment 1 are input to the above-mentioned I / O state input unit 2,
The / O state input unit 2 outputs a signal indicating the operation state of each control element to the operation state change detection unit 3 (step S ₁ ).

Then, the change detecting section 3 detects whether or not there is a change in the I / O state (step S ₂ ). As a result, if there is no change (NO), this detection work is further continued, and if there is a change (YES), a signal representing the changed I / O state is determined by the above-described diagnosis processing unit 10. Output to the unit 11.

Upon receiving the signal from the change detection unit 3, the determination unit 11 determines whether the actual operation pattern represented by the input signal is the step in the independent operation group corresponding to the operation pattern stored in the normal pattern storage unit 4. It determines whether to match the stored pattern (step S _3). As a result, if they match (YES), since it is when there is no any abnormal inherently returns to step S _1, the detection operations of the change in the operating state of the equipment 1 is made further repeated. On the other hand, when the determination result is a mismatch, the determination unit 11 outputs a mismatch determination signal.

Monitored control unit 13, element indicating a mismatch than the determination signal of the mismatch already checked whether it is excluded from the monitor (step S _4). Then, the program proceeds to step S ₇ to be described later when the result is YES, the other N
In the case of O, the mismatch determination signal is sent to the determination unit 12.

The determination unit 12, based on the determination signal of the mismatch output from the determination unit 11, mismatch element is determined by a learning function whether it is true anomaly (Step S _5). If the result of this determination is YES, it is considered that the mismatched element actually has an abnormality, so an abnormality instruction (alarm signal) is issued to notify the operator. On the other hand, if the determination result is NO, a determination signal is output to notify that the mismatch element is not a true abnormality.

Monitored control unit 13 which has received the decision signal excludes elements of the discrepancy from the monitor (step S _6).
That is, in the case where the actual operation pattern of the equipment 1 and the storage pattern that is stored in the normal pattern storage 4 and is the reference of the corresponding step in the independent operation group corresponding to the actual operation pattern indicate a mismatch. ,
The unmatched elements that are determined not to be true abnormalities by the learning function of the determination part 12 even though an abnormality is detected in the above determination part 11 may have an error in the grouping of the elements. At this point, it is temporarily excluded from the monitoring target.

Then, in the subsequent cycle, the change step in which the operation state of the mismatched element changes is continuously the same, that is, the only independent operation group to be synchronized is extracted and the grouping is corrected.

Next, the extraction of the synchronized grouping and the modification of the grouping will be described.

As described above, in step S _4, whether element indicating disagreement with monitored control unit 13 based on the determination signal discrepancies from the determination unit 11 has already been excluded from monitored are checked. Then, the process proceeds to step S ₅ as above when the check result is NO, when an element of the discrepancy is already excluded from monitored in earlier cycles, the result of the check is YES proceed to the next step S _7.

In step S _7, each independent operation group of the equipment 1, the change step of changing the operating state of the elements of the mismatch occurs is temporarily stored in the step storage unit 14.
In this case, the change step is not stored in the group in which the change of the operation state of the inconsistent element was denied without synchronization in the previous cycle and was deleted (hereinafter referred to as NG group).

Then, the contents stored in step S ₇ is whether there is a conflict with previously temporarily stored contents, to check each of all of the independent operating groups except the NG group (Step S _8).

If the result of the above check is YES, the group is not synchronized and denied, and the NG group is deleted (step
S _9).

When the check result in the step S ₈ there is NO group (group that may), the extraction unit
15 by checking whether or not only one only groups that have the potential (Step S _10). As a result, if the group is likely is two or more (NO), because a group of synchronization can not determine the flow returns to step S _1, further repeating the above cycle. If there is only one such group, the extraction unit 15 outputs an extraction signal.

Upon receiving the extraction signal, the storage change control unit 16 outputs the information to the normal pattern storage unit 4 and stores the storage contents of the operation states of the mismatched elements from the independent operation group in which the storage contents were stored first. The memory is changed to the independent operation group extracted by the extraction unit 15 (step
S _11).

After the new normal pattern is formed as described above, the mismatched elements excluded from the monitoring target are returned to the monitoring target by the monitoring target control unit 13 (step
S _12), then step S ₁ returns performs normal monitoring thereafter.

That is, in the above-mentioned playback type sequence monitor device, it is premised that there is a mistake in the grouping itself, and the control in which an abnormality is detected due to the mistake in the grouping despite the fact that the equipment is operating normally. By learning the elements of the system by the learning function, and automatically searching for the group that should truly contain the above element and correcting the grouping, a highly reliable system that eliminates malfunctions due to mistakes in the grouping is eliminated. It is an object of the present invention to provide a sequence program control system monitoring device, and as is apparent from the above description, in a sequence program control system monitoring device of equipment divided into a plurality of independent operation groups, an operation pattern different from storage A judgment unit is provided to judge whether the mismatched element is a true abnormality when the In addition, since the non-matching elements that are not true abnormalities are temporarily excluded from the monitoring target by the monitoring target control unit, the erroneously grouped elements can be accurately grasped, and the mismatching elements can be monitored. Can be removed once. Then, a step storage unit is provided for storing a change step in which the operation state of the mismatched element changes in each independent operation group, and the change step is not continuously the same in each independent operation group by the extraction unit ( Since the independent operation group that does not synchronize is deleted and the only independent operation group in which the change step is continuously the same (synchronizes) is automatically extracted, the mismatch element should be truly included. Independent operation groups can be searched automatically. Further, the information is output to the normal pattern storage unit, and the storage content regarding the mismatched element is automatically stored and changed from the independent operation group in which the storage content was initially stored to the independent operation group extracted by the extraction unit. Since the storage change control unit is provided, it is possible to automatically correct the grouping of elements that have been erroneously grouped.

As a result, a malfunction of the monitor device due to a grouping error can be eliminated, and the reliability of the monitor device itself can be improved.

However, in order to further improve the reliability of the monitor device, it is originally preferable that the grouping itself be as human-free as possible, and for that purpose, a trial and error element is excluded from the grouping system itself. There must be.

Next, a grouping method which is a premise of the above device will be described.

First, as a means for realizing the grouping method of the present embodiment excluding trial and error elements,
It has the configuration shown in FIG.

That is, first, reference numeral 17 denotes an I / O dependent influence setting unit that sets the degree of dependent influence of the signal I / O representing the operation state of each control element, and the I / O of the control element directly affects the I / O. The dependent influence degree of the I / O of the control element and the I / O of the target control element are set according to the number of I / Os of the other control element.

In this case, the dependent influence degree is represented by, for example, a first dependent influence degree “0” and a second dependent influence degree “1”, and is defined as follows.

First dependent influence degree “0”... I / of predetermined control element
O is the I / O of a specific control element among the I / Os of other control elements.
A relationship that only affects O.

Second dependent influence degree "1" ... I / of predetermined control element
The relationship where O affects the I / O of several other control elements.

Reference numeral 18 denotes a grouping processing unit, which is a control element that is determined to be dependent on the following first and second rules based on the dependent influence set by the dependent influence setting unit 17. I / Os are grouped into the same group, and those that are not are grouped into another group.

<First Rule> I / Os that are affected by I / Os having a dependent impact degree of 0 are set in the same group. However, even in that case,
For I / O for which a group has already been set, the earlier setting has priority.

<Second Rule> One of the I / Os affected by the I / Os having the dependent impact level 1 is set to the same group, and the other I / Os are set to a new group. However, a group has already been set
For I / O, the above setting has priority.

Grouping is performed as described above, and input to the sequence monitor 100 described above.

Now, the above-described grouping method will be specifically described with reference to a sequence program control system including a plurality of control elements A to K as shown in FIG. 4 as an example.

First, the system shown in FIG.
Section, H section, U section, and S section, each starting with an arrow (a),
(B), (c), (d), (e), and (f) perform simultaneous and parallel operations in each direction, and the above-described dependent influence degrees 0, 1, 2, and 3
.. Grouping control elements that perform a sequence operation with a predetermined relationship according to n−1 based on the first and second rules, A = Gr.No.1 M = Gr.No.2 B = Gr.No.5 U = Gr.No.5 → V = Gr.No.5 C = Gr.No.1 N = Gr.No.2 L = Gr.No.2 O = Gr.No.2 D = Gr.No.1 P = Gr.No.2 E = Gr.No.1 S = Gr.No.6 → T = Gr.No.6 F = Gr.No.1 Q = Gr.No.2 G = Gr.No.3 R = Gr.No.2 H = Gr.No.4 I = Gr.No.1 J = Gr.No.1 K = Gr.No.1

When this is organized and shown by group, Gr.No.1 = A, B, C, D, E, F, I, J, K Gr.No.2 = L, M, N, O, P, Q , R Gr.No.3 = G Gr.No.4 = H Gr.No.5 = U, V Gr.No.6 = S, T, and are grouped extremely simply and accurately without human judgment factors. There is no trial and error element. In addition, the number of groups is reduced to the minimum number in combination. Therefore, the number of preparation steps can be significantly reduced.

For example, in the above case, first, T (T = G
If (r.No.6) is set to Gr.No.1, then T = Gr.No.1 K = Gr.No.1 A = Gr.No.1 B = Gr.No.1

If, for example, now C = Gr. No. 1, L = Gr. No. 2
M = Gr.No.2 or Gr.No.3 S = Gr.No.2 or Gr.No.3, Gr.No.4 T = Gr.No.2 or Gr.No.3, Gr. It becomes No. 4 and contradicts (duplicate).

Therefore, the hypothesis of C = Gr. No. 1 is denied, and C
= Gr.No.2 L = Gr.No.1 → M = Gr.No.1 D = Gr.No.2 U = Gr.No.5 E = Gr.No.2 N = Gr.No.1 F = Gr.No.1 O = Gr.No.1 G = Gr.No.3 (where P = Gr.No.1 H = Gr.No.4 S = Gr.No.5 I = Gr.No.5 No.2 → T = Gr. No.6 and contradicts) J = G
r.No.2 P = Gr.No.6 H = Gr.No.4 Q = Gr.No.6 I = Gr.No.1 R = Gr.No.6 J = Gr.No.1 S = Gr .No.1 (K has already been set to V = Gr.No.5 Gr.No.1), and it is accurately grouped even if it starts from any control element point. You.

In the above case, for example, as shown in FIG. 5, the multi-cycle storage unit 20 for teaching the I / O transition of at least two cycles or more (preferably several tens to several hundred cycles) from the above grouping result and Executes a playback type sequence monitor based on the data in the multi-cycle storage unit 20 to extract grouping mistakes.
A configuration is provided in which a playback type sequence monitor execution unit 21 is provided, and the following operation is performed thereby to further improve the grouping accuracy itself.

(A) Among the I / O transition cycles stored in the multiple cycle storage unit 20, the cycle when an abnormality occurs in the equipment is invalidated.

(B) An arbitrary cycle among the cycles stored in the multiple cycle storage unit 20 is executed as a basic I / O transition pattern.

(C) Re-edit a more accurate I / O transition pattern by correcting the grouping.

Therefore, in addition to further improving the grouping accuracy, verification work after re-greeping is also facilitated, and the number of preparation steps can be further reduced.

[Brief description of the drawings]

FIG. 1 is a basic circuit diagram of a playback sequence monitor device of a sequence program control system in an embodiment of the present invention, FIG. 2 is a flowchart showing a monitor operation of the playback device, and FIG. FIG. 4 is a block diagram showing a configuration of a grouping means for implementing a grouping method of control element I / O in FIG. 4, FIG. 4 is a control system diagram showing a configuration of a general sequence program control system, and FIG. FIG. 3 is a block diagram illustrating a basic configuration of a grouping error extracting unit attached to the back sequence monitor device. DESCRIPTION OF SYMBOLS 1 ... Equipment 2 ... I / O state input part 3 ... Change detection part 4 ... Normal pattern storage part 10 ... Diagnosis processing part 17 ... I / O dependent influence setting part 18 ... Grouping processing part 100 …… Sequence monitor

Claims (1)

(57) [Claims] 1. A method for detecting a change in the operation state of each of a plurality of control elements constituting a control system of the control equipment, and detecting the detected pattern with a reference change pattern in a normal operation state of each control element stored in advance. In a monitoring system for a sequence program control system, the normal or abnormal control state of the control system is compared and diagnosed by grouping the control system into predetermined control element groups. The control elements are based on whether the signals representing the signals affect only certain other ones of them or the signals affecting other ones of them. The first and second dependent influences are determined for each signal representing the operating state, and the control element determined to be the first dependent influence is determined from the determination result. The signals indicating the operation states of the control elements affected by the signal indicating the operation state of the control elements belong to the same group, and the control indicating the operation state of the control element determined to have the second dependent influence degree controls the control elements. 3. A grouping method for a sequence program control system monitor, wherein a signal indicating an operation state of each element is grouped into one of the same group and another signal into a new group.