JP2611892B2 - Failure inspection method for sequence control equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention can be used for inspecting equipment such as a boiler, which performs sequence control.

[0002]

2. Description of the Related Art Conventionally, in the inspection of sequence control equipment, a human has designed an inspection process. In other words, humans have determined what settings to operate the device and what to check. In order to clarify the determined inspection process, a method of expressing the inspection method in a flowchart format has been proposed.
However, in any case, humans must decide the inspection process. Therefore, as the size and complexity of the sequence control device increase, it becomes very difficult to inspect the sequence control device.

[0003]

As described above, with the increase in the scale and complexity of the sequence control equipment, an extremely large amount of cost and time are required for the inspection of the equipment. In the present invention, by using a process flow describing the operation specifications of the sequence control device, it is possible to increase the productivity of the inspection of the sequence control device by checking whether the sequence control device performs an operation inconsistent with the process flow. The purpose is.

[0004]

According to the present invention, an inspection process is automatically generated according to a processing flow describing the operation of an apparatus, and an inspection of a sequence control apparatus is performed based thereon. In the fault inspection method proposed in the present invention, a sequence controller and a controlled device controlled by the sequence controller are connected by at least one set of input-side and output-side connection wires, and inserted separately into these connection wires. The connected interface circuit is connected to the inspection apparatus by dividing it into an input side and an output side, and transfer of signals between the sequence controller and the controlled device is performed by the interface.
Carried out by the inspection device through an over scan circuit, wherein either said sequence controller and the controlled device is operating in the processing flow as a preset interface
An operation of inspecting via the interface circuit, and causing the inspecting apparatus to function as the controlled device through the interface circuit.
And an operation of inspecting the controlled device via the interface circuit by causing the inspection device to function as the sequence controller.

[0005]

According to the above arrangement, all signals between the sequence controller and the controlled device are measured, and after completion of the measurement, whether or not the operation according to the flowchart is performed based on the measurement result is checked. You can find out if there are any. In addition, the sequence controller can be inspected by causing the inspection device to function as a controlled device, and the controlled device can be inspected by causing the inspection device to function as a sequence controller, and the operation of these devices can be confirmed.

[0006]

FIG. 1 is a block diagram of an inspection system using a failure inspection method proposed in the present invention. In this method, the sequence controller (1) and the controlled device controlled by it
The wiring connecting between the (2), and insert the interface circuit (3), inserted interferon over scan circuit (3) and the inspection device
Connect (4). And the sequence controller (1)
The transfer of the controlled device (2) between the signal interface times
The inspection is performed from the inspection device (4) via the road (3) . Note that the sequence controller (1) in FIG. 1 is a device for realizing sequence control, and represents a computer or a sequencer. The inspection device (4) is realized using a computer.

In the inspection apparatus (4), the controlled equipment is
A processing flow describing the operation of (2) is stored. Inspection by the inspection device (4) consists of two modes, an "operation measurement mode" and an "operation confirmation mode".
Control signals Aout, Bout, Cou output from the inspection device (4)
t, Ain, Bin, Cin.

In the operation measurement mode, signals between the controlled device (2) and the sequence controller (1) are transmitted to the interface circuit.
In this mode, all measurements are performed via the path (3), and after completion of the measurement, it is checked whether or not the operation according to the flowchart is being performed based on the measurement result, and whether or not a failure has occurred. In operation measurement mode, signals Ain, Aout, Bin, Bout are all 1
And by setting the signals Cin and Cout to zero.

In the operation confirmation mode, the inspection device (4) is made to play the role of the controlled device (2), and is controlled by the interface circuit (3).
A mode for checking the sequence controller (1),
There are two types of inspection modes, in which the inspection device (4) plays the role of a sequence controller (1) and inspects the controlled device (2) via the interface circuit (3) . In this test method, only the signals Cin and Bout are set to 1 and the others are set to 0 to set the operation check mode to check the sequence controller (1). Also, only the signals Bin and Cout are set to 1 and the others are set to 0. Can be set to the mode to inspect the controlled device (2).

The inspection device (4) is a sequence controller
Controlled device only from the signal between (1) and controlled device (2)
Since the operation of (2) cannot be observed or operated, the operation of the controlled device (2) from outside or the controlled device (2)
Cannot confirm the operation to the outside. Therefore, in the operation check mode of the controlled device (2), the inspection is performed while interacting with the inspector using the three switches of “operation complete switch”, “normal switch”, and “abnormal switch”. The operation completion switch (5) is used to confirm the completion of the process to be operated by the inspector instructed by the inspection device (4).
It is for letting you know. The normal switch (6) and the abnormal switch (7) are used to inform the inspection device (4) of the judgment result of the check items presented by the inspection device (4) and performed by the inspector. ) Is the inspection equipment (4)
When the controlled device (2) performs the operation presented by the user, the abnormal switch (7) is pressed at any other time.

Using these three switches, a controlled device
The operation check mode of (2) is executed as follows. Instruct the inspector to perform the operation to be given to the controlled equipment (2) based on the processing flow, have the inspector perform the operation, and after the operation is completed, press the operation completion switch of the inspection device (4). . As a result, the inspection device (4) observes the output signal from the controlled device (2) and checks whether the signal is the result according to the processing flow. In addition, based on the signal output from the inspection device (4) to the controlled device (2), the operation of the controlled device (2) to be generated is presented to the inspector, and the inspector checks whether the device is operating normally. Then, the result is input to the inspection device (4) by the normal switch (6) or the abnormal switch (7). If the abnormal switch (7) is pressed, the inspection device (4) gives a judgment result that the controlled device (2) has a fault, and if the normal switch (6) is pressed, the next operation is performed. Proceed to the confirmation process.

Inspection device (4) and sequence controller
If signals are input and output in synchronization with (1) and the controlled device (2), a lot of inspection time is required when executing the operation check mode. Therefore sequence controller
In the operation check mode of (1), the inspection device (4) and the sequence controller (1) are not synchronized, the sequence controller (1) is in the input waiting state, and the sequence controller (1) and the controlled device (2 ) Is measured by the inspection device (4), and it is checked whether or not the sequence controller (1) is performing the operation according to the processing flow.

According to the present invention, if a failure occurs in the controlled device (2) or the sequence controller (1), the controlled device (2) and the sequence controller (1) output the output described in the processing flow. Utilizing the property of outputting a signal different from the above, the presence of a fault in the controlled device (2) and the sequence controller (1) is detected. for that reason,
In the operation check mode of the sequence controller (1) and the controlled device (2), all processes in the process flow describing the operation of the device stored in the inspection device (4) during the inspection must be performed at least once. Execute and check, and branch at least once to all conditional branch destinations in the processing flow.
The inspection device (4) controls signals between the sequence controller (1) and the controlled device (2). The inspection device (4) outputs from the sequence controller (1) to the controlled device (2) and outputs from the controlled device (2) to the sequence controller (1).
While monitoring the output to the server, it is checked whether or not the operation according to the processing flow is executed.

FIG. 2 shows an example of a processing flow of the sequence control device. Hereinafter, an inspection example of the controlled device that operates according to the processing flow of FIG. 2 will be described. The controlled device to be taken as an example here is a device having SW # 1 and SW # 2 as switches and LAMP # 1 and LAMP # 2 as indicators. When the initialization request signal INIT is set to 1 for the controlled device, The controlled device initializes its own operation, and the signal AC indicates that initialization has been completed successfully.
K is a device that outputs a signal of 1.

When the sequence controller is inspected in the operation check mode of the present inspection method, the control signals Cin and Bout are set to 1 and the other control signals are set to 0. Then, a signal generated when SW # 1 is turned off is output from the inspection apparatus to the sequence controller, and it is confirmed that a signal in which the signal INIT becomes 1 is not generated from the sequence controller. Then, after the signal ACK is output from the inspection apparatus, a signal generated when SW # 1 is turned on is output. As a result, the sequence controller outputs the initialization request signal INIT, and does not proceed to the next processing until the initialization completion signal ACK becomes 1. In this state, the inspection apparatus measures the signal INIT output from the sequence controller and checks whether it is 1 or not.

Next, after the inspection apparatus generates a signal generated when SW # 1 is on and a signal generated when SW # 2 is on, the signal ACK to the sequence controller is set to 1. Then, the sequence controller does not proceed to the next process in the determination of “SW # 1 is OFF?”, So the process to be executed from the determination of “ACK = 1?” To the determination of “SW # 1 is OFF?” Check that everything is running correctly. In this state, since the normal operation of the process “LAMP # 1 OFF” executed when “SW # 2 ON?” In FIG. 2 is not satisfied has not been confirmed, this occurs when SW # 1 is turned off. After the signal is output from the inspection device to the sequence controller, it is executed again from the beginning of the processing flow, the signal generated when SW # 2 is turned off is generated, and the signal generated when SW # 1 is turned on Then, the ACK signal is sequentially output from the inspection apparatus to the sequence controller, and the process of “LAMP # 1 off” which is an uninspection process is executed. The execution result of that process is "SW # 1 is OFF?"
Since the processing content is the same as the processing of “LAMP # 1 off” immediately before the conditional branch processing, it cannot be determined whether or not the execution result of “LAMP # 1 off” which is the unchecked processing has been correctly executed. In the processing in the input wait state in such a processing flow, a processing in which the execution result of the processing cannot be measured is input to the inspection apparatus by an interrupt to check whether or not the processing has been executed correctly.

When the controlled device is inspected in the operation check mode, the inspection is performed with the cooperation of an inspector. FIG.
In the case of inspecting the controlled device controlled by the processing flow of (1), the inspection apparatus issues a message to the inspector to press SW # 1. As a result, when the inspector turns on SW # 1 and presses the operation completion switch of the inspection device, the inspection device checks whether a signal generated when the SW # 1 is turned on is output from the controlled device. . Thereafter, an INIT signal is given from the inspection device to the controlled device, and it is checked whether or not the ACK signal is output from the controlled device. Then, a signal for turning on LAMP # 1 is output from the inspection apparatus to the controlled device, and the inspector is notified that LAMP # 1 should be turned on. I will have it. Then, when the normal switch is pressed, the inspection apparatus instructs the inspector to turn on SW # 2. When the inspector turns on SW # 2 and presses the operation completion switch, the inspection apparatus checks whether a signal generated by pressing SW # 2 is output from the controlled device. After that, the inspection apparatus outputs a signal for turning on LAMP # 2 to the controlled device, and gives an instruction to the inspector to confirm whether LAMP # 2 is on. The inspector
The confirmation result is notified to the inspection device by a normal switch or an abnormal switch.

In the same manner, it is confirmed that LAMP # 1 is turned off and that SW # 1 operates normally. In this state, “SW # 2
"ON?" Is not satisfied, the confirmation of the normal operation of the processing of "LAMP # 1 off" to be executed has not been completed, so the inspection is restarted from the beginning of the processing flow. The process up to the operation confirmation of the "LAMP # 1 lighting" process is inspected in the same way as the previous time, and after the operation confirmation of the "LAMP # 1 lighting" process is completed, the inspection device turns off SW # 2 to the inspector. Give instructions.
When the inspector turns off SW # 2 and presses the operation completion switch, the inspection apparatus outputs a signal for turning off LAMP # 1 to the controlled device in accordance with the processing flow. And the inspection device is
Instruct the inspector to check whether LAMP # 1 is turned off. As described above, the inspection of the controlled device proceeds through the dialogue between the inspector and the inspection device, and it is determined whether or not all the processing flows are correctly executed and whether or not all the conditional branch destinations are correctly branched. inspect.

[0019]

According to the present invention, it is possible to accurately and easily inspect a device realizing sequence control and its controlled device using the processing flow of the sequence control device. Inspection of the controlled equipment requires the cooperation of the inspector, but the inspection process automatically determines the inspection process based on the processing flow, and the inspector presents the operation contents and confirmation items to be performed by the inspector. Therefore, the inspection can be easily performed. further,
In this method, the inspection of the device that realizes the sequence control is automatically performed by the inspection device. As a result, this method significantly improves the productivity of the inspection of the sequence control device.
Further, since the present inspection method can inspect all processes and branch destinations in the processing flow, unlike the conventional method in which a human decides an inspection process, no inspection leakage occurs.

[Brief description of the drawings]

FIG. 1 is a block diagram illustrating a configuration example of an inspection system according to the present invention.

FIG. 2 is a flowchart illustrating a processing example of a sequence control device according to the present invention.

[Explanation of symbols]

1 sequence controller 2 controlled device 3 interferents over scan circuit 4 testing device 5 operation completion switch 6 normal switch 7 abnormal Switch

 ──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Eiji Tasaka 7-cho, Horie-cho, Matsuyama-shi, Ehime Miura Industrial Co., Ltd. Examiner Katsutoshi Shiozawa JP-A-54-103976 (JP, A) JP-A-49-38073 (JP, A) JP-A-63-211406 (JP, A)

Claims (1)

(57) [Claims] 1. A sequence controller (1) and controlled equipment controlled by the sequence controller (1)
And (2) are connected by at least one pair of input and output connection wirings, and an interface circuit (3) separately inserted into these connection wirings is connected to the inspection apparatus (4) with respect to the input side and the output side. The signal transfer between the sequence controller (1) and the controlled device (2) is performed in advance.
The inspection device (4) through the interface circuit (3)
The sequence controller (1) and the controlled device (2) perform an operation to check via the interface circuit (3) whether or not the device is operating according to a preset processing flow; and Inspection equipment (4) with the controlled equipment (2)
Operations and, the inspection device (4) to said sequence controller (1) the interface is the role of which is the role inspecting <br/> said sequence controller (1) via the interface circuit (3) A failure inspection method for a sequence control device, comprising an operation of inspecting the controlled device (2) via a circuit (3) .