JP2889603B2 - Control device failure analysis device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial applications]

The present invention relates to a failure analysis device for a case where a machine device is abnormally stopped due to occurrence of a trouble while being operated by its control device.

[Prior art]

Conventionally, the number of times a plurality of mechanical devices in a series of flow operations have abnormally stopped due to some trouble during automatic operation by the control device, and the stop time until the return (for example,
The only way to obtain the total (one month as a monitoring period) is for an operator or the like to take a record each time, and to tabulate based on those records.

[Problems to be solved by the invention]

As described above, if a mechanical device stops abnormally due to any trouble during its automatic operation by the control device, the worker or the like needs to concentrate on returning to the stopped state as soon as possible. The measurement and recording of the number of stops and the stop time for each device or operation is sparse, and furthermore, when working unattended, it is impossible to measure itself and obtain accurate data. Could not. The present invention has been made in order to solve the above-described problems, and has as its object the purpose of the present invention when each of the mechanical devices stops abnormally due to trouble during automatic operation by the control device. An object of the present invention is to provide a failure analysis device of a control device capable of accurately and automatically measuring the number of stops or the stop time within a predetermined period for each operation process.

[Means for Solving the Problems]

According to a configuration of the invention for solving the above-mentioned problem, an input / output state of a plurality of input / output devices for controlling a mechanical device is set in advance for each of a plurality of operating processes in one cycle operation in which the mechanical device repeatedly executes. State storing means for storing, every time the machine device is abnormally stopped during operation, state detecting means for detecting the input / output state of a plurality of input / output devices in the operation process in which the abnormal stop occurred, and state detecting means. Operating step determining means for comparing the detected input / output state with the input / output state of each of the plurality of operating steps stored in the state storage means to identify the operating step in which the abnormal stop has occurred; Integrated storage means for integrating and storing at least one of the number of abnormal stop times and the stop time from the abnormal stop time to the return time for each operation step specified by the means during a preset period. And it said that there were pictures.

[Action]

The progress of the input / output state of each input / output device that changes with a plurality of operation steps in one cycle operation repeatedly executed by the mechanical device is stored by the state storage means. On the other hand, each time the mechanical device is abnormally stopped during operation by the state detecting means, the input / output state of a plurality of input / output devices in the operation process in which the abnormal stop has occurred is detected. The operation process determining means compares the input / output state detected by the state detection means with the input / output state of each of the plurality of operation steps stored in the state storage means, and compares the input / output state at the time of abnormal stop of the mechanical device. The operation process in is specified. For each of the specified abnormal stop operation steps, the integration storage means integrates and stores at least one of the number of abnormal stops and the stop time from the abnormal stop time to the return time during a preset period.

【Example】

Hereinafter, the present invention will be described based on specific examples. FIG. 1 is a configuration diagram showing the overall configuration of a failure analysis device for a control device according to the present invention. 10, 20, and 30 are machines for automatically machining a workpiece, and the machines 10, 20, and 30 are control devices 11, 21, and 31, respectively.
Is automatically controlled by Reference numeral 40 denotes an automatic transfer device, which is automatically controlled by a control device 41 of the automatic transfer device.
Machined one after another by 10,20,30. Reference numeral 50 denotes a computer, and its CPU 51 has output signals from the control devices 11, 21, and 31 of the mechanical devices 10, 20, and 30 and output signals from the control device 41 of the automatic transfer device 40, which are interfaces 55 and 56, respectively. Has been entered through. 52 is a ROM storing a control program of the CPU 51, 53
Achieves a state storage means and the like with a RAM for storing data.
Further, a keyboard 61 for inputting various data and a CRT display device 62 for displaying the data on the screen are connected to the CPU 51 via an interface 57. Further, a printer 63, which is an external output device, is also connected to the CPU 51 via the interface 57. First, a description will be given with reference to FIG. 4 showing a machine and an electric configuration for operating a cylinder as an example in a mechanical device unit (for example, the mechanical device 10) and FIG. 5 (a) showing a cycle chart in the operation. I do. As shown in FIG. 4, the cylinder 71 is at the original position at the left end, and the dog 72 integrally provided with the cylinder 71 has the LS1 (limit switch) turned on. When SOL1 (solenoid valve) is turned on (ON state), the cylinder 71 is moved toward the forward end, which is the right end, and the dog 72 sets LS1 (limit switch) to (OFF state) at the beginning of the movement, Just before LS2
(Limit switch) is set to (ON state) (forward in the cycle chart of FIG. 5A). Next, when SOL2 (solenoid valve) is turned on (ON state), the cylinder 71 is moved from the forward end, which is the right end, toward the original position, which is the left end, and the dog 72 is moved to the LS2 position at the beginning of the movement.
(Limit switch) is set to (OFF state) again, and LS1 (Limit switch) is set to (ON) again just before the home position is reached.
State) and returns to the initial state (retreat in the cycle chart of FIG. 5 (a)). In order to perform the above operations, the signal lines of LS1, LS2, SOL1, and SOL2, which are input / output devices, are I / O units.
The I / O unit 76 is connected to a programmable controller 77, and the programmable controller 77 is connected to the computer 50 described above. still,
Reference numeral 78 denotes an operation panel connected to the I / O unit 76 for each mechanical device. Next, when sampling at the unit
Based on FIG. 2 which is a flow chart showing the processing procedure of the CPU 51, FIG. 4 and FIG. 5 (a) show the result of time sharing the input / output state in a short time (0.1 second). This will be described with reference to FIG. 5 (b) and FIG. 5 (c) obtained by editing and rounding the result of the time sharing. In step 100, the input / output state of each input / output device is time-shared, and as shown in FIG. 5 (b) with respect to FIG. 5 (a) which is a cycle chart of the operation of FIG.
Sampling and storage are performed every second, and the process proceeds to step 102. In step 102, it is determined whether the storage of the input / output state of each input / output device in one operation cycle of the mechanical device has been completed. Here, if storage of the input / output state of each input / output device in one operation cycle has not been completed, the determination is NO, and the process of step 100 is repeated. Then, when the storage of the input / output state of each input / output device in one operation cycle is completed in step 102, the determination is YES, and the process proceeds to step 104. In step 104, those data patterns of the same input / output state stored in step 100 which cannot be distinguished as different machine operations are edited as one data. Then, the process proceeds to step 106, where a number is added to each pattern for each operation edited in step 104, and the program ends. When the processing of steps 104 and 106 is performed, as shown in FIG. 5B, the time-shared data does not change in the input / output state of each input / output device. Since the same operation is performed at the location (time), data is edited for each operation by editing and rounding. That is, the data shown in FIG. 5 (b) is edited and rounded to consist of only the characteristic data pattern of the input / output state of each input / output device. ) Is a state transition table as shown in FIG. Next, a flowchart showing a processing procedure of the CPU 51 at the time of abnormal stop of the mechanical device (for example, the mechanical device 10) is a third flowchart.
The description will be given with reference to FIG. 6, which is an explanatory diagram showing the data flow at that time based on the drawing. The machine number j of the mechanical device that has stopped abnormally in step 200 is determined. Next, the process proceeds to step 202 to start time measurement for the machine number j of the mechanical device that has abnormally stopped to know the stop time of the machine number j of the mechanical device. Next, the process proceeds to step 204 for achieving the state detecting means. As shown in FIG. 6, for example, as shown in FIG. As the input / output state of each input / output device in the stopped mechanical device 10 (device number j), LS1, LS2, SOL1
By reading SOL2, the stop state in abnormal stop is detected. Then, the process proceeds to step 206 for achieving the operation process discriminating means, and a state transition table (FIG. 5 (c)) including the input / output state of each input / output device and the pre-sampled data pattern at the abnormal stop detected in step 204 Is performed, and the operation number in the state transition table is obtained. For example, the input / output states LS1, LS2, SOL1, and SOL2 of each input / output device read in step 204 may coincide with the operation 005 in the state transition table (FIG. 5C) composed of sampled data patterns. I understand. That is, in this case, the cylinder 71 shown in FIG.
Was found to have stopped abnormally during retreat. Next, the routine proceeds to step 208, in which the number of times of the abnormal stop 1 this time is integrated and stored in the file position C (n) corresponding to the machine number and the operation number (FIGS. 7A and 7B). . Then, in step 210, it is determined whether or not a malfunction in the mechanical device is repaired, the abnormal stop is released, and the operation cycle of the mechanical device is restarted. Waiting for the driving cycle to resume, step 212
Then, the stop time during which the abnormal stop was performed is integrated and stored in the file position Ct (n) corresponding to the machine number and the operation number (FIGS. 7A and 7B). To end. Incidentally, the accumulation storage means is achieved by step 208 and step 212. In this way, the number of stops and the stop time in the abnormal stop for each machine number and its operation number are totaled each time. Then, when the preset time (for example, one month) is added, the computer automatically outputs the number of stops and the number of stops for each machine number as shown in FIG. A totaling table of time, a Pareto chart for each stop count as shown in FIG. 8 (b) and a Pareto chart for each stop time as shown in FIG. 8 (c) are created and output. In addition, as an output item for each operation of the specific mechanical device, a summary table of the number of stops and the stop time for each operation number as shown in FIG. 9A and the number of stops as shown in FIG. 9B Another Pareto chart and a Pareto chart for each stop time as shown in FIG. 9 (c) are created and output. In this way, an accurate table and Pareto chart in abnormal stop are automatically created for each machine and each operation. Therefore, by using these tables and Pareto diagrams, it is easy to find the machine numbers and operation numbers in the order of the number of stoppages and the like and the problems are large, and it is possible to take a reliable measure, so that the entire machining line can be used. The operating rate and quality control are significantly improved. In the above-described embodiment, the computer 50 automatically samples the input / output state of each input / output device in one operation cycle of each mechanical device and edits the result for each operation, and creates and stores a state transition table. However, the state transition table may be created by an operator or the like manually inputting from the keyboard 61 and storing it.

【The invention's effect】

The present invention, every time the machine is stopped abnormally during operation,
State detecting means for detecting an input / output state of a plurality of input / output devices in an operation step in which an abnormal stop has occurred; and an input / output state detected by the state detection means. An operation process discriminating means for specifying an operation process in which an abnormal stop has occurred in comparison with the elapse of the input / output state of the operation process, and the number of abnormal stops and the time of the abnormal stop for each operation process specified by the operation process discriminating means And an integration storage means for integrating and storing at least one of the stop time up to the return time during a preset period, so that the number of stop times or the stop time within a certain period for each operation process of the mechanical device is provided. It becomes possible to measure accurately and automatically. As a result, failure analysis for each operation step is facilitated.

[Brief description of the drawings]

FIG. 1 is a configuration diagram showing the entire configuration of a failure analysis device for a control device according to a specific embodiment of the present invention. FIG. 2 and FIG.
FIG. 4 is a flowchart showing a processing procedure of a CPU used in the apparatus of the embodiment. FIG. 4 is an explanatory diagram showing an example of a mechanical device unit according to the apparatus of the embodiment. FIG. 5A is a cycle chart corresponding to the case of FIG. FIG. 5B is an explanatory diagram showing data obtained by time sharing the input / output state of each input / output device in FIG. 5A. Fig. 5 (c)
FIG. 5B is an explanatory diagram showing a state transition table in which FIG. 5B is edited. FIG. 6 is an explanatory diagram showing the input / output state of each input / output device detected by the computer according to the apparatus of the embodiment in which the mechanical device in which the abnormal stop has occurred is detected at the time of the abnormal stop. 7 (a) and 7 (b) are explanatory diagrams for explaining the counting of the number of stops and the stop time with respect to the machine number and the operation number. Fig. 8 (a)
FIGS. 4C to 4C are tables showing the number of times of stoppage and the number of times of stoppage for each machine number printed out as output items for each machine by the failure analysis device of the control device of the present invention, and a Pareto chart for each number of times of stoppage and for each stoptime. FIGS. 9 (a) to 9 (c) are tabulation tables of stop times and stop times for each operation number printed out as output items for each operation of a specific machine by the failure analysis device of the control device of the present invention, and for each stop number. 6 is a Pareto diagram for each of the stop time and the stop time. 10,20,30… Mechanical device 11,21,31… Control device 40… Transport device, 50… Computer 51… CPU, 52… ROM, 53… RAM 55,56,57… Interface 61 …… Keyboard, 62 …… CRT display 63 …… Printer

────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-1-93897 (JP, A) JP-A-60-62817 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) G05B 23/02 G06F 11/34

Claims (1)

(57) [Claims] 1. State storage means for preliminarily storing input / output states of a plurality of input / output devices for controlling a mechanical device for each of a plurality of operating processes in a one-cycle operation in which the mechanical device repeatedly executes; Each time the mechanical device is abnormally stopped during operation, a state detecting means for detecting an input / output state of the plurality of input / output devices in the operation process in which the abnormal stop occurred, and a state detected by the state detecting means. An operation step discriminating means for comparing an input / output state with the input / output state of each of the plurality of operation steps stored in the state storage means to identify an operation step in which the abnormal stop has occurred; Integrate for integrating and storing at least one of the number of abnormal stop times and the stop time from the abnormal stop time to the return time for each operation process specified by the process determining means during a preset period. Failure analysis apparatus of the control apparatus characterized by comprising a 憶 means.