JP3444080B2 - Simulation equipment - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a simulation device for simulating a sequencer for controlling equipment.

[0002]

2. Description of the Related Art A sequencer (also called a sequence control circuit) such as a PLC (Programmable Logic Controller) is widely used today as a device for controlling various facilities installed on a production line.

When the production line is started up, it is necessary to confirm a series of operations and functions by the PLC and to make adjustments before actually operating the equipment. Such work is usually done by prior simulation.

In this respect, in the conventional simulation, it is general to connect the actual equipment to the PLC and operate the equipment by turning on / off the switch of the equipment artificially by a person and confirm the movement. is there. This simulation is based on various operating states of the equipment (independent operation, automatic operation,
Continuous operation, etc.) and various abnormality processing are performed.

[0005]

However, in such a conventional simulation method, since a person operates the equipment, it is basically difficult to do, it takes time, and an error may occur.

Further, conventionally, since it is manually performed as described above, in a so-called tampering test (for example, when the power of the line is turned off and the restartability of the equipment is verified), the coordinator manually performs the stop test. Necessary and therefore difficult to implement at all times.

The present invention has been made by paying attention to the above problems in the simulation of a sequencer such as a PLC, and provides a simulation apparatus capable of surely performing various simulations including tampering tests in a short time and without fail. The purpose is to

[0008]

In order to achieve the above object, the invention according to claim 1 is a simulation apparatus for simulating a sequencer for controlling equipment, wherein a mode setting for setting a mode of the simulation is provided.
Setting means and the stains set by the mode setting means.
Depending on the simulation mode,
Equipment response means for reproducing the response operation of the equipment to be controlled,
The simulation set by the mode setting means
Operation of the actual equipment depending on the operation mode.
Pseudo operation generation means for generating pseudo, and the pseudo operation raw
The simulated operation signal generated by the
The transmission timing is set after each
Transmission that shifts and repeatedly transmits to the sequencer multiple times
And a simulation device having means .

In the present invention, the mode setting means is
For example, the simulation mode may be selected by the user.
Mode, and the equipment response means is set by the mode setting means.
Depending on the set simulation mode, the sequence
The response behavior of the equipment controlled by
Output (response) to the sequencer. This makes the actual
Pseudo sequence without connecting equipment to PLC
Automatically simulate various operations of the server according to the setting mode
Can be installed. In addition, the pseudo operation generation means sets the mode
The predetermined simulation mode is set by means
When the
The means for generating and transmitting is generated by the pseudo operation generating means.
The transmission timing of the generated pseudo operation signal is shifted.
Repeatedly sent to the sequencer (1) multiple times.
Believe. As a result, the operation of the worker is simulated.
The result is forcibly sent to the sequencer, so
Simulation mode that requires a series of operations (even if
If you do this, you can automatically carry out tests.

The invention according to claim 2 is the above-mentioned claim 1.
In the simulation device of
This is an operation to turn off the power of the equipment. This turns off the equipment
Simulate a broken state.

According to a third aspect of the present invention, in the simulation apparatus according to the first aspect, there is provided address conversion means for converting an input / output address of the sequencer.

In the present invention, the address conversion means converts the input / output address of the sequencer. As a result, it is possible to unify the variations in the input / output of the sequencer to be simulated.

According to a fourth aspect of the invention, in the simulation apparatus according to the first aspect, there is provided a response time changing means for changing the response time of the equipment response means to a value set by an operator.

According to the present invention, the response time changing means changes the response time of the equipment response means to the value set by the operator. This makes it possible to create an environmental condition close to the response time of the actual equipment and to verify the operation when the timing is changed.

[0015]

[0016]

According to a fifth aspect of the present invention, in the simulation apparatus according to the first aspect, there is provided abnormality generating means for artificially generating an abnormality relating to equipment when a predetermined simulation mode is set by the mode setting means. I have.

In the present invention, the abnormality generating means artificially generates an abnormality relating to the equipment when the predetermined simulation mode is set by the mode setting means, and outputs it to the sequencer. As a result, it is possible to perform a simulation when an abnormality occurs in the equipment.

[0019]

Therefore, according to the invention of claim 1, various operations of the sequencer can be simulated automatically in accordance with the setting mode without connecting actual equipment to the sequencer. Compared to the case of, it will be possible to confirm the operation and functions in advance and make adjustments in a short time and surely,
It is possible to reduce the time required for actual equipment startup adjustment and improve its accuracy. Also, the operation of the worker is reproduced in a pseudo manner.
And the result is forcibly sent to the sequencer.
Simulation mode that requires a certain series of operations (
For example, it is possible to automatically perform a fiddling test, and
It becomes possible to perform a realistic simulation.

According to the invention of claim 2, the actual equipment
Can simulate the situation when the
Wear.

According to the invention of claim 3, the above-mentioned claim
In addition to the effect of the invention described in 1 , the input / output address of the sequencer is converted, so that the variation in the input / output of the sequencer to be simulated can be unified.

According to the invention of claim 4, the above-mentioned claim
In addition to the effect of the invention described in 1, it is possible to create an environmental condition close to the response time of actual equipment, and it is possible to verify the operation when the timing is changed, so that the accuracy of simulation is improved and It is possible to find out troubles and problems in advance.

[0023]

According to the invention of claim 5 , the above-mentioned claim
In addition to the effect of the invention described in 1, the abnormality relating to the equipment is generated in a pseudo manner, so that the simulation when the abnormality occurs in the equipment can be performed.

[0025]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing the overall configuration of a simulation apparatus according to an embodiment of the present invention. This system targets PLC1 as a sequencer for controlling various equipment (for example, line operation board, welding equipment, robot, machine equipment) installed in a production line (hereinafter, this PLC1 is a simulation target PLC or simply a target). PLC), PLC2 that is the main subject of the simulation for this target PLC1.
(Hereinafter, this PLC 2 will be referred to as a simulation host PLC.
Or simply referred to as a host side PLC). A normal operation panel 3 is connected to the target PLC 1,
A predetermined operation panel 4 described later is connected to the host side PLC 2.

The target PLC1 is a normally used P
The LC is a main circuit 5 that manages the whole and controls the line control panel, a welding control circuit 6 that controls the welding apparatus, and a robot control circuit 7 that controls the robot, corresponding to the equipment to be controlled. And an actuator control circuit 8 for controlling the mechanical device, and a monitor circuit 9 for monitoring the operating state of each facility. The operation panel 3 is connected to the main circuit 5 and the monitor circuit 9. The signal of each operation switch on the operation panel 3 is sent to the main circuit 5 in the target PLC 1, and the operating state of each equipment is monitored by the monitor circuit 9 in the target PLC 1.
Is output from a display lamp or a screen on the operation panel 3.

For example, although not shown, the operation switch on the operation panel 3 is capable of operating an emergency stop switch used when the system is stopped rapidly, a power switch used when supplying power to the system, and equipment. Operation ready input switch to be used when placing in a state, cycle start switch used to start repeat operation, start switch used to start equipment, and to restore the system when the system stops due to an error. A reset switch and the like used at times are provided. These operation switches are operated by an operator. The above operation switches are
An operation preparation disconnection circuit that constitutes the main circuit 5 in the target PLC 1;
It is connected to an input power ON circuit, an output power ON circuit, an automatic operation condition circuit, an equipment start circuit, an abnormality recovery circuit, etc. (not shown). The equipment starting circuit is connected to the welding control circuit 6, the robot control circuit 7, and the actuator control circuit 8 and has a function of sending a starting signal to these circuits 6 to 8. Further, a cycle counter (not shown) that displays the number of repeats when the cycle start switch is turned on is connected to the equipment starting circuit.

When the equipment installed in the production line is actually operated, the target PLC 1 uses the main circuit 5 as the line operation board, the welding control circuit 6 as the welding device, the robot control circuit 7 as the robot, and the actuator control circuit 8 as the robot. Are used by connecting them to the respective mechanical devices, but when performing a preliminary simulation before that, they are connected to the simulation host side PLC 2 via the host connection circuit 10 as shown in FIG.

The host side PLC 2 has a main circuit 11 for performing overall control, a welding response circuit 12 for outputting a response corresponding to an actual welding device, and a robot response circuit 13 for outputting a response corresponding to an actual robot. And an actuator response circuit 14 that outputs a response corresponding to an actual mechanical device.
And have. These circuits 11 to 14 are respectively connected to the main circuit 5, the welding control circuit 6, the robot control circuit 7, and the actuator control circuit 8 in the target PLC 1 via the address conversion circuit 15. In addition, the host PLC2
Is a response time variable circuit 16 for varying the response times of the response circuits 12 to 14, an abnormality generation circuit 17 that artificially generates an abnormality relating to each facility, and a pseudo operation of an operator in the actual facility. And a pseudo operation circuit 18 for generating The response time varying circuit 16 and the abnormality generating circuit 17 are connected to the respective response circuits 12 to 14, and the pseudo operation circuit 18 is connected to the main circuit 11.

On the operation panel 4 of the host side PLC 2, a digital switch 19 used when changing the response time of each equipment, an abnormality occurrence switch 20 for selecting a mode (abnormality occurrence mode) for simulating various kinds of abnormality processing,
A continuous operation switch 21 for selecting a mode for performing a continuous operation simulation (continuous operation mode), a tampering switch 22 for selecting a mode for simulating a tampering test (a tampering test mode), and the like are provided. The digital switch 19 is connected to the response time variable circuit 16, the abnormality occurrence switch 20 is connected to the abnormality occurrence circuit 17, and the switch 2 which is called the continuous operation switch 21.
2 is connected to the pseudo operation circuit 18. Use the error occurrence mode to verify the recoverability when an error occurs in each equipment (for example, limit switch error, welding error, etc.), and use the continuous operation mode to continuously move the equipment. It is used to verify whether it works reliably, and the tampering test mode is used, for example, to verify the restartability of equipment when the line is suddenly cut off.

The mode setting means is the abnormality generation switch 20, the continuous operation switch 21, and the tampering switch 22, the equipment response means is the welding response circuit 12, the robot response circuit 13, and the actuator response circuit 14, and the address conversion means is The address conversion circuit 15, the response time changing means by the digital switch 19 and the response time varying circuit 16, the pseudo operation generating means by the pseudo operation circuit 18, the transmitting means by the main circuit 11, and the abnormality generating means by the abnormality generating circuit 17. Each is configured.

Although the host-side PLC 2 and the operation panel 4 are separately configured here, the present invention is not limited to this, and the two are integrally configured so that the operation unit is the host. It is also possible to incorporate it in the side PLC.

FIG. 2 is an explanatory diagram of the address conversion function.
The address conversion circuit 15 in the host-side PLC 2 is composed of, for example, a conversion file. By setting each input / output number in this conversion file, the host side PL
The input / output addresses of the target PLC1 viewed from C2 are unified.

Specifically, taking the input / output (I / O) of the actuator control circuit 8 in the target PLC 1 as an example, in the mutually related solenoid valve and limit switch, the signal to the solenoid valve is, for example, the output address "O". : 002/15 ”and the signal of the limit switch for detecting the operation limit is input address“ I:
000/01 ”, the input and output forming these pairs are converted to the address of the same number (here, for example,“ 1 ”) by the conversion file 15, and the actuator response circuit 14 has the converted address. Exchanges signals with. The conversion file is provided with an appropriate number (for example, 20) of input / output numbers (1 to 20) of pairs so that it can correspond to most facilities. These conversion files are prepared at least for each equipment.
The parameters for determining the address translation are set in advance before the simulation is executed.

FIG. 3 is a block diagram of a circuit configuration for realizing the response time variable function. As shown in the figure, the response time variable circuit 16 includes a digital switch 19 of the operation panel 4.
A digital input section 23 for input-processing a signal (digital input) from the digital input section, a radix conversion section 24 for converting the output of the digital input section 23 into a decimal number, and an amplification section for amplifying the output of the radix conversion section 24 by a predetermined magnification. It consists of 25. For example, each response circuit 12 to 14 is provided with a timer unit 26, and the output of the response time variable circuit 16 (more specifically, the amplification unit 25) is stored in a memory 27 in each timer unit 26 as a timer set value. It is supposed to be stored.

For example, taking the case where the timer set value is variable in units of 0.1 seconds from 0 to 1.5 seconds, 4-bit data is sent from the digital switch 19 to the digital input section 23. The radix 16 (= 2 ⁴ ) hexadecimal number represented by the 4-bit data is converted to a decimal number by the radix conversion unit 24 to be 0 to 15. The timer base value at this stage is 0.01 second. Therefore, the output of the radix conversion unit 24 is amplified 10 times by the amplification unit 25 and 0 to
Each timer unit 2 is set to 1.5 seconds, and the result is used as a timer setting value.
6 in the memory 27.

The response time will be explained using an example similar to FIG.
It looks like this: The signal to the solenoid valve is the target PL
The output address of the actuator control circuit 8 of C1 is "O:
002/15 ", the address conversion circuit (conversion file) 15 in the PLC 2 on the host side outputs" output 1 ".
Of the actuator response circuit 14
It is received by the output 1 reception unit 28 therein. At the same time as this reception, the timer unit 26 is activated, and when the timer set value has elapsed, the corresponding input 1 transmission unit 29 outputs a response (corresponding to the signal of the limit switch), and the address conversion circuit (conversion file) 15 It is sent from the address of "input 1" to the input address "I: 000/01" of the actuator control circuit 8 of the target PLC 1.

For example, since the response time differs depending on each equipment such that the stroke of the cylinder is long or short, by making the response time variable as in the present invention, it is possible to create an environmental condition close to the response time of the actual equipment. it can. Also, by changing the response time, it becomes possible to operate the trial in continuous operation mode faster or slower than the speed of the actual machine to verify whether the equipment operates normally, troubles and circuit defects etc. It is possible to excavate in advance.

Next, an example of simulation by pseudo operation will be described. FIG. 4 is a flowchart showing an example of a simulation of a tampering test. The operation shown here is mainly executed in the pseudo operation circuit 18 in the host PLC 2.

Here, the case of an instantaneous power failure will be taken as an example of a tampering test. Specifically, the power is turned off once every 5 seconds, and the power failure timing is gradually shifted by 0.1 seconds each time the equipment completes one cycle, and this is repeated for 50 cycles at any timing. Verify that the equipment can be restarted properly in the event of a power outage.

That is, the PLC on the host side by the worker
When the test switch 22 that is called the continuous operation switch 21 on the operation panel 4 of No. 2 is turned on, the pseudo operation circuit 18
Performs a predetermined initialization and sets the parameter T1 to the initial value x
(For example, 0) (second), the parameter T2 is set to 5 (second), and the value of the cycle counter C is set to the initial value 1 (step S1). Here, the parameter T1 determines the timing of occurrence of a tampering (power failure) and is the first timer time after completion of the cycle, and the parameter T2 is the interval of tampering occurrence (time interval) and the second time after completion of the cycle. It is the subsequent timer time.

When the initial setting of step S1 is completed, the built-in timer is started (step S2), and the operation preparation ON state (the same state as the operation preparation ON switch on the operation panel 3 of the target PLC 1 is turned ON by the operator). Whether the cycle start is ON (step S3), the cycle start switch on the operation panel 3 of the target PLC 1 is turned on by the operator.
It is checked whether or not it is in the same state as N (step S5) and whether it is in the equipment start-up state (the same state as when the start switch on the operation panel 3 of the target PLC 1 is turned on by the operator) (step S7). As a result, if NO in step S3, the operation preparation input signal is applied to the target PLC.
Output to the output power ON circuit of the main circuit 5 in 1 to forcibly set the operation preparation ON state (step S4), and step S5
If the answer is NO, the target signal for the cycle start ON signal is PL.
Output to the automatic operation condition circuit of the main circuit 5 in C1 to forcibly set the cycle start to the ON state (step S6). If NO in step S7, the start signal is the equipment start circuit of the main circuit 5 in the target PLC 1. To force the equipment start-up ON state (step S8). The above signals are sent from the pseudo operation circuit 18 to the target PLC 1 via the main circuit 11 and the address conversion circuit 15.

Thereafter, it is judged whether or not a predetermined time T1 (first time after completion of cycle) or T2 (second time or more after completion of cycle) has elapsed (step S
9) If the time has not passed, the process returns to step S3, and if the time has passed (time-up), an emergency stop signal is sent via the main circuit 11 and the address conversion circuit 15 to the operation preparation disconnection circuit of the main circuit 5 in the target PLC 1. To the emergency stop state (the same state as when the operator turns on the emergency stop switch on the operation panel 3 of the target PLC 1) (step S1).
0).

Thereafter, it is judged whether or not the cycle is completed (step S11), and if NO, the process immediately returns to step S2, but if YES, the value x of the parameter T1 is increased by 0.1 (second). After that (step S12), the value of the cycle counter C is incremented by 1 (step S13), and unless the counter value C exceeds 50 (times) (step S14), the process returns to step S2. At this time, the emergency stop state of the equipment is from step S3 to step S
It will be restored and restarted through the process of 8.

As described above, by artificially reproducing the operation of the worker in the actual equipment and forcibly operating the input of the target PLC 1 from the host side PLC 2 through the communication line, it is difficult for the conventional human operator in terms of timing. It is possible to automatically perform tedious tests that require a long time or take a long time, and more realistic simulations can be performed.

It should be noted that the contents of the tampering test are not limited to the above examples, of course, and the tampering test of any kind can be carried out if the procedure of the operation of the operator in the actual machine is programmed in advance. it can.

FIG. 5 is a flow chart showing an example of simulation of abnormality processing. The operation shown here is mainly executed by the abnormality generation circuit 17 in the host-side PLC 2.

When the operator turns on the abnormality occurrence switch 20 on the operation panel 4 of the PLC 2 on the host side, the abnormality occurrence circuit 17 artificially causes an abnormality relating to each equipment,
Perform the restoration process. Here, as the abnormality relating to the equipment, for example, an abnormality relating to a mechanical device (actuator abnormality), an abnormality relating to a welding device (welding abnormality), and an abnormality relating to a robot (robot abnormality) are considered.

That is, the actuator abnormality is randomly generated, and when the abnormality occurs, the abnormality occurrence instruction is output to the actuator response circuit 14 (step S2).
1). The actuator response circuit 14 returns an abnormality to the actuator control circuit 8 in the target PLC 1 when receiving an abnormality occurrence instruction, and otherwise performs a normal operation. After that, it is determined whether there is any abnormality (step S
22) If there is an abnormality, a reset signal is output to the abnormality recovery of the main circuit 5 in the target PLC 1 to forcefully recover from the abnormal state (step S23), and the process returns to step S22.
If there is no abnormality, the process proceeds to the next step S24.

In step S24, a welding abnormality is randomly generated, and when the abnormality occurs, an abnormality generation instruction is output to the welding response circuit 12 (step S24). The welding response circuit 12 returns an abnormality to the welding control circuit 6 in the target PLC 1 when receiving an abnormality occurrence instruction, and otherwise performs a normal operation. Then, it is determined whether or not there is an abnormality (step S25), and if there is an abnormality, a reset signal is output to the abnormality recovery of the main circuit 5 in the target PLC 1 to forcefully recover from the abnormality state (step S26). It returns to step S25. If there is no abnormality, the next step S27
Proceed to.

In step S27, a robot abnormality is randomly generated, and when an abnormality occurs, an abnormality generation instruction is output to the robot response circuit 13 (step S2).
7). The robot response circuit 13 returns an abnormality to the robot control circuit 7 in the target PLC 1 when receiving an abnormality occurrence instruction, and otherwise performs a normal operation. Then, it is determined whether or not there is an abnormality (step S28), and if there is an abnormality, a reset signal is output to the abnormality recovery of the main circuit 5 in the target PLC 1 to forcefully recover from the abnormality state (step S29). It returns to step S28. If there is no abnormality, the process proceeds to the next step S30.

In step S30, it is determined whether or not the simulation is ended by inputting a simulation end signal or the like. If NO, the process returns to step S21, and if YES, the series of abnormal process simulations is ended.

In this way, since the part corresponding to the actual machine is managed in the host side PLC 2, it is possible to artificially generate an abnormality relating to each equipment, and automatically perform a simulation when an abnormality occurs in the equipment. It becomes possible.

It should be noted that this abnormality processing simulation can be combined with the continuous operation mode.

[Brief description of drawings]

FIG. 1 is a block diagram showing an overall configuration of a simulation apparatus according to an embodiment of the present invention.

FIG. 2 is an explanatory diagram of an address conversion function.

FIG. 3 is a block diagram of a circuit configuration for realizing a response time variable function.

FIG. 4 is a flowchart showing an example of a simulation of a tampering test.

FIG. 5 is a flowchart showing an example of a simulation of abnormal processing.

[Explanation of symbols]

1… Simulation target PLC (sequencer) 2 ... Simulation host side PLC 3, 4 ... Operation panel 11 ... Main circuit (transmitting means) 12 ... Welding response circuit (equipment response means) 13 ... Robot response circuit (equipment response means) 14 ... Actuator response circuit (equipment response means) 15 ... Address conversion circuit (address conversion means) 16 ... Response time variable circuit (response time changing means) 17 ... Abnormality generation circuit (abnormality generation means) 18 ... Pseudo operation circuit (pseudo operation generation means) 19 ... Digital switch (response time changing means) 20 ... Abnormality occurrence switch (mode setting means) 21 ... Continuous operation switch (mode setting means) 22 ... Twist switch (mode setting means)

Claims (5)

(57) [Claims] 1. A simulation apparatus for simulating a sequencer (1) for controlling equipment, comprising a mode setting device for setting a mode of the simulation.
Setting by the steps (20, 21, 22) and the mode setting means (20, 21, 22)
Depending on the simulation mode
Reproduce the response operation of equipment controlled by service (1)
Set by equipment response means (12, 13, 14) and the mode setting means (20, 21, 22)
Depending on the simulation mode
Pseudo-operation generator that pseudo-generates the operator's operation
The stage (18) and the pseudo-operation generated by the pseudo-operation generation means (18).
The operation signal is sent when the simulation cycle ends.
In addition, the transmission timing is shifted and the sequencer (1)
And a transmission means (11) for repeatedly transmitting a plurality of times.
That the simulation device. 2. The pseudo operation is an operation of turning off the power of the equipment.
The simulation apparatus according to claim 1, wherein 3. An address conversion means (15) for converting an input / output address of the sequencer (1).
1. The simulation device according to 1 . 4. The equipment response means (12, 13, 14)
2. The simulation apparatus according to claim 1, further comprising response time changing means (16, 19 ) for changing the response time of ( 1 ) to a value set by an operator. 5. An abnormality generating means (17) for artificially generating an abnormality relating to equipment when a predetermined simulation mode is set by the mode setting means (20).
The simulation apparatus according to claim 1, further comprising: