JP4486050B2 - Control system for production equipment and control management system for production equipment - Google Patents

Description

  The present invention includes a master control device that controls the entire production facility, and a plurality of slave control devices that are subordinately controlled by the master control device and control a drive unit having at least an actuator in the production facility. The present invention relates to a control system for equipment and a control management system for production equipment.

  Conventionally, as a control system for such production equipment, for example, Patent Document 1 discloses a control system for a component mounting apparatus. This control system is composed of a main board that controls the entire production facility, and a plurality of slave boards that control I / O boards (parts) in servo motors, actuators, and other drive units and sensors in the production facility. The main board issues a fault diagnosis instruction to each slave board, and the slave board that received the diagnosis instruction performs a fault diagnosis of itself and the I / O board and sends the diagnosis result to the main board. Thus, the failure diagnosis is managed in an integrated manner on the main board. Such failure diagnosis information can be recognizable to the operator by being input to the server from the main board via the LAN or the like (see, for example, Patent Document 2).

JP-A-4-282707 JP 2003-69730 A

  However, in such a conventional control system configuration, since a configuration in which all the slave boards are directly connected individually to the main board is adopted, cable connection connectors for the number of installed slave boards, Individual communication cables are required. Therefore, in a control system for controlling production equipment having a more complicated equipment configuration, the number of slave boards to be installed increases, and accordingly, the installation quantity of connectors for cable connection also increases. Furthermore, not only the number of communication cables for individually connecting the main board and individual slave boards increases, but also the cable length increases. Therefore, there is a problem that it is difficult to reduce the equipment cost required for the hardware configuration of the control system for production equipment. In addition, if the number of cables and the length are increased in this way, there is a problem that the production equipment may not be made compact.

  In addition, the diagnostic result information of the fault diagnosis processing performed on each slave board is collected on the main board, and then the information is input from the main board to the server through the LAN, so that the operator is diagnosed through the server. In the configuration of the conventional control system in which the result information is notified, there are many steps until the operator recognizes the information, and there is a problem that the speed of information transmission is excluded.

  In particular, in a configuration in which a flexible cable is used as a communication cable in a control system and a slave board is provided on a movable part, when the movable part is moved, the flexible cable is moved accordingly. Therefore, as the number of movements by the movable part increases, the deterioration of the cable progresses, and eventually the communication may be interrupted or the cable itself may be disconnected.As a result, appropriate operation control for the movable part can be performed. It may become impossible, that is, a fatal failure of the device may occur. Accordingly, it is required to accurately diagnose such cable deterioration and prevent a fatal failure of the apparatus in advance, and such deterioration information needs to be notified to the operator promptly. However, the above-described system configuration has a problem that such a request cannot be satisfied.

  Accordingly, an object of the present invention is to solve the above-described problem, and a main control device that controls the entire production facility, and a drive that is subordinately controlled by the main control device and has at least an actuator in the production facility. Control system and control management system capable of realizing reliable and prompt communication while reducing the equipment cost required for the hardware configuration in a control system for production equipment comprising a plurality of subordinate control devices for controlling a part Is to provide.

  In order to achieve the above object, the present invention is configured as follows.

According to the first aspect of the present invention, a main controller that controls the entire production facility;
A plurality of sub-control devices that are subordinately controlled by the main control device and control a drive unit having at least an actuator in the production facility;
A communication cable constituting one closed control loop is provided by connecting the master control device and the plurality of slave control devices in succession,
Provided is a control system for a production facility, wherein periodic and real-time serial communication for controlling the production facility is performed in the control loop.

According to the second aspect of the present invention, as each of the slave control devices,
A plurality of slave control devices for controlling a plurality of drive units for controlling the drive unit;
The slave control device for controlling the information acquisition unit for controlling a plurality of information acquisition units for acquiring positioning information for positioning control of the drive unit,
As the above control loop,
A drive control loop in which the main control device and the slave control devices for controlling the respective drive units are connected in series by the communication cable;
The control for production facilities according to the first aspect, comprising: an information acquisition control loop in which the main control device and the slave control devices for controlling the respective information acquisition units are connected in series by the communication cable. Provide a system.

According to the third aspect of the present invention, the production facility has a fixed part and a movable part moved with respect to the fixed part,
In the control loop, at least one slave control device is provided in the movable portion, and another slave control device or the main control device is provided in the fixed portion, and the control device and the fixed portion on the movable portion side are provided. The control device on the side is connected by a flexible cable as the communication cable,
A communication information transmitting device provided in either one of the control unit on the fixed part side or the control unit on the movable part side;
A communication information receiving device connected to the communication information transmitting device via the flexible cable so that the communication information output from the communication information transmitting device can be received while being provided on the other of the above,
A communication error detection unit that detects whether or not a communication error has occurred with respect to reception of the communication information for each serial communication cycle in the communication information receiving device;
A storage unit for accumulating and recording the number of communication error occurrences detected by the communication error detection unit;
When the data of the number of times of accumulation and the data of the specified number of times set in advance can be read from the storage unit for comparison processing between the two, and the number of times of accumulation is equal to or more than the specified number of times by performing the comparison process The control system for production facilities according to the first aspect further includes a cable deterioration diagnosis device including a deterioration diagnosis processing unit that outputs a deterioration warning as deterioration diagnosis processing of the flexible cable.

According to the fourth aspect of the present invention, the flexible cable is an optical fiber capable of communicating the communication information as optical information,
In the cable deterioration diagnosis device,
The communication information transmitting device is a light emitting device that transmits the optical information,
The communication information receiving device is a light receiving device that receives the transmitted optical information,
The communication error detection unit provides the control system for production equipment according to the third aspect, which detects the communication error based on the optical information received by the light receiving device.

  According to a fifth aspect of the present invention, there is provided the control system for production equipment according to any one of the first to fourth aspects, wherein an optical fiber is used as the communication cable constituting the control loop. .

According to a sixth aspect of the present invention, the production facility is a component mounting apparatus that produces a mounting substrate in which components are mounted on a substrate,
The control device on the movable part side is a head control device mounted on a mounting head device that performs component mounting on the substrate by being controlled to move relative to the substrate,
The control device on the fixed part side is a mounting control device that performs movement control of the mounting head device through the head control device and is fixed to the component mounting device main body side,
In the control loop, the cable deterioration diagnosis is performed while performing the periodic real-time serial communication via the flexible cable for movement control of the mounting head device through the head control device by the mounting control device. An apparatus provides the control system for production facilities as described in the 3rd aspect or 4th aspect which implements the deterioration diagnosis process of the said cable.

According to a seventh aspect of the present invention, a control system for a plurality of production facilities according to any one of the first to sixth aspects;
The control loop in each of the control systems is connected via a communication network, and serial communication is performed via the communication network and the control loop with the master control device or the slave control device in at least one control loop. Thus, a control management system for a production facility is provided, comprising a management computer for managing the control state of the production facility.

  According to the present invention, the master control device and each slave control device are connected by the communication cable so as to form a continuous control loop. In this case, the number of installed devices increases, and the number of cable connection connectors that need to be provided in the main control device can be reduced. Moreover, since it is only necessary to connect adjacent control devices so as to form the continuous control loop, the wiring of the communication cable can be reduced. In addition, by reducing wiring, it is possible to reduce the cause of failure in production facilities, and as a result, it is possible to realize a stable control system with few failures at low cost.

  Furthermore, since the management computer adopts a configuration capable of serial communication with the master control device or the slave control device in the control loop via the control loop and the communication network, the management computer and each control device It is possible to realize direct information communication between the two, and it is possible to promptly notify the operator of important information such as failure information.

  Embodiments according to the present invention will be described below in detail with reference to the drawings.

(First embodiment)
FIG. 1 is a control block diagram showing the configuration of a control system for production equipment according to the first embodiment of the present invention. As shown in FIG. 1, the control system 101 (or control network) includes one master (main control device) 3 and a plurality of slaves (secondary control devices) 5 (that is, eight slaves 5A to 5H). It is a control system configured as a series of control loops connected by a plurality of optical fiber cables (hereinafter simply referred to as “optical fibers”) 4 which is an example of a flexible cable for communication. The control system also includes, for example, a cable deterioration diagnosis device that performs optical fiber deterioration diagnosis as equipment state diagnosis processing. In the following embodiments, the case where the control system includes a cable deterioration diagnosis device will be described as an example. However, the present invention is not limited to the configuration provided with such a deterioration diagnosis device. Absent.

  Specifically, a first slave 5A is connected via an optical fiber 4 as a control device starting from the master 3, and the first slave 5A is connected to a second optical fiber 4 via a second optical fiber 4. It is connected to the slave 5B. Thereafter, the third slave 5C, the fourth slave 5D, the fifth slave 5E, the sixth slave 5F, the seventh slave 5G, and the eighth slave 5H are connected via the respective optical fibers 4 in order. In addition, the eighth slave 5H is connected to the master 3 via the optical fiber 4.

  In the control system 101, optical information (optical signal data) that is communication information output from the master 3 is transmitted to each slave 5 through each optical fiber 4 by periodic real-time serial communication. It has become so. Each slave 5 can perform a predetermined control operation based on the optical information input through the optical fiber 4, and the optical information created based on the control operation is stored in the slave 5. It can be output and input to another slave 5 or master 3 through the optical fiber 4. Thus, the optical information created and output by the master 3 and each slave 5 can be transmitted through the optical fiber 4 to a specific destination (master 3 or specific slave 5) to which the optical information is to be transmitted. It is possible.

  Further, as shown in FIG. 1, in the control system 101, the master 3, the first to fifth slaves 5A to 5E, and the seventh to eighth slaves 5G to 5H are fixed to, for example, the apparatus main body side. It is a fixed part. On the other hand, the sixth slave 5F is a movable part that is moved with respect to the fixed part, and the sixth slave 5F and the sixth slave 5F are moved together with the movement of the sixth slave 5F. The optical fiber 4 connecting the 5 and the seventh slaves 5E and 5G is also moved. The optical fiber (that is, the movable cable) 4 that moves in this way is supported by a movable cable guide (not shown) so as not to impede mobility.

  Here, in order to explain the configuration of the optical fiber 4 deterioration diagnosis apparatus provided in the control system 101 having such a configuration and the specific procedure of the diagnosis process, the master 3 and slave 5 of the control system 101 A schematic explanatory diagram showing the configuration in detail is shown in FIG. In the schematic explanatory diagram shown in FIG. 2, the number of slaves 5 included in the control system 101 is reduced for the purpose of facilitating understanding of the configuration of the optical fiber 4 degradation diagnosis apparatus and the contents of the processing. This configuration is disclosed.

  Specifically, as shown in FIG. 2, the control system 101 includes the first control device 10, the second control device 20, the third control device 30, and the fourth control device 40. 4 are connected so as to form a series of control loops (control network). These four control devices 10 to 40 correspond to either the master 3 or the slave 5 in the control system 101 configured as shown in FIG. In the control system 101 shown in FIG. 2, the first control device 10, the third control device 30, and the fourth control device 40 are fixed portions, and the second control device 20 is the fixed portion. It becomes a movable part moved with respect to. Therefore, the optical fiber 4 connecting the first control device 10 and the second control device 20 and the optical fiber 4 connecting the second control device 20 and the third control device 30 are movable cables. ing.

  As shown in FIG. 2, the first control device 10 includes a processing unit that performs processing for generating information to be communicated as optical information as serial data, control operation processing based on input optical information (serial data), and the like. A processing unit 11 as an example, and a light emitting unit 12 that converts serial data created by the processing unit 11 into optical information and emits the converted optical information so as to be communicable via the optical fiber 4 (communication information transmission) Light receiving unit 13 (which is an example of a device and a light emitting device) that receives optical information input through the optical fiber 4, converts the received optical information into serial data, and allows the processing unit 11 to input the optical information. A communication information receiving device and a light receiving device). In the first control device 10, each of the light emitting unit 12 and the light receiving unit 13 and the processing unit 11 are connected to each other by a conductor wiring cable, for example, a copper wiring.

  In addition, the second control device 20, the third control device 30, and the fourth control device 40 have the same configuration as the first control device 20, and the second control device 20 includes a processing unit. 21, a light emitting unit 22, and a light receiving unit 23, the third control device 30 includes a processing unit 31, a light emitting unit 32, and a light receiving unit 33, and the fourth control device 40 includes a processing unit 41, a light emitting unit. 42 and a light receiving unit 43.

  The light receiving unit 13 in the first control device 10 has a function of detecting the amount of light based on optical information received through the optical fiber 4 and inputting the detected amount of light to the processing unit 11 as light amount data. is doing. In addition, the processing unit 11 to which such light amount data is input creates and outputs light amount adjustment data to the light emitting unit that has emitted the light information that is the basis of the light amount data based on the light amount data. It has a function. For example, the light amount adjustment data based on the light information received by the light receiving unit 13 of the first control device 10 is created by the processing unit 11, and the second control device 20 and the third control device 30 are respectively set. The light is input to the light emitting unit 42 of the fourth control device 40 via the optical fiber 4. The functions of the light receiving unit and the processing unit are common to the other control devices 20, 30, and 40.

  Here, the function of the processing units included in each control device for the deterioration diagnosis of the optical fiber will be described using the processing unit 21 of the second control device 20 as a representative. In the description, a block diagram showing a main control configuration of the processing unit 20 is shown in FIG.

  As illustrated in FIG. 3, the processing unit 21 includes a communication error detection unit 24 having a function of detecting whether or not a communication error has occurred in serial data input from the light receiving unit 23, and the communication error detection unit 24. The detected number of occurrences of communication errors can be accumulated and recorded, and the storage unit 25 that stores information related to other communication errors, and the storage unit 25 stores the data of the integration number and the preset number of times of data. A deterioration diagnosis processing unit 26 that performs deterioration diagnosis processing by reading out more and comparing the two is provided.

  Here, “communication error” in serial communication will be described. First, in the description, the format of serial data will be described using the schematic explanatory diagram shown in FIG.

  As shown in FIG. 4, the serial data format F is composed of one start bit, for example, 5 to 8 data bits, one parity bit, and one stop bit. The start bit indicates that communication data is to be started, and is always displayed as 0. The hardware on the serial data receiving side, for example, constantly monitors the idle communication line, and if 0 is confirmed in the start bit, the timing is reset at that time, and data is fetched at regular intervals. Will be started. The start bit plays a role of notifying the start point of such data fetching process.

  The data bit is a part composed of communication information. The parity bit is used to ensure communication reliability and is used to perform a simple error check on transmitted data. When a parity error is detected in the hard wafer on the serial data receiving side, a parity error is generated. The stop bit plays a role of notifying the end point of 1-byte communication. When the stop bit is confirmed on the receiving-side hard wafer, it is determined that the 1-byte communication has been completed. On the other hand, if the stop bit is not confirmed, a framing error is generated on the assumption that the communication has not been normally performed.

  In the present embodiment, the “communication error” detected by the communication error detection unit 24 is a general error that occurs in such serial communication. For example, a parity error, a framing error, and an overrun error Etc. are included.

  A procedure for performing the deterioration diagnosis process for the optical fiber 4 in the control system 101 having such a configuration will be described below. In describing the procedure of the deterioration diagnosis process, a schematic explanatory diagram showing the communication cycle of serial data is shown in FIG. 5, and a flowchart showing the procedure of the deterioration diagnosis process is shown in FIG. The specific procedure of the deterioration diagnosis process is described as an example of the deterioration diagnosis process for the optical fiber 4 connecting the first control device 10 and the second control device 20 in the control system 101. To do.

  As shown in FIG. 5, in serial communication, serial data communication is performed at predetermined communication cycles (for example, a cycle such as 1 ms or 3 ms). That is, when the first communication C1 is performed and a predetermined communication cycle elapses from the start of the first communication C1, the second communication C2 is performed, and the third communication is performed every time the communication cycle elapses. Periodic communication is performed such that C3 and fourth communication C4 are performed. In each of such communications C1 to C4, serial data created by the processing unit 11 of the first control device 10 is output as optical information from the light emitting unit 12, and the second control device 20 of the second control device 20 is transmitted through the optical fiber 4. The light receiving unit 23 receives the light and inputs it as serial data to the processing unit 21. Such a series of operation processing is repeated every communication cycle.

  First, in step S1 of the flowchart of FIG. 6, the processing unit 21 starts receiving serial data in the second communication C2. When the reception is started, a reception interruption is performed for the second communication C2 (step S2), and a communication error has occurred in the second communication C2 by the communication error detection unit 24 of the processing unit 21. Whether or not is detected is performed (step S3). When the communication error detection unit 24 determines that no communication error has occurred for the second communication C2, normal communication processing (reception / transmission processing) is performed by the processing unit 21 (step S9). Then, the deterioration diagnosis process for the second communication C2 is completed.

  On the other hand, when the communication error detecting unit 24 detects that a communication error has occurred in the second communication C2 in step S3, the communication error detection unit 24 performs the operation immediately before the second communication C2 in step S4. It is confirmed whether or not a communication error has occurred in the first communication C1 that is communication. Specifically, the communication error detection unit 24 searches and acquires information that a communication error has occurred for the first communication C1 from the information regarding the communication error stored and held in the storage unit 25. If the information is acquired, it is determined that a communication error has occurred. If the information cannot be acquired, it is determined that no communication error has occurred.

  If it is determined in step S4 that a communication error has occurred in the first communication C1, the system stop process for the control system 101 is performed in step S7, and the subsequent serial communication is stopped.

  On the other hand, if it is determined in step S4 that no communication error has occurred in the first communication C1, the number of communication errors that have occurred in the second communication C2 is accumulated and stored in the storage unit 25 (communication error). Along with the integration count), it is recorded that a communication error has occurred in the second communication C2 (step S5).

  Thereafter, in step S6, the data of the communication error integration number stored in the storage unit 25 and the data of the predetermined number which is a criterion of the upper limit value of the integration number stored in advance are stored from the storage unit 25. It is taken out by the deterioration diagnosis processing unit 26, and the deterioration diagnosis processing unit 26 compares and determines whether or not the number of integrations is equal to or more than the specified number. When it is determined that the cumulative number is equal to or greater than the specified number, a warning that the optical fiber 4 that has performed the communication has deteriorated is issued because a communication error has occurred a predetermined number of times or more. Is output from the deterioration diagnosis processing unit 26 (fiber deterioration warning processing). The warning is transmitted through a display device or the like so as to be recognized by an operator who manages or monitors the control system 101, for example. The operator who has recognized the deterioration warning can take appropriate measures against deterioration such as replacement of the optical fiber 4 targeted for the warning.

  Thereafter, in step S10, transmission / reception processing is performed assuming that the serial data of the first communication C1 is received as the second communication C2 instead of the serial data of the second communication C2 in which the communication error has occurred. . For example, the serial data of the second communication C2 is corrected with the serial data of the first communication C1, or the serial data of the second communication C2 is discarded and the serial data of the first communication C1 is used as it is. The above transmission / reception processing is performed by using it. If it is determined in step S6 that the cumulative number has not reached the specified number, the transmission / reception process in step S10 is performed without performing the fiber deterioration warning process in step S8.

  This completes the deterioration diagnosis process for the second communication C2. Subsequently, the deterioration diagnosis process shown in the flowchart of FIG. 6 is sequentially repeated for the third communication C3 and the fourth communication C4.

  In the above-described deterioration diagnosis processing, the cable deterioration diagnosis processing device is processed by the processing unit 21 in the second control device 20, that is, the processing unit 21 including the communication error detection unit 24, the storage unit 25, and the deterioration diagnosis processing unit 26. Is configured. In addition, it can be said that such a cable deterioration diagnosis processing apparatus further includes a light receiving unit 23 of the second control device 20 and a light emitting unit 12 of the first control device 10. This is because the optical information emitted from the light emitting unit 12 is received by the light receiving unit 23 through the optical fiber 4 and is a device for diagnosing deterioration of the optical fiber 4.

Here, FIG. 7 is a graph showing a relationship between the amount of light received through the optical fiber 4 and the number of occurrences of communication errors. In FIG. 7, the amount of received light is shown on the horizontal axis, and the number of occurrences of communication errors is shown on the vertical axis. As shown in FIG. 7, no communication error occurs when the amount of received light is in a predetermined range, that is, in the range of V _{2 to} V ₃ . If it is in such a range of received light quantity, in the deterioration diagnosis process shown in FIG. 6, it is determined in step S3 that no communication error has occurred, and a normal transmission / reception process is performed.

On the other hand, in FIG. 7, in the case where the predetermined range is exceeded and, for example, the range of the light amounts V _{1 to} V ₂ or the range of the light amounts V _{3 to} V ₄ is reached, a communication error occurs only once. Will occur. That is, although it does not go until a communication error occurs continuously in the communication cycle, a single communication error occurs. In such a case, in the deterioration diagnosis process shown in FIG. 6, it is determined that a communication error has occurred in the second communication C2, but no communication error has occurred in the first communication C1. The necessity of executing the deterioration warning process is determined based on the number of communication errors accumulated without stopping the control system 101.

Further, in FIG. 7, when the received light amount decreases or increases, for example, when the light amount is less than the light amount V ₁ or exceeds the light amount V ₄ , a communication error tends to occur continuously in the communication cycle. become. In such a case, in the deterioration diagnosis process, it is determined that a communication error has occurred twice in succession, and in order to quickly avoid the risk of erroneous control in real-time control being executed, the control system 101 stop processing is performed. In FIG. 7, in the range where the light amount V ₁ is less than or the range where the light amount V ₄ is exceeded, the number of occurrences of communication errors increases rapidly, and there is a risk that stable control in the control system 101 cannot be performed. Can be seen to increase rapidly. Therefore, in order to output a deterioration warning before entering such a range, the prescribed number of occurrences of a communication error set in advance is the range of the light amounts V _{1 to} V ₂ shown in FIG. It is preferable to use a communication error integration number N ₀ corresponding to a range of _{3 to} V ₄ . Note that the number of communication errors can be set stepwise so that, for example, 10 is the first warning and 30 is the final warning. This is because it has been confirmed that the communication error occurrence time interval is rapidly shortened after the number of integrations is ten or more.

  In the above description regarding the deterioration diagnosis process, a procedure is adopted in which it is determined whether a communication error has occurred twice in succession, and when the occurrence is confirmed, the control system 101 is stopped. In this case, instead of such a case, there is no step for checking whether or not a communication error has occurred twice in succession, and the deterioration diagnosis process is performed only by the accumulated number of communication errors. It may be the case. Such a request for system stop processing is determined by the operation control contents and characteristics of the device provided with the control system 101, and does not involve (or even involves) danger in operation control performed by erroneous control. This is because there may be cases where the control system is not requested until the control system is stopped.

  Further, in the above description, the case where the deterioration diagnosis process for the optical fiber 4 connecting the first control device 10 and the second control device 20 is performed as the optical fiber deterioration diagnosis processing has been described. The deterioration diagnosis process for other optical fibers 4 can be performed in the same procedure.

  Further, in the deterioration diagnosis process, the case where the deterioration warning process is performed by accumulating the number of occurrences of communication errors and reaching the specified number of times has been described, but the present embodiment is limited only to such a case. Is not to be done. Instead of such a case, it may be a case where the degradation warning process is performed when the occurrence time interval of the communication error is measured and the occurrence time interval is equal to or less than a predetermined time interval. . This is because the communication error occurrence time interval tends to be shortened with the deterioration of the optical fiber.

  In addition, there are power supply systems other than the signal system for communication errors, but in the case of such power system errors, the power becomes weak, for example, the light emission amount decreases or the light emission stops. Since a state occurs, it is possible to clearly distinguish an error in the signal system.

According to the control system 101 of the first embodiment, one master 3 and eight slaves 5A to 5H are connected using an optical fiber 4 so as to form a continuous closed control loop. Since it has a hardware configuration, the number of installed optical fibers 4 and the cable length can be shortened and the number of installed cable connection terminals in the master 3 can be reduced as compared with the conventional control system. Can do. Therefore, the cost required for the hardware configuration can be reduced, and the installation amount (number × length) of the optical fiber 4 that may cause a communication error due to the deterioration thereof is reduced to generate a communication error. The possibility can be reduced.
Furthermore, by providing a device for performing an optical fiber deterioration diagnosis process in such a control system, the optical fiber 4 that connects the first control device 10 that is a fixed portion and the second control device 20 that is a movable portion. On the other hand, unlike the conventional method, the optical fiber 4 that is likely to deteriorate is provided separately from the optical fiber 4 and the deterioration diagnosis is not performed indirectly. Since the deterioration diagnosis can be performed directly, a reliable deterioration diagnosis can be realized while ensuring wiring saving.

  In addition, in the method of measuring the amount of received light as in another conventional method, it may be difficult to perform highly accurate diagnosis processing due to variations in the amount of received light that is measured. In the optical fiber deterioration diagnosis process of the embodiment, since the deterioration diagnosis is performed based on the number of occurrences of the communication error by detecting the communication error in the serial communication instead of performing the light amount measurement, the accuracy is high. Diagnosis can be realized.

  In particular, such communication errors in serial communication tend to increase gradually as the optical fiber 4 deteriorates, but the accumulated number of generated communication errors has reached a specified number. Thus, by outputting the deterioration warning, it is possible to perform reliable diagnosis processing that eliminates variations.

  In addition, while performing deterioration diagnosis by detecting such a communication error, the content of the communication information in which the communication error has occurred is corrected based on the communication information received immediately before. Therefore, even if such a communication error occurs, the communication quality in the serial communication is not deteriorated.

  Furthermore, in the serial communication using the optical fiber 4 in a normal state, when the occurrence of a communication error that is generated twice less frequently is detected, the optical fiber 4 is deteriorated and is normal. Since it is determined that communication cannot be performed and the control system 101 is stopped, erroneous control of the control system 101 due to deterioration of the optical fiber 4 can be reliably prevented.

  Particularly, in real-time communication, the control operation is performed every moment based on the communicated information. Therefore, the deterioration diagnosis process of such an optical fiber 4 can be performed and the operator can recognize in advance. Effective, can prevent serious miscontrol.

  In particular, in the control system 101, it is possible to specify which slave 5 has detected the communication error, so it is possible to specify whether or not the movable cable is connected according to the specified slave 5. As a result, it is possible to estimate that a communication error occurring in the movable cable is caused by the optical fiber 4 and a communication error occurring in the other fixed cable is caused by the light emitting element, so that the countermeasure processing becomes easy. .

(Second Embodiment)
In addition, this invention is not limited to the said embodiment, It can implement with another various aspect. For example, an optical fiber deterioration diagnosis method in the control system according to the second embodiment of the present invention will be described. The optical fiber deterioration diagnosis method in the control system according to the second embodiment is the same as the fiber deterioration diagnosis process of the first embodiment in the processing contents for diagnosing optical fiber deterioration. In addition, it differs from the first embodiment in that the amount of emitted light is further adjusted by the light emitting unit. Hereinafter, this different point will be described. In this description, since the configuration of the control system 101 is the same as that of the first embodiment, FIG. 2 is used, and the communication mode in serial communication is also the same. The figure is used in common. A procedure for adjusting the amount of emitted light in the deterioration diagnosis process of the second embodiment is shown in the flowchart of FIG.

  First, in the control system 101 having the configuration shown in FIG. 2, serial communication is performed from the first control device 10 to the second control device 20, and as shown in FIG. When the second communication C2, the third communication C3, and the fourth communication C4 are periodically communicated, the deterioration diagnosis process for the second communication C2 is performed by the second control device 20 in FIG. The procedure shown in the flowchart of FIG.

  In the deterioration diagnosis process, when the fiber deterioration warning process is performed in step S8 of FIG. 6 (step S8 of FIG. 8), first, the first communication is performed in the processing unit 21 of the second control device 20. The transmission / reception process of the second communication C2 is performed using the serial data in C1 (step S11 in FIG. 8). Thereafter, the processing unit 21 of the second control device 20 transmits the fiber deterioration warning information to the first control device 10 in the third communication C3 based on the fiber deterioration warning information in the second communication C2. Is performed (step S12). The transmission of such information is received by the first control device 10 via the respective optical fibers 4 and the third control device 30 and the fourth control device 40 (step S13). .

In the 1st control apparatus 10 which received this deterioration warning information, the light emission quantity is adjusted with respect to the light emission part 12 from the process part 11 (step S14). Specifically, the processing unit 11 adjusts the light emitting unit 12 to increase the light emitting unit 12 by a predetermined light emitting amount, for example, a light emitting amount of about 5 dBm. Note that the light emission amount for performing such adjustment can be determined from, for example, the correlation graph between the light reception light amount and the number of communication error occurrences shown in FIG. The control device 20 is considered to have received the light amount in the range of the light amounts V _{1 to} V ₂ , and the light emission amount of the first control device 10 is in the range of the light amounts V _{2 to} V _3. The amount of emitted light is adjusted. Thereby, the light amount adjustment process in the optical fiber deterioration diagnosis process is completed. When such adjustment of the amount of emitted light is performed, the degradation warning information is cleared to zero, and it is confirmed that the warning is surely cleared, and the fiber degradation diagnosis process is completed. In order to check the adjustment result of the light emission amount, the deterioration diagnosis process is further performed, and the fiber deterioration warning information is not output, so that the adjustment result can be checked. In the deterioration diagnosis process performed after the adjustment of the amount of emitted light, the reference for outputting the fiber deterioration warning information can be made different from the initial deterioration diagnosis process (for example, the reference is set loosely).

  In this way, in the light amount adjustment method that increases the light emission amount by a predetermined amount on the upstream side, assuming that the received light amount has decreased due to the deterioration warning process being performed, for example, The second control device 20 repeatedly increases the predetermined light amount until the occurrence of a communication error stops, and finally increases the light amount until the light emission amount limit is reached. it can.

  In addition, since a communication error occurs even if the amount of light is larger than the predetermined range, if the occurrence of the communication error does not stop, the emitted light amount is decreased by a predetermined amount. It is also possible to perform such processing.

  According to the second embodiment, in addition to performing the deterioration warning process in the optical fiber deterioration diagnosis process, the light emission amount of the light emitting unit 12 is increased by, for example, a predetermined light quantity based on the deterioration warning. Adjustment processing can be performed, the frequency of occurrence of communication errors can be reduced after the deterioration warning, and stable communication can be realized.

(Third embodiment)
Next, an optical fiber deterioration diagnosis method in the control system according to the third embodiment of the present invention will be described below. The degradation diagnosis method of the third embodiment is to adjust the amount of light in the same manner as the degradation diagnosis method of the second embodiment, but the processing contents of the light amount adjustment are different. Specifically, the received light amount is detected, and the emitted light amount is adjusted based on the detected received light amount data. Hereinafter, specific processing contents of the light amount adjustment will be described. The configuration of the control system 101 is the same as that of the first embodiment shown in FIG. 2, and the processing procedure for performing the degradation warning itself is the same as the procedure of the first embodiment (flowchart of FIG. 6). It is.

  First, in the serial communication according to the third embodiment, as shown in the schematic explanatory diagram of FIG. 9, 100% light emission is performed by the light emitting unit 12 and the like after each periodic communication C1 to C4 is completed. The point is different from the serial communication of the first embodiment and the second embodiment. That is, 100% light emission is performed using the time when there is no communication information that exists during periodic communication, and how much light can be received by the light receiving unit 23 or the like with respect to this 100% light emission. The amount of emitted light is adjusted by detecting whether or not.

  A specific procedure for adjusting the amount of emitted light is shown in the flowchart of FIG. First, in step S21 of the flowchart of FIG. 10, the light emitting unit 12 of the first control device 10 emits light with a light emission amount of 100% for a certain time, for example, at a timing after the second communication C2 is completed. I do. The emitted light quantity is measured by the light receiving unit 23 of the second control device 20 through the optical fiber 4 (step S22). The light quantity data measured in this way is input to the processing unit 21 as, for example, A / D converted and digitized light quantity data of 0 to 5V.

  In the processing unit 21 to which the light amount data is input, the light amount data is output by the third communication C3 (step S23). The third communication C3 including the light quantity data is received by the first control device 10 through the respective optical fibers 4 and the third control device 30 and the fourth control device 40 (step S24). ).

  In the first control device 10, the received light amount data is D / A converted and input to the light emitting unit 12, and the light emission amount of the light emitting unit 12 is adjusted based on the light amount data (step S25).

  According to the third embodiment, while accurately diagnosing the deterioration warning process of the optical fiber 4 based on the number of occurrences of communication errors, the received light quantity is measured separately from the diagnostic process, and light is emitted based on the received light quantity. Since the amount of light is adjusted, it is possible to suppress an increase in the frequency of occurrence of communication errors that increase due to the progress of deterioration of the optical fiber 4, and to realize more stable and high-quality communication.

  Further, the 100% light emission uses a vacant time band in serial communication, and thus does not affect normal communication.

  Further, such an automatic light amount adjustment process is preferably performed, for example, as an initial light amount adjustment after laying the optical fiber 4 in the control system 101, so that the time required for the adjustment can be shortened. . In particular, in a control system, the degree of reduction in the amount of light varies depending on the length of the optical fiber, and therefore, individual automatic adjustment of the amount of light based on the amount of received light is effective.

  In each of the above embodiments, as an example of the flexible cable, a method and an apparatus for performing a deterioration diagnosis process of the optical fiber 4 are described. However, such a deterioration diagnosis process is performed using a flexible cable other than the optical fiber 4. For example, it is applicable also to a conductor wiring cable. That is, the deterioration diagnosis process can be applied to any flexible cable that performs real-time serial communication.

  However, as in the case of an optical fiber cable, each of the embodiments described above is applied to a flexible cable having a characteristic that the communication error is not suddenly interrupted, but the number of occurrences of communication errors gradually increases and deterioration progresses. It is possible to obtain a more advantageous effect by applying the deterioration diagnosis process.

(Example)
Here, an embodiment in which a control system to which such an optical fiber degradation diagnosis apparatus using an optical fiber is applied is applied to a control system for a component mounting apparatus. First, a schematic perspective view showing a main configuration of the component mounting apparatus 201 to which such a control system is applied is shown in FIG.

  As shown in FIG. 11, the component mounting apparatus 201 includes a loader 51 that loads a circuit board 52 on which an electronic component is mounted onto a stage 53 on a base 56, and a circuit board 52 on which the electronic component is mounted from the stage 53. Unloader 61 to be carried out, parts feeders 58 and 68 for supplying relatively small electronic components such as chip components, tray supply unit 59 for supplying relatively large electronic components such as IC chips, and the like An electronic component to be supplied is sucked and held by a suction nozzle 60, and a front head (shown as a front head) 54 in the figure for mounting the electronic component on the circuit board 52 disposed on the stage 53, and a suction nozzle. And a rear head (rear head) 64 shown in FIG. Further, the component mounting apparatus 201 supports the front head 54 and moves forward and backward in the X-axis direction shown in the figure. Similarly to the front head moving device 55 constituted by a Y axis robot (referred to as a front Y axis robot) 55Y that moves the front head 54 back and forth in the Y axis direction by moving in the axial direction. A rear head moving device 65 configured to move the rear head 64 is provided, which includes an axis robot 65X and a rear Y axis robot 65Y. In addition, a fixed camera 57 that captures an image is provided on the base 56 between the parts feeder 58 and the stage 53 in order to recognize and hold the suction holding posture of the electronic component by the suction nozzle 60 of the front head 54. Similarly, in order to recognize and hold the suction holding posture of the electronic component by the suction nozzle 70 of the rear head 64, a fixed camera 67 that captures the image is provided.

  In the component mounting apparatus 201 having such a configuration, an electronic component supplied from the parts feeder 58 or the tray supply unit 59 is mounted on the circuit board 52 supplied to the stage 53 by the loader 51 by the front head 54. Alternatively, an electronic component supplied from the parts feeder 68 is mounted by the rear head 64. In this mounting operation, the front head moving device 55 moves the front head 54 in the horizontal direction, and the rear head moving device 65 moves the rear head 64 in the horizontal direction.

  Next, the configuration of the control system 202 in the component mounting apparatus 201 will be described below with reference to FIG. 12 and FIG. 11 which are control block diagrams showing main control configurations.

  First, as shown in FIGS. 11 and 12, the component mounting apparatus 201 includes a main control device 203 that comprehensively controls the operation of each of the above-described components. Servo motor master 213 that performs overall control of drive units (motors, actuators, etc.) in each component, and imaging of an object and positioning images necessary for positioning control of the drive unit A plurality of control sections (mainly a camera master 223 that performs overall control of the system (camera related)) and an I / O master 233 that performs overall control of the detection system (sensor related) that similarly detects the positioning information. It is an example of a control device. These control sections are connected to a plurality of slaves 205A, 205B, and 205C (only a part of the plurality of slaves), which are examples of slave control devices, by optical fibers. A series of control loops are formed for each. Moreover, as shown in FIG. 11, a part of these optical fibers is a movable cable 204 that connects between a slave that is a fixed portion and a slave that is a movable portion.

  Next, the control loop configured for each of these control sections will be described in detail. As shown in FIG. 12, for example, eight slaves are connected to the servo motor master 213 by optical fibers to form a series of control loops. Specifically, a front X-axis slave (which is an example of a component mounting control unit) 215 </ b> A that performs drive control of the front X-axis robot 55 </ b> X is connected to the servo motor master 213 via an optical fiber 214. A front Y-axis slave 215B that performs drive control of the front Y-axis robot 55Y is connected to the front X-axis slave 215A via an optical fiber 214. Subsequent X-axis slave 215C that controls the driving of the rear X-axis robot 65X, the rear Y-axis slave 215D that controls the driving of the rear Y-axis robot 65Y, and the substrate conveyor that controls the driving of the substrate conveyor of the loader 51 and unloader 61. The slave 215E, the component supply unit slave 215E that controls the drive of the parts feeders 58 and 59, the rear head slave (which is an example of a head control device) 215G that controls the drive of the rear head 64, and the drive of the front head 54 A front head slave 215 </ b> H that performs control is connected via an optical fiber 214, and a front head slave 215 </ b> H is further connected to a servo motor master 213 via an optical fiber 214. An optical fiber 214 is connected as a movable cable 204 before and after the front X-axis slave 215A, the rear X-axis slave 215C, the rear head slave 215G, and the front head slave 215H arranged in the movable part.

  The camera master 223 includes a front head slave 225A that controls the imaging operation of a head camera (not shown) installed in the front head 54, and a camera master 223 that controls the imaging operation of a head camera (not shown) installed in the rear head 54. The head slave 225B, the fixed recognition 1 slave 225C that controls the imaging operation of the fixed camera 57, and the fixed recognition 2 slave 225D that controls the imaging operation of the fixed camera 67 are sequentially connected via the optical fiber 224. A series of control loops are configured. In such a control loop, captured image information is communicated. An optical fiber 224 is connected as a movable cable 204 before and after the front head slave 225A and the rear head slave 225B arranged in the movable part.

  The I / O master 233 includes a front X-axis slave 235A, a front Y-axis slave 235B, a rear X-axis slave 235C, a rear Y-axis slave 235D, a safety detection slave 235E, which control the sensors in the respective components. The interlock slave 235F, the board conveyor slave 235G, the component supply unit slave 235H, the rear head slave 235I, and the front head slave 235J are sequentially connected via the optical fiber 234, and a series of control loops are configured. In such a control loop, ON / OFF information of each sensor is communicated. An optical fiber 234 is connected as a movable cable 204 before and after the front X-axis slave 235A, the rear X-axis slave 235C, the rear head slave 235I, and the front head slave 235J arranged in the movable part.

  Each of these control loops has the same configuration as a series of control loops connected by the optical fiber 4 in the control system 101 of the first embodiment. Each master 213, 223, and 233 includes a communication error detection unit 216, 226, 236, a deterioration diagnosis processing unit 217, 227, 237, and a storage unit 218, 228, 238, respectively. The slave has the same configuration as that of the control system 101 of the first embodiment.

  As described above, since the control system 202 has the same configuration as the control system 101 of the first embodiment, the optical fiber deterioration diagnosis process can be performed in various controls related to component mounting. The optical fiber 214, 224, and 234 that communicate with each other can be directly diagnosed for deterioration, so that reliable deterioration diagnosis can be realized while ensuring wiring saving. The same effect as that of the first embodiment can be obtained.

  Further, in the control system 202, each slave is not directly connected to each master 213, 223, 233, but a configuration in which a series of control loops are configured is employed. In the master, it is possible to eliminate the necessity of providing a large number of connectors and the like for directly connecting a large number of slaves, and to realize wiring saving. As a result, the equipment cost can be reduced and the factors such as equipment failure can be reduced, and a low-cost and highly reliable component mounting apparatus can be provided.

  In such a control system 202, as shown in FIG. 12, a series of control loops such as a drive unit system, an image capturing system, and a detection system are separately formed. By notifying the other control loop of the cable deterioration information detected in one of the control loops, it is possible to reduce the possibility of equipment malfunctioning due to the cable deterioration. For example, when cable deterioration is detected by the fixed recognition 1 slave 225C in the control loop of the image pickup system, the deterioration diagnosis result information is notified from the camera master 223 to the servo motor master 213, and the camera As a result, the scanning accuracy of the camera can be maintained by lowering the passing speed of the head portion that passes through the head, that is, lowering the driving speed of the motor and lowering the scanning speed of the camera. In addition, although such control was mentioned as an example about the camera, the same control can be performed also in another structure part.

  Further, in the case where a plurality of component mounting apparatuses having a series of control loops composed of such optical fibers as the control system are installed, the main control unit in each component mounting apparatus is controlled by a management computer. By constructing a communication network connected to a LAN, for example, a LAN, a control management system or a component mounting system for production equipment that can perform more efficient management can be provided.

  Specifically, the component mounting apparatuses 201A and 201B installed in the factory A, the component mounting apparatuses 201C and 201D installed in the factory B, and the factory C are installed as in the control management system shown in FIG. By connecting each main control unit in the component mounting apparatuses 201E and 201F to, for example, the LAN 302 using the optical fiber 304, each component is installed in the production computer department and the management computer 303 connected to the LAN 302. It is possible to directly communicate with individual slaves in the control system of the mounting apparatus 201, and it is possible to quickly confirm information, thereby realizing efficient production management. Such a communication network may be wired or wireless, and may be a network constructed only when communication is required.

  It is to be noted that, by appropriately combining arbitrary embodiments of the various embodiments described above, the effects possessed by them can be produced.

It is a mimetic diagram showing composition of a control system provided with an optical fiber degradation diagnostic device with which a control system concerning a 1st embodiment of the present invention is provided. FIG. 3 is a control block diagram further schematically showing the control system of the first embodiment. It is a control block diagram which shows the structure of the process part in a 2nd control apparatus. It is a schematic explanatory drawing which shows the structure of the serial data format in serial communication. In the said 1st Embodiment, it is a schematic explanatory drawing which shows the state currently communicated serially. It is a flowchart which shows the procedure of the optical fiber degradation diagnostic process in the said 1st Embodiment. It is a figure of the graph format which shows the correlation with the light reception light quantity and the frequency | count of occurrence of a communication error. It is a flowchart which shows the procedure of the light quantity adjustment in the optical fiber deterioration diagnostic process performed with the control system concerning the 2nd Embodiment of this invention. It is a schematic explanatory drawing which shows the state in which communication is performed periodically in the optical fiber deterioration diagnosis process performed in the control system according to the third embodiment of the present invention. It is a flowchart which shows the procedure of the light quantity adjustment in the optical fiber deterioration diagnostic process of the said 3rd Embodiment. It is an Example which shows the application example of the optical fiber degradation diagnostic apparatus with which the control system of this invention is provided, Comprising: It is a model perspective view which shows the structure of the component mounting apparatus with which the optical fiber degradation diagnostic apparatus was applied to the control system. It is a control block diagram which shows the structure of the control system of the component mounting apparatus of FIG. It is a control block diagram which shows the structure of the control management system which manages a some control system.

Explanation of symbols

3 Master 4 Optical fiber 5 Slave 10 First control device 11, 21, 31, 41 Processing unit 12, 22, 32, 42 Light emitting unit 13, 23, 33, 43 Light receiving unit 20 Second control device 24 Communication error detection Unit 25 storage unit 26 deterioration diagnosis processing unit 30 third control device 40 fourth control device C1 first communication C2 second communication C3 third communication C4 fourth communication F serial data format 101 control system unit

Claims (6)

A main controller that controls the entire production facility;
A plurality of sub-control devices that are subordinately controlled by the main control device and control a drive unit having at least an actuator in the production facility;
A communication cable constituting one closed control loop is provided by connecting the master control device and the plurality of slave control devices in succession,
In the control loop, it performs periodic and in real time the serial communications for control of the production equipment,
As each of the above slave control devices,
A plurality of slave control devices for controlling a plurality of drive units for controlling the drive unit;
The slave control device for controlling the information acquisition unit for controlling a plurality of information acquisition units for acquiring positioning information for positioning control of the drive unit,
As the above control loop,
A drive control loop in which the main control device and the slave control devices for controlling the respective drive units are connected in series by the communication cable;
A control system for a production facility, comprising: an information acquisition control loop in which the main control device and the slave control devices for controlling the respective information acquisition units are connected in series by the communication cable. . The production facility has a fixed part and a movable part moved with respect to the fixed part,
In the control loop, at least one slave control device is provided in the movable portion, and another slave control device or the main control device is provided in the fixed portion, and the control device and the fixed portion on the movable portion side are provided. The control device on the side is connected by a flexible cable as the communication cable,
A communication information transmitting device provided in either one of the control unit on the fixed part side or the control unit on the movable part side;
A communication information receiving device connected to the communication information transmitting device via the flexible cable so that the communication information output from the communication information transmitting device can be received while being provided on the other of the above,
A communication error detection unit that detects whether or not a communication error has occurred with respect to reception of the communication information for each serial communication cycle in the communication information receiving device;
A storage unit for accumulating and recording the number of communication error occurrences detected by the communication error detection unit;
When the data of the number of times of accumulation and the data of the specified number of times set in advance can be read from the storage unit for comparison processing between the two, and the number of times of accumulation is equal to or more than the specified number of times by performing the comparison process The control system for production facilities according to claim 1, further comprising a cable deterioration diagnosis device including a deterioration diagnosis processing unit that outputs a deterioration warning as deterioration diagnosis processing of the flexible cable. The flexible cable is an optical fiber capable of communicating the communication information as optical information,
In the cable deterioration diagnosis device,
The communication information transmitting device is a light emitting device that transmits the optical information,
The communication information receiving device is a light receiving device that receives the transmitted optical information,
The production system control system according to claim 2 , wherein the communication error detection unit detects the communication error based on the optical information received by the light receiving device. The control system for production facilities according to any one of claims 1 to 3 , wherein an optical fiber is used as the communication cable constituting the control loop. The production facility is a component mounting apparatus that produces a mounting substrate in which components are mounted on a substrate.
The control device on the movable part side is a head control device mounted on a mounting head device that performs component mounting on the substrate by being controlled to move relative to the substrate,
The control device on the fixed part side is a mounting control device that performs movement control of the mounting head device through the head control device and is fixed to the component mounting device main body side,
In the control loop, the cable deterioration diagnosis is performed while performing the periodic real-time serial communication via the flexible cable for movement control of the mounting head device through the head control device by the mounting control device. apparatus, a control system for a production facility according to claim 2 or 3 which comprises carrying out the deterioration diagnosis processing of the cable. A control system for a plurality of production facilities according to any one of claims 1 to 5 ;
The control loop in each of the control systems is connected via a communication network, and serial communication is performed via the communication network and the control loop with the master control device or the slave control device in at least one control loop. A control management system for a production facility, comprising: a management computer for managing a control state of the production facility.

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