JP5970944B2 - Sequence circuit confirmation device - Google Patents

Description

  The present invention relates to a sequence circuit checking apparatus that identifies a failed component facility when a failure occurs in the component facility of a production facility, and confirms the operation of the component facility after countermeasures against the failure.

  For example, Japanese Patent No. 3373163 (Patent Document 1) describes a program editing apparatus capable of editing a program of a programmable controller. This program editing apparatus is an apparatus that can automatically add an interlock contact between a plurality of programmable controllers. Thereby, it is possible to efficiently and accurately create a sequence program used by a programmable controller in which a plurality of programmable controllers cooperate.

  Japanese Patent No. 2682328 (Patent Document 2) describes an automatic check device for a sequencer ladder circuit. This automatic check device is a device that can automatically check whether the sequencer ladder circuit is logically matched. As a result, it is possible to correct in advance a defective portion of the sequencer ladder circuit.

Japanese Patent No. 3373163 Japanese Patent No. 2682328

  When a failure occurs in a component of a production facility, it is necessary to identify the component component that has failed and check the operation of the component facility after countermeasures against the failure. It is not possible to respond when a failure occurs in the component equipment. Therefore, the worker specifies the component equipment that has failed manually, or chases the component equipment that has failed with a long ladder circuit, repairs the failed component equipment, and performs cycle operation to perform the cycle operation. Must be confirmed. For this reason, it is a very time-consuming work, and the failure may recur depending on the work level of the worker.

  The present invention has been made in view of such circumstances, and a sequence circuit confirmation device capable of automatically identifying a malfunctioning component facility in a production facility and automatically confirming the operation of the component facility after failure countermeasures. The purpose is to provide.

(Claim 1) A sequence circuit confirmation apparatus according to the present invention is a sequence circuit confirmation apparatus for production equipment component equipment, a failure information acquisition unit for obtaining information on a failure of the construction equipment, and the failure information acquisition. A component circuit acquisition unit that identifies the component facility that has failed based on failure information by a unit, acquires a component circuit of the sequence circuit that includes the identified component facility, and the component circuit acquired by the component circuit acquisition unit includes A check circuit is created by adding a check circuit for checking the operation of the group circuit acquired by the group circuit acquiring unit to the group circuit of the sequence circuit and a group circuit acquiring unit for acquiring the group circuit to which the group circuit belongs. A confirmation circuit creation unit.

  (Claim 2) The confirmation device for the sequence circuit may include a confirmation circuit execution unit that executes the confirmation circuit created by the confirmation circuit creation unit.

  (Claim 3) The sequence circuit check device may include a group circuit creation unit that creates a table of the group circuit by collating the component circuit and the process of the production facility.

  (Claim 4) The confirmation device for the sequence circuit may include a display control unit for displaying a determination result determined by execution by the confirmation circuit execution unit on a display device.

(Claim 5) The check circuit has a timer for measuring an operation confirmation time of the component equipment,
The sequence circuit confirmation device compares the operation confirmation time of the component equipment measured by the timer with a processing time of a table of a predetermined processing time range in the component circuit, and is executed by the confirmation circuit execution unit. You may make it provide the operation | movement determination part which determines operation | movement of the said confirmation circuit .

  (Claim 1) As a result, it is possible to automatically create an operation confirmation circuit after failure countermeasures in the production equipment, thereby reducing the burden on the worker and operating without being affected by the worker level. Confirmation can be made.

  (Claim 2) As a result, the operation check circuit of the component equipment can be automatically checked after taking measures against the failure, so that the operation check does not depend on the operator's work level and the failure is prevented from recurring. can do.

  (Claim 3) Thereby, the table of the group circuit can be automatically created, so that the work load on the operator can be greatly reduced.

  (Claim 4) Thereby, the operator can determine the validity / invalidity of the component equipment after the countermeasure against the failure, and therefore can take further countermeasures when it is invalid.

  (Claim 5) Thereby, the operation of the group circuit including the check circuit can be easily determined.

Embodiment of the present invention: It is a functional block diagram of a sequence circuit confirmation device. Embodiment of the present invention: a first flowchart for explaining the operation of the sequence circuit checking apparatus. Embodiment of this invention: It is a 2nd flowchart explaining operation | movement of the confirmation apparatus of a sequence circuit. It is a figure which shows the table which linked | related failure information and structural equipment. It is a figure which shows the step number attached | subjected to the structure circuit of the sequence circuit containing a structure installation. It is a figure which shows the table which made the some structural circuit corresponding to the process of production equipment the group circuit. It is a figure which shows the table which linked | related the check circuit which checks a group circuit and a failure. It is a figure which shows the table of the predetermined processing time range in a structure circuit. It is a figure which shows the table of the determination with respect to the group circuit number displayed. It is a figure which shows an example of production equipment. It is a figure which shows the confirmation circuit which added the check circuit to the sequence circuit of the production facility of FIG. 12 is a flowchart for explaining the operation of the confirmation circuit of FIG. 11.

(1. Configuration of sequence circuit confirmation device)
A sequence circuit checking device will be described with reference to the functional block diagram of FIG. The sequence circuit confirmation device 10 is a device for confirming the operation of the component facility 2 after countermeasures against failure of the component facility 2 of the production facility 1. This sequence circuit confirmation device 10 includes a failure information acquisition unit 11, a configuration equipment identification unit 12, a configuration circuit acquisition unit 13, a group circuit acquisition unit 14, a check circuit acquisition unit 15, and a verification circuit creation unit 16. , A confirmation circuit execution unit 17, an operation determination unit 18, a display control unit 19, a display device 20, a group circuit creation unit 21, and a storage unit 22.

The failure information acquisition unit 11 acquires failure information from the component facility 2 of the production facility 1. Examples of the failure information of the component equipment 2 include specific failure contents such as a gap failure of a proximity switch and a contact failure of a contact switch, a countermeasure method, and the like. Note that failure information may be input by an operator after countermeasures against failure.
The constituent equipment specifying unit 12 specifies the constituent equipment 2 corresponding to the fault information acquired by the fault information acquiring unit 11 based on a table in which the fault information stored in advance in the storage unit 22 is associated with the constituent equipment 2. . For example, as shown in FIG. 4, the table that associates the failure information with the component equipment 2 is that the component facility Ta is in the case of the failure information A, the component facility Tb is in the case of the failure information B, and so on. It is table T1 matched as described above. When the failure information acquired by the failure information acquisition unit 11 is A, Ta is specified as the configuration facility 2 by the configuration facility specification unit 12.

  The configuration circuit acquisition unit 13 acquires the step number assigned to the configuration circuit of the sequence circuit including the configuration facility 2 specified by the configuration facility specification unit 12 from the storage unit 22, and stores the acquired step number in the storage unit 22. Remember as. The sequence circuit is, for example, a circuit represented by ladder logic shown in FIG. 11 (excluding circuits indicated by dotted lines CL1 and CL2). The component circuit is a circuit represented by a rung (row) of the ladder logic shown in FIG. 11, and each component circuit is given a step number. When the constituent equipment specified by the constituent equipment specifying unit 12 is Ta, the step number given to the constituent circuit of the sequence circuit including the constituent equipment Ta by the constituent circuit acquiring unit 13 is, for example, Na as shown in FIG. , Nb..., EOF are acquired and stored as table T2.

  The group circuit acquisition unit 14 includes the configuration circuit acquired by the configuration circuit acquisition unit 13 based on a table in which a plurality of configuration circuits corresponding to the processing steps of the production facility 1 stored in advance in the storage unit 22 are group circuits. Get the group circuit number of the group circuit to which it belongs. A table in which a plurality of component circuits corresponding to the processes of the production facility 1 are group circuits is, for example, as shown in FIG. 6, a plurality of component circuits for executing each process of the production facility 1 are group circuits. The circuit is represented by step numbers Na, Nf, Ng..., Nh, Nk, Nm..., Nb, Ns, Nt... Of each component circuit, and numbers Ga, Gb. This is a table T3 associated with each other. If the step number acquired by the component circuit acquisition unit 13 is Na, Nb,..., EOF, the group circuit number Ga, Gc, to which the step number Na, Nb,. ..., EOF is acquired. The group circuit is automatically created in accordance with the operation order of the production facility 1 from a program group of N steps (N is a predetermined value of 5 steps or more) before and after the step matching the failure information A. Also, confirmation can be changed by the operator.

  The check circuit acquisition unit 15 is a check circuit corresponding to the group circuit number acquired by the group circuit acquisition unit 14 based on a table in which the group circuits stored in advance in the storage unit 22 are associated with check circuits for checking failures. Get the number. The check circuit is, for example, a circuit indicated by dotted lines CL1 and CL2 in the ladder logic shown in FIG. 11, and is a circuit for checking the operation of the group circuit of the group circuit number acquired by the group circuit acquisition unit 14. . The table in which the group circuit and the check circuit for checking the failure are associated with each other is, for example, as shown in FIG. 7, the number of the check circuit that can check the operation of the group circuit with group circuit numbers Ga, Gb, Gc. This is a table T4 in which Ca, Cb, Cc. If the group circuit numbers acquired by the group circuit acquisition unit 14 are Ga, Gc..., The check circuit numbers Ca, Cc.

The confirmation circuit creation unit 16 creates a confirmation circuit by adding the check circuit of the check circuit number acquired by the check circuit acquisition unit 15 to the group circuit of the group circuit number acquired by the group circuit acquisition unit 14. The confirmation circuit is, for example, a circuit represented by ladder logic to which check circuits CL1 and CL2 shown in FIG. 11 are added.
The confirmation circuit execution unit 17 executes the confirmation circuit created by the confirmation circuit creation unit 16.

  The operation determination unit 18 determines whether the operation of the confirmation circuit executed by the confirmation circuit execution unit 17 is good or bad based on a table of predetermined processing time ranges in the constituent circuits of the group circuit stored in advance in the storage unit 22. As the predetermined processing time range in the component circuit, a design instruction value is used in the initial stage, and an average value and a value considering variation are used when it is determined that production is stable at the time of production preparation. The table of the predetermined processing time ranges in the constituent circuits is, for example, as shown in FIG. 8, step numbers Na, Nb... And processing time ranges ta to tk, th to tk. Is a table T5 in which Although the operation of the group circuit including the check circuit can be easily determined by setting the processing time range, other comparison elements may be set. The actual values tc, tm,... Of the processing times of the constituent circuits of the step numbers Na, Nb,... Executed by the confirmation circuit execution unit 17 are added to the table T5. The operation determination unit 18 compares the processing time ranges ta to tg, th to tk... Of the constituent circuits of the step numbers Na, Nb... With the actual processing time values tc, tm. ... NG and determinations OK, NG... Are added to the table T5.

The display control unit 19 displays the determination result determined by the operation determination unit 18 on the display device 20. For example, as shown in FIG. 9, a table T6 of determination OK, NG... For the group circuit numbers Ga, Gc. As a result, the operator can determine the validity / invalidity of the component equipment 2 after the countermeasure against the failure, and can take further countermeasures when it is invalid.
The group circuit creation unit 21 collates an arbitrary number of configuration circuit groups before and after the configuration circuit acquired by the configuration circuit acquisition unit 13 with the process of the production facility, so that the production facility 1 as shown in FIG. A table T3 in which a plurality of constituent circuits corresponding to the process are group circuits is automatically created. Thereby, an operator's work burden can be reduced significantly. Note that a configuration of a confirmation device that does not include the group circuit creation unit 21 may be used. In this case, the above-described table T3 is created in advance by an operator and stored in the storage unit 22.

(2. Processing by sequence circuit confirmation device)
Next, processing performed by the sequence circuit checking apparatus 1 will be described with reference to FIGS. As shown in FIG. 2, when failure information is acquired from the component facility 2 of the production facility 1 (step S1), the component facility 2 corresponding to the acquired failure information is identified from the table in which the failure information and the component facility 2 are associated with each other. (Step S2). Specifically, if the failure information acquisition unit 11 in FIG. 1 acquires the failure information A, the component facility specifying unit 12 obtains the component facility Ta from the table T1 shown in FIG. Identify.

  Next, the sequence circuit of the production facility 1 is read (step S3), and the presence / absence of the component circuit of the sequence circuit including the identified component facility 2 is determined (step S4). If there is a constituent circuit of the sequence circuit including the specified constituent equipment 2, the step number of the constituent circuit is stored (step S5). On the other hand, when there is no constituent circuit of the sequence circuit including the specified constituent equipment 2, it is determined whether or not all sequence circuits have been read (step S6), and all sequence circuits have not been read. In step S3, the above process is repeated. Specifically, the configuration circuit acquisition unit 13 of FIG. 1 acquires the step numbers Na, Nb..., EOF attached to the configuration circuit including the configuration equipment Ta from the sequence circuit from the storage unit 22, The acquired step numbers Na, Nb,..., EOF are stored in the storage unit 22 as a table T2 shown in FIG.

  Next, it is determined whether or not the acquisition of the group circuit including the stored step number is completed from the table in which the plurality of component circuits corresponding to the process of the production facility 1 are group circuits (step S7). If acquisition of the group circuit including the stored step number has not been completed, the group circuit is acquired (step S8). Then, it is determined whether or not a table in which a plurality of constituent circuits corresponding to the process of the production facility 1 are group circuits is empty (EOF) (step S9), and when the table is empty (EOF) Returns to step S7 and repeats the above-described processing for the next group circuit. On the other hand, if the table is not empty (EOF) in step S9, a check circuit corresponding to the acquired group circuit is acquired from a table in which the group circuit and the check circuit for checking the failure are associated with each other. It is added and registered in the confirmation circuit table (steps S10 and S11), and the process returns to step S7 to repeat the above processing.

  Specifically, the group circuit acquisition unit 14 in FIG. 1 reads the group circuit number Ga to which the stored step numbers Na, Nb,..., EOF belong from the table T3 shown in FIG. , Gc,..., EOF is acquired. Then, the check circuit acquisition unit 15 in FIG. 1 stores the check circuit numbers Ca, Cb,... Corresponding to the acquired group circuit numbers Ga, Gc... From the table T4 shown in FIG. Cc ... is acquired. 1 stores a check circuit corresponding to the acquired check circuit numbers Ca, Cb, Cc... And a group circuit corresponding to the acquired group circuit numbers Ga, Gc. 22 and a check circuit is added before and after the group circuit to create a confirmation circuit.

  On the other hand, when the acquisition of the group circuit including the stored step number is completed in step S7, as shown in FIG. 3, the execution order of the created confirmation circuit is set (step S12), and the confirmation circuit table is used. The confirmation circuit is read and executed (steps S13 and S14). Then, the operation of the confirmation circuit is determined (step S15), and it is determined whether or not the operation determination is normal (step S16). If the operation determination of the confirmation circuit is normal, it is registered as normal (step S17), and if the operation determination of the confirmation circuit is not normal, it is registered as abnormal (step S18). Then, it is determined whether or not the execution of the confirmation circuit in the confirmation circuit table has been completed (step S19). If the execution of the confirmation circuit in the confirmation circuit table has not been completed, the process returns to step S13 and the above processing is repeated. . On the other hand, when the execution of the confirmation circuit in the confirmation circuit table is completed in step S19, the final determination result is displayed (step S20), and all the processes are terminated.

  Specifically, the confirmation circuit executing unit 17 in FIG. 1 stores the actual values tc, tm,... Of the processing times of the constituent circuits of the executed step numbers Na, Nb,. 8 is added to the table T5 shown in FIG. 1 compares the processing time ranges ta to tg, th to tk... Of the constituent circuits with step numbers Na, Nb... With the actual processing time values tc, tm. Then, the determinations OK, NG... Are added to the table T5. 1 displays the table T6 shown in FIG. 9 or the table T5 shown in FIG. 8 on the display device 20.

  Here, a specific example of the production facility 1 will be described to confirm the operation of the component facility 2. For example, the production facility 1A shown in FIG. 10 is configured to reciprocate the table 6 in the left-right direction by driving a motor 4 disposed on the base 3 and a ball screw 5 connected to the motor shaft. When the table 6 moving in one direction contacts the limit switches (LS) 7 and 8 arranged at the left and right ends of the moving range of the table 6, the table 6 is configured to be movable in the reverse direction. . In this example, a case will be described in which the operation of the left end limit switch (LS) 7 which is the component facility 2A is confirmed.

  The sequence circuit of this production facility 1A is a circuit represented by ladder logic shown in FIG. 11 (except for circuits indicated by dotted lines CL1 and CL2). The check circuit of the limit switch (LS) 7 at the left end as the component facility 2A is a circuit indicated by the dotted line frames CL1 and CL2, and is added before and after the sequence circuit to constitute a confirmation circuit. In the normal operation of the production facility 1A, as shown in FIGS. 11 and 12, when activated (step S21), the table 6 moves leftward (step S22). Then, it is determined whether or not the left end limit switch (LS) 7 is turned on (step S23). When the left end limit switch (LS) 7 is turned on, the table 6 is stopped (step S24).

  Then, it is determined whether or not the timer T1 is turned on (time up) (step S25). When the timer T1 is turned on (time up), the table 6 moves rightward (step S26). When the determination operation is not performed, the check routine is not started because the check start flag (X100) is not turned on (step S27). Then, it is determined whether or not the right end limit switch (LS) 8 is turned on (step S28). When the right end limit switch (LS) 8 is turned on, the table 6 is stopped (step S29). Then, it is determined whether or not the timer T0 is turned on (time up) (step S30). When the timer T0 is turned on (time up), the process returns to step S21 and the above-described operation is repeated.

  The check start flag (X100) is a switch installed on the operation panel or the like, a button displayed on the operation screen, and the like, and is turned on / off by the operator. Alternatively, the check circuit may be turned on when creating the check circuit. When the check start flag (X100) is turned on, the check routine is started. The determination operation starts the routine of the check circuit when the table 6 is moving rightward in step S26. It is determined whether or not the timer T10 is turned on (time up) (step S31). When the timer T10 is turned on (time up), the table 6 is stopped (step S32). Then, returning to step S22, the table 6 moves leftward. By this determination operation, the table 6 repeats reciprocating movement in the vicinity of the left end limit switch (LS) 7, so that the operation of the left end limit switch (LS) 7 can be confirmed a predetermined number of times.

(3. Modifications)
In the above-described embodiment, the configuration is applied to a production facility using a sequence circuit. However, the configuration may be applied to a production facility using a CNC (Computer Numerical Control) or a PLC (Programmable Logic Controller). .

(4. Effect of sequence circuit confirmation processing)
Since the operation of the component equipment 2 can be automatically confirmed after taking countermeasures against the failure in the component equipment 2 of the production facility 1, the operation confirmation does not depend on the work level of the worker, and the recurrence of the failure is prevented. can do.

DESCRIPTION OF SYMBOLS 1: Production equipment 2: Configuration equipment 10: Sequence circuit confirmation device 11: Failure information acquisition section 12: Configuration equipment identification section 13: Configuration circuit acquisition section 14: Group circuit acquisition section 15: Check circuit acquisition 16: Confirmation circuit creation unit 17: Confirmation circuit execution unit 18: Operation determination unit 19: Display control unit 20: Display device 21: Group circuit creation unit 22: Storage unit

Claims (5)

A device for checking the sequence circuit of the production equipment component equipment,
A failure information acquisition unit for acquiring information on a failure of the component equipment;
A component circuit acquisition unit that identifies the component facility that has failed based on failure information by the failure information acquisition unit, and acquires a component circuit of the sequence circuit that includes the identified component facility ;
A group circuit acquisition unit for acquiring a group circuit to which the component circuit acquired by the component circuit acquisition unit belongs;
Confirmation of a sequence circuit comprising: a confirmation circuit creation unit that creates a confirmation circuit by adding a check circuit for checking the operation of the group circuit acquired by the group circuit acquisition unit to the group circuit of the sequence circuit apparatus.   The sequence circuit confirmation apparatus according to claim 1, further comprising a confirmation circuit execution unit that executes the confirmation circuit created by the confirmation circuit creation unit.   3. The sequence circuit checking apparatus according to claim 2, further comprising a group circuit creating unit that creates a table of the group circuit by comparing the component circuit and a processing step of the production facility. The confirmation apparatus of the sequence circuit includes a display control unit for displaying the determination result of the determination performed in the confirmation circuit execution unit on the display device, verification device of the sequence circuit according to claim 2 or 3. The check circuit has a timer for measuring an operation confirmation time of the component equipment,
The sequence circuit confirmation device compares the operation confirmation time of the component equipment measured by the timer with a processing time of a table of a predetermined processing time range in the component circuit, and is executed by the confirmation circuit execution unit. The sequence circuit confirmation apparatus according to claim 2 , further comprising an operation determination unit configured to determine an operation of the confirmation circuit .

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