JPH05277895A - Displaying method for failure diagnosis of facilities - Google Patents

Abstract

PURPOSE:To automatically generate messages to cope with failure by previously registering an appropariate message corresponding to faulty facilities and by searching the message by using the identifier of the facilities. CONSTITUTION:In displaying failure diagnoses of a plurality of production facilities composing a production line, failure diagnostic messages MP of a plurality of all the production facilities are registered and memorized together with the identifier of the facility by a memory device. Next, the identifier of the faulty facility is detected. The failure diagnostic messages MP corresponding to the failure facilities are searched in the data file 56 of the memory device by using the identifier of the facilities to display the searched messages. Thus, messages to cope with the failure are automatically generated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an operation flow display device for production equipment controlled by, for example, a sequencer, and more particularly to improvement of operation flow display.

[0002]

2. Description of the Related Art In a production line such as an automobile assembly line, a sequence control unit having a built-in computer is provided for various installed facilities, and the sequence control unit controls the sequence of operations to be sequentially performed by each facility. Is known to do.
In such sequence control, a control program is loaded into a computer incorporated in the sequence control unit, and the sequence control unit sequentially advances each step of operation control for each of various equipment installed in the production line according to the sequence operation control program. It is designed to continue.

In production control by such sequence control, for example, as disclosed in JP-A-60-238906,
The operating status is displayed when a failure occurs.

[0004]

As shown in this prior art, when the operation of equipment is monitored, conventionally, a lamp or a CRT display device displays a current operation step or an operation step in which a failure has occurred. It is supposed to do. That is, the prior art only gives information on the operating state at a certain point, and in the operating sequence of the entire system, the present step or the step in which a failure has occurred can be placed in any operating stage. It does not give us any recognition. Therefore, in the prior art, the procedure of knowing the coping method and the operation is taken while referring to the failure manual based on the number of the stopped step and the like. For this reason, it has been pointed out that recovery takes time.

Therefore, the present invention has been proposed to solve the problems of the prior art, and its purpose is to display a fault diagnosis display of equipment capable of displaying instructions and explanations such as a coping method at the time of failure. It is to propose a method.

[0006]

[Means for Solving the Problems] and

The present invention for achieving the above object is a method for displaying a failure diagnosis of a plurality of production equipments that compose a production line, wherein a failure diagnosis message for the plurality of production equipments is provided in advance for each equipment. It is registered and stored in a storage device together with an identifier, the identifier of the failed equipment is detected, and a failure diagnosis message corresponding to the failed equipment is searched in the storage device using the identifier of the failed equipment, and is searched. Characterized by displaying a message.

According to the above method, since a message suitable for the failed equipment is registered in advance and the message can be searched by the identifier of the equipment, a message for automatically dealing with the failure is displayed. It is possible to generate.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to sequence control of an automobile production line will be described below with reference to the accompanying drawings. The embodiment described below is one in which the present invention is applied to automatic generation of a sequence control program in a process of docking an engine or a suspension on a vehicle body in a production line of an automobile. Therefore, first,
A vehicle assembly line that is a control target of the sequence control program will be described. <Example of Assembly Line> First, an example of a vehicle assembly line to be controlled by the sequence control program to be generated will be described with reference to FIGS. 1 and 2.

1 and 2 show a part of a vehicle assembly line. This line illustratively consists of three stations ST1, ST2, ST3. At the positioning station ST1, the body 11 of the vehicle is received on the pedestal 12 and the position of the pedestal 12 is controlled to control the body 11
Position. At the docking station ST2, the engine 14 mounted on a predetermined position on the pallet 13 and the front suspension assembly (not shown)
And rear suspension assembly 15 and body 11 are combined. At the fastening station ST3, the engine 14 combined at ST2 with respect to the body 11
The front suspension assembly 15 and the front suspension assembly 15 are fastened and fixed with screws. Further, a body 11 is provided between the positioning station ST1 and the docking station ST2.
An overhead transfer position 16 is provided for holding and transporting. A pallet transfer position 17 for transferring the pallet 13 is provided between the docking station ST2 and the fastening station ST3.

The pedestal 12 in the positioning station ST1 reciprocates along a rail 18. In the positioning station ST1, the pedestal 12 is moved in a direction (vehicle width direction) orthogonal to the rails 18 to position the body 11 placed on the pedestal 12 in the vehicle width direction of its front portion. Positioning means (BF) and positioning means (B) for positioning the rear portion in the vehicle width direction.
R) and the direction in which the pedestal 12 is along the rail 18 (front-back direction)
And a positioning means (TL) for performing positioning in the front-rear direction by moving the same. Further, ST1 is engaged with front left and right portions and rear left and right portions of the body 11 to position the body 11 with respect to the pedestal 12, and ascending / descending reference pins (FL, F).
R, RL, RR) are provided. Then, the positioning device and the elevating reference pin constitute a positioning device 19 in the positioning station ST1. That is, the positioning means and the lifting reference pins are control targets of the positioning device 19 of the sequence control program.

The transfer device 16 includes a positioning station S.
The guide rail 20 is provided above the T1 and the docking station ST2 so as to be bridged therebetween, and the carrier 21 that moves along the guide rail 20. An elevating hanger frame 22 is attached to the carrier 21, and the body 11 is supported by the elevating hanger frame 22. Lifting hanger frame 22
In the left front support arm 22F, as shown in FIG.
The left and right front support arms 22FR are attached via the pair of front arm clamp portions 22A, respectively, and the left rear support arm 22RL and the right rear support arm 22RR (not shown) respectively include the pair of front arm clamp portions 22B. Is installed through. Each of the left front support arm 22FL and the right front support arm 22FR rotates around the front arm arm clamp portion 22A as a rotation center, and along the guide rail 20 in a state where the front arm clamp 22A is released from the clamp. When the extended position is taken and the front arm clamp portion 22A is used for clamping, as shown in FIG.
Take a position that extends in a direction orthogonal to. Similarly, each of the left rear support arm 22RL and the right rear support arm 22RR also rotates around the rear arm clamp portion 22B as a rotation center, and when the clamp by the rear arm clamp portion 22A is released, the guide 20 is rotated. It also has a position extending along it, and when it is clamped by the rear arm clamp portion 22B, it takes a position extending in a direction orthogonal to the guide rail 20.

When the body 11 is transferred to the transfer device 16, the transfer device 16 is left at a position (original position) above the front end portion of the rail 18 as indicated by a chain line in FIG. The front support arm 22FL and the right front support arm 22FR each extend along the guide rail 20 after the clamp by the front arm clamp portion 22A is released. Further, each of the left rear support arm 22RL and the right rear support arm 22RR is released from the rear arm clamp portion 22B, extends along the guide rail 20, and then the elevating hanger frame 21B is lowered. In this state, the pedestal 1 on which the body 11 is placed
2 is moved along the rail 18 to the front end portion thereof so as to take a position corresponding to the lifted hanger frame 21B of the transfer device 16 that has been lowered. And
Left front support arm 22FL, right front support arm 22FR
Each of them is rotated to take a position below the front part of the body 11 to extend in a direction orthogonal to the guide rail 20, and is clamped by the front arm clamp part 22A. In addition, the left rear support arm 22RL and the right rear support arm 22RR are rotated to move the body 1
The rear arm clamp portion 22B is positioned below the rear portion of the rear arm 1 and extends in a direction orthogonal to the guide rail 20.
It will be in the state of being clamped by. After that, the elevating hanger frame 21B is raised, and the body 11 is attached to the elevating hanger frame 21B of the transfer device 16 as shown in FIG.
L, right front support arm 22FR and left rear support arm 22
It is supported by the RL and the right rear support arm 22RR.

Further, the pallet conveying device 17 is provided with a pair of guide portions 24L and 24R provided with a large number of support rollers 23 for receiving the lower surface of the pallet 13, and the guide portions 24L and 24R, respectively, extending in parallel. And a pair of transport rails 25L and 25R, and a pallet locking portion 26 that locks the pallet 13, respectively.
And pallet transfer tables 27L and 27R which are designed to move along the pallet transfer table 27L and the pallet transfer table 27L.
And a linear motor mechanism (not shown) that drives 27R.

When the front suspension assembly and the rear suspension assembly 15 are respectively assembled to the docking station ST2, a pair of strut of the front suspension assembly and a strut 15A of the rear suspension assembly 15 are respectively supported to take an assembly posture. Left and right front clamp arms 30L and 30R, and a pair of left and right rear clamp arms 31L and 31R are provided. The left and right front clamp arms 30L and 30R are attached to the attachment plate portions 32L and 32R so as to be movable back and forth in a direction orthogonal to the transport rails 25L and 25R, respectively, and the left and right rear clamp arms 31L and 31R are attached respectively. It is attached to the plate portions 33L and 33R so as to be movable back and forth in a direction orthogonal to the transport rails 25L and 25R. The front end portions of the left and right front clamp arms 30L and 30R that face each other and the front end portions of the left and right rear clamp arms 31L and 31R that face the front suspension assembly strut 15A or the rear suspension assembly 15 strut 15A, respectively. It has a mating engaging portion. Then, the mounting plate portion 32L
Can be moved in a direction along the transport rails 25L and 25R with respect to the fixed base 35L by the arm slide 34L. The mounting plate portion 32R is attached to the fixed base 35R by the arm slide 34R, and the transport rails 25L and 25R.
It is movable in the direction along R. The mounting plate portion 33L is
With respect to the fixed base 37L by the arm slide 36L,
It is movable in the direction along the transport rails 25L and 25R. Further, the mounting plate portion 33R includes the arm slide 36.
The R is movable in the direction along the transport rails 25L and 25R with respect to the fixed base 37R. Therefore,
The left and right front clamp arms 30L and 30R can move back and forth and left and right under the condition that their front ends are engaged with the struts of the front suspension assembly. In addition, left and right rear clamp arms 31L and 31R
Are movable in the front-rear direction and the left-right direction in a state in which their tips are engaged with the struts 15A of the rear suspension assembly 15. Further, the left and right front clamp arms 30L and 30R, the arm slides 34L and 34R, the left and right rear clamp arms 31L and 31R, and the arm slides 36 and 36R are the docking device 4
Configures 0.

Further, in the docking station ST2, a pair of slide rails 41L and 41R installed so as to extend in parallel with the transport rails 25L and 25R, respectively.
And a slide device 45 including a movable member 42 that slides along the slide rails 41L and 41R, a motor 43 that drives the movable member 42, and the like. Movable member 4 in this slide device 45
On the second side, engaging means 46 for engaging a movable engine support member (not shown) provided on the pallet 13 is provided.
And 2 for positioning the pallet 13 at a predetermined position.
Elevating pallet reference pins 47 are provided. In the slide device 45, the body 11 supported by the elevating hanger frame 22 in the transfer device 16 is
When the engine 14, the front suspension assembly, and the rear suspension assembly 15 arranged on the pallet 13 are combined, the engaging means 46 engages with the movable engine support member on the pallet 13 positioned by the lifting pallet reference pin 47. In this state, the engine 14 is moved back and forth, whereby the engine 14 is moved back and forth with respect to the body 11 to avoid interference between the body 11 and the engine 14.

At the fastening station ST3, the body 11
A robot 48A for performing screw tightening work for fastening the engine 14 and the front suspension assembly combined therewith, and the body 11 and the rear suspension assembly 15 combined therewith.
Robot 4 for performing screw tightening work for fastening
8B and are arranged. Furthermore, the fastening station S
At T3, two lifting pallet reference pins 47 for positioning the pallet 13 at a predetermined position are provided.

In the vehicle assembly line described with reference to FIGS. 1 to 3, the positioning device 19, the transfer device 16 in the positioning station ST1, the docking device 40 and the slide device 45 in the docking station ST2, the pallet transfer device 17, and The robots 48A and 48B at the fastening station ST3 are
The sequence control unit connected to them performs sequence control based on the sequence control program generated by the program generation device of this embodiment. That is, the positioning device 19, the transfer device 16 and the like are "equipment" that are the sequence control targets. <Operation Blocks and Operation Steps> The assembling operations in the production line shown in FIGS. 1 and 2, that is, the operations performed by all the “equipment” to be sequence-controlled can be decomposed into a plurality of “operation blocks”. Where “motion block”
Can be defined as a set of unit operations.

The most important property of a motion block is that it can complete a motion in the intermediate process from the start to the end of a motion block independently of other motion blocks without interference. Is. Due to these properties, it is possible to describe the operation block as one block (lump). In other words, a motion block is related to other motion blocks only at the level of the motion block. In order for an operation block to start operation, it is necessary to end the operation in another operation block. There may be one or more other operation blocks. That is, the end of the operation of one operation block becomes a start condition of another operation block (one or a plurality of operation blocks) connected to it, or the end of the operation of a plurality of operation blocks becomes a start condition. is there.

Further, according to the above-mentioned characteristics, the activation of another operation block is not performed in the intermediate stage of the operation in the operation block. In addition, there is no need to wait for activation from another operation block in the intermediate stage of the operation block. From the above definition of the action block, the following ancillary action block properties can be derived. That is, it is desirable that the motion block be the largest one among the set of unit motions that satisfy the above properties. This property is not absolutely necessary. However, if this property is satisfied, the number of operation blocks that describe the production line decreases,
The description of the whole process is simplified and is very easy to see.

4 to 6 show the overall flow of operations in the production line shown in FIGS. Figure 1,
When the production line shown in FIG. 2 is described by operation blocks that satisfy the above-mentioned conditions, 19 operation blocks a to s are obtained as shown in FIGS. 4 to 6. The block diagram thus obtained is obtained after the operator analyzes the operation in the production line of FIGS. 1 to 3. In the figure, two (or more) operation blocks connected by a horizontal double line mean that they operate in parallel. Further, when the two operation blocks are vertically connected by a solid line, the operation of the operation block in the upper position is completed and the operation of the block in the lower operation is started. The double-lined square means the beginning of each block.

The operation block a means the forward movement of the pedestal 12 and is called "advance receiving". When this "load receiving forward" block is completed, a block b named "reference output" and a block c named "receiver output" are performed in parallel. In the “reference output” block b, the reference pins (F
The L reference pin and the RR reference pin are driven to a position named "out", and the TL positioning means and the like are driven to a position named "return". In block c, the pedestal 12 moves to the docking position. In the block named “transfer lifting” of the block d, the transfer device 16 moves up at the station ST1. When the operation of the block d is completed, the operation block is processed in two flows following the block d. That is, following the "transfer rising" block, a block e named "reference return" and a block h named "transfer forward" operate in parallel. In block e, the operation of returning the reference pin issued in block b to the "return" position is performed. On the other hand, in the block h, the transfer device 16 advances to the station 2.

In the block f, which is named "receipt of cargo receiving", which follows the block e, the operation of retracting the pedestal 12 is performed. In block h, the transfer device 16 advances to the station ST2. On the other hand, in the guide part, strut clamp part, and pallet slide part, the block 1
(“Pin lift”), block m (“lift lift”), and block n (“pallet advance”) are executed respectively. Completion of block m (“lift lift”) and block n (“pallet advance”) activates block o (“arm out”).

When the operations in the blocks h, 1, and o are completed, the operation block i named "transfer lowering" is executed. The above-described flowchart of the set of operation blocks in FIGS. 4 to 6 is a block of the set of operations that meet the above-described conditions. As described above, the operator creates a flow chart creation program described later. It was created in. The name given to each motion block expresses the characteristics of the motions (plurality) in the motion block in short words.

Each operation block consists of a plurality of operation steps. In principle, an operation by one actuator (solenoid or the like) corresponds to the operation in one operation step. FIG. 7 is a flowchart of a plurality of operation steps performed in the "reference output" block b. In the figure, the label attached to each step is the name of the step given by the operator. According to the flow chart of FIG. 7, in the "RR slide out" step, the right slide rail 41R on the rear side is set to the "out" state, and in the "FL reference pin A out" and "FL reference pin B out" steps, "Exit" the above-mentioned lifting reference pins A and B (front left side) for positioning the vehicle body 12 with respect to the pedestal 12.
To the state of. In the "RR reference pin output" step, the raising / lowering reference pin on the right side of the rear portion is also set to the "out" state. In addition, "TL position return", "BR position return", "B
In each step of "F position return", the positioning means TL, BR, BF are returned to the "return" position. In this way, the "reference output" block b in FIG. 4 is represented by the step operation shown in FIG. This operation step flow chart is also created by the above-mentioned flow chart creating program.

Each label in the operation step flow chart as shown in FIG. 7, for example, which expresses the operation of one operation block, specifies the actuator device driven in the operation step and, as described above, directly describes the operation of the actuator. It is supposed to be expressed in. For example, the name "RR reference pin out" is given to the step "RR reference pin out" in which the RR reference pin is in the "out" state. Here, the RR reference pin in the first half part of this name specifies the actuator driven in the operation step, and the next "out" means the drive state of the actuator. In other words, for humans and devices who can understand the meanings given to the names of the operation blocks and operation steps in the flow charts of FIGS. 4 and 7, those flow charts describe the operations in the production line of FIG. It is easy to understand that it has become a thing. The purpose of the automatic generation system of the sequence control program of this embodiment is to automatically generate the ladder programs as shown in FIGS. 8 to 10 from the flowcharts of FIGS. The ladder programs shown in FIGS. 8 to 10 are ladder program elements corresponding to part of the operation of the operation block b shown in FIG. 7. <Ladder Program> Here, the symbols of the ladder program will be described. The equipment itself, such as the lifting reference pin, of the production line in FIG. 1 is not a control target on the ladder program, and the solenoid or the like that drives it becomes a problem. Therefore, the equipment of the production line is shown in FIG.
Can be equivalentized by a cylinder actuator as shown in FIG. The "out" state and the "return" state of this actuator are defined by the position of the piston that moves left and right in the cylinder in the drawing. The piston assumes either its "out" or "return" state when the solenoid valve is energized or de-energized by the input signal B ₀ . These two states are confirmed by two limit switches. That is, "equipment" in FIG.
As the output from the limit switch, the output A _O (“outgoing confirmation” signal) from the limit switch and the output A _i (from the limit switch) to confirm the return to the original position. Return confirmation signal).

FIG. 12 is a diagram for explaining the logic of the output drive operation of the element of FIG. In order for the solenoid to turn on, the interlock condition ILC is satisfied. The interlock condition ILC generally includes various activation conditions specific to its operating step. Since the execution condition of each operation step is the operation end of the operation step of the preceding stage, the interlock condition ILC has, for example, a signal indicating that the output state of the operation step of the preceding stage is confirmed (for example, in FIG. 11). A _O ) is usually included.

FIG. 13 shows an example of a typical operation circuit used when automatically generating the entire sequence. In FIG. 13, the condition C _A is closed in the automatic mode (the mode in which the production line operates according to the sequence control program) when this operating circuit is operating. Condition C _S is closed when this operating circuit is operating in manual mode. C _S is normally closed. Therefore, in the normal automatic mode, if the interlock conditions ILC ₀ and _Al are satisfied, the output B _O is output. On the other hand, ILC ₁ describes the logic of operating conditions in the manual mode. In the manual mode, since the contact C _S is opened, B _O is output if the conditions A _k and ILC ₁ are simultaneously satisfied, or if the conditions A _k and A _I are simultaneously satisfied. In general, A _I is the logic for killing the manually operated interlock condition ILC ₁ .

The ladder pattern of FIG. 13 is a standard pattern used to express a ladder program of a certain operation step. Other ladder patterns prepared in this system are shown in FIGS. FIG. 14 is a pattern which describes the start and stop of the operation block in a standard manner. FIG. 15 is the same as the pattern described with reference to FIG. In FIG. 16, one contact condition is added to the pattern of FIG.

Labels 1360 and 1372 in FIG. 8 are ladder programs corresponding to "RR slide out" in FIG. In the logic of label 1360, "B4 step 1 output" (B4STEP1OUTPUT) at the address 5041 is (B4 step OFF * reference pin return * container forward + B
4 step 1 output) * B4 step 2 output / * B4 step 3 output / =
When 1 is satisfied, "1" is output. Here, B4 is the block number of the "reference output" block b in FIG. Further, “/” represents a logical NOT. Also, "B
"4 steps OFF" means that all steps of block 4 are off (i.e. not executed). Further, "reference pin return" and "conveyance table forward" at address 1753 mean the end of the operation in the "consignment forward" block preceding the "reference reference" in block 4. Also, B4
It can be easily guessed about the step 2 output / and B4 step 3 output /. Thus, the action at label 1360 represents the condition under which the first motion step "RR slide out" of the "reference out" block should be activated correctly. Therefore, if all the operation steps of "advance receipt of goods" of the block are completed, the above conditional expression is satisfied, and "B4 step 1 output" becomes "1". Once the “B4 step 1 output” becomes “1”, the “B4 step 1 output” remains “1” due to the latch condition of the label 1360.

The output "B4St1" of the label 1372 of FIG.
"RR slide out" becomes "1" because B4 step 1 output * cargo cradle forward * B4 operation ON * RR
This is when the slide out / = 1 is satisfied. Here, it is noted that B4St1 is the first step of block number 4. "R
The "R slide" operation is performed when "B4 step 1 output" is "1" and the "RR slide" actuator is not on.
It is when the step is executed.

The ladder program of FIGS. 9 and 10 is shown in FIG.
It is easily understood that the two operation steps of "FL reference pin A output" and "FL reference pin B output" of "1. Thus, when the "reference output" block of the block b of FIG. 4 is represented in a form corresponding to the operation step flowchart of FIG. 7, "RR slide output" and "FL reference pin A output" of the operation step flowchart are shown. It can be understood that the three steps of "," and "FL reference pin B output" correspond to the ladder programs of FIGS.

In FIG. 17, the master table 101
Is a table of device names, types of operations, and names of input signals and output signals when these devices are represented by the symbols shown in Fig. 7 for all the equipment (actuators, etc.) of the target production line. It is a
A detailed example thereof is shown in FIG. Since this master table 101 expresses the actual input / output relationship of each device, it will be referred to as "real I / O map" hereinafter. The database 100 includes a library that stores names and the like given to all equipment (devices such as actuators) used in this production line. This library is provided to prevent the operator from giving arbitrariness to the device name. The database 100 includes a “block flow map” and a “step flow map” in addition to the library. The block flow map is shown in Figure 1.
8 is a map as shown in FIG. 8, and the operation block flow chart shown in FIGS. 4 to 6 intended to facilitate human understanding is mapped as shown in FIG. 18 to enable computer data processing. It is a thing. The step flow map enables the data processing of the computer by mapping the operation step flowchart shown in FIG. 7 as shown in FIG.

The system of FIG. 17 uses the "real I / O map" in the database 100 and master table 101 described above.
Besides, "data generation", "automatic programming",
It consists of four subsystems, "Simulation" and "Fault diagnosis / CRT operation panel". The "automatic programming" subsystem is based on the "real I / O map" in these database 100 and master table 101.
Ladder program for sequence control is automatically generated. The data generation program 102 is for creating or modifying the “real I / O map” in the database 100 or the master table 101. Therefore, this subsystem is mainly used in the "sequence program creation" process. As will be described later, this "automatic programming" subsystem is a "block flow map" or "step flow map" (these maps describe the production line for which a ladder program is to be automatically generated). And a "real I / O map" that generally expresses the input / output relationship of the devices used in the production line are combined to create a ladder program. In this combination, the names of blocks, steps, and devices used in the "block flow map" and "step flow map" and the device names stored in the "real I / O map" are combined. Made by linking.

"Simulation" Subsystem 105
Automatically generates a program for simulating the ladder program generated by the automatic programming subsystem 104. This generated simulation program is mainly used in the "trial" stage. "Trouble diagnosis / CRT operation panel" subsystem is "Trial"
In a stage or an "operating" stage, a simulation result is diagnosed or a failure in an actual operating stage is diagnosed, and those diagnostic results are mainly displayed on a CRT display device. In this display device, the name of the failure location or the like is indexed from the device name in the "real I / O map" so that the operator can easily understand.

As described above, the central data in this system is the "real I / O map" (FIG. 20) in the master table 101, and this "real I / O map" and the block flow in the database 100. The maps and step flow maps are organically linked to automatically generate ladder programs, simulation programs, and the like. Therefore, the hardware configuration of the present system will be described below, and then the above three maps will be described in order. <Hardware Configuration> FIG. 21 is a rewrite of the embodiment system described with reference to FIG. 17 from the viewpoint of the hardware configuration. As shown in the figure, the present system from the viewpoint of hardware configuration includes a control target equipment 50 (corresponding to various “equipment” in FIG. 1), a CPU 60, and a CRT panel control unit for controlling a CRT as a user interface. 53 and a data file 56 for storing the above-mentioned map and database. The CPU 60 is an automatic programming / data input control program (control unit) 55 that automatically generates a ladder program and the above-mentioned map.
And a fault diagnosis control program (control unit) for performing fault diagnosis
52 and a simulation control program (control unit) 54 for performing simulation control. These units are connected by a communication line 61, and a data file 56
A semiconductor memory is suitable for high speed.

The CRT panel control unit 53 has a touch panel 57 mounted on the display screen in addition to the CRT display device 58. This system requires an interface with the operator during the automatic programming process, simulation process, failure diagnosis process, etc.
The control unit 53 displays a plurality of windows on the CRT 58 by the well-known multi-window display control, and the operator selects a desired item from the plurality of items in the displayed window by using the touch panel 57. Therefore, it goes without saying that a pointing device may be used instead of the touch panel 57.

FIG. 22 shows a program structure in the automatic programming / data input control section 55. A so-called operating system is stored in the lowermost layer, and a multi-window system, a Japanese front-end processor (JFEP) for inputting Japanese, a graphic processor for creating a flowchart, and a library are created. A program, a program for creating an actual I / O map, a program for creating a flow map,
From this flow map, the ladder program (Fig. 8 to Fig. 1
0) and a compiler that creates 0).

The figure processor is a processor for creating the flowcharts of FIGS. 4 to 6 and 7, and has a function of writing a box as a symbol of the flowchart, a function of giving a name to the box, and a function in the box. It consists of the function of inputting sentences and the function of connecting multiple boxes. While this graphics processor is operating, CR
On the screen of the T device 58, items that can be input from the above-mentioned library in the data file 56 are displayed in the multi-window mode. Here, the item is literal data such as the device name, the operation step name, and the operation block name described above. Operator touch panel 5
7, it becomes possible to make a desired input by selecting a specific item. In addition, it is possible to freely input names that are not in the library with the help of Japanese FEP described above. The reason why the items that can be input are displayed in the window and the desired item is selected from them is to prevent the names from being arbitrary. It should be noted that such a multi-window control system, graphic processor, and Japanese FEP are already well known, and detailed description thereof is unnecessary. The main function of Japanese FEP is to convert the input of Japanese romaji reading into a sentence containing kanji and kana. Therefore, when this system is used in the English-speaking world, naturally, Japanese FEP is unnecessary.

FIG. 23 shows a part of the data stored in the library. As shown in the figure, the data includes a "device name" field and an "operation name" field. The data in these fields are displayed separately when the various maps are created. In the library, this split into two fields is
This is because the “device name” and the “operation name” have unique meanings. <Block Flow Map> FIG. 18 is a block flow map that plays an important role in this system. This map is obtained by using the operation block flowcharts of FIGS.
It is converted by the flow map creation program 60 (FIG. 22) 55 and is stored in the data file 56. This map has seven items, namely, "block number", "block name", and "F", as shown in FIG.
It consists of "ROM", "TO", "pointer of step flow map", "device type", and "operating time". The block name is the name given to the block. The block can be uniquely specified by the block name, but the block can be easily specified by adding the block number. In the ladder programs shown in FIGS. 8 to 10, the signal name is attached with, for example, “B4”
It is obtained by referring to this block number. “FROM” indicates from which other upper block the block is connected. When a plurality of block numbers are written in the "FROM" portion, it indicates that the block is connected to the block. “TO” indicates to which other lower block the block is connected. In the "TO" part,
When a plurality of block numbers are written, it indicates that the block is connected to those blocks. FIG. 18 shows the connection relationship between blocks in the block flowcharts of FIGS. As described above, the graphic processor expresses the connection relationship between the boxes in the flowcharts of FIGS. 4 to 6 as vector data, and it is easy to create the block flow map of FIG. 18 from such data. ..

The "step flow map pointer" of the block flow map indicates at which memory address the step flow map (FIG. 19) of the block is created. <Real I / O Map> Before explaining the step flow map, the real I / O map will be described with reference to FIG. This real I
The / O map defines the input / output relationship for each of all the equipment (actuators) provided in the production line to be designed. "Name" in the figure
Is a "name" uniquely assigned to the actuator device. The other items that define this map are Action, Output B, Confirm A, and Manual.
It is four of "C". The “output B” is data for the device to perform the operation specified in the “operation” field when the signal having the logical value 1 is written in the memory address specified in the “output B” field. .. This "output B" corresponds to the output B described in FIG. "Confirmation A"
Is a memory address that the system refers to when the device confirms the operation when the device performs the operation specified in the "operation" field. This “confirmation A” is shown in FIG.
This corresponds to the "confirmation A" described in. The "manual C" is to write a logical value 1 to the memory address indicated in the "manual A" field when the program is constructed to perform the manual operation. The actual I / O map will be specifically described with reference to FIG. 20. In order for the device named “BF positioning” to perform the “out” operation, 1 is written in the “B _A0 ” address, and the result of the operation Is confirmed by confirming whether 1 is written in the address "A _C0 ". In addition, "BF
In order for the "Positioning" device to perform the "return" operation, 1 is written in the "B _A1 " address, and the result of the operation is confirmed by checking whether 1 is written in the "A _C1 " address. It Addresses such as "B _A0 " and "A _Co " are
It corresponds to the so-called memory map I / O address. These addresses correspond to the pin numbers of the backplane of the sequencer controller 51 of FIG. This pin is connected to the relevant actuator. The control unit 51 scans the contents of these memory addresses (“output B” and “manual A”), and when the contents of these addresses become 1, the corresponding actuator is driven. Then, if the confirmation switch (see FIG. 8) of the actuator changes,
The logical value is written in, for example, the address "A _C0 ".

This real I / O map is created by using a Japanese FEP or a real I / O map creation program (FIG. 22), and each "name" and "action" field is constructed to be searchable. There is. <Step Flow Map> The step flow map of FIG. 19 is a map that describes the operation on the actual production line. As shown in FIG. 19, the items of this map represent the “block number” indicating the number of the block to which the step belongs, the “step number”, the “name” of the step, and the “motion” type of the step. "Operation", "FROM", "TO", "Output B",
These are "confirmation A", "manual A", and "operating time". "FR
Fields such as “OM” and “TO” represent connection relationships between steps, as in the case of the block flow map. The "Run Time" field is the nominal time it takes for the step to run.

The motion step flow chart (FIG. 7) is
It was created by using the graphic processor (FIG. 15A), and the data is vectorized data. The data for the first six fields of the step flow map, that is, "block number", "step number", "name", "operation", "FROM", and "TO" are shown in FIG. In step S8, the vector flow is created from the vectorized motion step flow chart in the same manner as the block flow map. The remaining fields, namely "output B" and "confirmation A"
The data for "manual A" is stored in these fields when the ladder program compiler (FIG. 22) of the automatic programming control unit 55 generates the ladder program (when the procedure of FIG. 17 is executed). Embed the data from the "real I / O map". <Monitoring Execution State> FIG. 24 shows an example of the icons displayed on the CRT device 58. The CRT device 58 in this embodiment system is used for system monitoring at the time of execution and diagnosis at the time of failure. Monitoring at the time of execution is started by pressing the icon on the left side of FIG. 24, and monitoring at the time of failure diagnosis is started by pressing the icon on the right side.

FIG. 25 shows the coupling in the system in execution monitoring mode. That is, the ladder program generated by the CPU 60 is loaded into the sequencer control unit 51, and the control unit 51 controls each equipment according to this program. On the other hand, the CRT control unit 53 receives the control result of the sequence control in each facility by the CPU 60 and sequentially displays it on the CRT 58.

FIG. 26 shows an example of the display screen of the CRT 58 when the blocks B2 and B4 of FIG. 4 are being executed. In this example, it is assumed that the block B2 is completed and that the process up to step 3 of the block B4 is executed. Therefore, first, in order to show that the process is executed up to block B4, "B2 (consignment advancing)" in area 300 and area 3
“B4 (reference output)” of 01 is displayed in green. However, “B6 (transfer increase)” in the area 302 of the block B6 which has not been executed yet is displayed in red. Further, since the steps 1 and 2 of the block B2 are completed, those number display areas are also displayed in green. Similarly, the step numbers 1, 2, and 3 of the block B4 are also displayed in green. However, step 4 of block B4 not yet executed
8 and steps 1 and 2 of block B6, their step numbers are displayed in red. Further, in each display area of each block, the confirmation signal A, the output signal B, and the manual signal C are displayed in green (on) or red (off) depending on the on / off state.

FIG. 27 is a flow chart showing the cooperation of the control procedure between the CPU 60 and the CRT control unit 53. The CPU 60 executes the sequence ladder program illustrated in FIGS. That is, unless an error is detected in steps S2 and S4, the steps are executed one after another. Each time it is executed in step S2, the BmSn (block m step n) is sent to the control unit 53 side.

The unit 53 side updates the display every time it receives BmSn (block m step n) in step S10. FIG. 28 is a detailed flowchart of the display update procedure of this step S10. Step S32
Then, when the end of the block is notified from the CPU 60, the block number is received from the CPU 60 in step S44. Then, the display position of the display image of the block corresponding to the block number is detected, and the block number portion (areas 300, 301, 302, etc. in FIG. 26) is changed to green. Then, the display is made at step S48. If the step is completed, the CPU 6 is reached in step S36.
Receive BmSn (block m step n) from 0.
Then, change the number field of the corresponding step to green. In step S40, the actual I / O map (FIG. 20) is searched by using the name of the step flow map (FIG. 19) having the received BmSn number as a key, and the output B, confirmation A, and manual C of the device are searched. Read the value of each signal stored in the field. And step S4
In 2, the block number and the step number are displayed in green, and the signals are displayed in green or red depending on their values.

Thus, by displaying the completed block and step number in green, the operator can instantly know the current operating point or the step number at which a failure has occurred. In particular,
Display the blocks and steps that have been executed until then,
Further, since the blocks and steps to be executed in the future are displayed in red, the operator can grasp the current situation with a glance and position the current situation in the overall situation. <Display of Operation Guide> When a failure is detected, this system can display on the CRT 58 where the failure has occurred and what kind of action should be taken. The operation guide is written in Japanese so that the operator can easily understand it.

For example, "please check limit switch AAAA ", "please CCCC BBBB manually", "please move to DDDD screen". It should be noted here that the message in the above guide is a standard sentence. But,
It means that the failure buoy peculiar to the failure and the handling of the failure are obtained from the actual I / O map (FIG. 20). This is because if the BmSn in which the failure has occurred is known, the device name at that step can be known from the step flow map and the actual I / O map. In the example message above, AAAA and BBBB are the device names, and CCCC is the operation of the device, ie, "
The message is completed by inserting an "out" or "return".

The display control of the operation guide will be described with reference to the flowchart of FIG. In step S4,
When the CPU 60 detects an error, in step S6,
BmSn is sent to the CRT control unit 53.
In step S16, the name of the device of the operation step is known from the sent BmSn by the step flow map (FIG. 19), and the name of the device is further input.
The / O map (FIG. 20) is searched to retrieve the message pointer MP of the device having that name. FIG. 29
Shows a more detailed structure of the real I / O map. The I / O map of FIG. 29 has a message pointer MP added to that of FIG. This message pointer MP
Is a pointer that stores the text type of the message specific to the device in which the detected error occurred. The above three message sentences are examples. The reason why multiple message texts are set is that different messages deal with failures depending on the device type.

In step S8, the message text corresponding to the pointer MP is stored in a predetermined memory (for example, in FIG.
1 data file 56). Then, in step S20, the device name is inserted in the AAA field or the like of the message. In step S22,
Create a response. For example, step 1 of block B4
If an error is detected in (B4S1), the device name is determined to be “RR slide out” from the step flow map of FIG. 19, and the MP is determined to be “1000 address” from the I / O map of FIG. , At that time, if the confirmation signal should have been 1 but was 0, "R
The place where "R slide out" was supposed to be "out" was "return", so manual signal C (address 1300)
The message should be " Check limit switch " RR slide out " .""Please manually output address 1300. " Here, the operation is easier if the following method is used. Becomes That is, a unique name (for example, "RR slide output manual") is attached to the signal at the address 1300, and the signal name is displayed as an icon on the CRT screen. , The icon is turned on via the touch panel 57.

Here, another method for displaying and outputting the guide message regarding the failure will be described. As another method, FIG. 30 is realized by incorporating a failure detection circuit in the sequencer. In the figure, B ₁ ~
B _{n + 1} is a switch indicating a failure factor, and A _{1 to} A _n are alarm devices. In terms of technique, A _n that is turned on by a B _i factor is constantly monitored, and when A _n is turned on, the occurrence factor (which B caused A _n to turn on) is searched for.
The actual I / O map includes a map for the factor B in advance, and the name of the device is extracted from the symbols B _{1 to} B _{n + 1} . The above message is associated with the alarm device A.

By using the above method, the system can automatically display the information related to the failure such as the failure countermeasure guide and the cause of the failure automatically without the intervention of the operator. Furthermore, the failure guide message can be created extremely easily by way of the I / O map. <Modification> The present invention can be variously modified without departing from the gist thereof. For example, the above-described embodiment has been applied to the automobile production line, but the present invention is not limited to that application.

[0053]

As described above, the present invention is a method for displaying a failure diagnosis of a plurality of production equipments forming a production line, wherein the failure diagnosis message of the plurality of production equipments is provided in advance for each equipment. Stored in the storage device together with the identifier of, the faulty equipment identifier is detected, a fault diagnosis message corresponding to the faulty equipment is searched in the storage device by using the faulty equipment identifier, and is searched. It is characterized by displaying a message.

According to the above method, the message suitable for the failed equipment is registered in advance, and since the message can be searched by the identifier of the equipment, the message for automatically dealing with the failure is displayed. It is possible to generate. In particular, according to the method of the second term, the failure diagnosis message common to some equipments is stored as a message database with the display field of the procedure for coping with the failure of those equipments blanked, and further stored. The on / off operation of each of the plurality of equipment is stored as an equipment device table, and in the display step, the on / off operation of the equipment is displayed in the handling procedure display field in the message corresponding to the equipment found in the search step. By inserting, the message can be standardized.

Further, according to the method of the third term, in the storing step, a message common to some facilities is stored with the name display field of those facilities being blank, and in the displaying process, it is searched for in the searching process. By inserting the name of the equipment in the name display field in the message corresponding to the equipment, the message can be standardized.

[Brief description of drawings]

FIG. 1 is a diagram illustrating a production line of an automobile to which the present invention is applied.

FIG. 2 is a diagram illustrating an automobile production line to which the present invention is applied.

FIG. 3 is a diagram illustrating an automobile production line to which the present invention is applied.

FIG. 4 is a flow chart showing an operation block flow chart by dividing the operation in the production line of FIGS.

FIG. 5 is a flow chart showing an operation block flow chart by dividing the operation in the production line shown in FIGS.

FIG. 6 is a flow chart showing an operation block flow chart by dividing the operation in the production line shown in FIGS.

FIG. 7 is a flowchart showing an operation in one block shown in FIGS. 4 to 6 and called an operation step flow chart.

8 is a ladder program diagram showing a partial operation of the step of FIG.

9 is a ladder program diagram showing a partial operation of the step of FIG.

10 is a ladder program diagram showing a partial operation of the step of FIG.

FIG. 11 is a symbolic view of equipment on a production line.

[Fig. 12]

[Fig. 13]

FIG. 14

FIG. 15

FIG. 16 is a pattern diagram of a ladder element used in the example system.

FIG. 17 is a view for explaining the mutual association of programs and data in the system of this embodiment.

FIG. 18 is a diagram of a map called a block flow map in the example system.

FIG. 19 is a diagram of a map called a step flow map in the embodiment system.

FIG. 20 is a diagram of a map called an actual I / O map in the example system.

FIG. 21 is a diagram illustrating a hardware configuration of an example system.

FIG. 22 is a diagram showing a configuration of an automatic programming / data input unit of the example system.

FIG. 23 is a diagram illustrating a library structure of device names and operation names.

FIG. 24 is a diagram showing a display example of an icon for switching between the execution mode and the diagnosis mode in the embodiment system.

FIG. 25 shows the CRT 58 and C in the embodiment system.
The block diagram explaining the relationship between PU60 and sequencer control part 51.

FIG. 26 is a diagram illustrating a display example of blocks and steps in an execution mode.

FIG. 27 is a flowchart showing a control procedure according to the embodiment.

FIG. 28 is a flowchart showing the “display update” procedure of the flowchart of FIG. 27 in more detail.

FIG. 29 is a diagram showing an example of an actual I / O map applied to display a coping message at the time of failure.

FIG. 30 is a ladder program diagram showing a control procedure for another method for displaying a coping message at the time of a failure.

Claims (3)

[Claims] 1. A method for displaying a failure diagnosis of a plurality of production equipments forming a production line, wherein failure diagnosis messages of the plurality of production equipments are registered and stored in advance in a storage device together with an identifier of the equipment for each equipment. Then, the identifier of the failed equipment is detected, the failure diagnostic message corresponding to the failed equipment is searched in the storage device using the identifier of the failed equipment, and the searched message is displayed. Equipment failure diagnosis display method. 2. The equipment failure diagnosis display method according to claim 1, wherein in the storing step, the failure diagnosis message common to some equipments is displayed as a procedure for coping with the failure of those equipments. The field is blanked and stored as a message database, and the on / off operation of each of the plurality of equipment is stored as an equipment device table. In the display step, the message in the message corresponding to the equipment found in the search step is stored. An on-operation or an off-operation of the equipment is inserted in the handling procedure display field. 3. The equipment failure diagnosis display method according to claim 1, wherein in the storing step, a message common to some equipments is stored with the name display field of those equipments blank and stored. In the step, the name of the equipment is inserted into the name display field in the message corresponding to the equipment found in the searching step.