JPH07160314A - Input/output signal operation diagnostic device for programmable controller - Google Patents

Abstract

PURPOSE:To specify the place of trouble when the trouble occurs by comparing a read actual machine input/output signal with a previously registered diagnostic pattern. CONSTITUTION:A programmable controller PC 10 which controls a production line by using the input/output signal operation diagnostic device and the production line 20 which is controlled by the PC are connected. The PC 10 fetches an input signal being data on a kind from the production line and an application program on the PC 10 supplies an output signal to a controlled device 20 so as to perform determined control. Then the input/output signal operation diagnostic device compares the actual machine input/output signal read out of the PC 10 with the previously registered diagnostic pattern to specify the trouble occurrence place. A trouble recovery time can, therefore, be made much shorter than before and economical loss is minimized.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for diagnosing the quality of input / output signal operation of a programmable controller as it is used in an actual machine.

[0002]

2. Description of the Related Art When controlling with a programmable controller in a production line or the like, there are not many troubles because application programs are fully tested before online operation. Most of the troubles are caused by operations related to input / output signals. This is due to a defect. Such a malfunction of the input / output signal is, for example, a malfunction due to loose mounting in the case of a limit switch, or even if the limit switch is operating, the interface relay between the limit switch and the programmable controller is In some cases, contact failure may occur due to deterioration over time, and a switch signal may not be input to the programmable controller. In many cases, the occurrence timing of these causes cannot be predicted.

Therefore, at the time of occurrence of the above trouble, the trouble occurrence point is specified by connecting an indicator lamp or a programming panel for monitoring the internal operation of the programmable controller and checking the operation of the ladder diagram. .

[0004]

However, in the above-mentioned prior art, various problems occur as the control scale (the number of input / output points) by the programmable controller increases. In other words, the range that must be investigated to identify the trouble occurrence point becomes wider, and the operating conditions of the ladder diagram due to the input / output signals become more complicated, so much time and labor are required for restoration, and as a result, the production equipment It caused a great financial loss, such as a long break.

An object of the present invention is to provide a diagnostic device which can identify the location of the trouble when it occurs.

[0006]

In order to achieve the above object, the present invention provides a computer storing an input / output signal operation diagnosis program, which holds an input memory for holding an input signal and an output signal. Output memory for
The programmable controller includes an application memory for storing the application program and a data memory for the application program to hold data. The diagnostic pattern can be registered automatically by reading the input / output signal of the actual machine based on the address of the input / output signal registered in advance and automatically creating it.

[0007]

According to the above means, the trouble occurrence point can be specified by comparing the actual machine input / output signal read from the programmable controller with the diagnostic pattern registered in advance, and the trouble recovery time can be compared with the conventional case. It can be greatly shortened, and it is possible to minimize economic loss.

[0008]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a block diagram showing an embodiment of a connection between a programmable controller PC10 for controlling a production line using the input / output signal operation diagnosis apparatus according to the present invention and a production line controlled by this PC. The PC takes in input signals which are various data from the production line 20, and gives an output signal to the controlled device 20 so as to perform a predetermined control by the application program Ap7a shown in FIG. FIG. 2 shows data exchange between the output memory 5 and the input memory 6 inside the programmable controller PC10 and the input / output signal operation diagnostic device 8, data exchange between the application program Ap7a and each memory, and system management software OS2. FIG. 4 is a block diagram showing the exchange of data of the above.

FIG. 3 is an internal memory map of the PC shown in FIGS. 1, 2, 5, and 6. FIG. 4 is a timing chart from the closed state to the opening of the motor valve. FIG. 5 is a block diagram showing a device configuration of the input / output signal operation diagnosis device 8 according to the present invention and the programmable controller PC to be diagnosed by using the input / output signal operation diagnosis device 8. FIG. 6 is a flow chart of the input / output signal operation diagnosis device diagnosis processing and the processing flow of the application program of the PC.

First, the configuration of FIG. 2 will be described. The application program Ap7a is a program for controlling the production line 20, and its processing procedure is described as what is called a ladder diagram, and the data memory 7b is Ap7a.
It is a data memory area of an address designated by the operand of the ladder diagram of a. In the operation of Ap7a, the system management software 2 reads the external input state written in the input memory 6 from the production line 20 via the input unit 4, and the Ap7a reads the input state and processes it according to the procedure described in Ap7a. A value is written in the output memory 5 in order to output the result to the outside as a signal (motor start command) meaning start of the motor. In this way, the system management software 2 outputs an output signal, which means the activation of the motor, to the external production line 20 via the output unit 3 based on the contents written in the output memory 5.

Next, a method of diagnosing the input / output signal operation using the input / output signal operation diagnosis device 8 will be described. Diagnosis of the input / output signal operation using the input / output signal operation diagnosis device 8 is equivalent to diagnosing whether the input / output of the signal for processing by the Ap7a is in accordance with the Ap7a processing timing. That is, an output signal to the production line is output according to the contents written in the output memory 5, the equipment operates, and the result is written in the input memory 6 as a response signal from the equipment. . Therefore, the diagnosis of the input / output signal operation may be performed by checking whether the input / output signal operation timing is within the determined time range.

This will be described with reference to FIG. A normal rotation command of the motor is output from the programmable controller 10 of FIG. 2, the motor valve opens, the closed end limit switch LS becomes inoperative (OFF) T1 seconds after the normal rotation command of the motor, and the normal rotation command of the motor is detected. After T2 seconds, the open end limit switch LS operates (turns on) to take in the operation signal of the open end limit switch LS, and the programmable controller 10 turns off the output of the motor forward rotation command. In this series of operations, the input / output signal operation diagnostic device 8 of FIG. 2 outputs the normal rotation command of the motor output from the programmable controller 10 to the output memory 5 of FIG.
From this, as a starting point, the closed end limit switch LS signal is turned off after T1 seconds, and the open end limit switch LS signal is turned on after T2 seconds. Diagnose by reading. For input / output, the allowable range of ± α may be determined in advance in accordance with the operating characteristics of the equipment and diagnosed. Although the diagnostic device has an allowable range according to the operating characteristics, some diagnostic objects do not have the allowable range. Although the input / output of the digital signal has been described here, the analog method can be diagnosed by the same method.

Next, the configuration of FIG. 3 will be described. Figure 3
Is a memory map of the programmable controller PC, which can be easily understood by comparing with FIG. 2 as follows. [OS area that manages the system of the programmable controller] Fig. 3 Fig. 2 System area 21: System management software 2 [Application program (ladder diagram) area] Fig. 3 Ap area 22a: Ap (ladder diagram) 7a [Application Data Memory Area Used by Program] FIG. 3 FIG. 2 Data Memory Area 22b: Data Memory 7b [Memory Area for Holding Output Signal] FIG. 3 Output Memory Area 23: Output Memory 5 [Hold Input Signal] Memory area for input] FIG. 3 FIG. 2 Input memory area 24: Input memory 6

Next, the configuration of FIG. 5 will be described. Figure 5
2 shows in detail the device configuration of FIG. 2, in which an application program is incorporated into the programmable controller PC10 using a program loader and monitor device 32, and the input / output signal operation diagnosis device 8 has a keyboard 34. Using the mouse 35, the address of the signal to be checked is registered among the input / output signals designated by the application program incorporated in the programmable controller PC10.

The processing progress and results of the input / output signal operation diagnosis device 8 can be monitored on the CRT screen of the input / output signal operation diagnosis device 8. However, when they are to be recorded, an external output device 36 ( For example, it is possible to output to a printer. With such a configuration, the input / output signal operation diagnosis method of the programmable controller PC10 is as already described.

Next, the processing flowchart of FIG. 6 will be described. FIG. 6 shows a processing flowchart of a ladder diagram installed in the programmable controller PC and a processing flowchart of an input / output signal operation diagnostic program installed in the input / output signal operation diagnostic device. PC
In the ladder diagram of Fig. 3, scanning is started at a predetermined scan cycle (S1), data is read from the input memory and the data memory (S2, 5), and processed according to a predetermined procedure (S1).
4) Output an output signal to perform the predetermined control (S6, 7), save some data in the data memory, finish the process, and wait for the start of the next scan (S8). When the input / output signal operation diagnosis program installed in the input / output signal operation diagnosis device RUNs, the data at the starting address is first read from the input memory, data memory or output memory asynchronously with the PC, and the starting condition is met. If there is a signal change, the diagnosis is started, and if not, the data is continuously read from the input memory, the data memory or the output memory until the predetermined condition is satisfied (S10).

When the signal as the starting point is read (S11),
The change in the signal other than the starting point is read from the input memory or the output memory (S12), and whether the signal operating time is within a predetermined time range is compared with a diagnostic pattern registered in advance (S13), It is determined whether the time is out of the determined time range (S14), and if it is out, the operation is stopped (S16). If it is within the determined time range, another signal is read from the input memory or the output memory, and the like is repeatedly performed until the signal at the end point is read (S15). If all the signal operation times do not fall outside the predetermined time range until the signal as the end point is read, the process returns to the beginning and the same processing is repeated.

The diagnostic pattern can be registered by automatically reading the input / output signal of the actual machine based on the address of the input / output signal registered in advance and automatically creating it.

The present invention will be described below in more specific examples with reference to the drawings. FIG. 7 is a configuration diagram in the case of performing the opening / closing operation of the valve of the hopper by hydraulic control. Figure 8
It is a time chart of the operating state of each solenoid valve and limit switch at that time. A valve 101 is provided below the hopper 100, and the valve 101 is opened and closed by a rack gear 103 and a pinion gear 102. The LS striker 112 attached to the rack gear 103 is
With the movement of the rack gear 103, the four limit switches LS. 1 to LS. 4 is operated. LS. 1
Is a limit switch for detecting the open end position. 2 is
Open deceleration position detection limit switch, LS. 3 is a closed deceleration position detection limit switch, and LS. 4 is
It is a closed end position detection limit switch. Rack gear 10
3 is moved by a hydraulically controlled cylinder 104. 110 is an accumulator.

The cylinder 104 is controlled by moving oil through a pipe provided between the pump and the tank. In the middle of the piping, flow rate adjusting valves 105, 106, 109 for closing operation, opening operation and pilot, and a pilot check valve 107 for closing and holding and check valves 108, 1
11 is provided. Further, electromagnetic hydraulic switching valves 113 and 114 for changing the direction of oil flow in the pipe are also provided. SOL. 1, SOL. 2 and SOL. Three
Is a solenoid for controlling these valves. In particular, reference numeral 113 is a shockless electromagnetic hydraulic switching valve, which has a deceleration operation mechanism inside to reduce a shock that occurs at the moment of switching the hydraulic switching valve.

Next, the operation will be described with reference to FIG. When moving the valve 101 of the hopper 100 from the closed position to the open position, when in the closed position, the LS striker 112 moves the L
S. 3 and LS. Since it is in contact with both 4
S. 3 and LS. The output of 4 is in the ON state.

In order to open the valve 101, the solenoid SOL. 3 and then SOL. Energize 1. As a result, the flow of oil between the ports of the electromagnetic switching valve 114, which had been flowing from P to A and B to T until then, is changed from P to B and from A to T. To do. As a result, the pilot check valve 107 for holding and closing is opened. Then, the flow of oil between the ports of the electromagnetic hydraulic pressure switching valve 113 is changed from P to A and from B to T.

As a result, oil causes the pilot check valve 107 to open from the pump via the electromagnetic switching valve 114, while pushing up the cylinder rod 104a via the electromagnetic hydraulic switching valve 113. Become. As the cylinder rod 104a rises, the LS striker 1
12 is LS. 4, LS. 3 away from LS.
2, LS. Touch 1 in order and turn on.
LS. 2 turns on, the SOL. Deenergize 1 and L
S. Until 1 is turned on, the deceleration operation of opening is performed. LS. When 1 is turned on, the opening operation is completed. In the open hold state, SOL. 3 is the excited state, LS. 1 and L
S. 2 is on.

Next, to change the valve from the open state to the closed state,
SOL. Energize 2. As a result, the electromagnetic switching valve 113
The oil flow between the ports is changed from P to B and from A to T. As a result, the oil flows from the pump to the pilot check valve 107 and the flow control valve with check 10.
Is supplied to the cylinder via 6, and the cylinder rod 104
Push down a. When pushed down, LS. 1 turns off, followed by LS. 2 is off. Then, LS. 3 is turned on, the SOL. 2 is stopped, and LS. Until 4 is turned on, the closing deceleration operation is performed. LS. 4 is turned on, the SOL. The excitation of No. 3 is stopped, and the closing operation is completed.

At this time, the oil flow between the ports of the electromagnetic switching valve 114 goes from P to A and from B to T. The closed pilot check valve 107 is closed, and the accumulator 110 holds the closed state.

When the diagnostic device of the present invention is used in such a system, the diagnostic status is shown on the CRT device of the diagnostic device as follows. Here, the diagnosis of the operation when changing from the open state to the closed state will be described.

First, the programmable controller is caused to perform a normal operation, and the operation shown in FIG.
A diagnostic pattern as shown in (a) is created in advance. Here, the signal that is the starting point in the normal state is the SOL. 2 excitation. That is, in the control operation, first, SOL. 2 (step 200) and then LS. 1 is turned off (step 201), and LS.
2 is also turned off (step 202). Next, LS. Three
Is turned on (step 203), and SOL. 2 is de-energized (step 204). Then, LS. 4 is turned on (step 206), and SOL. 3 is de-excited (step 206).

Note that this diagnostic pattern may be automatically generated from the ladder diagram of the programmable controller and the like, and the normal operation may be stored, or it may be created individually as a monitoring target and may be combined with the control operation. You may add a link.

In such an operation, the operation shown in each step operates within a preset time in relation to the previous operation. Therefore, for each operation shown in each step, for example, within how many seconds from the start of the previous operation or the end of the previous operation, the operation start or the operation detection is set. The setting may be automatically set from the ladder diagram.

The diagnosis is performed by actually executing the control and collecting the data from the site while the diagnosis pattern of the normal operation is stored.

Next, regarding the diagnosis result, no abnormal display is displayed when the operation is normal. However, when the predetermined series of operations is not performed within the predetermined time, the step is displayed in reverse video or in different colors, for example. In the case of FIG. 9B, steps 203 and 204 indicate that the signal has not changed within a predetermined time. There was an abnormality in the operation of the shaded portion in FIG. 9B, that is,
So-called trouble occurred in that part. Here, for example, the deceleration operation does not work and the valve 101 hits the main body of the hopper 100, so that a crack may occur in the valve body, which may cause a trouble.

[0032]

As is apparent from the above, according to the present invention, in the system in which the programmable controller and the input / output signal operation diagnosis device are connected by the transmission system, the personal computer asynchronously operates the input / output memory of the programmable controller. Since a means for diagnosing whether or not it is within a predetermined condition (input / output signal operation diagnosis pattern) is read from the result of reading, trouble occurred in the input / output signal operation of the programmable controller in the actual machine usage environment. Sometimes, the location can be identified, so that the trouble recovery time can be greatly shortened and the economical loss can be minimized.

[Brief description of drawings]

FIG. 1 is a diagram showing an embodiment of a connection between a programmable controller for controlling a production line using the input / output signal operation diagnosis apparatus according to the present invention and the production line.

FIG. 2 is a diagram showing data exchange between a memory inside a PC and an input / output signal operation diagnosis device.

FIG. 3 is a memory map of a PC.

FIG. 4 is a timing chart from when the motor valve is closed to when the motor valve is opened.

FIG. 5 is a block diagram showing a device configuration with a programmable controller for diagnosing using the input / output signal operation diagnosing device of the present invention.

FIG. 6 is a flowchart of the processing of the input / output signal operation diagnosis apparatus of the present invention and a flowchart of the processing of the application program of the programmable controller.

FIG. 7 is a diagram showing an example of an application example of the present invention.

8 is a diagram showing a time chart in the example of FIG. 7. FIG.

9 is a diagram showing an example of CRT display at the time of diagnosis in the example of FIG.

[Explanation of symbols]

 2 system management software (OS) 3 output unit 4 input unit 5 output memory 6 input memory 7a application program Ap (ladder diagram) 7b data memory 8 input / output signal operation diagnostic device 10 programmable controller 20 production line 21 system area 22a application Program area 22b Data memory area 23 Output memory area 24 Input memory area 32 Program loader and monitor device 34 Keyboard 35 Mouse 36 External output device

Claims (1)

[Claims] 1. An input memory for holding an input signal, an output memory for holding an output signal, an application memory for storing an application program, and an application memory for storing data. A programmable controller having a data memory and a computer that stores an input / output signal operation diagnostic program, and outputs an input / output signal from the input / output memory or the data memory based on the input / output signal operation diagnostic program of the computer. An input / output signal operation diagnosis device for a programmable controller for diagnosing the quality of an input / output signal by comparing a change in a read input / output signal with a pre-registered diagnostic pattern.