JPH0778005A - Programmable controller - Google Patents

Abstract

PURPOSE:To obtain PC(programmable controller) which prevents dangerous operation due to a defect in maintenance of equipment and informs a user of equipment in trouble and its cause in case of abnormality occurrence. CONSTITUTION:A RAM 4 is stored with a main program, which is executed while the input signal of a RAM 7 is read out. When the arithmetic result is stored as an output signal in the RAM 7 and the output signal is transferred to the outside, a decision program stored in a RAM 8 is executed and if abnormality is confirmed, the corresponding basic message is selected in a RAM 11. Further, the name of the abnormal equipment is specified on the basis of the output signal of the abnormality and they are put together into an error message, which is outputted by a CPU 2 to a display device 20.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a programmable controller (hereinafter referred to as "PC") having a function of monitoring the presence or absence of an abnormality in an external device, a function of avoiding danger in the event of an abnormality, and a function of reporting the cause of the abnormality together with the location of the abnormality. That said).

[0002]

2. Description of the Related Art The structure of a general PC program is activated by a timer interrupt or an external interrupt in a main program which is scanned and arithmetically processed at regular intervals. It is in the form of adding a program. When creating such a PC sequence program, each output condition must be incorporated into a series of programs, which complicates the program and changes programs that are not related to output conditions. Even if there is, there is a problem that it takes time to change the program because it is affected, and a change mistake is likely to occur.

Further, in a control device using a PC, there are more external input / output devices and mechanical troubles than the failure of the PC. However, at present, there is no function to automatically detect a failure and inform the user of its cause. Therefore, if that function is required, the program designer should create a program for that and realize that function. Was there. However, the message contents were rough and a large-capacity program memory was required.

The present invention has been made to solve such a problem, and makes it possible to separately manage the conditions necessary for the safe operation of the device and its processing program and normal programs. By doing so, it is possible to subdivide the management level such as changing the program, and to obtain a PC that makes clear the message contents at the time of an abnormality without increasing the memory capacity.

[0005]

A PC according to the present invention includes a first storage means for storing a main program, a second storage means for storing an input signal and an output signal, and a storage for the second storage means. When the output signal is transferred to the outside, it is determined whether the items related to the output signal satisfy a predetermined condition, and when the above condition is satisfied, the output signal is transferred to the outside as it is, and the condition is satisfied. When there is not, a third storage means for storing a first determination program for performing a predetermined arithmetic processing to generate a signal corresponding to the abnormality, and a message set according to the condition are stored as a basic message. The fourth storage means and the main program stored in the first storage means
An arithmetic processing unit that executes and operates while reading an input signal of the storage unit and stores the operation result as an output signal in the second storage unit; and stores the output signal in the third storage unit when transferring the output signal to the outside. By executing / calculating the determined determination program, the output signal is directly transferred to the outside as it is, or an output determination processing means for outputting a signal corresponding to the abnormality to the outside, and matters related to the output signal are predetermined. When the condition is not satisfied, the basic message corresponding to the condition is selected from the fourth storage means, and the abnormal device name or the input / output number name is specified based on the output signal and the condition, and these are specified. Error message creating means for synthesizing to create an error message, and display means for displaying the error message created by the error message creating means A.

Further, it has an input judgment processing means for taking in the input signal as a matter related to the output signal when the input signal is taken into the second storage means.

[0007]

In the present invention, the arithmetic processing means executes and arithmetically operates the user program stored in the first storage means while reading the input signal of the second storage means, and the arithmetic result is stored in the second storage as an output signal. Store in the means. Then, when the output signal stored in the second storage means is transferred to the outside, the output determination processing section executes and calculates the first determination program stored in the third storage means to output the output signal. It is determined whether or not the items related to are satisfying a predetermined condition. When the above conditions are met, the data is directly transferred to the outside, and when the above conditions are not met,
Predetermined arithmetic processing is performed to generate a signal corresponding to the abnormality and output to the outside. The error message creating means selects the basic message of the condition from the fourth storage means when the matter related to the output signal does not satisfy the condition, and based on the output signal and the condition, for example, an error target. Specify the device name and synthesize them to create an error message. Then, the error message is output and displayed on the display means. Thus, when there is some abnormality, the output determination processing unit outputs a signal corresponding to the abnormality to the outside, and the error message creating means displays the error message including the abnormal device name on the display means. Therefore, the external controlled device is prevented from causing an abnormal operation such as a runaway, and the abnormal device is clarified.

[0008]

1 is a CPU of a PC according to an embodiment of the present invention.
It is a block diagram which shows the hardware constitutions of a module. Figure 1
In the figure, 1 is a CPU module of a PC, and 2 is a CP having functions of an arithmetic processing means, an output determination processing means, an input determination processing means, an error message creating means, etc. of the present invention.
U and 3 are ROMs in which a system program is stored, and the CPU 2 is RA based on this system program.
The main program stored in M4 and the input / output determination processing program stored in RAM 8 are executed.

Reference numeral 5 is a RAM for storing data such as numerical values and characters used by the user in the application. A RAM 6 stores signals other than input / output signals, and stores, for example, bit signals used for the arithmetic processing of the CPU 2. A RAM 7 stores an input signal from the input module 21 and an output signal for external output.
Is.

Reference numeral 8 denotes a RAM in which an input / output judgment processing program and the like are stored. This program is a program for judging whether or not the input / output signals satisfy the conditions, and when the conditions are not satisfied. It is composed of a program for performing processing corresponding to the abnormality,
The contents shown below are programmed. (A) Conditions for controlling the operating state of the PC, the whole or part of program execution, or the whole or part of output operation, and the control contents in that case. (B) Normal / abnormal determination condition for output ON (or OFF) operation. Operation confirmation signal and operation monitoring time. Interlock condition (operating condition / prohibition condition). (C) Processing contents when output operation abnormality is determined. (D) Output message type when abnormality is determined.

Reference numeral 9 stores the contents for controlling the output (ON / OFF) as a result of the fact that the items related to the input signal or the output signal are judged not to satisfy the predetermined conditions by the execution / calculation of the input / output judgment processing program. RAM that is
The RAM 9 is used not only for abnormality determination but also for a pause function that is a function for stopping the whole or a part of the device controlled by the PC, and stores a pause parameter and the like. 10, the output signal is ON (or O
This is a RAM in which the operation duration time is stored for each output transfer in order to monitor the time from FF) to confirmation that the output operation is completed.

Reference numeral 11 is a RAM in which the character information of the basic message corresponding to the above-mentioned message type is stored. When the output signal is determined to be abnormal by the input / output determination processing program, the basic message of the corresponding message type is selected. The character information is basically prepared on the system side, but can be specially prepared by the user. Reference numeral 12 is an R storing the signal name (device name) corresponding to the output number of the output signal for external output
The signal name is AM, and this signal name is for identifying the location of the abnormality and is combined with the basic message. When the RAM 12 is not prepared in the CPU module 1 of the PC of the present invention, the output number is set instead of the signal name. Reference numeral 13 denotes an interface (hereinafter referred to as “I / F”) connected to the display device 20.
An input / output IF 4 is connected to the input module 21 and the output module 22.

The programmable controller of this embodiment is configured as described above, and when the operation is started, C
The PU 2 reads the main program stored in the ROM 4 and sequentially performs arithmetic processing. Then, among the calculation results, the output signal to be transferred to the outside is stored in the RAM 7. When the CPU 2 completes the arithmetic processing for one scan in the main program, it shifts to the output transfer processing for transferring the output signal stored in the RAM 7 to the outside. In this output transfer, the CPU 2 reads the input / output determination processing program stored in the RAM 8 and executes it to determine whether or not there is an abnormality from the viewpoint of whether or not the items related to the output signal satisfy a predetermined condition. To do. If there is no abnormality, the output signal is output to the output module 22 via the input / output IF 14, and when it is determined that the condition is not satisfied and there is an abnormality, a control signal according to the abnormality is generated and input / output is performed. It outputs to the output module 22 via IF14. Then, a basic message is selected from the RAM 11 based on the message type for the abnormality, and a signal name (device name) corresponding to the output signal (output number) of the abnormality is selected from the RAM 12 to synthesize them and an error message is displayed. create. Then, the error message is output to the display device 20 via the IF 13 and displayed. RAM8 and RAM9 are used to determine whether there is an abnormality.
The error message created based on the data stored in the memory is created in the event of an abnormality. As described above, the basic message and the RAM for each message type stored in the RAM 11 are stored.
It is created based on the signal names stored in 12, but a simple case will be described below.

First, the monitoring of the output operation is as follows. [Monitoring time] AND [Operating condition] AND [Prohibition condition] = [1/0] (Less than: 1) (ON: 1) (OFF: 1) (Excess: 0) (OFF: 0) (ON: 0) Here, the calculation result is "1" only when the output operation time does not exceed the predetermined monitoring time, the operation condition is satisfied and the condition is ON, and the prohibition condition is canceled and the condition is OFF. Next, it is judged that the operation is normal. If the output operation time exceeds the preset monitoring time, the operation condition is not established and is OFF, or the prohibition condition is not released and is ON. When it corresponds, the operation result is “0” and it is determined that the operation is abnormal. When the calculation result is 0 (abnormal operation), the pause status is set to "0". Further, when the abnormal processing setting other than the output processing by the pause function is set, the PC is temporarily stopped or the PC is stopped. Then, the following process is performed. [Pause parameter] OR [Pause status] AND [Status] (Non-hold: 0) (Pause: 0) (OFF: 0) (Hold: 1) (Non-pause: 1) (ON: 1) = [Output module To le]

As described above, the pause status becomes "0" when there is an abnormal operation, but it is also possible to set a pause parameter in addition. This pause parameter is a parameter for setting whether the output is forcibly turned off or held when an abnormality occurs or the pause function is activated. The above status corresponds to the output signal. The result of the above logical operation is the input / output IF 14
To the output module 22 via. When the above processing is completed for all output signals stored in the RAM 7, input transfer processing is performed next.

In input transfer, the input module 21
I / O as a matter related to the output signal from the
It is taken into the RAM 7 via / F14. For example, when operating the lifting cylinder, the detector that detects the upper limit position and the detector that detects the lower limit position do not operate at the same time, but if the signals from these detectors are input at the same time, the operation is abnormal. Therefore, in such a case, for example, the pause function of the PC can be performed by performing the pause function as the abnormal processing to perform the suspension or stop processing of the PC. Input module 21
When the above processing is completed for all the input signals from, the main program stored in the RAM 4 is read again and executed. The above process is cyclically repeated until the end instruction is given.

Next, the error message is as follows. The error message is created by combining the basic message corresponding to the message type for the abnormality and the signal name of the abnormality after the abnormality processing as described above, and has a style as shown in FIG. 2, for example. . This is an error message when the lifting operation time of the lifting cylinder exceeds the monitoring time. The characters in "" are the signal name of the lifting cylinder and the character information selected by the setting, and the other character information is the basic message. , Which is selected from the message types for abnormalities.
Then, this error message is output and displayed on the display device 20 via the IF 13.

FIG. 3 is a diagram showing the details of the above-mentioned input / output determination processing program in the form of a ladder program. This program is an example of an input / output determination processing program for a lifting cylinder. In the figure, TMR / T1 is a supply rising time excess monitoring timer, TMR / T2 is a supply rising operation failure monitoring timer, TMR / T3 is a supply falling operation time over monitoring timer, and TMR / T4 is a supply falling operation failure monitoring timer. . MT / ST10 to MT / ST15 are message types. When an output is made from them, the pause status PSQ100 or PSQ100 is turned ON, and the basic message is selected based on the output message type, and Output number (Q10
The signal names (supply up, supply down) corresponding to 0, Q101) are selected. Then, an error message is created based on these character information. For example, error messages for rising supply are listed below for each message type. As described above, the character inside the parentheses is the character information selected by the abnormal signal name and its setting, and the other character information is the basic message for each message type.

MT / ST10: "Supply supply" has been "stopped" because the operating time of "supply supply" has exceeded the setting. Check the "supply rise" cylinder and the "supply rise end" detector. MT / ST11: "Supply supply" has been "stopped" because the operation of "supply increase" is defective. Check the "supply rise" cylinder and the "supply rise end" detector. MT / ST12: "Supply supply" has been "stopped" because the operating conditions for "supply increase" are insufficient. Check the "supply rise" cylinder and the "supply rise end" detector. MT / ST13: "Supply supply" has been "stopped" because the prohibition condition of "supply increase" has not been released. Check the "supply rise" cylinder and the "supply rise end" detector. MT / ST14: "Supply rising""Supply rising edge" detector and "Supply falling""Supply falling edge" detector were detected at the same time, so "Stopped". "Supply up" cylinder,
Check the “supply rising end” detector, “supply falling” cylinder and “supply falling end” detector. MT / ST15: "Supply rising", "Supply falling", "Supply rising end" detector, and "Supply falling end" detector are in the ON state, so "stopped". Check the "supply rise" cylinder, "supply rise end" detector, "supply fall" cylinder and "supply fall end" detector. Regarding the supply drop of the output number Q101, only the signal name of "supply rise" is changed to "supply drop", and the basic message for each message type is the same.

QWT / Q100 is a transfer rising output status module transfer process. When the condition of QWT / Q100 is satisfied, the terminal Q100 of the output module 22 is turned on, and when it is not satisfied, it is turned off. Terminal Q100 is O
When it is N, the double solenoid is driven and the lift cylinder moves up. QWT / Q101 is the transfer processing of the supply / decrease output status module.
When the condition 101 is satisfied, the terminal Q101 of the output module 22 is turned on, and when not satisfied, it is turned off. Terminal Q
When 101 is ON, the double solenoid is driven and the lift cylinder moves down.

Here, for convenience of explanation, the output number Q100, which is a lift command for the lifting cylinder, is turned on, and QWT.Q.
It is assumed that 100 is established, and that it is transferred to the output module 22 as it is, and the lifting cylinder has started the lifting operation. At this time, the input signal I20 corresponding to the detection signal of the supply rising end of the lifting cylinder is not input, its normally closed contact is closed, and the timer TMR · T1 starts measuring the rising time. Within a predetermined time (for example, within 3 seconds)
When the ascending / descending cylinder reaches the ascending end, the input signal I20 is input at that time, the normally closed contact is opened, and the time measurement of the timer TMR.T1 is reset. However, if the normally closed contact of the input signal I20 is still closed after that time, the timer TMR.T1 will open the normally open contact T.
MR / T1 is closed and MT / ST10 is output. This output turns on the pause status PSQ100 and opens its normally closed contact, so that QWT.Q100 is not established, and this QWT.Q100 (OFF) is transferred to the output module 22 as an output signal. At this time, the basic message is RA based on the message type MT / ST10.
At the same time as reading from M11, the signal name for the output number Q100 is read from RAM12 and they are combined to create an error message. Then, the error message is output to the display device 20 via the IF 13 and displayed. In this case, the error message is "Stop supply" because the operation time of "supply rise" exceeded the setting as described above. ]. On the other hand, the double solenoid connected to the terminal Q100 of the output module 22 is turned off and the lifting cylinder is stopped. However,
At this time, if the pause function is working, QWT · Q100 is established and the double solenoid continues to be driven depending on the setting status of the pause parameter PTQ100.

Since the lifting cylinder is moving up in this case, the input signal I2 corresponding to the detection signal at the lowering end of the supply is input.
1 is not input and its normally open contact is not closed, but if this contact is closed for some reason, timer M
TR / T2 starts measuring time. Then, when a predetermined time (for example, 0.5 seconds) elapses, the normally open contact TMR · T
2 is closed, MT / ST11 is output as an ascending operation failure, and the pause status PSQ100 is turned on. As a result, the normally closed contact of pause status PSQ100 is opened and QWT / Q100 is no longer established.
Q100 (OFF) is output module 2 as an output signal
2 is transferred. At this time, the message type MT / S
The basic message is read from the RAM 11 based on T11, and the signal name for the output number Q100 is read from the RAM 12
Read from and combine them to create an error message. Then, the error message is output to the display device 20 via the IF 13 and displayed. This message is "Stopping""Increase in supply" because the operation of "Increase in supply" is defective. ]. On the other hand, also in this case, the double solenoid is turned off and the lifting cylinder is stopped.

If the rising operation condition is not satisfied and the corresponding input signal I30 is not input, the normally closed contact remains closed. When the rising prohibition condition is not released and the input signal I31 is input, the normally open contact is closed. In these cases, the rising operating condition is not satisfied and MT / S
T12 is output, or MT / ST13 is output as the prohibition condition is not released. The pause status PSQ is output by the output of MT / ST12 or MT / ST13.
100 is turned on and its normally closed contact is opened. As a result, QWT / Q100 is not established, and QWT / Q100
(OFF) is transferred to the output module 22 as an output signal. In this case, the error message for message type MT / ST12 is "Stop""Increase in supply" because the operating condition of "Increase in supply" is insufficient, as described above. ], And the message type MT / ST1
The error message for 3 is "Stopped""Increase in supply" because the prohibition condition of "Increase in supply" has not been released. ].

Since the input signal I20 corresponding to the detection signal at the supply rising end and the input signal I21 corresponding to the detection signal at the supply falling end are not input at the same time, their normally open contacts are closed at the same time. However, if it is closed at the same time for some reason, MT / ST14
Is output, and the pose status PS
Turn on Q100 and PSQ101. Further, the lifting cylinder can perform only one operation of raising or lowering, and the output number Q100 corresponding to the supply rising command and the output number Q101 corresponding to the supply lowering command are not turned on at the same time. And the normally closed contacts are opened simultaneously, and the input signal I20,
When the normally closed contact of I21 is opened, MT / ST15 is output, and the pause status PSQ
Turn on 100 and PSQ101.

When the pause statuses PSQ100 and PSQ101 are turned on as described above, the normally closed contacts are opened to QWT.Q100 and QWT.Q10.
Both of 1 are not established, and QWT / Q100 (OFF) and QWT / Q101 (OFF) are transferred to the corresponding terminals of the output module 22. MT / ST14 or MT / S
When T15 is output, an error message corresponding to each output is created and displayed on the display device 20.
The error message for the message type MT / ST14 was "Stopped" because it simultaneously detected "Supply rising edge detector" of "Supply rising" and "Supply falling edge detector" of "Supply falling". , And the message type MT
The error message to ST15 is "" Increase in supply ",
"Supply falling", "Supply rising end detector", "Supply falling end detector" are "ON", so "Stopped". ].
And in this case as well, the double solenoid is turned off,
It stops even if the lifting cylinder is moving up or down.

Further, in order to perform the control for lowering the lifting cylinder, the normally open contact Q1 of the output number Q101 of the supply lowering
When the lifting cylinder is lowered by closing 01 to establish QWT · Q101, the same processing as in the case of the output number Q100 described above is performed, and if there is an abnormality, the pause status PSQ101 is turned on. When the pause status PSQ101 is turned ON, a basic message is selected based on the corresponding message type, and then the signal name (supply down) of the output number Q101 is read out and they are combined to create an error message. Then, the error message is transferred to the display device 20 and displayed. At this time, since the QWTQ 101 is not established, the table solenoid is stopped and the lifting cylinder is also stopped moving down.

[0027]

As described above, according to the present invention, the main program and the input / output determination processing program are separately managed independently of each other. Therefore, even when the operation order or the like needs to be changed. The input / output determination processing program that does not change can be managed separately, and the management level such as program changes can be subdivided. Further, since the determination processing of the output signal, the input signal, etc. is sequentially performed, it is possible to prevent an abnormal operation due to a programming error or a device maintenance failure. Further, as described above, since it is not necessary to include a safety circuit for interlock, monitoring time, etc. in the main program, the effect of facilitating the program change work by the sequence change is obtained.

Further, when an error occurs, the error message creating means synthesizes the basic message according to the error detection and its signal name to create an error message and displays it on the display means. The abnormality can be easily detected, and the action for the abnormality can be appropriately and quickly performed. Further, since the basic message is shared, the memory for storing the message has a small capacity.

[Brief description of drawings]

FIG. 1 is a block diagram showing a hardware configuration of a CPU module of a PC according to an embodiment of the present invention.

FIG. 2 is a diagram showing an example of an error message.

FIG. 3 is a diagram showing an example of an input / output determination processing program.

Claims (2)

[Claims] 1. A first storage means for storing a main program, a second storage means for storing an input signal and an output signal, and an output signal stored in the second storage means for external transfer. , Determines whether or not the items related to the output signal satisfy a predetermined condition, and when the condition is satisfied, the condition is directly transferred to the outside, and when the condition is not satisfied, a predetermined arithmetic process is performed to perform the calculation. Third storage means for storing a first determination program for generating a signal corresponding to the abnormality, fourth storage means for storing a message set according to the condition as a basic message, and the first storage The main program stored in the means is executed and operated while reading the input signal of the second storage means, and the operation result is stored in the second storage means as an output signal. And arithmetic processing means, when transferring the output signal to the outside, by performing and computing the third determination program stored in the storage means,
Output determination processing means for transferring the output signal as it is to the outside or outputting a signal corresponding to the abnormality to the outside, and when matters related to the output signal do not satisfy a predetermined condition, correspond to the condition Error message creating means for selecting a basic message from the fourth storage means, specifying an abnormal target device name or an input / output number name based on the output signal and the condition, and synthesizing them to create an error message And a display unit for displaying the error message created by the error message creating unit. 2. The programmable controller according to claim 1, further comprising an input determination processing unit that receives the input signal as a matter related to the output signal when the input signal is stored in the second storage unit.