JPS63292205A - Device for diagnosing deterioration in programmable controller - Google Patents

Abstract

PURPOSE:To save the capacity of a memory and to perform fault diagnosis more precisely, by designating an input/output arbitrarily, and generating the teaching pattern of only the input/output possible to be related to a fault. CONSTITUTION:A mode setting means, an input/output designation control means, and a teaching operation control means which monitors the outputs pattern of a programmable controller, stores the input/output pattern after change, and deletes a deletion designated input/output pattern out of obtained input/output pattern strings from input/output pattern strings setting a mode at a teaching mode as a condition are provided. Also, a diagnosing operation control means which judges no arrival of each input/output pattern consisting of a stored input/output pattern string within a preset monitoring time as deterioration in an equipment targeted to be controlled and informs a discrepant part between the input/output pattern at that time and a taught input/output pattern as a deterioration correlative part setting the mode at a diagnosis mode as the condition is provided. In such a way, it is possible to generate the model pattern of the change of an input/output signal in the normal operation of a machine targeted to be controlled efficiently and automatically.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to a fault diagnosis device for a programmable controller.

(Summary of the invention) In this invention, there is an input/output designation mode and a teaching mode.

It has a diagnosis mode, and the input/output designation mode allows you to specify particularly necessary items of failure diagnosis target I10 or delete less important problems, and the teaching mode automatically memorizes the input/output status when the output pattern changes. Compress.

This usually occurs when the input/output pattern and teaching pattern differ depending on the diagnostic mode.

(Prior art and its problems) Conventionally, when a failure occurs in a device controlled by a programmable controller, maintenance personnel visually observe the condition or inspect it with a tester, synchroscope, etc. I had discovered the location of the failure.

However, this takes time to find faults, and in order to reliably find faults, it is necessary to be quite familiar with sequence circuits and their machines.

Therefore, a model pattern of input/output signal changes during normal operation of the machine is created manually in advance, and when the machine is in operation, a diagnostic built into the programmable controller 1 to the roller itself is used to check whether the model pattern matches the actual pattern. The decision was made by a program, but this takes time to create the input/output change model pattern, and only someone who is familiar with the sequence circuit in question can create it.
There is also a rare possibility that failures will occur outside of the model pattern.

Furthermore, it is quite troublesome to incorporate a fault diagnosis program into an already completed user program.

(Object of the Invention) The present invention is capable of efficiently and automatically creating a model pattern of input/output signal changes that occur during normal operation of a machine to be controlled, and without incorporating a fault diagnosis program into the user program. It is an object of the present invention to provide a fault diagnosis device for a programmable controller that is capable of diagnosing a fault in a machine.

(Structure and Effects of the Invention) In order to achieve the above object, the present invention changes the operation mode to one of an input/output designation mode, a teaching mode, and a diagnostic mode.
mode setting means that can be set alternatively to input/output specification mode, and input/output specification control that specifies registration or deletion of inputs and outputs that are particularly desired to be diagnosed or not desired in the programmable controller, subject to setting to input/output specification mode. Under the condition that the programmable controller is set to teaching mode, the output pattern of the programmable controller is monitored, and each time the input/output pattern changes, the input/output pattern after the change is memorized, and the input/output pattern sequence obtained is deleted. A teaching operation control means for deleting a specified input/output from an input/output pattern sequence, and a teaching operation control means for deleting a specified input/output from an input/output pattern sequence, and a teaching operation control means for deleting a designated input/output from an input/output pattern sequence, and a teaching operation control means for deleting a designated input/output from an input/output pattern sequence, and each input/output pattern constituting the stored input/output pattern sequence arriving within a set monitoring time, subject to setting to a diagnostic mode. a diagnostic operation control means that determines whether the deterioration occurs, and if it does not arrive, determines that deterioration has occurred in the device to be controlled, and notifies a point of mismatch between the input/output pattern at that time and the taught input/output pattern as a deterioration correlation point; It is characterized by comprising the following.

According to such a configuration, in response to the setting to the input/output designation mode, it is possible to arbitrarily select input/outputs particularly necessary for diagnosis or input/outputs unnecessary for diagnosis.

Further, in response to setting to the teaching mode, a teaching pattern is automatically created for only input/outputs that may be related to the failure.

Furthermore, in response to the setting to the diagnostic mode, a fault diagnosis operation is performed.

By specifying any input/output and automatically creating a teaching pattern for only input/output that may be related to a failure, unnecessary input/output patterns are not stored, resulting in significant memory savings and more accurate failure diagnosis. can be done.

(Explanation of Examples) Figure 1 shows the building blocks to which the present invention is applied.
FIG. 2 is a block diagram showing the overall configuration of a type of programmable controller 1 to roller.

This system has a system bus 1 and a CPU unit 2. Multiple I10 units 1-3. It is configured by connecting the driver and the failure diagnosis unit 4 according to the present invention. By the way, the power supply unit] and others are omitted from illustration.

As shown in FIG. 2, the fault diagnosis unit 4 includes a calculation section 41 mainly composed of a microprocessor, a storage section 42 mainly composed of RAM, a timekeeping section 43 mainly composed of a reference clock, a counter, etc. Display unit 4 capable of displaying input/output and failure occurrence corresponding to failure correlation locations
4, and an operation section 45 having the function of issuing commands such as mode switching and activation. Also, the calculation section 41
can be connected to the system bus via an interface 46.

As shown in the general flowchart of FIG. 3, the operation of the failure diagnosis device 4 is such that the mode of the operation unit 45 is switched to the input/output designation mode (step 305).

Depending on whether the setting is teaching mode (step 300) or diagnosis mode (step 301),
Input/output designation operation control processing (step 306), teaching operation control processing (step 302), or diagnostic operation control processing (
Either step 303) is alternatively executed.

Furthermore, the operation unit control process (step 304) includes a process for setting various parameters. Note that this process (step 304) is executed in parallel with other processes.

As shown in FIG. 4, when the input/output designation operation control process is started, the input/output number is registered (step 4).
00) is determined, and if the registration is not specified, the input/output No.
, is designated for deletion (step 401), and if deletion is designated, the designation 110NO, is designated for deletion (step 402).

On the other hand, when input/output registration is specified (Step 400 Portrait)
, designated as non-deletable I/, 0 l10NO.

I10 specifies that it cannot be deleted (step 403) L, and the process continues.

Next, the teaching motion control process will be explained. The teaching operation control process involves the teaching ■motion and the teaching ■motion. In the teaching ■ operation, input/output patterns are registered, and in the teaching ■ operation, the input/output patterns registered in the teaching operation are compressed.

As shown in FIG. 5, when the teaching operation control process is started, it is confirmed whether the teaching operation is in progress (step 500).
), if it is not in operation, a confirmation is made as to whether it is in operation (step 501).

Teaching ■ If the operation is not in progress, it is confirmed whether an instruction to start teaching is required (step 502). If there is a start instruction, the teaching operation flag is set (step 503), and the process counter 5TEP is set to Q (step 504). after that,
The current input/output pattern is registered in the storage area <5TEP=O as shown in FIG. 9 (step 505), and the 5TEP value is updated (step 506).

When the next teaching operation control process is called, since the teaching operation is in progress (step 500), it is checked whether there is an instruction to end the teaching operation (step 507), and if it is not completed, it is checked whether there is a change in the output pattern (step 508). confirm.

If a change is necessary, a changeable input/output pattern is registered (step 505), 5TEP is updated, processing is continued, and the previous processing is performed until an end instruction is received (defined in step 507).

If there is no change in the output pattern (No in step 507), no processing is performed and the process moves to the next processing.

If there is an instruction to end (step 5070), the teaching operation flag is reset (step 509), and the teaching operation (step 510) is performed.

Therefore, if inputs 1 to 3 as shown in FIG. If there are outputs 1 to 3, the input/output changes for each scan of the user program will be as shown in Figure 8, and at times t, t4 + t7 + t9 when the output changes occur, the input/output pattern will be as shown in Figure 9. be registered.

As shown in FIG. 6, when the teaching operation is started, first a confirmation is made as to whether the teaching operation is in progress (step 601).
If the process is not in operation, the teaching ① operation flag is set (step 602>), and the process counter 5TEP is set to O (step 603).

Next, the input/output pattern of 5TEP=O is set as the reference input/output pattern (step 604), the comparison result data is reset (step 605), the 5TEP value is updated, and the process continues (step 606).

Next, when the teaching ■ operation is called, since the teaching ■ operation is in progress (step 601), it is checked whether 5TEPfO is greater than the end value (step 607).

If it is not larger than the end value, the exclusive OR (FOR) of the input/output pattern of the corresponding 5 TEP value and the single input/output pattern is taken. Only the output is par 1 on the comparison result data.
'', and is roughly logically summed (OR) with the previous comparison result to become new comparison result data (step 608
), the 5TEP value is updated (step 606), and the process continues. Therefore, in the final comparison result data, "'1" is set for Ilo that has changed even once.

On the other hand, when the 5TEP value becomes the final 5TEP value + 1 (step 607 affirmative), the deletion specification I10 is deleted from the registered data (step 609), and "0" is displayed on the comparison result data.
(No change) The registered data No. is extracted (step 6000).

When there is no change Ilo (step 611 affirmative)
, determines whether the Ilo cannot be deleted (step 612
). If it is not I10 that cannot be deleted, it is deleted from the registered data (step 613). If deletion is impossible I10, the process returns to step 610.

If there is no change Ilo, step 611 is negative), teaching ■ Reset the operating flag Step 61
4) Continue processing.

Here, assuming that the input/output designation operation is such that input 2 cannot be deleted (10) and input 3 is set to be deleted I10, a teaching pattern as shown in FIG. 10 is created by teaching operation (2).

In other words, input 2 cannot be deleted because there is no input change or it is not designated by the input/output designation, and input 3 is deleted because it is designated for deletion by the input/output designation even though there is an input change.

The reason for manually deleting input/output or specifying registration is as follows.
It is as follows. During input/output, input/output for display of the machine, etc. that does not cause any problem with the operation of the machine, or that is OFF during normal operation.
There are inputs and outputs that are turned ON when an error occurs.

If input/output deletion specification registration is not performed, in the former case, a change in the display unit that cannot be called a malfunction will be considered an abnormality, and in the latter case, since there is no input/output change during normal operation, it will be removed from the diagnostic registration I10. This causes the problem that even when an abnormality occurs, it is not recognized as abnormal.

In order to prevent these, things that especially need to be monitored are manually registered, and things that do not need to be monitored are removed from the diagnosis target I10 to perform accurate diagnosis.

As shown in FIG. 7, when the bond cutting operation control process is started, it is checked whether a diagnosis is being made (step 701), and if the diagnosis is not being made (no in step 701), the process is continued until a start instruction is given.

If there is a start instruction (step 702 affirmative), a diagnostic flag is set (step 703) and 5TEP.

Steps 704 and 705 to reset the match flag,
Set the input/output pattern of 5TEP=O as reference data (step 706), start the l timer (step 707), and wait for the current input/output pattern to match the reference pattern before the monitoring timer times up (step 708). 709). In addition, as the investment appraisal time, for example, 1
4-1+, t7 t<, ts i7 multiplied by an appropriate coefficient may be used. If both patterns match (
Step 708 Portrait) and set a match flag (Step 7
10) Turn off the abnormal output, update 5TEP (steps 711 and 712>, and repeat the above processing).

On the other hand, if the monitoring timer times up during this time (step 709 affirmative), it is diagnosed as an abnormality, a mismatch point between the current person's output pattern and the reference input/output pattern is found, this is determined as a failure correlation point, and the corresponding output is turned on (step 715). As a result, the failure-related locations are visually notified.

[Brief explanation of drawings]

Fig. 1 is a block diagram showing a programmable controller to which the present invention is applied, Fig. 2 is a block diagram showing details of the fault diagnosis device, Fig. 3 is a general flowchart of the fault diagnosis device, and Fig. 4 is input/output specification. Flowchart showing the operation control process, FIG. 5 is a flowchart 1 showing the teaching T operation control process, FIG. 6 is a flowchart showing the teaching ■ operation control process, FIG. 7 is a flowchart showing the diagnostic operation control process, Fig. 8 is an explanatory diagram showing an example of input/output pattern transition, Fig. 9 is an explanatory diagram showing a reference input/output pattern created by teaching operation, and Fig. 10 is an explanatory diagram showing a reference input/output pattern created by teaching operation. FIG. 11 is a memory map showing the overall configuration of the storage section. 1... System bus 2... CPU unit 3... I10 unit [・ 4... Trouble diagnosis unit 41... Arithmetic unit 42... Storage unit 43... Time measurement unit 44... Display Section 45...Operation section 46...Interface

Claims (1)

[Claims] (1) A mode setting means that can selectively set the operation mode to one of input/output specification mode, teaching mode, or diagnostic mode, and a programmable controller that can be used especially for diagnosis, provided that the input/output specification mode is set. An input/output designation control means for registering or deleting inputs and outputs that are desired or undesired, and a programmable controller that monitors the output pattern of the programmable controller under the condition that it is set to teach mode, and updates the input and output patterns after each change. A teaching operation control means for storing an output pattern and deleting an input/output designated for deletion from the input/output pattern sequence obtained from the input/output pattern sequence; It is determined whether each constituent input/output pattern arrives within the set monitoring time, and if it does not arrive, it is determined that the device to be controlled has deteriorated, and the input/output pattern at that time and the taught input/output pattern are A fault diagnosis device for a programmable controller, comprising: diagnostic operation control means for notifying a mismatch point as a deterioration correlation point.