KR20150102792A - Plc simulator - Google Patents

Abstract

One embodiment of the present invention relates to a PLC simulator. The technical problem to be solved is to simulate a PLC controlling a load facility in a plant automation system by verifying various kinds of PLC codes with software. For this, the PLC simulator according to one embodiment of the present invention includes a plurality of PLC modules with PLC software and a simulation module which performs a simulation for the verification of the PLC code. The PLC module includes a first communication unit, a first input signal supply unit, a first output signal supply unit, the PLC software, a memory unit which stores an operation program and operation data, and a control unit which controls the operation of each component.

Description

PLC SIMULATOR DEVICE {PLC SIMULATOR}

One embodiment of the present invention relates to a PLC simulator device for verifying a plurality of PLC codes by implementing a PLC for controlling load devices in a factory automation system with respective software.

As the industry becomes more sophisticated and rapidly evolving, factory automation systems are also evolving at a faster rate than ever before.

As the industry develops, existing factory automation systems must also be quickly replaced with new factory automation systems. If the introduction of new factory automation systems is delayed, this will lead to a huge loss of import and credit.

A large number of automation facilities constituting a factory automation system are controlled and driven by a PLC. The PLC (Programmable Logic Controller) internally stores the ladder diagram information in the form of Boolean logic as a control program.

In factory automation systems, automation facilities are driven by the PLC output signal output from the PLC. The process status during driving or after driving is detected by the sensor and transmitted to the PLC as a PLC input signal. The PLC input signal is a signal containing information on the updated process conditions.

The PLC performs the internal logic operation again according to the PLC input signal and outputs the PLC output signal. The PLC output signal is a signal that causes the automation equipment to perform a process to be performed next according to the updated process condition. Automation facilities perform processes according to updated process conditions according to PLC output signal.

In order to actually operate the factory automation system, the process control technician writes the control program for the automated manufacturing process including the PLC code, and applies it to the actual facilities to start the trial operation. However, because the control program can contain human errors, the process control technician needs to test the factory automation system by testing against the ladder diagram with the PLC code before commissioning.

For rapid introduction of factory automation systems, testing factory automation systems is now commonplace, and the field of testing control programs in factory automation systems has become an area of concern for control engineers. And, after successfully designing the PLC, verifying the control program has become a necessary process before introducing the automated control system.

In the simulation method for PLC code verification for controlling a plurality of lines in the factory automation system, as shown in FIG. 1, a line in the factory automation system is divided into PLC control units, and individual software PLC codes There is a simulation method for verification.

1 is a block diagram schematically showing a conventional PLC simulation system.

Referring to FIG. 1, a PLC simulation program included in a PLC simulation system according to the related art uses an input / output model that defines the operation characteristics of the field facility as a discrete event and a graphic model that defines the operation state of the field facility. In accordance with the PLC input / output signal transmitted / received from /

However, the simulation method for verifying the individual software PLC code corresponding to each PLC control unit by dividing the line in the factory automation system shown in FIG. 1 into PLC control units is a method in which one PLC per vendor type (vender type) Since a simulation for code verification is performed only for a software PLC, a factory automation system for controlling a plurality of lines and facilities can not be configured as a software PLC. In addition, it is impossible to verify errors and abnormal conditions that can occur in the communication process of I / O signals between each PLC and HMI (Human Machine Interface) in a real factory automation system composed of a network by a single software PLC code verification performed on one PC I have a problem.

Registered Patent Publication No. 10-1243441 'Reconstructable Component Based PLC Simulator' Registered Patent Publication No. 10-0325340 'Program Simulation Method for Programmable Logic Controller'

One embodiment of the present invention provides a PLC simulator device capable of performing simulation for verifying various kinds of PLC codes by using PLC software that realizes software of a plurality of PLCs controlling a load facility in a factory automation system.

A PLC simulator device according to an embodiment of the present invention includes PLC software for realizing PLC input signal and PLC output signal in order to control a load facility in a factory automation system, PLC module; And an operation state of a load facility for an automated manufacturing process controlled according to a PLC output signal received from the PLC module and an operation state of the load facility corresponding to the operation state, And a simulation module for performing simulation on the PLC code verification by generating a PLC input signal including the operation change and transmitting the generated PLC input signal to the PLC software, A first communication unit for transmitting and receiving data; A first input signal supply unit for supplying the PLC input signal received from the simulation module to the PLC software; A first output signal supply unit for supplying a PLC output signal generated by the PLC software to the simulation module; A PLC software for generating a PLC output signal by applying a PLC input signal received from the simulation module to a predetermined operation program and supplying the PLC output signal to a first output signal supply unit; A memory unit for storing the operation program and operation data thereof; And a control unit for controlling the operation of each component.

Wherein the simulation module comprises: a second communication unit for transmitting and receiving data with the PLC module; A second output signal supply unit for supplying the PLC output signal received from the PLC module to the simulation unit; A second input signal supply unit for transmitting a corresponding PLC input signal to a PLC module in which a PLC output signal acting as a cause of each of the PLC input signals supplied from the simulation driving unit is generated; A simulation unit for determining whether the PLC code operates normally using operation change information of a load facility controlled by the PLC software according to the received PLC output signal; And a second controller for controlling the operation of each component.

The simulation module may further include a program creating unit that creates the operation program supplied to the PLC module.

Wherein the simulation unit includes: a signal defining unit that defines an operation state of a load facility controlled according to the received PLC output signal and a PLC input signal according to the operation state; Using the operation data of the load facility corresponding to the operation state of the load facility, graphically expressing an operation change according to the operation state of the load facility, generating a PLC input signal including the operation change information, A graphic transmission unit for transmitting to the PLC module through a supply unit; And an LED output unit for outputting an operation change according to an operation state of the load facility in a predetermined pattern to a plurality of LEDs using operation data of the load facility corresponding to the operation state of the load facility.

The PLC module and the simulation module can be connected by the RS 232C method.

The PLC input signal and the PLC output signal may include at least one of an analog signal, a digital signal, and a high-speed counter signal.

The PLC simulator device according to an embodiment of the present invention performs simulation for verifying various types of PLC codes by using PLC software that implements a plurality of PLCs controlling software of a load facility in a factory automation system, It is possible to provide a simulation function showing the same effect as the mechanical load facility.

1 is a block diagram schematically showing a conventional PLC simulation system.
2 is a block diagram schematically showing a PLC simulator apparatus according to an embodiment of the present invention.
3 is a block diagram schematically showing the PLC module of FIG.
FIG. 4 is a block diagram schematically showing the simulation module of FIG. 2. FIG.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings, in which those skilled in the art can readily implement the present invention.

FIG. 2 is a block diagram schematically showing a PLC simulator device according to an embodiment of the present invention, FIG. 3 is a block diagram schematically showing the PLC module of FIG. 2, and FIG. 4 is a block diagram schematically showing the simulation module of FIG. Block diagram.

Referring to FIG. 2, the PLC simulator apparatus according to an embodiment of the present invention includes a PLC module 10 and a simulation module 20. Meanwhile, the PLC input signal and the PLC output signal in the present invention may include at least one of an analog signal, a digital signal, and a high-speed counter signal. To this end, the simulation module 20 may separately include input / output means (not shown) of an analog or digital signal, pulse generating means (not shown), and the like.

The PLC module 10 is provided with a plurality of PLC modules for controlling the load equipment in the factory automation system. The PLC module 10 includes PLC software (Programmable Logic Controller) implemented by software for verifying the PLC code for generating the PLC input signal and the PLC output signal Respectively. The PLC module 10 may be installed in a plurality of personal computers (PCs) for controlling load facilities in a factory automation system.

3, the PLC module 10 includes a first communication unit 110, a first input signal supply unit 120, a first output signal supply unit 130, a PLC software 140, a memory unit 150, And a first controller 160.

The first communication unit 110 is a device for transmitting and receiving data with the simulation module 20 and is connected to the simulation module 20 through an RS 232C method to transmit and receive a PLC input signal or a PLC output signal. In the present invention, the RS 232C method is described as an example of the protocol of the first communication unit 110. However, the present invention is not limited to this, and various communication methods such as serial communication and TCP / IP protocol can be applied.

The first input signal supplying unit 120 supplies the PLC input signal received from the simulation module 20 to the PLC software 140. The first input signal supplying unit 120 supplies the PLC input signal to the PLC software 140 through the first communication unit 110, And transmits the PLC input signal received from the signal supply unit 230 to the PLC software 140.

The first output signal supply unit 130 is a device for supplying a PLC output signal generated by the PLC software 140 to the simulation module 20 and is received by the PLC software 140 through the first communication unit 110 And transmits the PLC output signal to the second output signal supply unit 220 of the simulation module 20.

The PLC software 140 applies a PLC input signal received from the simulation module 20 to a preset operation program to generate a PLC output signal and supply the PLC output signal to the first output signal supply unit 130. That is, the PLC software 140 generates a PLC output signal by applying the PLC input signal received from the first input signal supply unit 120 to a predetermined operation program, and outputs the generated PLC output signal to the first output signal supply unit (130). At this time, the PLC software 140 can store ladder diagram information in the form of Boolean logic as a control program. In accordance with the PLC input signal received from the first input signal supply unit 120, The PLC output signal can be generated and output by performing logic operation using ladder diagram information.

For example, the PLC software 140 may be designed for application to a variety of load facilities, as shown in Table 1 below.

turn PLC software function One Logic Ports Driving of logic circuit ports 2 Digital Function Flip-flop and Timer, Counter Driven 3 Motor Control 1 Starting and stopping asynchronous motors 4 Motor Control 2 Adjustment of motor rotation direction (forward rotation, reverse rotation) 5 Motor Control 3 Y-△ operation control of motor 6 Motor Control 4 Reverse motor Y-drive 7 Motor Control 5 Position control system by motor 8 Motor Control 6 HIGH / LOW speed control of motor 9 Motor Control 7 Control of decentralized motor 10 Motor Control 8 Control of Winding Rotor Motor 11 Conveyor Belt 1 Operation of three conveyor systems for single item manufacturing 12 Conveyor Belt 2 Operation of 5 conveyor systems of 4 items 13 Reactive Power Circuit design for capacitive correction 14 Radiators Control of electric heater 15 Sequential Light Sequential lighting circuit of 8 lamps 16 Filling System 1 Lubrication Control of Test Tubes 17 Filling System 2 Three-tank lubrication control 18 Carbon Treatment Carbon manufacturing process control 19 Embossing Process Embossing process of metal disk by air pressure 20 Ventilation System Ventilator control of underground parking lot 21 Traffic Light 1 Pedestrian traffic light control circuit 22 Traffic Light 2 Crossroad traffic light control circuit 23 Canalization System Two different items of piping system 24 Tank Level Control 1 Tank level control (quantitative and qualitative control) 25 Tank Level Control 2 Tank level control using pressure sensor 26 Reactor Control Control of chemical reactions of solids, gases and catalysts 27 Hoist Control Operation Control of Hoist for 4 Layers 28 Storage Bin Warehouse logistics control by 4 pumps 29 Pumping System 1 Control of Vacuumization Process of Beverage Tank by Pump 30 Pumping System 2 Tank level control by 3 pumps 31 Beverage Dispenser Sequential control of beverage vending machines 32 Machining Line Sequential control of machining lines 33 Mixer System Control of mixing process between different solids

The memory unit 150 stores an operation program and operation data. The memory unit 150 has a function of storing an operation program used for the PLC simulation and the type and attributes of the operation data. The memory unit 150 may be implemented as a memory device such as an EEPROM, a NAND memory, or a flash memory.

The first control unit 160 controls the operation of each component and includes a first communication unit 110, a first input signal supply unit 120, a first output signal supply unit 130, a PLC software 140, PLC code verification for generating the PLC input signal and the PLC output signal can be performed.

The simulation module 20 uses the operation state of the load facility for the automated manufacturing process controlled according to the PLC output signal received from the PLC module 10 and the operation state of the load facility corresponding to the operation state, And a PLC input signal including the operation change is generated and transmitted to the PLC software 140 to perform a simulation on the PLC code verification. At this time, the PLC input signal generated in the graphic model can be transmitted to a plurality of software PIs through the input / output model.

4, the simulation module 20 includes a second communication unit 210, a second output signal supply unit 220, a second input signal supply unit 230, a simulation unit 240, a program creation unit 260, And a second controller 250.

The second communication unit 210 is a device for transmitting and receiving data with the PLC module 10 and is connected to the PLC module 10 by an RS 232C method to transmit and receive a PLC input signal or a PLC output signal. In the present invention, the RS 232C method is described as an example of the protocol of the second communication unit 210. However, the present invention is not limited thereto, and various communication methods such as serial communication and TCP / IP protocol can be applied.

The second output signal supply unit 220 is a device for supplying a PLC output signal received from the PLC module 10 to the simulation unit 240. The second output signal supply unit 220 receives the first output signal of the PLC module 10 through the second communication unit 210, And transmits a PLC output signal from the signal supply unit 130 to the simulation unit 240.

The second input signal supply unit 230 supplies the PLC input signal supplied from the simulation driving unit to the PLC module 10 (that is, the PLC software 140) And transmits the input signal. For example, the second input signal supply unit 230 may transmit a PLC input signal related to motor drive control to the PLC software 140.

In this way, RS 232C communication between the second communication unit 210 of the simulation module 20 and the first communication unit 110 of the plurality of PLC modules 10 allows communication between the PLC software 140 and the simulation unit 240 A PLC input signal and a PLC output signal for verifying the PLC code can be transmitted.

Accordingly, in the case of the simulation method for verifying the individual software PLC code corresponding to each PLC control unit by dividing the lines and facilities in the conventional factory automation system into PLC control units, one software for each PLC vendor type (vender type) A network communication environment configuration is not established between a plurality of PLC software 140 that occurs because a simulation for code verification is performed only for the PLC, and thus, a communication process of input / output signals between the PLC software 140 and the HMI It is possible to solve the problem that verification of possible errors and abnormal states is not performed.

The simulation unit 240 determines whether or not the PLC code operates normally using the operation change information of the load equipment controlled by the PLC software 140 according to the PLC output signal received from the second output signal supply unit 220 do.

The simulation unit 240 includes a signal definition unit 241, a graphic transmission unit 242, and an LED output unit 243. [

The signal definition unit 241 defines an operation state of a load facility controlled according to a PLC output signal received from the second output signal supply unit 220 and a corresponding PLC input signal. That is, the signal definition unit 241 determines the operation state of the lines and facilities controlled according to the PLC output signals received from the plurality of PLC modules 10, and the PLC input signals according to the operating states of the lines and the facilities, Is defined.

The graphic transfer unit 242 graphically displays the operation change according to the operation state of the load facility using the operation data of the load facility corresponding to the operation state of the load facility and generates a PLC input signal including the operation change information And transmits it to the PLC module 10 through the second input signal supply unit 230. That is, when operation change information of a load facility controlled by a plurality of PLC software 140 is generated, a PLC input signal corresponding to each state is generated in the graphic transfer unit 242 and transferred to the PLC software 140, If an operation according to a normal sequence by a logical operation is performed, it can be determined that there is no abnormality in the PLC code. On the other hand, if there is no change in status due to a specific state, it can be determined that there is an abnormality in the PLC code. Such a change in operation of the load facility may indicate a transition of a discrete event occurring in accordance with a plurality of PLC output signals in a signal defining unit 241 in which a series of operation states occurring in the load facility is defined as a discrete event.

The LED output unit 243 outputs the operation change according to the operation state of the load facility in a predetermined pattern through the plurality of LEDs using the operation data of the load facility corresponding to the operation state of the load facility. The LED output unit 243 outputs an LED pattern of operation state changes of the load equipment controlled by a plurality of PLC software 140 according to a PLC output signal received from the PLC software 140, It is possible to grasp whether it operates normally.

The program creating unit 260 functions to create an operation program supplied to the PLC module 10. [ That is, when the operation program is created by the user, the program creating unit 260 can execute the PLC simulation in sequence according to the program.

The second control unit 250 is an apparatus for controlling the operation of each component. The second control unit 250 controls the operation state of the load facility for the automated manufacturing process controlled according to the PLC output signal received from the PLC module 10, A PLC input signal including the operation change is generated and transmitted to the PLC software 140 by using the operation data of the load facility to graphically display the operation change of the load facility according to the operation state, .

The PLC module 10 and / or the simulation module 20 may be installed inside the protective case in order to prevent the heat generated by the respective components of the PLC simulation and the heat generated by the simulation. The protective case may include a polyolefin resin composition comprising 25 to 39% by weight of an olefin resin and 61 to 75% by weight of an inorganic filler, and the inorganic filler may be glass fiber, barium sulfate, or a mixture thereof.

The olefin-based resin preferably contains 25 to 39% by weight of the ultrafine crystalline resin and improves the flowability of the inorganic filler and improves the heat resistance, rigidity and thermal deformation of the polyolefin resin composition. When the amount of the inorganic filler is less than 25% by weight, the inorganic filler is excessively used to lower the flowability and moldability of the resin. When the amount exceeds 39% by weight, the injection molded article is improved in strength, impact resistance, paintability and dimensional stability It has an ineffective problem.

More specifically, the ultra-crystalline olefin-based resin is selected from the group consisting of isotactic polypropylene, propylene-ethylene copolymer, propylene-1-butene copolymer, propylene- Copolymers of propylene with at least one selected from the group consisting of propylene, propylene, and mixtures thereof, or a mixture thereof.

The olefin resin preferably has a melt index of 1 to 70 g / 10 min (230?), More preferably 3 to 30 g / 10 min.

It is preferable that the isotactic peptad fraction of the homo part in the olefin resin is 96 to 99% by C13-NMR. If it is less than 96%, the heat resistance, rigidity and heat change of the polyolefin resin composition are deteriorated .

The inorganic filler is preferably glass fiber, barium sulfate, or a mixture thereof. The inorganic filler includes 61 to 75% by weight of the inorganic filler and improves strength, impact resistance, and surface coating property when the injection-molded article is manufactured. If the amount of the inorganic filler is less than 61% by weight, the strength and impact resistance are lowered and the problem is caused by the low weight. When the inorganic filler is more than 75% by weight, the production process is not smooth due to high weight and high rigidity.

The glass fiber preferably has a chopped strand shape having an average particle diameter of 5 to 15 탆 and a length of 1 to 16 mm. When the average particle diameter is less than 5 탆, the glass fiber tends to be broken during mixing The stiffness effect is insufficient. When the thickness exceeds 15 탆, the deformation of the molded article may be deteriorated and the appearance of the molded article may be deteriorated. If the length is less than 1 mm, the strength, impact resistance and weight are lowered. If the length is more than 16 mm, it is difficult to input the material in the processing step.

More specifically, it is preferable that the glass fiber is a glass fiber whose surface has been treated with a modified polypropylene obtained by grafting an unsaturated carboxylic acid or an anhydride thereof. In producing an injection molded article, the strength, impact resistance and heat resistance It plays an effective role in improvement. The unsaturated carboxylic acid is preferably one selected from the group consisting of acrylic acid, tricrylic acid, maleic acid, fumaric acid, itaconic acid, crotonic acid, ditralic acid, sorbic acid and phosphoric acid, and the anhydride is preferably an acid anhydride, an ester, And metal salts, and specific examples thereof include maleic anhydride, itaconic anhydride, anhydrodithioconic acid, sodium acrylate, and sodium methacrylate. In order to treat the surface of the glass fiber, it is preferable to use a modified polypropylene prepared by charging an unsaturated carboxylic acid or its anhydride and a catalyst to a crystalline polypropylene into a twin-screw extruder and melting by heating at a temperature of 180 to 220 degrees, It is preferable that the modified polypropylene and the glass fiber are treated at a ratio of 1: 9.

The barium sulfate preferably has an average particle diameter of 0.5 to 1 μm by laser diffraction scattering. When used in combination with glass fibers, the barium sulfate plays an effective role in exhibiting high weight characteristics. If less than 0.5 μm, high weight and high rigidity properties And it is difficult to inject in the processing step. When the thickness exceeds 1 탆, there is a problem that the gloss of the surface appearance of the molded article is lowered during the production of an injection molded article.

When the glass fiber and barium sulfate are mixed and used as an inorganic filler, the mixing ratio of glass fiber and barium sulfate is preferably 2: 8 to 8: 2, more preferably 4: 6 to 5: 5.

The polyolefin resin composition may be prepared by charging an olefin resin and an inorganic filler, mixing the mixture in a ribbon mixer for 0.5 to 4 hours, and then melting and kneading the mixture at a temperature of 180 to 220 degrees using a twin screw extruder. When kneading with an extruder for maintaining the shape, the extruder can be fed from the side of the extruder. Such a polyolefin resin composition may be formed using a conventional molding method such as injection molding and extrusion molding.

The present invention is not limited to the above-described embodiments, but may be modified in various ways within the scope of the present invention as set forth in the following claims. It will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.

10: PLC module 20: Simulation module
110: first communication unit 120: first input signal supply unit
130: first output signal supply unit 140: PLC software
150: memory unit 160: first control unit
210: second communication unit 220: second output signal supply unit
230: second input signal supply unit 240:
241: Signal definition section 242: Graphic transmission section
243: LED output unit 250: second control unit
260: Program creation section

Claims (6)

A plurality of PLC modules each having PLC software that implements PLC software in order to verify a PLC code that generates a PLC input signal and a PLC output signal in order to control a load facility in a factory automation system; And
Wherein the operation state of the load equipment for the automated manufacturing process controlled according to the PLC output signal received from the PLC module and the operation data of the load equipment corresponding to the operation state are used to change the operation of the load equipment according to the operation state And generating a PLC input signal including the operation change and transmitting the generated PLC input signal to the PLC software, the simulation module performing a simulation for the PLC code verification,
The PLC module
A first communication unit for transmitting / receiving data to / from the simulation module;
A first input signal supply unit for supplying the PLC input signal received from the simulation module to the PLC software;
A first output signal supply unit for supplying a PLC output signal generated by the PLC software to the simulation module;
A PLC software for generating a PLC output signal by applying a PLC input signal received from the simulation module to a predetermined operation program and supplying the PLC output signal to a first output signal supply unit;
A memory unit for storing the operation program and operation data thereof; And
And a first controller for controlling the operation of each component.
The method according to claim 1,
The simulation module
A second communication unit for transmitting / receiving data to / from the PLC module;
A second output signal supply unit for supplying the PLC output signal received from the PLC module to the simulation unit;
A second input signal supply unit for transmitting a corresponding PLC input signal to a PLC module in which a PLC output signal acting as a cause of each of the PLC input signals supplied from the simulation driving unit is generated;
A simulation unit for determining whether the PLC code operates normally using operation change information of a load facility controlled by the PLC software according to the received PLC output signal; And
And a second controller for controlling the operation of each component.
The method of claim 2,
Wherein the simulation module further comprises a program creating unit for creating the operation program supplied to the PLC module.
The method of claim 2,
The simulation unit
A signal defining unit for defining an operation state of a load facility controlled according to the received PLC output signal and a PLC input signal corresponding thereto;
Using the operation data of the load facility corresponding to the operation state of the load facility, graphically expressing an operation change according to the operation state of the load facility, generating a PLC input signal including the operation change information, A graphic transmission unit for transmitting to the PLC module through a supply unit; And
And an LED output unit for outputting an operation change according to an operation state of the load facility using a plurality of LEDs in a predetermined pattern by using operation data of the load facility corresponding to the operation state of the load facility. .
The method according to claim 1,
Wherein the PLC module and the simulation module are connected by an RS 232C method.
The method according to claim 1,
Wherein the PLC input signal and the PLC output signal include at least one of an analog signal, a digital signal, and a high-speed counter signal.

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