JP2905051B2 - Programmable controllers and peripherals - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to the storage of devices used for each step and transition of a sequential function chart (hereinafter referred to as "SFC") program, or the grouping of related devices by a sequence program. ON / OF
The present invention relates to a programmable controller and a peripheral device that detect a failure of a device controlled by the programmable controller by storing an F state.

[0002]

2. Description of the Related Art FIG. 21 is a block diagram showing a schematic configuration of a conventional fault diagnosis system for a programmable controller. In FIG. 21, reference numeral 1C denotes a programmable controller (PC) having a conventional configuration, and 3 denotes a controller controlled by the programmable controller 1C. Control object, 2B
Is a peripheral device connected to the programmable controller 1C, and 4 is an input / output signal between the control target 3 and the programmable controller 1C.

The programmable controller 1C includes a control execution unit 5 for controlling the input / output signal 4, an execution step table 5A for storing a step number of the SFC program currently being executed, and a programmable controller 1C.
For controlling the program (sequence program)
And a communication unit 10 for communicating with the peripheral device 2B.

The peripheral device 2B includes a communication section 11 for communicating with the programmable controller 1C, a program editing section 12 for creating a program for controlling the programmable controller 1C, and a monitor section 13 for displaying the state of the programmable controller 1 and the like. And a screen / key input unit 15.

[0005] FIG.
It is explanatory drawing which shows the example of a structure of the controlled object 3 controlled by C. In the figure, 20 is a clamp, 21 is a work, 2
2 is a drill for processing the work 21, 23 is a clamp 20
The limit switches LS1 and LS2 for detecting the upper end of the clamp 20 are limit switches LS0 and LS2 for detecting the lower end of the clamp 20, respectively.
5 is a limit switch LS for detecting the setting of the work 21.
100 and 26 are limit switches LS10 and LS11 for detecting the left end of the drill 22. 27 are limit switches LS11 and 28 for detecting the right end of the drill 22. Signals Y1 and 29 for operating the clamp 20 upward are signals for operating the clamp 20 downward. Y0 and 29A are signals Y10 and 29B for operating the drill 22 to the left, and Y1 and 29B are signals Y1 for operating the drill 22 to the right.
It is one.

FIG. 23 is an explanatory diagram showing a configuration example of an SFC program for controlling the control target 3. In FIG. 23, reference numeral 30 denotes an SFC program for controlling the control target 3 shown in FIG.
Are stored in the control program storage unit 6 of the programmable controller 1C. The SFC program 30
When the work 21 is set, the clamp 20 and the drill 2
2 is a control program for operating the control program 2.

FIG. 24 is a program table of an SFC program for controlling the control target 3. This program table includes a step operation program table 40 indicating the contents of the operation corresponding to the steps of the SFC program 30 and a transfer condition program table 41 indicating the transfer conditions corresponding to the transfer of the SFC program 30. It is stored in the control program storage unit 6.

FIG. 25 is a flowchart showing the processing operation of the conventional control execution unit 5, and FIG. 26 is a display screen of the peripheral device 2B for creating the conventional step operation program table 40 and transition condition program table 41. An example is shown.

Next, the operation will be described. In the programmable controller 1C, the control execution unit 5 controls the input / output signal 4 based on the contents of the control program stored in the control program storage unit 6 to operate the control target 3.

The SFC program stored in the control program storage section 6 is created by the peripheral device 2B.
In the peripheral device 2B, the program editing unit 12
Edit the C program 30. Then, on the display screen as shown in FIG. 26, the step and the transition contents of the SFC program 30 are input, and the step operation program table 40 and the transition condition program table 4 are inputted.
Create 1.

After completion of the creation, the peripheral device 2B transmits the created SFC program to the programmable controller 1C by the communication unit 11. When receiving the SFC program, the communication unit 10 of the programmable controller 1C stores the SFC program in the control program storage unit 6.

The control execution unit 5 is started by power input of the programmable controller 1C, and performs a sequence control process based on a flowchart shown in FIG. In this sequence control process, first, the step number stored in the execution step table 5A is extracted (step S250). Assuming that S0 is stored when the power is turned on, the program corresponding to the corresponding step number in the step operation program table 40 is executed (step S251). In this case, for example, if S0 is stored in the execution step table 5A when the power is turned on, the program of S0 is executed.

Next, a transition number T0 below the corresponding step is extracted from the SFC program 30 (step S2).
52), the program “LD LS100” corresponding to the corresponding transfer number T0 in the transfer condition program table 41 is executed (step S253), and thereafter, it is determined whether or not the transfer condition is satisfied (step S254).

In step S254, LS100
Is established when the work 21 is set. Therefore, when it is determined that the condition is satisfied, the step number S1 under the corresponding transition number T0 is determined by the SFC program.
And S5 are taken out (step S255). After that, the step numbers S1 and S5 are stored in the execution step table 5A (step S256), and the process returns to step S250 to repeat the same processing.

On the other hand, in step S254,
If it is determined that the condition is not satisfied, step S
Returning to step 250, the same processing is repeatedly executed. At this time, for example, if the LS 10 fails and does not turn on, the SF
The C program 30 executes “LD L”, which is the condition of the transition T4.
Since S0 "is not established, the operation stops at S5.

This state is determined by the monitor unit 13 of the peripheral device 2B.
By reading the contents of the execution step table 5A, the execution step S5 can be extracted. The transition condition of S5 from the SFC program 30 is T4.
The processing content of No. 4 is “LD LS0” from the transition condition program table 41.
Can be determined to be the cause of the failure.

As another technical reference related to the present invention, there is a "monitor for a programmable controller" disclosed in Japanese Patent Application Laid-Open No. Hei 3-91005.

[0018]

However, when the LS 10 fails and remains in the ON state, the S5 in the SFC program 30 immediately shifts to S6 because T4 is satisfied. M0 is turned off. As a result, since “LD M0”, which is the condition of T1, is not satisfied, the SFC program 30 does not shift to S1. That is, since the transition establishment condition of the peripheral device 2B is M0, it cannot be directly linked to the cause of LS0.

As in the above-described example, when related devices are used between the steps of the program, it is difficult to identify and determine the faulty device from the stopped step, and the fault diagnosis efficiency is low. There was a problem.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-described problems. Even when a related device is used between steps of a sequence program including an SFC program, a faulty device is specially replaced. Without making a program, it is possible to judge (specify) accurately and easily, and to perform an efficient failure diagnosis.
Another object of the present invention is to provide a user-friendly programmable controller and a peripheral device that automatically and accurately create a data table used for failure diagnosis without any trouble.

[0021]

To achieve the above object, a programmable controller according to the present invention comprises:
In the programmable controller that executes the sequence program described in the sequential function chart, the device used in the transition condition to the next step is stored for each step of the sequential function chart, and the device is used in other steps Device condition storage means for storing a device condition table that also stores the devices used in the transition condition from the step to the next step; and Fault detecting means for detecting a fault location based on the device stored in the condition storing means.

In order to achieve the above object, a peripheral device of a programmable controller according to the present invention comprises:
In the peripheral device of the programmable controller according to the above invention, for each step of the sequential function chart, a device used in a condition for transition to the next step is written in a device condition table, and the device is used in another step. Investigate whether or not
If it is used in another step, it has a device condition creation means for automatically creating a device condition table by writing the device used in the transition condition from that step to the next step together in the device condition table. The device condition table created by the device condition creating means is transmitted to the programmable controller by the communication means.

According to another aspect of the present invention, there is provided a programmable controller for executing a sequence program, wherein devices of the sequence program are grouped according to operation. A combination of device condition storage means for storing a device condition table storing devices for each group, and a normal ON / OFF state of devices for each group stored in the device condition table stored in the device condition storage means O that stores an ON / OFF state table that stores
It has N / OFF state storage means, and failure detection means for detecting a failure location based on a combination of ON / OFF states stored in the ON / OFF state storage means.

According to the next aspect of the present invention, the programmable controller can execute the sequence program under normal execution.
When a step including a device specified by a group is executed, the ON / OFF state of the device and the ON / OFF state of another device in the same group as the device are searched, and the ON / OFF state of the device for each group in a normal state. And automatically creates an ON / OFF state table.

In order to achieve the above object, a peripheral device of a programmable controller according to the present invention comprises:
In the peripheral device of the programmable controller according to the above invention, all the instructions of the sequence program are scanned, and it is determined whether or not a device designated by the instruction has a group designation symbol added thereto. Register the grouping in the table,
There is provided a device condition creating means for automatically creating a device condition table, and the device condition table created by the device condition creating means is transmitted to the programmable controller by the communication means.

According to another aspect of the present invention, there is provided a programmable controller for executing a sequence program, wherein a sequence program is created for each device related to an operation. A device condition storage unit for storing a device condition table storing devices, and a combination of a normal ON / OFF state of the device for each sequence program stored in the device condition table stored in the device condition storage unit. ON / OFF state storage means for storing an ON / OFF state table to be executed, and failure detection means for detecting a failure location based on a combination of ON / OFF states stored in the ON / OFF state storage means. Is what it is.

In the programmable controller according to the next invention, the ON / OFF state of each device and the ON / OFF state of another device in the same sequence program as the device under normal execution of each sequence program
/ OFF state is searched, and the ON / OFF state combination of the device at the normal time for each sequence program is detected and
The N / OFF state table is automatically created.

In order to achieve the above object, a peripheral device of a programmable controller according to the present invention comprises:
In the peripheral device of the programmable controller according to the above-mentioned invention, the peripheral device of the programmable controller has device condition creating means for scanning all instructions of each sequence program, registering a device designated by the instruction for each sequence program, and automatically creating a device condition table. The device condition table created by the device condition creating means is transmitted to the programmable controller by the communication means.

In order to achieve the above object, a peripheral device of a programmable controller according to the present invention comprises:
A plurality of programmable controllers according to the above-described invention are communicably connected by being assigned unique numbers, and have monitor means for displaying the number of the programmable controller as the notification source and the failure location by notification of the failure location from the programmable controller. Is what it is.

[0030]

In the programmable controller according to the present invention, the device used as the data of the device related between the steps of the sequence program described in the SFC language for each step of the sequential function chart under the transition condition to the next step When the device is used in another step, the device condition table storing the device used in the transition condition from the step to the next step is also stored in the device condition storage means. And
When a failure occurs in the control target, the failure detection means detects a failure location based on the device stored in the device condition table.

In the peripheral device of the programmable controller according to the next invention, the device condition creating means writes, in each step of the sequential function chart, a device used as a condition for transition to the next step in a device condition table, and writes the device condition table. Investigate whether is used in another step, and if it is used in another step, write the device used in the transition condition from that step to the next step together in the device condition table Automatically creates a device condition table, and transmits the device condition table created by the device condition creation means to the programmable controller by the communication means.

In the programmable controller according to the next invention, the devices of the sequence program are grouped into those related to the operation as the data of the devices related between the steps of the sequence program described in a ladder language or the like. A device condition table storing devices for each group is stored in the device condition storage means, and a normal ON / OFF state combination of devices for each group stored in the device condition table stored in the device condition storage means Is stored in the ON / OFF state storage means, and the failure detection means detects a failure location based on the combination of the ON / OFF states stored in the ON / OFF state storage means.

In the programmable controller according to the next invention, when a step including a device designated by a group is executed under normal execution of a sequence program, the ON / OFF state of the device and the ON / OFF of another device in the same group as the device are performed. An ON / OFF state table is automatically created by detecting a combination of ON / OFF states of devices in each group in a normal state.

In the peripheral device of the programmable controller according to the next invention, the device condition creating means scans all the instructions of the sequence program and determines whether or not the device designated by the instruction has a group designation symbol added thereto. The devices designated by the same group are registered in the device condition table by grouping them, the device condition table is automatically created, and the device condition table created by the device condition creating means is transmitted to the programmable controller by the communication means.

In the programmable controller according to the next invention, a sequence program is created for each device related to the operation, and a device condition table storing devices for each sequence program is stored in device condition storage means. An ON / OFF state table for storing a combination of ON / OFF states of the devices in a normal state for each sequence program stored in the device condition table stored in the means is ON / O.
The failure detection means detects a failure location based on a combination of ON / OFF states stored in the FF state storage means and stored in the ON / OFF state storage means.

In the programmable controller according to the next invention, under normal execution of each sequence program, the ON / OFF state of each device and the ON / OFF of other devices in the same sequence program as that device
/ OFF state is searched, and the ON / OFF state combination of the device at the normal time for each sequence program is detected and
Automatically create an N / OFF state table.

In the peripheral device of the programmable controller according to the next invention, the device condition creating means scans all the instructions of each sequence program, registers the device specified by the instruction for each sequence program, and automatically updates the device condition table. The device condition table created by the device condition creating unit is created and transmitted to the programmable controller by the communication unit.

In the peripheral device for a programmable controller according to the next invention, a plurality of programmable controllers are connected to each other with unique numbers and are communicable with each other. Displays the number and fault location.

[0039]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below in detail with reference to the accompanying drawings.

First Embodiment FIG. 1 is a block diagram showing a schematic configuration of a failure diagnosis system for a programmable controller according to a first embodiment.

In FIG. 1, 1 is a programmable controller, 2 is a peripheral device of the programmable controller 1, 3 is a controlled object controlled by the programmable controller 1, and 4 is an input / output signal.

The programmable controller 1 stores a control execution unit 5 for controlling input / output signals, an execution step table 5A for storing a currently executed step number of the SFC program, and a program for controlling the programmable controller 1. Control program storage unit 6
A failure monitor 7 for determining that a failure has occurred;
A device condition storage unit 9 for storing a device condition table for associating and determining a device at a failure location (potentially a failure location) at the time of failure determination by the failure monitor unit 7, and a communication unit for communicating with the peripheral device 2 10 and a failed device storage unit 16 that stores the state of the device at the failure location indicated by the internal data of the device condition table stored in the device condition storage unit 9.

The peripheral device 2 includes a communication unit 11 for communicating with the programmable controller 1, a program editing unit 12 for creating a program for controlling the programmable controller 1, a monitor unit 13 for displaying the internal state of the programmable controller 1, It comprises a device condition creation unit 14 for creating a device condition table for determining a failure, and a screen / key input unit 15.

As the control target 3, the configuration example shown in FIG. That is, FIG. 22 is an explanatory diagram illustrating a configuration example of the control target 3 controlled by the programmable controller 1. In the figure, reference numeral 20 denotes a clamp, 21 denotes a work, 22 denotes a drill for processing the work 21, and 23 denotes limit switches LS1 and 24 for detecting the upper end of the clamp 20.
Is a limit switch LS for detecting the lower end of the clamp 20.
0, 25 are limit switches LS100, 26 for detecting the setting of the work 21; 26 are limit switches LS10, 27 for detecting the left end of the drill 22; 27 are limit switches LS11, 28 for detecting the right end of the drill 22; The signals Y1, 29 are signals Y0, 29A for operating the clamp 20 downward, the signals Y10, 29B for operating the drill 22 to the left, and the signal Y11 for operating the drill 22 to the right.

An example of the configuration of the SFC program for controlling the control target 3 will be described with reference to FIG. FIG.
Is an SFC program for controlling the control target 2 shown in FIG.
Are stored in the control program storage unit 6. The program table of the SFC program 30 for controlling the control target 3 will be described with reference to FIG. In FIG. 24, reference numeral 40 denotes a step operation program table;
Reference numeral 1 denotes a transition condition program table.

FIG. 2 shows a device condition table 50 stored in the device condition storage section 9. The device condition table 50 is a data table for associating and determining a device at a failure location (potential failure location) when the failure monitor 7 determines a failure, and as shown in FIG. For each step in the function chart, the device used in the transition condition to the next step is stored, and if the device is used in another step, the condition is used in the transition condition from that step to the next step. The device used is also stored.

FIG. 3 is a flowchart showing the processing operation of the device condition creation unit 14 in the peripheral device 2, and FIG.
5 is a flowchart showing a processing operation of the failure monitor unit 7 in the programmable controller 1.

Next, the operation will be described.

In the peripheral device 2, the SFC program 30, the step operation program table 40,
A transition condition program table 41 is created.

Next, a device condition table 50 is created by the device condition creating unit 14. The processing by the device condition creation unit 14 will be described with reference to the flowchart shown in FIG.

In FIG. 3, when the process is started, first, it is determined whether or not the creation process of the device condition table 50 in all steps is completed (step S60). If it is determined in step S60 that the creation of the device condition tables 50 in all the steps has been completed, the creation of the device condition tables 50 ends.

On the other hand, if it is determined in step S60 that the creation of the device condition tables 50 in all the steps has not been completed, the SFC program 30
Steps for further processing are taken out from the top (downward order) (step S61). Next, the next transition number of the currently extracted step is extracted (step S62).
The device used for the corresponding transfer number is extracted from the transfer condition program table 41 and stored at the position of the step number being processed in the device condition table 50 (step S63).

Thereafter, it is checked from the step operation program table 40 whether a device stored by another step number is used (step S64). In other words, it is checked whether or not the device stored at the position of the step number being processed in step S63 is being used in another step, and it is determined whether or not the device stored by another step number is being used. (Step S65).

If it is determined in step S65 that the device stored in another step number is used, that is, the device stored in the position of the step number being processed in step S63 is used in another step. If so, the transition number to the next step is extracted from the step (step S66), the device used by the corresponding transition number is extracted from the transition condition program table 41, and the device being processed in the device condition table 50 is processed. It is stored in the position of the step number (step S6
7).

Thereafter, the flow returns to step S60, and the same processing is repeatedly executed. In step S65, even when it is determined that the device stored by another step number is not used, the process returns to step S60 and the same processing is repeatedly executed.

According to the above-described processing, the peripheral device 2 writes the device used in the transition condition to the next step in the device condition table for each step of the sequential function chart, and uses the device in another step. It is checked whether or not the device condition table 50 is used in another step, and the device used in the transition condition from that step to the next step is also written in the device condition table, and the device condition table 50 is automatically updated. create.

As described above, when the creation process of the device condition table 50 in all steps is completed and the device condition table 50 is created, the communication unit 11 of the peripheral device 2 causes the SFC program 30 and the step operation program table 40 , The transfer condition program table 41 and the device condition table 50 are transmitted to the programmable controller 1.

In the programmable controller 1, these are received by the communication unit 10 and the SFC program 3
0, the step operation program table 40, and the transition condition program table 41 are stored in the control program storage unit 6, and the device condition table 50 is stored in the device condition storage unit 9.
To be stored.

After executing the above processing, the programmable controller 1 executes processing based on the contents of the control execution unit 5 and the control program. At this time, when the step does not shift for a predetermined time due to the failure of the external device, the control execution unit 5 activates the failure monitoring unit 7.

In this case, the failure monitor 7 executes a process based on the flowchart shown in FIG. When the failure monitor unit 7 is started, first, the execution step table 5A
The step number being executed is extracted (step S7).
0). This step is a stop step.

Next, from the device condition table 50,
The related device at the position of the taken out step number is taken out (step S71). Further, the status of the device is checked (step S72), and the status of the device is stored in the failed device storage unit 16 (step S73).

Therefore, by reading the data in the failed device storage unit 16 via the communication unit 11 by the monitor unit 13 of the peripheral device 2, it is possible to confirm the device associated with the stopped step.

For example, when LS0 breaks down and remains ON, the SFC program 30
Since the transition T4 of the (machining start flag) is LS0 as the transition condition, it is already established when executing S5, and the routine immediately proceeds to S6 (drill left). Therefore, M0 is OF
It becomes F. At the transition T1 (machining start flag) of S1, the transition condition M0 is OFF, so the transition condition is not satisfied, and the SFC program 30 does not transition from S1.

In the above case, the failure monitor 7 determines that a failure has occurred if the steps do not shift for a certain period of time.
1 related devices M0 and LS0 are stored in the faulty device storage unit 1.
6 is stored. At this time, when the peripheral device 2 reads the faulty device storage unit 16, the stopped step S1 is stopped.
Are easily found to be M0 and LS0.

Second Embodiment FIG. 5 is a block diagram showing a schematic configuration of a fault diagnosis system for a programmable controller according to a second embodiment.

In FIG. 5, 1A is a programmable controller according to this embodiment, 2 is a peripheral device of the programmable controller 1A, 3 is an object to be controlled, and 4 is an input / output signal.

The programmable controller 1A includes a control execution section 5, an execution step table 5A, a control program storage section 6, a failure monitor section 7, a failure monitor section 7 for determining that a failure has occurred, and a control execution section. O to store the combination of device ON / OFF status (during normal execution)
An ON / OFF state storage unit 8 for storing an N / OFF state table and a device condition table for associating and determining a device at a failure location (potential failure location) when the failure monitor unit 7 determines a failure. The communication device 10 includes a device condition storage unit 9 for performing communication, a communication unit 10 for communicating with the peripheral device 2, and a failed device storage unit 16.

As in the first embodiment, the peripheral device 2 includes a communication unit 11 for communicating with the programmable controller 1A.
A program editing unit 12 for creating a program for controlling the programmable controller 1A, a monitor unit 13 for displaying a state inside the programmable controller 1A, a device condition creating unit 14 for creating a device condition for determining a failure, And a screen / key input unit 15. The configuration example of the control target 3 according to this embodiment uses the same configuration as that shown in FIG. 22 described in the first embodiment.

FIG. 6 shows an example of a sequence program stored in the control program storage section 6 and an internal table. 6, reference numeral 90 denotes a ladder format sequence program for controlling the control target 3 shown in FIG. 22, and a group designation 91 indicating a related device is added to the device designated by the instruction. ing. The designation 91 is “￥ G integer”, for example, “￥
G1 ".

In FIG. 6, reference numeral 92 denotes a device condition table for registering devices related to groups. The device condition table 92 stores devices for each group and stores them in the device condition storage unit 9.

In FIG. 6, reference numeral 93 denotes an ON / OFF state table for registering a combination of ON / OFF states of devices related to the group in a normal state.
The ON / OFF state table 93 is stored in the ON / OFF state storage unit 8. The ON / OFF state table 93 is a combination of the ON / OFF states of the devices (M0 and LS0) belonging to “G1” in the normal state for each group stored in the device condition table 92 (this embodiment). Then, three types are stored.

The programmable controller 1A in this embodiment, when executing a step including a device designated by a group under normal execution of a sequence program, sets the ON / OFF state of the device and other devices in the same group as the device. The ON / OFF state of the device is searched for, the combination of the ON / OFF state of the device in each group in the normal state is detected, and the above ON / OFF state table 93 is automatically created.

FIG. 7 shows the device condition creation unit 1 of the peripheral device 2.
8 and FIG. 9 are flowcharts showing an ON / OFF state table creation processing operation and a processing operation by the failure monitor unit 7 in the programmable controller 1A.

Next, the operation will be described.

In the peripheral device 2, a sequence program 90 is created by the program editing unit 12. When the sequence program 90 is created, in order to indicate the devices related to the operation together with the device number, the device to be grouped is input with the designation 90 of the group.

Next, a device condition table 92 is created by the device condition creating section 14 based on the flowchart shown in FIG.

In FIG. 7, when the processing is started, first, it is determined whether or not all the instructions have been completed (step S1).
00). If it is determined in step S100 that all the instructions have been completed, the process ends.

On the other hand, in step S100,
If it is determined that all instructions have not been completed, an instruction to be processed is extracted from the sequence program 90, and a device specified by the instruction is extracted (step S10).
1). Next, specify the group to the extracted device 9
It is determined whether or not 1 is present (step S102).

If it is determined in step S102 that the extracted device has a group designation 91, the device number is stored as a related device in the corresponding group of the device condition table 92 (step S1).
03).

Thereafter, the flow returns to step S100 to repeat the same processing. If it is determined in step S102 that the extracted device does not have the group designation 91, the process returns to step S100 to repeatedly execute the same processing.

With the above-described processing, the peripheral device 2 scans all the instructions of the sequence program, determines whether or not the device designated by the instruction has the group designation symbol “$ G integer” added thereto, The device designated by the group is registered in the device condition table 92 by grouping, and the device condition table 92 is automatically created.

As described above, when all the steps are completed and the device condition table 92 is created, the sequence program 90 and the device condition table 9
2 to the programmable controller 1A.

In the programmable controller 1A, the sequence program 90 received by the communication unit 10 is stored in the control program storage unit 6, and the device condition table 92 is stored in the device condition storage unit 9.

When the programmable controller 1A starts the control processing, the processing is executed based on the contents of the control execution section 5 and the control program storage section 6.

At this time, the failure monitor unit 7 turns ON / OF
If the ON / OFF state table 93 is not stored in the F state storage unit 8, the processing for creating the ON / OFF state table is executed based on the flowchart shown in FIG. O
In the process of creating the N / OFF state table, first, the step being executed is extracted from the execution step table 5A (step S110). Next, the device of the corresponding step is checked from the sequence program 90, and it is determined whether or not there is a group designation 91 (step S11).
1). In step S111, designation of a group 91
If it is determined that there is a
Then, a related device matching the corresponding group is extracted (step S112).

Thereafter, the states of all the devices belonging to the same group are checked (step S113), and the combination of the ON / OFF states of the devices of the same group is set to ON.
It is stored in the position of the corresponding group in the / OFF state table 93 (step S114).

On the other hand, in step S111,
If it is determined that there is no group designation 91, the process ends.

Thus, under normal execution of the sequence program, when the step including the device designated by the group is executed, the ON / OFF state of the device and the ON / OFF of another device in the same group as the device are performed.
Search the FF status and find the O
An ON / OFF state table 93 is automatically created by detecting a combination of N / OFF states.

When the ON / OFF state table 93 is created as described above, the failure monitor 7 executes processing based on the flowchart shown in FIG. The control execution unit 5 activates the failure monitor unit 7 when executing one instruction of the sequence program 90. When the failure monitor 7 is started, first, the ON / OFF state table 9
3 is extracted (step S120), and it is determined whether all groups have been completed (step S12).
1). If it is determined in step S121 that all groups have been completed, the process ends.

On the other hand, in step S121,
If it is determined that all the groups have not been completed, the current ON / OFF state of the related device is checked (step S122). Thereafter, the ON / OFF state of the related device is compared with the ON / OFF state (normal value) of the device stored in the ON / OFF state table 93 (step S123). As a result, there is a device in a different state. In some cases, the device in the different state is stored in the failed device storage unit 16 (step S124), and
Returning to 121, the same processing is repeatedly executed.

Therefore, by reading data from the faulty device storage unit 16 by the monitor unit 13 of the peripheral device 2, if there is data of a device in a different state, it is known that a fault has occurred. For example, when LS10 is broken down and remains ON, in the ON / OFF state table 93, when M0 is ON, LS0 should be OFF, so LS0 is determined to be a failed device. At this time, the peripheral device 2 stores the failed device storage unit 1
By monitoring No. 6, the faulty device is found to be LS0, so that the cause of the fault can be easily found.

Third Embodiment Next, a third embodiment will be described. The configuration of the fault diagnosis system for the programmable controller according to this embodiment uses the same configuration as that shown in FIG. 8 (second embodiment), and the control target 3 has the configuration example shown in FIG. Used.

FIG. 10 is an explanatory diagram showing a control program stored in the control program storage section 6. FIG.
In the figure, 130 indicates a sequence program 1 and 131 indicates a sequence program 2. In FIG. 10, a device condition table 132 is stored in the device condition storage unit 9. In FIG. 10, reference numeral 133 denotes an ON / OFF state table.
It is stored in the OFF state storage unit 8.

In this embodiment, sequence programs 1 and 2 are created for each device related to the operation, and the device condition table 132 stores a device for each sequence program.

The ON / OFF state table 133 stores a combination of the ON / OFF state of the device in the normal state for each sequence program stored in the device condition table 132.

The programmable controller 1A in this embodiment, under the normal execution of each sequence program, turns on / off each device and turns on other devices in the same sequence program as that device.
The ON / OFF state table 132 is automatically created by retrieving the ON / OFF state, detecting the combination of the ON / OFF state of the device in the normal state for each sequence program.

FIG. 11 is a flow chart showing the processing operation by the device condition creation unit 14 of the peripheral device 2, and FIG.
FIG. 2 and FIG. 13 are flowcharts showing the processing operation of creating the ON / OFF state table in the programmable controller 1A and the processing operation by the failure monitor unit 7.

Next, the operation will be described.

In the peripheral device 2, the program editing unit 12 creates the sequence programs 130 and 131 shown in FIG. The sequence program 13
0 and 131 are separately created.

Next, the device condition creation unit 14
The device condition table 132 is created based on the flowchart shown in FIG. In the process of creating the device condition table, first, it is determined whether or not all programs have been completed (step S140). If it is determined in step S140 that all programs have been completed, the process ends.

On the other hand, in step S140,
When it is determined that all the programs have not been completed, it is determined whether or not all the conditional instructions of the corresponding sequence program have been completed (step S141).

If it is determined in step S141 that all the conditional instructions of the corresponding sequence program have been completed, the process returns to step S140 and the same processing is repeated.

On the other hand, in step S141,
When it is determined that all the conditional instructions of the corresponding sequence program have not been completed, the device designated by the conditional instruction is taken out (step S142). Thereafter, the device is stored as a related device in the corresponding program group of the device condition table 132 (step S14).
3) Returning to step S141, the same processing is repeatedly executed.

As a result, under normal execution of each sequence program, the ON / OFF state of each device and the ON / OFF state of other devices in the same sequence program as that device are searched, and the normal state of each device for each sequence program is searched. The ON / OFF state table 132 is automatically created by detecting the ON / OFF state combination at the time.

As described above, when all the sequence programs are completed and the device condition table 132 is created,
Sequence program 1 by the communication unit 11 of the peripheral device 2
30 and 131 and the device condition table 132 are transmitted to the programmable controller 1A.

In the programmable controller 1 A, the communication unit 10 receives the device condition table 132, stores the sequence programs 130 and 131 in the control program storage unit 6, and
2 is stored in the device condition storage unit 9.

When the programmable controller 1A starts the control processing, it executes each processing based on the contents of the control execution section 5 and the control program storage section 6.

At this time, the failure monitor unit 7 turns ON / OF
If the ON / OFF state table 133 is not stored in the F state storage unit 8, the ON / OFF state table creation processing is executed based on the flowchart shown in FIG. In the process of creating the ON / OFF state table, first,
The step being executed is extracted from the execution step table 5A (step S150), and the program group of the corresponding step is acquired (step S151). Next, a related device that matches the corresponding program group is extracted from the device condition table 132 (step S152), the ON / OF state of the device is checked (step S153), and the ON / OF state of the device is set to O.
The data is written to the position of the corresponding group in the N / OFF state table 133 (step S154).

Thus, under normal execution of each sequence program, the ON / OFF state of each device and the ON / OFF state of other devices in the same sequence program as that device are searched, and the normal state of each device for each sequence program is searched. An ON / OFF state table is automatically created by detecting a combination of ON / OFF states at the time.

When the ON / OFF state table 133 is created in this way, the failure monitor 7 executes processing based on the flowchart shown in FIG. That is, the control execution unit 5 activates the failure monitoring unit 7 when executing one instruction of the sequence program. When activated, the failure monitor unit 7 retrieves the corresponding program group from the ON / OFF state table 133 (step S160) and checks the current ON / OFF state of the related device (step S161). Next, the ON / OFF state of the related device and the ON / OFF state table 1
The ON / OFF state (normal value) of the device stored in the device 33 is compared with the normal state (S162). As a result, if there is a device in a different state, the device in the different state is stored in the failed device storage unit 16 ( Step 163).

Therefore, if the data of the faulty device storage unit 16 is monitored on the monitor unit 13 of the peripheral device 2,
The failed device associated with the stopped step can be immediately identified. For example, when the LS 10 breaks down and remains in the ON state, the ON / OFF state table 1
In M33, when M0 is turned on, LS0 should be off, so LS0 is determined to be a failed device. At this time, when the faulty device unit 16 is monitored by the peripheral device 2, it is found that the faulty device is LS0, so that the cause of the fault can be easily found.

Fourth Embodiment Next, a fourth embodiment will be described. The configuration of the fault diagnosis system for the programmable controller according to this embodiment uses the same configuration as that shown in FIG. 5 (second embodiment), and the control target 3 also has the configuration example shown in FIG. Is used.

FIG. 14 is an explanatory diagram showing an example of a sequence program stored in the control program storage section 6. In the figure, 170 is a sequence program, 17
Reference numeral 1 denotes a sequence program designated by a group, and 172 denotes a group designation.

In FIG. 14, reference numeral 173 denotes a device condition table, which is stored in the device condition storage unit 9, and 174 denotes an ON / OFF state table, which is stored in the ON / OFF state storage unit 8. ing.

FIG. 15 is a flowchart showing the processing operation of the device condition creation unit 14, and FIGS.
5 is a flowchart showing a processing operation of the failure monitor unit 7.

Next, the operation will be described.

In the peripheral device 2, the sequence editor 170 shown in FIG. 14 is created by the program editor 12. After creating the sequence program 170, the group designation 172 is input to an arbitrary device number of the sequence program 170, and the sequence program 171 is created. This means that the group designation can be set to a completed sequence program after the program is input, in other words, to a completed sequence program. Further, the device condition table 173 is stored in the device condition creation unit 14 in FIG.
5 is created based on the flowchart of FIG.

In FIG. 15, when the process is started, first, it is determined whether or not all instructions have been completed (step S1).
80). If it is determined in step S180 that all instructions have been completed, the process ends.

On the other hand, in step S180,
If it is determined that all the instructions have not been completed, an instruction to be processed is extracted from the sequence program 171 and the device specified by the instruction is extracted (step S1).
81). Next, it is determined whether or not the extracted device has a group designation 172 (step S182).

If it is determined in step S182 that the extracted device has the group designation 172, the device number is stored as a related device in the corresponding group of the device condition table 173 (step S183).

Thereafter, the flow returns to step S180 to repeatedly execute the same processing. If it is determined in step S182 that the extracted device does not have the group designation 172, the process returns to step S180 to repeatedly execute the same processing.

By the above-described processing, the peripheral device 2 scans all the instructions of the sequence program, determines whether or not the device designated by the instruction has a group designation symbol “$ G integer” added thereto, The device designated by the group is registered as a group in the device condition table 92, and the device condition table 173 is automatically created.

As described above, when all the steps are completed and the device condition table 173 is created, the communication unit 11 transmits the sequence program 171 and the device condition table 173 to the programmable controller 1A.

In the programmable controller 1A, the sequence program 171
Is stored in the control program storage unit 6, and the device condition table 173 is stored in the device condition storage unit 9.

When the programmable controller 1A starts the control processing, it executes the processing based on the contents of the control execution section 5 and the control program storage section 6.

At this time, the failure monitor unit 7 turns ON / OF
If the ON / OFF state table 174 is not stored in the F state storage unit 8, processing for creating the ON / OFF state table is executed based on the flowchart shown in FIG. In the process of creating the ON / OFF state table, first,
The step being executed is extracted from the execution step table 5A (step S190). Next, the device of the corresponding step is checked from the sequence program 90, and it is determined whether or not there is a group designation 172 (step S).
191). If it is determined in step S191 that there is a group designation 172, a related device matching the corresponding group is extracted from the device condition table 92 (step S192).

Thereafter, the states of all the devices belonging to the same group are checked (step S193), and the ON / OFF states of the devices of the same group are stored in the ON / OFF state table 174 at the corresponding group positions (step S194). .

If it is determined in step S191 that there is no group designation 172, the present process is terminated.

Thus, under normal execution of the sequence program, when a step including a device designated by a group is executed, the ON / OFF state of the device and the ON / OFF of another device in the same group as that device are performed.
Search the FF status and find the O
An ON / OFF state table 174 is automatically created by detecting a combination of N / OFF states.

When the ON / OFF state table 174 is created as described above, the failure monitor 7
The processing is executed based on the flowchart shown in FIG. The control execution unit 5 activates the failure monitor unit 7 when executing one instruction of the sequence program 171. When the failure monitor unit 7 is started, first, the group is extracted from the ON / OFF state table 174 (step S20).
0), it is determined whether all groups have been completed (step S201). If it is determined in step S201 that all groups have been completed, the process ends.

On the other hand, in step S201,
If it is determined that all the groups have not been completed, the current ON / OFF state of the related device is checked (step S202). Thereafter, the ON / OFF state of the related device is compared with the ON / OFF state (normal value) of the device stored in the ON / OFF state table 174 (step S203). As a result, there is a device in a different state. In some cases, the devices in the different states are stored in the failed device storage unit 16 (step S204), and the process returns to step S201 to repeat the same processing.

Therefore, by reading data from the faulty device storage unit 16 by the monitor unit 13 of the peripheral device 2, if there is data of a device in a different state, it can be determined that a fault has occurred. For example, when LS10 fails and remains ON, in the ON / OFF state table 174, when M0 turns ON, LS0 turns OFF.
Therefore, LS0 is determined to be a failed device. At this time, when the faulty device storage unit 16 is monitored by the peripheral device 2, it is found that the faulty device is LS0, so that the cause of the fault can be easily found.

Embodiment 5 Next, a fifth embodiment will be described. FIG. 18 is a block diagram illustrating a schematic configuration of a failure diagnosis system for a programmable controller according to this embodiment.

In FIG. 18, reference numeral 1B denotes a programmable controller (PC1 to PCn) which has the same configuration as any of the programmable controllers of the first to fourth embodiments. 2A is a plurality of programmable controllers 1 to n (1
B) a peripheral device connected to and controlling them, 11 is a communication unit with the programmable controllers 1 to n (1B),
12 is a program editing unit, 13A is a monitor unit, 14 is a device condition creation unit, and 15 is a screen / key input unit. In this case, the programmable controllers 1 to n (1B) are assigned unique numbers (1 to n) and communicably connected to the peripheral device 2A.

FIG. 19 is a flowchart showing the processing operation of the monitor unit 13A, and FIG. 20 shows an example of a display screen displayed by the peripheral device 2A at the time of failure. The control target in this embodiment is the same as the configuration shown in FIG.

Next, the operation will be described.

In this embodiment, the programmable controllers 1 to n (1B) create a sequence program and an ON / OFF state table based on any of the processes described in the first to fourth embodiments. . Then, in this state, the programmable controllers 1 to n (1B) execute control processing.

In the peripheral device 2A, the monitor unit 13A monitors the programmable controllers 1 to n (1B) via the communication unit 11 based on the flowchart shown in FIG. That is, in the flowchart of FIG. 19, first, the data in the failed device storage unit 16 of the programmable controller n is read (step S22).
0), it is determined whether or not there is data (step S22)
1).

If it is determined in step S221 that there is data, the data is displayed on the screen (step S222). The screen display in this case is, for example, a screen as shown in FIG.
The C number, the failure device, and the failure state of the device are displayed.

Next, after the number of n is set to the next PC number (step S223), the process returns to step S220 and the same processing is repeatedly executed.

On the other hand, in step S221,
If it is determined that there is no data, the process proceeds to step S223, and the same processing is repeatedly executed.

According to the above-described processing, for example, when LS0 of the programmable controller 1 is ON, a display as shown in FIG. 20 is displayed on the screen of the peripheral device 2A. One of the peripheral devices 2
A can be easily determined.

[0143]

As can be understood from the above description, according to the programmable controller of the present invention, the SFC
For each step in the sequential function chart, the device used in the transition condition to the next step is stored as device data related between the steps of the sequence program described in the language, and the device is stored in another step. If a failure occurs in the control target, use the device condition table that stores the devices used in the transition condition from that step to the next step. Since the failure detection means detects a failure location based on the device that has been used, it is easy to determine a failed device without creating a special program even when a related device is used between steps of a program. Can be.

According to the peripheral device of the programmable controller according to the next invention, the device condition creation means writes, in each step of the sequential function chart, a device used under the condition for shifting to the next step in the device condition table, Investigate whether the device is used in another step, and if it is used in another step, add the device used in the transition condition from that step to the next step together with the device condition table To automatically create the device condition table, the device condition table can be created without any trouble and without mistake, and accurate failure detection can be performed.

According to the programmable controller of the next invention, the device of the sequence program is grouped by the devices related to the operation as the data of the device related between the steps of the sequence program described in the ladder language or the like. The device condition table storing the device for each group is stored in the device condition storage means, and the normal ON / OFF state of the device for each group stored in the device condition table is stored.
An ON / OFF state table storing the combination of OFF states is stored in the ON / OFF state storage means,
Since the failure detecting means detects the failure location based on the combination of the ON / OFF states stored in the F state storage means, even when the related device is used between the steps of the program, the failure device is specially identified. It can be easily determined without creating a program.

According to the programmable controller of the next invention, when a step including a device designated by a group is executed under normal execution of a sequence program, the ON / OFF state of the device and other devices in the same group as the device The ON / OFF status of the device is searched, and the ON / OFF status of the device for each group in the normal state
Since the ON / OFF state table is automatically created by detecting the combination of states, the ON / OFF state table is created without any trouble and without mistake, and accurate failure detection can be performed.

According to the peripheral device of the programmable controller according to the next invention, the device condition creating means scans all the instructions of the sequence program and determines whether or not the device designated by the instruction has a group designation symbol added thereto. Then, the device specified by the same group is registered as a group in the device condition table, and the device condition table is automatically created.
It can be created without any trouble and without mistake, and accurate failure detection can be performed.

According to the programmable controller of the next invention, a sequence program is created for each device related to the operation, and a device condition table storing devices for each sequence program is stored in the device condition storage means. An ON / OFF state table that stores a combination of ON / OFF states of the devices at normal times for each sequence program stored in the device condition table stored in the condition storage unit is ON.
Since the failure detection means detects a failure location based on a combination of ON / OFF states stored in the ON / OFF state storage means, the related device is used between steps of the program. In this case, the faulty device can be easily determined without creating a special program.

According to the programmable controller of the next invention, under normal execution of each sequence program, the ON / OFF state of each device and the ON / OFF state of other devices in the same sequence program as that device are searched. The ON / OFF state table is automatically created by detecting the normal ON / OFF state combination of devices for each sequence program.
The / OFF state table is created without any trouble and without mistake, and accurate failure detection can be performed.

According to the peripheral device of the programmable controller according to the next invention, the device condition creating means scans all the instructions of each sequence program, registers the device designated by the instruction for each sequence program, and registers the device condition table. Is automatically created, the device condition table is created without any trouble and without mistake, and accurate failure detection can be performed.

According to the peripheral device of the programmable controller according to the next invention, a plurality of programmable controllers are connected to each other with a unique number and are communicable with each other. Since the controller number and the failure location are displayed, it is possible to easily determine which device of which connected programmable controller has failed by using one peripheral device.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a schematic configuration of a failure diagnosis system for a programmable controller according to the present invention.

FIG. 2 is an explanatory diagram showing an internal table of a sequence controller according to the present invention.

FIG. 3 is a flowchart showing a processing operation of a device condition creation unit by a sequence controller according to the present invention.

FIG. 4 is a flowchart showing a processing operation of a failure monitor unit by a sequence controller according to the present invention.

FIG. 5 is a block diagram showing another schematic configuration of the failure diagnosis system for the programmable controller according to the present invention.

FIG. 6 is an explanatory diagram showing an example of a control program stored in a control program storage unit and an internal table according to the present invention.

FIG. 7 is a flowchart showing a processing operation by a device condition creation unit according to the present invention.

FIG. 8 is a flowchart showing a processing operation by a failure monitor unit according to the present invention.

FIG. 9 is a flowchart showing a processing operation by a failure monitor unit according to the present invention.

FIG. 10 is an explanatory diagram showing a control program stored in a control program storage unit according to the present invention.

FIG. 11 is a flowchart illustrating a processing operation of a device condition creation unit according to the present invention.

FIG. 12 is a flowchart showing a processing operation of a failure monitor unit according to the present invention.

FIG. 13 is a flowchart showing a processing operation of a failure monitor unit according to the present invention.

FIG. 14 is an explanatory diagram illustrating an example of a control program stored in a control program storage unit according to the present invention.

FIG. 15 is a flowchart showing a processing operation of a device condition creation unit according to the present invention.

FIG. 16 is a flowchart showing a processing operation of a failure monitor unit according to the present invention.

FIG. 17 is a flowchart showing a processing operation of a failure monitor unit according to the present invention.

FIG. 18 is a block diagram showing another schematic configuration of the failure diagnosis system for the programmable controller according to the present invention.

FIG. 19 is a flowchart showing a processing operation of a monitor unit according to the present invention.

FIG. 20 is an explanatory diagram showing a display screen displayed by a peripheral device at the time of failure according to the present invention.

FIG. 21 is a block diagram showing a schematic configuration of a conventional fault diagnosis system for a programmable controller.

FIG. 22 is an explanatory diagram showing a configuration example of a control target controlled by a programmable controller.

FIG. 23 is an explanatory diagram illustrating a configuration example of an SFC program that controls a control target.

FIG. 24 is an explanatory diagram showing a program table of an SFC program for controlling a control target.

FIG. 25 is a flowchart illustrating a processing operation of a conventional control execution unit.

FIG. 26 is an explanatory diagram showing a display screen of a peripheral device for creating a conventional step operation program and transition condition program table.

[Explanation of symbols]

1, 1A, 1B Programmable controller, 2, 2
A Peripheral device, 3 control target, 7 failure monitor section, 8
ON / OFF state storage unit, 9 device condition storage unit, 1
2 Program editor, 14 Device condition generator, 3
0 SFC program, 90, 130, 131, 17
0,171 Sequence program, 91 group designation, 172 group designation.

Claims (9)

(57) [Claims] 1. A programmable controller for executing a sequence program described in a sequential function chart, wherein, for each step of the sequential function chart, a device used under a condition for transition to the next step is stored, and the device is stored in a memory. If it is used in another step, a device condition storage means that stores a device condition table that also stores the devices used in the transition condition from that step to the next step, and a failure occurs in the control target And a failure detection means for detecting a failure location based on the device stored in the device condition storage means. 2. The peripheral device for a programmable controller according to claim 1, wherein a device used in a transition condition to a next step is written in a device condition table for each step of the sequential function chart, and the device is stored in another device condition table. Investigate whether or not it is used in the step, and if it is used in another step, write the device used in the transition condition from that step to the next step together with the device condition table and write it to the device condition table A peripheral device for a programmable controller, comprising: device condition creation means for automatically creating a condition table; and transmitting the device condition table created by the device condition creation means to the programmable controller by a communication means. 3. A programmable controller for executing a sequence program, wherein device devices of the sequence program are grouped into groups related to operation, and a device condition table storing a device condition table storing devices for each group is stored. Means; and an ON / OFF state storage for storing an ON / OFF state table for storing a combination of ON / OFF states of devices in a normal state for each group stored in a device condition table stored in the device condition storage means. And ON / OFF stored in the ON / OFF state storage means.
A fault detecting means for detecting a fault location based on a combination of OFF states. 4. Under normal execution of a sequence program, when executing a step including a device designated by a group, the ON / OFF state of the device and the ON / OFF state of another device in the same group as the device are searched. ON / OFF of devices in each group during normal operation
4. The programmable controller according to claim 3, wherein a combination of states is detected and an ON / OFF state table is automatically created. 5. The peripheral device of the programmable controller according to claim 3, wherein all instructions of the sequence program are scanned, and it is determined whether or not a device designated by the instruction has a group designation symbol added thereto. Device condition creating means for automatically creating a device condition table by registering devices designated by the same group in the device condition table, and programming the device condition table created by the device condition creating means by communication means A peripheral device for a programmable controller, which is transmitted to the controller. 6. A programmable controller for executing a sequence program, wherein a sequence program is created for each device related to an operation, and device condition storage means for storing a device condition table storing a device for each sequence program; O for storing a combination of the normal ON / OFF states of the devices for each sequence program stored in the device condition table stored in the device condition storage means
ON / OFF state storage means for storing an N / OFF state table; and ON / OFF state information stored in the ON / OFF state storage means.
A fault detecting means for detecting a fault location based on a combination of OFF states. 7. Under normal execution of each sequence program, an ON / OFF state of each device and an ON / OFF state of another device in the same sequence program as the device are searched, and when each device of each sequence program is normal. 7. The programmable controller according to claim 6, wherein an ON / OFF state table is automatically created by detecting a combination of ON / OFF states of the controller. 8. The peripheral device for a programmable controller according to claim 3, wherein all instructions of each sequence program are scanned, a device specified by the instruction is registered for each sequence program, and a device condition table is automatically set. A peripheral device for a programmable controller, comprising device condition creating means for creating, and transmitting the device condition table created by the device condition creating means to the programmable controller by communication means. 9. A plurality of programmable controllers according to claim 1, 2, 3, 6, or 7, each of which is uniquely numbered and communicably connected to each other. A peripheral device for a programmable controller, comprising monitor means for displaying a controller number and a failure location.