JP4548664B2 - Program creation system - Google Patents

Description

  The present invention relates to a program creation system suitable for use in the construction of ladder software for controlling the operation of a production facility such as a food production facility using a batch process.

  A sequencer or PLC (programmable logic controller) is exclusively used for operation control in food production facilities. This type of PLC operation control software is often designed using a ladder diagram. However, since the ladder diagram basically describes the control process in order on one line, for example, when constructing a hierarchical batch process, various operating conditions are likely to be complicated. Therefore, while being excellent in flexibility, it is often easy to have operation control software different from the production (control) intention.

On the other hand, in order to improve the efficiency of the design and production work of the specifications for sequence control and software, the output definition sheet describing the output command of each step and the transition conditions between steps in sequence control, and monitoring Create a program specification using an interlock definition sheet that describes the interlock and the specification of abnormal processing when the interlock occurs in a tabular format, and a parameter definition sheet, etc., and based on this program specification It is also proposed to create a control sequence program (see, for example, Patent Document 1).
JP 2002-323912 A

  However, even when such an output definition sheet, interlock definition sheet, etc. are used, when building a hierarchical batch process, for example, the interlock condition often enters in a complex manner across different hierarchies. It cannot be denied that a great deal of labor is required for condition setting and condition judgment. In particular, in general, software such as input / output control, operation control, calculation, alarm, and interlock is generally created on the same software level, and these software are often associated with each other in a complicated manner. Therefore, it is difficult to change the sequence control software accompanying the addition or modification of the equipment. In addition, there is a problem that problems such as incorrect setting of conditions and missing conditions are likely to occur.

  The present invention has been made in consideration of such circumstances, and its purpose is to introduce problems such as incorrect setting of conditions and missing conditions of the operating conditions of the ladder software that controls the operation of the production facility by the batch process. It is an object of the present invention to provide a program creation system that can be set and managed easily and efficiently without any trouble.

In order to achieve the above-mentioned object, the program creation system according to the present invention is used for construction of ladder software for controlling the operation of a production facility by a batch process,
Independent of the operation control software for the equipment that constructs the production equipment, the operation conditions necessary for batch process control of the production equipment are divided into control blocks for each level in which the operation control is hierarchized. For example , operating conditions between a plurality of control blocks are managed using a management table described in a matrix format, for example .
For each of the control block, and compares the operating conditions shown in the management table and the operation state of the other control blocks in the same hierarchy to determine whether the driver execution of the control block, respectively, the judgment result, the production It is characterized in that operating condition management means linked to operation control software of equipment for constructing equipment is provided .

Specifically, the operating condition management means is, for example, as described in claim 2
<a> The mutual interlock conditions between the plurality of operation modes in the production facility are respectively managed, and the execution of each operation mode is performed from the mutual interlock conditions of each operation mode and the operation state signals of other operation modes. A first function for determining availability;
<b> Manages the operation conditions of a plurality of operation steps that respectively execute the above operation modes and the step transition interlock conditions between these operation steps, and also determines the above step transition interlock conditions and the operation control software from A second function for determining whether or not to execute the operation of each operation step from the obtained operation state signal of each operation step;
<c> While managing the interlock condition of each operation step, the operation condition of each step is normal from the interlock condition of each operation step and the operation state signal of each facility device obtained from the operation control software. And a third function for determining whether there is an abnormality.

  By the way, the first function is, for example, as described in claim 3, in which a matrix table in which a plurality of operation modes are arranged vertically and horizontally is entered in the matrix table to indicate whether or not the operation is possible, and mutual interlocking between the plurality of operation modes is performed. It is realized as managing each condition. In addition, the second function is, for example, as described in claim 4, wherein the operation condition of each operation step is managed by entering the operation availability condition in a matrix table in which a plurality of operation steps are arranged vertically and horizontally. As realized. The third function is, for example, as described in claim 5, wherein the operation state of the facility device is entered in a matrix table in which interlock conditions of the facility device for constructing the production facility are arranged for each of a plurality of operation steps. Thus, this is realized as a determination of the feasibility of the operation condition of the operation step.

  According to the program creation system according to the present invention, the operating conditions necessary for batch process control of production equipment (for example, interlock conditions and operation transition conditions) are separated from the operation control software of the equipment that constructs the production equipment, Since the operation control is managed for each control block in each hierarchy, the operation control condition of each control block can be accurately set and linked to the operation control software of the equipment. In addition, it is possible to easily set the operating conditions while grasping the relationship with other control blocks at the hierarchical level, and to easily monitor the set operating conditions.

  Further, since the operation control is hierarchized and managed, it is possible to easily set operation conditions, interlocks, and the like between the upper and lower layers, and it is also possible to easily monitor the set operation conditions. In addition, it is possible to easily set operation switching conditions such as batch switching in the control block.

Hereinafter, a program creation system according to an embodiment of the present invention will be described with reference to the drawings.
This program creation system is realized as a function provided in a control device 2 mainly composed of a PLC (programmable logic controller) 1 for controlling the operation of a production facility by a batch process as shown in FIG. The PLC 1 basically includes operation information A given via a push button, a touch panel, etc., a status signal B indicating a device operation obtained from a sensor or the like incorporated in a facility device that constructs a production facility (not shown), and other devices. Is provided with an operation control unit (control ladder) 3 that inputs a signal C such as utility information obtained from the above and outputs an operation control command for the equipment that constructs the production facility in accordance with ladder software S that controls operation control and the like. Various operation control commands (control outputs) sequentially output from the operation control unit 3 are given to, for example, the power circuit 4, the air circuit 5, and the control circuit 6 in the control device 2. The operation of the power equipment (motor) 7 of the production facility is controlled by the power circuit 4, the valve 8 in the production equipment is controlled to be opened and closed by the air circuit 5, and other devices are further connected via the control circuit 6. 9 is output as a control signal.

  Basically, in the system configured as described above, the present invention is characterized in that the operating conditions necessary for batch process control of the production facility are separated from the operation control unit (control ladder) 3 in the PLC 1. Is provided with an operation condition management unit (operation condition management means) 10 for managing each operation block in each hierarchical level in which the operation control is hierarchized. The interlock conditions and operation conditions T of each control block managed by the operation condition management unit 10 are created by using a matrix table as will be described later on a personal computer, for example, and downloaded from peripheral devices such as the personal computer. Is given by. The operating condition management unit 10 associates the interlock conditions and the operating conditions T of each control block given in this way with the ladder software S constructed in the operation control unit 3 described above in association with each control block. Take the role of linking. The operation control unit 3 refers to the interlock conditions, operation conditions, etc. T linked to the ladder software S in this way to determine whether or not each control block can be operated, and when the operation conditions are satisfied. The operation control command (control output) described above is output.

  The interlock conditions, operating conditions, etc. T of each control block described above are the mutual operating conditions necessary for the batch process control of the production facility, for example, as shown in FIG. Interlock condition X, operation step mutual condition indicating operation conditions among a plurality of operation steps constituting each operation mode, operation step transition condition Y (Y1, Y2, Y3, Y4, ...), and further each operation step Each operation line condition Z (Z11, Z12, ~ Z1n, Z21, Z22, ~ Z2m, ~ Zij, ~) is hierarchized and given to each control block in each of these hierarchies.

  By the way, the mutual interlock condition X between the above operation modes is different when executing main operation modes in production equipment (food production equipment) such as extractor operation, kneader operation, and blending operation in the case of food production equipment, for example. This condition is determined according to the execution status of the operation mode. The operation step mutual condition and the operation step transition condition Y are conditions set in accordance with the execution status of other operation steps in the operation mode when executing the plurality of operation steps that constitute each operation mode described above. It is. The operation line condition Z for each operation step is set according to the operation state of each facility device that manages the operation step obtained as a bubble answer or connection condition.

  The operation control unit 3 described above is an interlock for each control block which is managed by the operation condition management unit 10 separately from the operation control software (ladder software S) of the equipment that constructs the production facility in this way. It is determined for each hierarchical level whether or not the conditions for executing the processing of each control block described above with reference to T, such as conditions and operation conditions (first to third functions), and the determination The batch process control of the production facility (food manufacturing facility) is executed by sequentially outputting the operation control command for each facility device according to the result.

  Here, the interlock conditions and operation conditions for each control block, T, etc., and batch process control referring to them will be described in detail. The operation mode in the food production facility is roughly the production operation and pipe cleaning. It is divided into driving (CIP). The manufacturing operation is further divided into a plurality of operation modes such as an extractor operation, a kneader operation, a milk powder dissolution operation, a preparation operation, a preparation discharge, and a sterilizer operation. The washing operation (CIP) is also divided into a plurality of operation modes such as extractor washing, powdered milk dissolution washing, and preparation tank washing. The first function described above plays a role of determining the interlock condition between the operation modes of the manufacturing equipment described above as the highest hierarchical level in the batch process control of the production equipment.

  Incidentally, the mutual interlock condition X between a plurality of operation modes creates a matrix table in which the operation modes described above are arranged as management items in the vertical (row) and horizontal (column), as shown in FIG. It is created by describing information on whether or not simultaneous operation in other operation modes is possible for each operation mode. Specifically, when executing a specific operation mode, for example, when it is necessary that another operation mode is in operation, a [○] mark is displayed, and when another operation mode is required to be stopped Is created by describing the [x] mark in the corresponding item of the matrix table, and the [-] mark if it does not depend on the operation state of other operation modes. In the example shown in FIG. 3, the extractor operation is set as a mutual condition between operation modes that can be executed on condition that the kneader operation is stopped and the extractor cleaning operation is stopped. The

  And if the mutual condition between such operation modes is set, the operation state signal obtained from the operation control software of the production facility is input in the operation control unit 3 described above, for example, as shown in FIG. It is determined whether or not each mutual condition is satisfied depending on whether or not the operation mode is operating (operating / stopping). And when all of the interrelationships with other operation modes are satisfied for each operation mode, in other words, when the determination result of [OK] is obtained over the entire horizontal row in the matrix table described above, It is determined that the operation mode can be executed. The determination result is used as an interlock indicating whether or not the operation in the operation mode is possible in the operation control in the PLC 1.

  Next, in the second function, step transition interlock conditions for a plurality of operation steps (operation processes) necessary to execute the operation mode determined as described above are examined. Specifically, the sterilizer operation (operation mode) described above is configured by operation steps such as sterilization operation, preparation operation, product replacement, product operation, water pushing operation, cooling stop, and filler feeding. Therefore, in order to determine the step transition interlock condition Y between these operation steps, for example, as shown in FIG. 5, a matrix table in which the operation steps described above are arranged as management items in the vertical (row) and horizontal (column), respectively. And describes whether or not simultaneous operation with other operation steps is possible for each operation step. In this case as well, when executing a specific operation step, for example, when another operation step needs to be in operation, it is necessary to mark [O] and other operation steps to be stopped. In the case, [x] mark is described in the corresponding item of the matrix table, and [−] mark is described in the matrix table when it is not influenced by the operation state of other operation steps. In the example shown in FIG. 5, the preparatory operation can be executed on condition that the sterilization operation is in operation and the other operation steps are stopped. Is set.

  Then, if the step transition interlock condition between the operation steps is set, the operation state signal obtained from the operation control software of the production facility is input to the operation control unit 3 described above, for example, as shown in FIG. As described above, it is determined whether or not the step transition interlock condition for each operation step is satisfied, depending on whether or not each operation step described above is in operation (during operation / stop). When all the step transition interlock conditions with other operation steps are satisfied for each operation step, in other words, a determination result of [OK] is obtained over the entire horizontal row in the matrix table described above. When it is, it is determined that the operation step can be executed. The determination result is output in real time and used as an interlock indicating whether or not the operation step is activated in the operation control in the PLC 1 described above.

  When the operation interlock (step transition condition) in each operation step is set as described above, the operation condition for each operation step is set as a third function. Specifically, the sterilizer operation in the operation step described above is performed under the operation control by the PLC 1 according to the interlock condition and the state of equipment (line condition) in each operation step, for example, according to the procedure shown in FIG. Is executed sequentially.

  Therefore, first, the operating conditions of each facility device in the production facility necessary to execute the operation of each operation step described above are set. For example, as shown in FIG. 8, the production equipment (food production equipment) is an extractor, a kneader (mixing machine), a dissolver, a preparation tank, a sterilizer, and a pump or valve for connecting these via a pipeline, a pipeline switching When constructed using a vessel or the like, the operating conditions of the equipment (pump, valve, conduit switching unit) necessary to execute the operation step are set for each operation step described above. In this case, in particular, each operation step is divided into a transient state and a steady state, and the operation conditions of each equipment are set.

  The setting of the operation condition Z of the equipment required for executing the operation of this operation step is performed by arranging the operation steps described as shown in FIG. A matrix table arranged as management items in (column) is created, and information indicating the operation state of each equipment is described for each operation step. In particular, whether each operation step is divided into a transient state and a steady state, and a matrix table is created that is arranged as a vertical (row) management item, and the operating state of each equipment is used as an interlock for each of these items. Fill in information about whether or not. In this case, for example, when the above equipment is used as an interlock, [○] and [×] marks are used depending on whether the operating state is suitable for operating conditions, and [−] when not used. Fill in the mark.

  Specifically, in the example shown in FIG. 9, when the sterilization operation (operation step) is a steady operation, the pumps [P-650] and [P-651] are operating and the valves [AV-15] and [P AV-16], [AV-22], [AV-23], [AV-28] are closed and valves [AV-17], [AV-19], [AV-20], [AV- 21], [AV-26], and [AV-27] are opened, and the conduit switches [MV-1], [MV-2], and [MV-3] are set to the [1] side. It is shown that it can drive | operate on the condition.

  With respect to the operation conditions of each operation step set in the operation condition management unit (operation condition management means) 10 in this way, the above-described operation control unit 3 has the facility equipment obtained from the operation control software of the production facility. An operation state signal (answer signal) is input, and for example, as shown in FIG. 10, it is determined whether or not the operation conditions of each operation step described above are satisfied. When all the operation conditions for each operation step are satisfied, in other words, when a determination result of [OK] is obtained over all the horizontal rows in the matrix table described above, the operation step can be executed. Judge that there is. Conversely, if there is a determination result of [NG] even in one of the horizontal row items in the matrix table, this is determined as abnormal. The determination result is output in real time and used as an interlock indicating whether or not the operation step is activated in the operation control in the PLC 1 described above. In particular, the determination result of [NG] is used as an interlock for abnormal operation stop.

  As described above, in the present system, the operation condition necessary for batch process control of the production facility is separated from the operation control software of the production facility executed by the operation control unit (control ladder) 3 in the PLC 1. (Operating condition management means) 10 is managed, and the batch information control of the production equipment is executed by linking the management information to the operation control software. Therefore, various operation conditions (interlock conditions, etc.) necessary for the operation of the production facility can be managed accurately for each operation mode and operation step independently of the operation control software. In addition, since various operating conditions necessary for the operation of production facilities are managed for each hierarchical level, the operating conditions are changed between upper and lower levels and further to other operating modes and steps. Even if it is complicated and complicated, the operating conditions can be accurately grasped for each operation step.

  Therefore, not only when switching the operation mode of the production equipment, but also when the production equipment is expanded or remodeled, the operating conditions in each operation mode (operation step) can be easily associated with the new equipment configuration. And it can be set appropriately. In particular, it is possible to set the interlock conditions etc. by simply changing the items in the matrix table described above and entering the operating conditions in the corresponding items, so the ladder software that manages batch process control regardless of the operating conditions Effects such as being able to be easily created are produced.

  In particular, according to the above-described embodiment, for example, selection of a production type is set as an operation condition in the upper layer, and it is possible to set a mutual interlock indicating whether operation is possible between production facility blocks in the lower layer. In addition, the mutual interlock between the manufacturing operation and the cleaning operation can be easily set. Furthermore, it is possible to easily monitor the progress conditions of the operation steps located in the lower layer of the production equipment block and the conditions at the time of batch switching, and easily monitor the operating conditions of the field equipment and the line conditions of the pipelines. There are advantages such as being able to be performed. As a result, comprehensively, it is possible to monitor conditions for ensuring product safety in various manufacturing facilities without any omission of monitoring and without fail, and there is a great practical effect. It is made.

  In addition, this invention is not limited to embodiment mentioned above. Here, the control process has a three-layer structure and its operating conditions are managed. However, depending on the specifications of the production equipment, it is of course possible to manage the conditions by further multilayering. Further, the present invention is not limited to food production facilities but can be similarly applied to batch production control of other production facilities. The matrix table may be prepared according to the operation mode and the like, and the present invention can be implemented with various modifications without departing from the gist of the present invention.

The figure which shows schematic structure of the program creation system which concerns on one Embodiment of this invention. The figure which shows the example of the management structure which hierarchized the operating condition required for batch process control. The figure which shows the example of the matrix table | surface for defining the interlock condition between several operation modes. The figure which shows the example of the judgment result of the interlock condition calculated | required from the matrix table | surface shown in FIG. The figure which shows the example of the matrix table | surface for defining the interlock condition between several driving | running steps required for implementation of driving | running mode. The figure which shows the example of the judgment result of the interlock condition calculated | required from the matrix table | surface shown in FIG. The figure which shows the example of the driving | operation procedure of the sterilizer driving | operation realized by linking interlock conditions and ladder software. The figure which shows the structural example of production equipment (food manufacturing equipment). The figure which shows the example of the matrix table for defining the operation state of the installation apparatus required in order to perform an operation step. The figure which shows the example of the judgment result of the interlock condition calculated | required from the matrix table | surface shown in FIG.

Explanation of symbols

1 PLC (Programmable Logic Controller)
2 Control Device 3 Operation Control Unit 4 Power Circuit 5 Air Circuit 6 Control Circuit 7 Power Equipment (Motor)
8 Valve 9 Other equipment 10 Operating condition management unit (Operating condition management means)
S Ladder software T Interlock condition / Operating condition X Mutual interlock condition Y Operating step transition condition Z Operating line condition

Claims (5)

A program creation system used to build ladder software that controls the operation of production equipment by a batch process,
Independent of the operation control software of the production facility, the operation conditions necessary for batch process control of the production facility are divided into control blocks for each level in which the operation control is hierarchized. It is managed using a management table that describes the operating conditions between control blocks, and for each control block, the operation state of other control blocks in the same hierarchy and the operating conditions indicated in the management table are collated , programming system, characterized in that whether the operation execution determination result obtained by each determination, providing the operating condition management means for linking to the operation control software of the equipment to build the production facilities. The operating condition management means includes
The mutual interlock conditions between a plurality of operation modes in the production facility are respectively managed, and whether or not each of the operation modes can be executed is determined from the mutual interlock condition of each operation mode and the operation state signal of another operation mode. A first function to
While managing the operation conditions of a plurality of operation steps that respectively execute the respective operation modes and the step transition interlock conditions between these operation steps, each obtained from the step transition interlock conditions and the operation control software A second function for determining whether or not to execute the operation of each operation step from the operation state signal of the operation step;
While managing the interlock condition of each operation step, the operation condition of each step is normal or abnormal from the interlock condition of each operation step and the operation state signal of each facility device obtained from the operation control software. The program creation system according to claim 1, further comprising a third function for determining whether or not.   The first function is to manage mutual interlocking conditions between a plurality of operation modes by entering each of the operation availability conditions in a matrix table in which a plurality of operation modes are arranged vertically and horizontally. 2. The program creation system according to 2.   3. The program creation according to claim 2, wherein the second function is to enter operation permission conditions in a matrix table in which a plurality of operation steps are arranged vertically and horizontally to manage the operation conditions of each operation step. system.   The third function is to enter the operation state of the facility device in a matrix table in which the interlock conditions of the facility device constructing the production facility are arranged for each of a plurality of operation steps, and The program creation system according to claim 2, wherein the establishment is determined.

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