DE19533787A1 - Method of indicating operating state and/or information about steps for starting up or restarting a technical system which performs a stepwise process - Google Patents

Abstract

The method involves displaying a guide for manual fault diagnosis for detecting the cause of a stoppage of a process not monitored wrt. a defined duration. A commentary about the associated measures is also displayed. For a process step which is monitored wrt. a defined elapsed time, when a stoppage occurs a message is displayed contg. the faulty transition conditions and information about their cause or the location of their origin.

Description

The invention relates to a method for displaying the loading drive status and / or information on measures to be taken start up or restart a technical system, the to carry out an automatically controlled by sequencers Process is determined.

Automatically controlled systems are usually included Control panels equipped with the help of the system operator on the one hand starts automatic mode (preselect operating mode, start, etc.), on the other hand in manual mode (from the automatic sequence deviating) executes control commands if this is for maintenance or Troubleshooting is required.

Due to malfunctions, but generally after interventions in the hand driven, a system can be adjusted so that the continuation of the car matics operation is blocked. It is then depending on the size and complexity the plant difficult for the worker or maintenance worker, through correct Sequence of operation of the hand buttons returns to the correct state to manufacture.

Some car manufacturers adopted the principle of very early on Sequence control applied in contactor or relay technology. On the The status of the sequencers also became control and hand panels how the signal status of all inputs and outputs of the control is displayed. By labeling, color coding and arrangement of the Operating and display elements were the functional assignment (key - Output - feedback) recognizable. Sequencer and standardized Control panels were important aids for troubleshooting.  

With the introduction of semiconductor technology, the so-called Function block was created. Recurring logical functions were summarized on a plug-in card. Due to the predefined structure of the sequencer and action modules not just programming, but also reading and understanding the circuit diagrams (programming tables) easier. With the help of Programming tables that were attached to the control panel, missing switching conditions or locking conditions quickly recognized. In the event of a malfunction, the maintenance engineer only needed towards signal tracking and troubleshooting in the system focus.

The transfer of the sequence control to the PLC has one Function blocks improved in so far as the number of Inputs (linkage / linkage depth) no longer by the number the plug contacts of the modules were limited.

The logical links of the sequencer and Action modules became more versatile despite the given logic structure usable, sequence controls are e.g. B. from DE 41 34 811 A1 known. Together with the PLC, conventional ones became over time Control elements and signal lamps by means of alphanumeric displays or Display devices replaced.

The disadvantage here is that a control panel, due to the be limited screen size, can only be displayed in sections, the system status or a hand table is no longer at a glance visible. The operator of a system must choose the desired or for Troubleshooting necessary hand buttons with status displays switch. Finding the desired hand buttons is time consuming and also requires a good knowledge of the system. If several Manual functions are carried out, the overview is lost. It is then, especially with complex systems difficult to restore the condition establish the necessary to continue the automatic operation is.

Sequences, the smallest unit of which is the step, are in the DE 41 34 811 A1 described in detail. You work in automatic mode without  manual intervention only depending on the transition conditions, while in jog mode the transition to a subsequent step only is carried out if an additional tap key is pressed. By this stopping after each step makes it possible to quasi in the process Watch slow motion.

The control commands of the sequencers are from downstream actions building blocks. The interfaces for this signal exchange are formed by step markers.

In manual mode, the actions can also deviate from that by Sequences of the specified sequence are triggered. Of the Steps in a sequencer or triggered by a hand tableau Control signals are only executed by the action modules if the programmed locking conditions are met and others Operational releases (e.g. automatic mode) are available.

The actions triggered by the action modules are made by Akto ren, e.g. B. valves, motor contactors, actuators, etc., executed and by Sen sensors (limit switches, light barriers, proximity initiators) upon termination tion for monitoring and as input signals to sequencers reported back. An action error caused by a missing transition condition is determined, may indicate a missing locking signal or due to an error behind the action module.

The interaction of a controller with a subordinate system, e.g. B. a screwdriver or robot, or with another Control unit is based on the same principle: The execution one generated by a step chain using an action module Control command is checked by the device controlled on and on the step chain is reported back for monitoring.

Higher-order action blocks can also be included in the sequencers be the z. B. refer to positioning, rules, etc. Such Function blocks are added with parameters (target position, Speed, setpoint, etc.) with an action. The supervisor carried function module reports the order acceptance to the sequencer back.  

This acknowledgment ensures that the person commissioned Function module has understood the order and is executing it.

The control sequence is dependent on operating conditions (protective grille, Operating mode, start, workpiece feed and removal etc.) dependent. The step chains are preferably designed such that not only the controlled actions but also the operating conditions (Process requirements) are monitored.

Monitoring the process requirements and the The control process takes place with the help of transition links. On There is an error if a sequencer is missing due to missing Transition conditions is stopped and not to the subsequent step can pass over. The link conditions of the transitions and Actions are designed so that they all control and Can cope with regulatory tasks. Preferably be combinatorial bit processing (AND, OR, NEGATION, Comparison functions). It can also make sense to have one Sequence chain or an action block a link block upstream.

In this known method, instead of signal lamps Alphanumeric display screen for status display used. Even conventional controls can be used on one Display device can be displayed. But this is the disadvantage mentioned above connected that a control panel shown only in sections can be lengthy, which makes finding a source of error lengthy or becomes time consuming. It is therefore cumbersome to continue the automatic operation of a system to restore.

This is where the invention comes in. The invention is based on the problem to develop a procedure with which a automatic, step-by-step technical process from one the process controlling or regulating device the operating state recorded and information about this operating state is generated, that appear on a screen in a form that is one enable quick detection of the operating status and simple and  clear, easy-to-understand instructions on how to use Recommissioning necessary measures or finding the restarting conditions preventing the process include the executing facility.

The problem is solved in a method of the type described at the beginning Genus according to the invention solved in that at a standstill any step in a process chain that is not be is monitored for a predetermined runtime on a display an indication of an error to be initiated manually using a panel diagnosis to identify the cause of the standstill and a comment is displayed for the related measures, and that if the process comes to a standstill because of exceeding based on a runtime specified for a step, in the same way as with a fault diagnosis initiated manually via the panel a message is generated on the display indicating the missing or missing Transition conditions and information about the manufacture or the Finding the causes of the missing or missing transition area contains conditions.

When the process stops, the operator recognizes Screen the cause of the standstill. The cause is not a malfunction but the z. B. manual adjustment of an organ, for. B. of a protective grille in a certain position, then the Organ setting displayed on the screen. The The operator can then make the adjustment of the organ or arrange for the institution to carry out its duties or Continuation of the process holds necessary attitude. Will the process due to one or more missing transition conditions of a Steps in a sequencer stopped, then on the screen the respectively missing transition condition is displayed and at the same time specified which measures to meet the transition conditions must be made, d. H. it will come with appropriate Indicate the hand button specified that must be pressed in order for a Responds to the actuator, by whose response the missing condition of the Step is generated. The operator can then easily press the hand button. If this causes the action, i. H. the transition condition necessary for the progress of the process  Sequence chain generated, then an indication of the missing condition displayed with an appropriate plain text. However, the action not executed, the screen of the faulty actuator shows Details on the location and location of supply lines to the actuator on. The cabling can then be carried out in the technical system Actuator and the actuator itself are checked. In this way systematically and thus time-saving the errors in the cable routing or in the actuator itself.

With the method described above, any interruption of the Process and the reason for the standstill are automatically recorded and displayed. Furthermore, the faulty elements and the necessary measures for troubleshooting in the correct Order shown.

In a preferred embodiment, each step is one Sequence a step comment assigned to the current state of the step, the transition links and that of the step actions to be performed, with the comment for a missing transition link and / or retrieval from a memory appears on the screen. Based on the comment that is Operators able to determine the fault or Perform actions that narrow the error, causing a systematic search for the error is possible. With this procedure the time required to locate an error can be reduced ren. At a standstill due to one or more transition areas conditions is in particular a message with an ordered Comment sent to a central monitoring position.

The smallest unit in the sequencer is the step. Every step a comment is preferably assigned, just like the actions and transitions is part of the user program.

The comment particularly describes the current state of a Sequence of steps, which actions the step carries out and which Conditions are checked with the transition. An active set Step can add the comment to your screen or display Display and / or transfer to a management level.  

With the help of this display, the system operator is informed about the System status is informed, but it can also with the help of this text be prompted for an action, which in turn is off the chain is monitored.

Completing step d. H. the transition to a subsequent step is from the processing release, waiting time release and the actual Transition link dependent. The sequencer display on the dis play or screen consists of several arranged in a row Fields in which the number (name) of the chain, the step set, the current operating mode, the remaining monitoring time and in Depending on certain criteria, the step comment is also shown be shown.

The operating mode mentioned above corresponds to Processing release, which is explained in more detail below. Is at the step-by-step mode is preselected or goes one Simultaneous chain in a simultaneous step, so the processing of the Transition locked. In the case of a simultaneous step, the lock is released a step action of another chain canceled, in the typing operation the operator press a tip button. The locked state will preferably together with the other operating states of the Step chain displayed.

In the locked state, it is also displayed whether the lock automatically, i.e. from another sequencer, or by the operator can be canceled by pressing the tip button.

Each step can also be parameterized with a monitoring time will. After this time, counting from the entry into the crotch, the diagnosis becomes active.

In special cases it may be necessary for technological reasons be that an action only after a waiting period that is related to a preceding action, may be carried out. A Waiting time is generated by inserting a step as a waiting step is marked. The monitoring time is also called Delay time used by the transition only after the  Time can be edited. As long as the waiting time runs through Remaining time can be seen that the transition has not yet been processed becomes.

Is a chain released for processing and there is no waiting time instructed or this expired, then the Transition linkage of the step set Stepping conditions checked. If the conditions are met, then the step advanced (transition). A step without Transition link is advanced unconditionally. Will one Transition not carried out due to a missing condition, see above there may be an error. The transition link is on the one hand for the progression and on the other hand for error detection responsible. Is a step with a monitoring time or Waiting time parameterized and if this time has expired, it will automatically made an error processing. If there is no transition afterwards, then an error flag is set, which in turn controls processes can be triggered. Furthermore, all inputs of the Transition linkage, the signal state of which prevents the transition, labeled according to the combinatorial processing.

According to this method, an OR function, if only one condition is met, all other conditions are independent of Signal status not recognized as faulty. Along with the current one Time, the complete link with identification of the missing inputs for display on a display device in a Error memory entered. With the next transition is through Entry of the current time the error is logged off and the Error flag is reset. The error processing of a chain can can also be triggered manually, but in the case of a Error message the error flag is not set.

The sequencer can not only generate error messages, it is also able to provide information by transmitting the step comments to send external facilities. The step comment can be a encoded message included, decrypted by the recipient and processed or displayed as plain text.  

In this way, a control station can Production data and others for plant monitoring required data to be informed. With the plain text output it is u. a. possible to call a maintenance engineer from a control center (e.g. with the text display "electrode change in station X necessary"). At The receiving office sends messages that require acknowledgment Signal back, which is checked by the transition link.

A step then triggers such a message if it is specified a receiving address has been instructed to do so and if the Editing the transition link has no effect. A downstream communication module then transmits the number of the sending step and the associated comment to the Receiver. The transfer also takes place with multiple processing the transition link only once until the execution of the Transition. Then, together with the old step number, the Unsubscribe the old message to the same recipient. After advancement, subsequent steps of the same chain Send messages.

After a transition, further step actions become automatic carried out. The edit release is updated that Monitoring or waiting time is started and the step flag is set to the new step number.

A step can also perform arithmetic operations, data transport (sliding, filling register), counting, etc., if he has a has received appropriate instructions. Controlling, monitoring and displaying with step chains saves cycle time because only the set step of a chain is processed (if approval exists) and the step actions are performed only once per step.

The action modules that follow the sequencer are used by everyone Cycle edited because it is also independent of the status of the controlling Chain must react spontaneously when z. B. a manual control is made and / or a locking condition changes.  

The respective action module does, like that Transition linkage, a combinatorial processing of Input variables. Input variables are read in by the control Signals (e.g. sensors) and block outputs (e.g. steps). As The comparison result of two quantities can also apply to the input quantity (bit or word processing).

Just like the sequencer in its structure from the control system or Automation device is specified, so is the structure of the Transition link and the action module specified. Control sequence, locking and monitoring functions are determined by parameterizing the specified blocks. The combinatorial processing of the input signals takes place for all Building blocks according to the same scheme and is so universally applicable that pre-linking is only necessary in very rare cases. The link consists of a variable number of Input elements that have a variable number of input signals can link. The function (AND / OR) of the input elements and their combinatorial connection is defined uniformly. The Input elements are added according to their function Identification letters marked.

With action modules of the type described above is also like sequencers, it is advisable to manually diagnose errors triggered. After editing an action block, it becomes the output is not set, then before it is reset, the Error processing in the same way as with the transition link performed. Immediate processing ensures that no Input signal can have a different state.

In a preferred embodiment of the invention, a detected errors checked whether only one input condition or meh Other entry conditions are missing. The error is missing on several Conditions, it is shown how these together are linked. Missing AND conditions must, albeit in belie biger order, all are searched. In the absence of OR conditions can be selected which of these ge to eliminate the error should be searched.  

For each missing condition, it is checked and displayed whether it can be produced by pressing a hand button.

If a missing condition is triggered by actuating an actuator in the Manual mode can be triggered after the activation of the Action module checked whether a corresponding sensor the end of Action indicates. If this is not the case, it is indicated that a Locking diagnosis can be triggered manually.

In particular, the control signals sent to block outputs and Control inputs occur, symbolic names with comments assigned, which are contained in a separate comment field. This Comment field shows information about the cable routing or the Installation path from or to the respective actuator or sensor. On the basis of such documentation, a necessary tracking or checking of lines for the purpose the detection of short circuits, earth faults or interruptions be carried out to the connected component, z. B. Bus errors, wire breaks, power failure, etc. relatively easy can be located.

Preferably the symbolic name and comment are for one Action module and the connected actuator are identical.

Each signal preferably receives in addition to the comment an assignment note for troubleshooting is used. When creating the user program automatically the comment "input" or "output" or "B-field x, y" (Hand table) entered. Will in the transition or Action diagnosis shows a signal as faulty, so the Maintenance personnel, whether he can correct the fault using the installation comment in the periphery must search (input) or whether the error in the upstream module is to be sought (output) or whether it is better as mentioned before, the hand panel for further troubleshooting or - used elimination.

A hand panel consists of several fields, which are used as a drive smallest functional unit is assigned to a system. A drive can  one or more actuators (forward, backward movement, Overdrive).

All hand buttons belonging to the drive are in a control panel (forwards, backwards), action modules (actuators) and all of the actuators triggered signals shown. Through suitable construction and labeling device (comment) and the status display, the operator can enter the Detect proper function or malfunctions of a drive. In one Display panel can also display signals from the hand buttons (or actuators) cannot be influenced. A corresponding Labeling is therefore advisable. Each signal can in meh other fields are displayed, but only to one field or drive be ordered. The display fields or assigned drives are numbered. The assigned signals become the assignment note the field number attached. Becomes one due to a manual key command triggered action not executed correctly or does not take place correctly Feedback of all involved sensors, there is an error in the Peri pherie before, with the help of the signal comments of the outputs and inputs can be found. An action block refuses a hand button command, one or more input conditions are missing. With ent speaking instruction is activated after pressing a hand button assigned action module diagnosed.

If a signal with such an assignment ratio is considered faulty recognized, the assigned field is displayed in the hand panel or featured. Furthermore, the target state of the faulty signal is displayed so that the operator knows the position of the drive should ask.

The invention is described below with reference to a drawing illustrated embodiment described in detail, from which further details, features and advantages result.

Show it:

Fig. 1 is a block diagram of a basic structure of a clock or sequence control;

Fig. 2 is a diagram of a step of a step chain;

FIG. 3 shows a link of a transition or action of a flow controller;

Fig. 4 is an overview diagram of a sequence control;

Fig. 5a-g a format shown on a screen with information on a step of a step chain;

Fig. 6 is a hand panel of a sequence control;

Fig. 7 is a flow chart showing the steps of detection and localization or elimination in an error;

Fig. 8a is a format of a fault indication;

FIG. 8b shows a format of another fault indicator;

FIG. 8c a link device schematically;

Fig. 9 shows a gripper schematically and

Fig. 10 is a flow chart for a by the gripper. Fig. 9 ge controlled process.

A sequence controller 1 shown in Fig. 1 includes sequencers 2, manual buttons in a process described in more detail below Hand panel 3, Action Blocks 4, optionally action blocks 5 higher order and optionally Vorverknüpfungsbausteine. 6 These blocks can belong to a programmable logic controller. The action modules 4 output signals to actuators 8 , which are located in a technical system with which a process is carried out. The actuators 8 or organs of the process actuated by them act on sensors 9 , of which others can also be provided for monitoring physical variables of the process such as pressure, temperature, current, voltage, etc. The sensors 9 can also detect process requirements 13 . Each input signal is either a reaction to a command (output) from the same controller, or it is generally assigned here to the process requirements. The sensors 9 , which also include switches, are connected to the sequence controller 1 and act, possibly also via pre-links 6 , on the transition links of the sequencers and the interlocking link of the action modules.

If necessary, the step chains 2 can act on higher-order action modules 5 by placing orders with them. The action blocks 5 of higher order return order confirmations to the sequencers 2 .

In Fig. 2, a step 10 with associated transition 11 of a step chain is shown in flow chart form. This step 10 is assigned a comment 7 , which indicates in plain text the function or effect of the step. The step comment can be on a display, e.g. B. Mo nitor, displayed and transferred to a control level, which if just has a display for display.

Due to the given structure, a step automatically carries out certain actions. This includes updating the status display, deregistering an error that may have been reported by the previous step, the error message if a monitoring time has expired, etc. In addition, arithmetic functions can be carried out based on an instruction in the user program and it is possible to order a higher-order action block, that can generate an acknowledgment. With the help of the step marker, step 10 can trigger further actions via action blocks (not shown), the implementation of which is checked by the transition link. The transition 11 takes place when the processing is released and when the waiting time has expired with a corresponding instruction and when the conditions checked by the transition link are fulfilled.

In Fig. 3 a standardized signal connection 12 is shown for transitions and actions. It consists of several AND and OR gates that process a series of input signals. The arrangement of these functional elements and their connection by downstream functional elements is predetermined by the system. The result of the link causes a transition or the control of an actuator. In the function block 12 shown, the number of input elements and their inputs and thus also the depth of linkage are variable. This standard module can be used to implement simple AND and OR functions as well as extensive combinatorial operations.

The input elements are connected in accordance with the Link marked with letters, and, provided that they are repeat, add a sequential number. The building block consists of at least one input element, starting with "UO.0" or "S". The following links can only be created if that previous one exists. An input link is considered to be present, if it links one or more input signals. With the help of Lettering, it is possible to tabulate the block, d. H. without graphics.

The code letters mean:

UO.0 to UO.n - U ND before O DER,
S - step control (OR),
A - automatic releases (AND),
H - hand keys & enable (AND), (S, A and H = control logic)
VU - locking AND,
VO - interlocking OR,
VUO.0 - VUO.n - locking AND before OR.

The function block 12 is preferably designed for the following applications:
In the case of an action block, control commands are processed with S, A and H, but these are only executed if the locking conditions checked by VU, VO and VUO.0 to VUO.n are fulfilled. If an actuator has no memory behavior, a latching (memory) circuit can be implemented with UO.0 to UO.n. FIG. 8c shows a typical action block. The use of UO.0 (AND) is usually sufficient as a transition link.

FIG. 4 schematically shows sequencers 14 , the status of each of which is entered in memory 17 . The contents of these memories 17 can be shown on a display 18 . A certain step chain 14 or its memory content 17 can be permanently assigned to the display 18 . (Several chains can also be assigned to corresponding display fields of a display device.) Chains that are not automatically displayed in this way can be called up for display (and also operation) by means of the control panel 16 .

Furthermore, an error memory 19 is present, in which, in the event of an error, information about the step within the sequencer is entered which are affected by the error. It is the missing transition condition. The step chains 14 solve z. B. the actions 20 from. In the event of an error, the actions 20 also transmit corresponding information to the error memory 19 . Information from the step chains 14 also reaches the message buffer 23 , from which they are transmitted to control centers 25 .

FIGS. 5a to 5g show how the chain 17 status on display 18 (or a display device) is represented alphanumerically. According to the invention, the step chain displays all the information that is important for the operator of the controlled system, while unimportant operating states remain hidden to avoid irritation. The reason for a standstill is displayed. A request for an intervention is clearly signaled by inverse (or colored) spelling.

The display format is divided into fields in which the following information is transmitted by the sequencer:
Field 26 specifies the number of the displayed sequencer and field 27 the respective step set. (Chain K11 corresponds to the application example Fig. 9). Field 28 signals the operating mode that influences the transition. If nothing appears in this field, processing and thus the automatic sequence of the sequencer is released. An entry indicates the conditions under which the current lock can be released. The inverse "jog" prompts you to press the jog key or to change the operating mode. The "Jog", "Jog mode off" and "Jog mode on" buttons are available on the control panel for this purpose. Each time the jog key is pressed, the transition processing is carried out once under the same conditions as in automatic mode.

The display "Simult" in Fig. 5g means that this is a Si multankette, which is waiting for an initiation from another chain or another step. Manual intervention is not necessary (therefore normal writing). After a trigger from another sequencer (simultaneous branching), the displayed sequencer returns to the operating mode that it had before the simultaneous step until it changes again to a simultaneous step. Field 29 shows how long the displayed step waits until it carries out the diagnosis. No display means that the step just taken does not carry out runtime monitoring and therefore no automatic diagnosis ( FIGS. 5d to 5g). In Fig. 5b it is shown that the time has expired (0 sec.) And the transition processing is waiting for the typing. Fig. 5c shows that a fault message was entered in the fault memory 19 before the specified time. The inverse notation prompts you to eliminate errors determined by the sequencer using the diagnostic method. Field 30 is reserved for the step comment that describes the function of the assigned step (actions, transition condition). A step can also issue control commands with the comment. Such a request to act is written inversely based on an instruction in the user program.

In Fig. 5e, as the operator is prompted to start the plant in this manner is shown. Steps in which runtime monitoring is active suppress the comment display and thus signal a perfect operating state. Steps without runtime monitoring indicate their comment ( Fig. 5d to 5f). This ensures that a standstill is signaled in any case, either with a time delay or immediately. In jog mode ( Fig. 5b), the step comment is displayed, because one deliberately wants to observe each step in the delayed sequence. If a step has already made a fault message ( Fig. 5c) or if a chain is on a simultaneous step ( Fig. 5g), the comment is displayed, just like in jog mode, because the automatic sequence of the chain is interrupted. With a corresponding instruction in the user program, the step comment can also be displayed without restriction, but this is only useful in special cases. The comment "M3" in the comment field indicates that the step comment is transmitted to the control center, which is connected to the message buffer 23 . In this case, the man at the facility is informed that a higher-level body is requested to act. Is the Anla gene operator z. B. due to an installation or project planning error not able to get the system up and running, he can trigger the transition diagnosis with the diagnostic button on the control panel.

After that, the troubleshooting is done in the same way as for the auto matically executed fault message.

Fig. 6 shows the handheld panel 3 shown on a screen for the sequence control. The panel divided into fields can be constructed with a screen as well as with conventional display and operating elements plus an alphanumeric display for fault notifications. The variant described here relates to a screen to which two hand keys arranged in the control panel 16 are assigned, which act on the respectively active or displayed field.

Each actuator or smallest functional unit (drive, valve) is a field with a running number 31, z. B. 15, 16, 17, is assigned. Use the cursor keys (up, down) to switch to the preceding or following field. You can also switch directly to any field by entering the count number. A field can be opened automatically due to an error. In this case, a line 40 is provided for the display of the disturbed step or the disturbed action block.

Likewise, the faulty signal of the faulty block, on the basis of which assignment the control panel was opened, is shown in this line, indicating the target state (1 = inverse, 0 = normal spelling). The displayed target state indicates which position the drive should be set. The function of the hand keys or actuators is indicated in line 41 , for example in FIG. 6 it is stated that the “lifting device station 4” can be controlled with the left key “up” and with the right key “down”. In field 42 , all signal states belonging to a functional unit are displayed by normal or inverse spelling of the symbol name. 4HT1V and 4HT1R represent the hand buttons; 4K1V, 4K1R, 4K1S, 4K1L are the motor contactors and 4S1V, 4S1RV, 4S1VR and 4S1R are the position reports of the drive. All signals can be influenced in manual mode, except 4S1S, which is therefore marked with an *. 4S1S reports e.g. B. a closed protective grille and is one of the process requirements.

In Fig. 6, a pointer (arrow) 43 is shown, which can be set with any cursor key (not shown) (left, right) to any signal address in the field 42 .

With a comment retrieval key, not shown, the comment on the signal selected with the cursor 43 can be fetched into a field 44 or displayed there. This comment not only describes the function of the actuator or sensor, but also contains all installation data up to the connected device.

If the cursor 43 is on an actuator, the error processing is triggered by the actuation of the assigned hand key or an error key in the assigned action module, which is written and displayed in the error memory in the same way as in the transition diagnosis.

If the manual keypad was automatically switched to on the basis of a fault message, you can leave the hand panel again with a "back" key and switch back to the faulty module shown in line 40 .

In Fig. 7, the process steps for error detection and diagnosis are shown in the flowchart. The method begins with operation 21 , in which it is checked whether a stopped step is equipped with a time monitor. Steps that do not perform automatic diagnostics automatically display the step comment in accordance with process 22 and thus transfer responsibility for rectifying the standstill to the system operator. (The possibility of transferring the step comment to a control center is not shown in FIG. 7). If the system operator has carried out the instruction given with the step comment or if other process requirements expected by the step have been fulfilled, error processing is ended in accordance with process 24 and because of the transition and the associated termination of the comment display. Can the plant operator not fix the standstill or not recognize the reason for the standstill, because e.g. If, for example, a sensor signal does not arrive in the control, it triggers the diagnosis in the step displayed according to operation 33 with a button. The actual troubleshooting begins with the subsequent process 45 .

If it is determined in process 21 that the set step is being monitored, then process 32 follows, which checks the running time of the step. If the permissible step duration has not yet been reached, error processing is aborted; however, if it is exceeded, the transaction diagnosis is triggered and troubleshooting is initiated with process 45 . Process 45 displays the missing transaction conditions stored in the fault memory, including all information that the operator needs for test processes 46 and 48 , on the display. If he determines in operation 46 that only one condition is missing, he continues the troubleshooting with operation 47 . If several conditions are missing, he then checks in the subsequent process 48 how these signals are linked to one another. In the case of an AND operation, he can arbitrarily decide in the subsequent process 49 which missing input signal he wants to start troubleshooting from process 47 . With an OR link, he must decide in process 50 which missing condition he wants to look for. In operation 49 or 50 , the system operator can use a key to select the missing input signal that he wants to search for from operation 47 .

In process 47 , the operator is informed with the aid of an automatically generated display whether the faulty signal in manual operation can be corrected from process 52 or whether it must be tracked to the source in process 51 exclusively with the aid of the signal comment. The displayed comment contains all the information needed to find the error.

This information includes information about terminals, the location of the connection terminals and the laying of cables from the input of the Automation device associated with the signal to the source, at which the signal is generated. This information sets the Plant operator, the source of the error, e.g. B. the short circuit or line break to locate in the course of the line.  

If the signal error has been found and corrected, process 51 proceeds to process 55 , in which further missing conditions are asked for.

If the missing condition can be reached by an action that can be initiated by hand key actuation, then a corresponding control panel is displayed in a process 52 following the process 47 . The operator of the system can press the identified hand button, which triggers an action module.

With the status display of all signals belonging to the drive in the hand panel, the operator checks in operation 53 whether the action is being carried out. If this is the case, he checks in the same way in operation 54 whether the actuating actuator generates the sensor signal that was previously missing. If the reaction to the action triggered by the hand key is OK, further errors are searched for with the transition to operation 55 . If the reaction is not correct, either the motor is not working properly or the feedback from the sensors is incorrect. In process 56 , the circled error is searched for with the aid of the signal comments up to the actuator or possibly sensor. After the error has been rectified, operation 55 continues.

If the operator determines in operation 53 that the action block being controlled does not carry out the action, he triggers operation 57 in the subsequent operation, in which the locking diagnosis is triggered. The locking diagnosis works on the same principle as the transition diagnosis. The missing input conditions of the checked action module, which prevent the action, are registered in the error memory and displayed in the subsequent process 45 . The subsequent troubleshooting is carried out according to the same scheme as before for the step chain.

If a signal error has been found and corrected in processes 51 , 54 or 56 , it is checked in the following process 55 whether further conditions are missing. If the step that triggered the diagnosis has carried out a transition, the operator is informed on the display about the end of the error and the troubleshooting is thus ended. Otherwise, it goes from process 55 to process 46 to search for the next signal errors that are still pending.

Fig. 8 shows a fault display that has been called from a fault memory. In a first line 59 , a counter number 60 , e.g. B. 3, which corresponds to the chronological sequence of the error entry, and the number of entries 61 , z. B. 5, and the time of the beginning 62 , z. B. 5:30 p.m. and end 63 , e.g. B. 5.41 p.m., the fault is shown. The displayed fault entry can be logged and then deleted automatically or manually.

In a second line 64 , the disturbed step is displayed with one of possibly several missing input signals and further information that support troubleshooting.

In column 65 the block address (name), for example. B. "chain 7 S 5" (S = step) and in column 66 the associated step comment, z. B. "Close tensioner" shown. Furthermore, in a column 67, the input member, the z. B. has the designation E: UO.0, with the faulty input signal, z. B. 154 V1 shown in column 68 . (With the help of cursor keys, all faulty input signals can be called up in succession.) The number of faulty input signals is displayed in a column 69 . (For example, 2 F means that two input signals are faulty.) The target state of an input signal is represented with normal or inverse notation. If the displayed signal of a disturbed action assigned in the hand panel, then in the column 70, for the appropriate control panel number. B. B field: 13, shown.

Below line 64 , the complete comment of the signal displayed in field 68 is shown in a field 71 . In a field 72 , the current state of the disturbed signal is also indicated by inverse notation for logic "1" or normal font for logic "0". Furthermore, the signal comment in field 74 , e.g. B. clamp is closed, and for the installation, by means of the set in the field 73 Darge signal memory address. B. 5E23, up to the actuator or sensor including location information. For example, in Fig. 8a this information is "distributor 14 , E-module type 1, addr. 13, terminal 1, station 1 on the right". With the help of this system documentation, the fault in the system can be circled or tracked down.

If the comment "Input" is in field 70 , troubleshooting is only possible with the aid of this automatically displayed signal comment. The error is deemed to have been eliminated if the current signal state (field 72 ) corresponds to the target state (field 68 ).

If, however, the displayed faulty signal is marked in field 70 as "output" (action, pre-link), the upstream block executes the error processing after pressing a trigger button and the missing conditions are displayed in the same way as for a faulty step.

If the disrupted signal shown, as shown in FIG. 8, is assigned to a control panel and the displayed signal comment is not sufficient for troubleshooting, the assigned control panel is also switched on for further troubleshooting with the trigger button. In manual operation, as shown in FIG. 8, the troubleshooting is expanded to the action level assigned to the disturbed signal. If an error is found and then rectified, the control panel is removed with the "Back" button and the previously displayed faulty block is removed as that.

FIG. 8b shows the manually triggered alarm message of a Aktionsbau steins and a preceding logic operation. The block or actuator name is displayed in field 75 and the comment in field 76 . The display of the disturbed input signals, as well as the troubleshooting and elimination takes place according to the same scheme as described in Fig. 8.

FIG. 8c shows the complete action module from FIG. Sb. According to the display in FIG. 8c, the sensor signal 1S3 is missing on the input element VU to control the actuator 1Y4V (close tensioner). Since only one error is entered, the signal states of the other block inputs are irrelevant for troubleshooting.

In Fig. 9, an insert 82 is shown schematically, which fetches components 83 from a stack and inserts them individually into a station 84 of a production line.

The components gripped by the gripper (hand) are moved by two further drives along the linear path sections designated 86 , 87 , 88 in FIG. 9, of which 86 , 87 are perpendicular. The actuators and sensors belonging to the insert 82 are shown in the following operating panel. The structure of the control panel is written in Fig. 6 be.

The insert that belongs to station 1 of a production line is controlled and monitored by the sequencer shown in FIG. 10. She has z. B. the designation "chain 11 " and consists of twelve steps, which are continuously designated with S0 to S11.

The function of the steps and thus also the way the insert works are described by the step comments in FIG. 10.

Steps S0, S2, S7 are waiting steps without time monitoring the step comments are shown on the assigned display shown. Before long operational breaks, where necessary Maintenance work is carried out, the chain at step S0 stopped. After such interventions, it often happens that drives no longer in their basic position, which corresponds to step S0 hen. That is why after a restart, and because this is not a post parts with each chain run, checked by step S1, whether the basic position is still available on all drives.  

If the chain stops at step S2 due to missing components, then the step comment is not only shown on the local display shows, but, according to the instruction "M3", also to the control center M3 transferred. In jog mode, the automatic The comment of each step is displayed.

An example of a malfunction caused by the Step S6 is reported. Assume that at step 56 the Monitoring time is exceeded.

Then the display shows:

This shows that the depositor is in his rear Position is (1S1R = "1") and that a second condition is missing.

After calling up the second error using the cursor key, that would be Show the following on the display:

The two missing signals 1S1R and 1S1V are AND conditions of the same input element E: UO.0 and both refer to the same field in the hand panel "B field: 4 ". By switching to manual mode, the assigned handheld panel section is shown instead of the signal comment, with the following on the display:

The system operator now tries to use the 1HT1V Step S6 to bring about required condition 1S1V and thereby on the status display that the desired action 1K1V is not off to be led. The operator then triggers the action diagnosis, in  which he brings the cursor to the 1K1V display and the handta again ste pressed. The following appears on the display:

It is indicated that action 1K1V cannot be executed because condition 1S2R is missing. By pressing the call button, the assigned panel section "B-field: 5 " appears on the display.

Since the missing end position 1S2R is not indicated here with the hand button either can be driven, the cursor is on the assigned action 1K2R set and the hand button pressed again. Then it shows Display the following:

The second action 1K2R lacks an input signal that has no assignment to the hand panel. Therefore, the signal com is for troubleshooting mentally sufficient. If the Sta If the 1SG1 does not appear, there is a sensor or installation error before, which can be found using the comment in the last line can. Once the error has been rectified, the status display changes as follows:

Since the last error in the chain has been eliminated, the Ab call button displays the last handheld panel. Appears on the display following display:

After pressing the HT2R manual button, the display on the changes Display as follows:

Since the condition for action 1K1V is now fulfilled, the Call button the previous tableau field, and it he the following display appears:

When the 1HT1V hand button is pressed, the insert is inserted into the position as shown in the sequencer becomes:

The end of the fault is documented with the entry of the time.

The goal of relieving the burden on the creator and operator with the help of the diagnosis, is achieved with the method described above. The advantages of Procedures are: low configuration effort, easy error detection maintenance and removal by workers, little knowledge required, low cycle load, low-cost visualization, low total costs.

The procedure replaces time-consuming diagnostic procedures that can be found in the Have not proven practice because of high costs and low benefits.  

The error detection process is based on sequencers, one universal instrument for all PLC tasks (control, monitoring, Show). It's just a locked command execution after switched.

The sequencer recognizes all types of errors, including missing ver locking (release) conditions that are in the action modules make it noticeable.

The starting point for troubleshooting is always that Step chain. If the missing transition condition is a signal from an action is influenced, must on the assigned hand tableau can be switched. By pressing the assigned hand button the missing transition condition can be generated if necessary. Will the Action is not carried out, so again the locking can be done manually diagnosis, which is referred to below as action diagnosis, is triggered the. A missing locking condition is treated the same way as a missing transition condition. With this procedure, egg Absolutely every operating and process error is eliminated with a minimum of effort can be felt.

The project engineer only has to assign all to one drive belonging signals (actuators, outputs, inputs, hand buttons) define and configure the sequencers so that the Transition linking not only all control processes, but all operating and process requirements are also monitored. The display a missing transition condition, the activation of the assigned hand buttons, action modules or pre-links, the Displaying the missing interlock (or switching condition) etc. takes over the system.

The process diagnosis determines all errors that lead to a plant standstill lead or prevent the start. She helps the system operator suitable display to remedy the error and / or the system (Process) to put in the state that is at the start or Continuation of the process flow is required.  

Every chain or action (every action module) of a PLC can be linked to one checked for transition or locking errors at a specific point in time will. Is that the action to be diagnosed? Link result equal to "0", so the error processing must immediately done, before the result in the latch is written (output reset). The same applies to the Step chain.

When processing errors, all inputs that identify the Prevent the output from setting or the chain from advancing. The Evaluation is stored in the error memory for display and other errors tracking stored. The logic structure with indicator is displayed of the relevant, unfulfilled inputs, or as described here ben, on demand only one unfulfilled entrance with Reference to the input element, from which also the logical processing processing is recognized.

In addition to this display, the as feh Follow clearly marked signals (on request also any signals) the additional information:

• - current signal state,
• - signal comment (symbol),
• - signal path to the source / destination,
• - connection addresses,
• - location information,
• - Assignment to the hand table (action), reference to previous linkage or assignment etc.

The diagnostic function determines why a transition or action is not is performed. No distinction is made between whether there is a missing one Condition, an interlock or other control signal the cause is. To determine the actual cause of the error (configuration, Operating errors, mechanical or electrical errors, etc.) and Troubleshooting, the information stored in the PLC displayed (user program and comments).  

Differentiate between the transition diagnosis and the locking diagnosis only by the different diagnostic trigger (the Error handling is the same in both cases).

The sequencer or step triggers its diagnosis with a time delay. The diagnosis of a step or an action can be made after selection (Selection) of the chain number or block number by pressing a key be triggered spontaneously.

One action (or more than one Actions) can be selected for a diagnosis.

After pressing the hand button, the activated action (s) triggered error processing. This The process (preselection and triggering) is repeatable.

All signals belonging to a drive are shown in the handheld panel displayed according to their assignment:

• - hand buttons,
• - directly / indirectly controlled actions (actuator),
• - Action confirmation (reaction, sensor).

The status display in the handheld panel shows the operator whether the handheld key command is carried out by the action module and whether the actuated actuator is working properly. If the command execution is not reported correctly, the signal comments ( Fig. 6, field 44 ) can be used to find the error that occurred on the route from the action module to the actuator, via the control device in the system and the sensors back to the control will. If an action module does not respond to the manual key command, the operator triggers the action diagnosis.

If an action from a step or another control signal is controlled and the output remains at "0", so it can does not have to be an error.

A so-called locking signal can be a deliberate shutdown bring about (e.g. when reaching the end position). The sequencer solves in principle an error message only if a locking error blocked the control process.  

Only with the help of the sequencers can a unique Locking diagnostics are triggered. A locking error always prevents an action from being carried out. This leaves the Response off and the transition diagnosis triggers an error message.

In the described method, the operator is informed of the transitions error led to the locking error, if such the Has caused standstill.

In the same way as with the automatic diagnosis can also an action diagnosis can be triggered in normal manual operation, as well like the transition diagnosis with displayed step chains.

The invention is based on the following principles:
When the process is started or the system is switched on, information about the process is always communicated, ie the system operator is always informed. With automatic monitoring of the process, the display preferably shows nothing or an indication of a trouble-free sequence on the display, while in the event of a standstill which is not being automatically monitored, the system operator is informed that no more is required for the continuation of the process sequence the controlling body but he or a higher-level body is decisive.

The process outputs the information that the plant operator at ei cause a fault or a fault in the process to the source of the fault The fault can therefore always be found. Either says the process of an error, or the operator determines that a standstill is assigned to an error. The ad contains information mations to determine the faulty signal and the faults circling the source and the measures to eliminate the error.

Claims (16)

1. A method for displaying the operating state and / or information about measures for starting up or restarting a technical system which is intended to carry out a process controlled by step chains, characterized in that
that during a standstill at any step of a step chain of the process, which is not monitored with regard to a predetermined runtime, on a display a reference to an error diagnosis to be initiated manually by means of a panel to identify the cause of the standstill and a comment for the related measures are displayed, and
that when the process comes to a standstill, which is based on exceeding a run time specified for a step, in the same way as in the case of an error diagnosis initiated manually via the panel, a message is generated on the display which indicates the missing or missing transition conditions and information about contains the creation or finding of the causes for the missing or missing transition conditions. 2. The method according to claim 1, characterized, that each step of a sequencer has a step comment associated with the current state of the step, the Transition links and those to be carried out by the step Actions indicates where the comment is missing Transition linkage and / or by retrieval from a memory appears on a screen. 3. The method according to claim 1 or 2, characterized, that at a standstill on one step due to lack of Transition conditions a step comment to a central Monitoring station sent and shown there on a display becomes.   4. The method according to one or more of the preceding claims che, characterized, that the display on the screen arranged several in series nete fields in which the numbers of the sequence, the set step, the current operating mode, the remaining one Monitoring time and depending on predefinable criteria the step comment is displayed. 5. The method according to claim 4, characterized, that the operating mode is jog or simultaneous operation. 6. Method according to one or more of the preceding Expectations, characterized, that each step is parameterized with a monitoring time, which is shown on the display as the remaining time. 7. Method according to one or more of the preceding Expectations, characterized, that when a chain is released for processing without waiting or after the waiting period has elapsed, that of the Transition link given inputs Stepping conditions are checked that at a not executed transition or if the waiting time is exceeded automatically processing errors by setting one Error flag is initiated in a memory and that all Inputs of the transition link, the signal state of which Transition prevented from being marked in a memory. 8. Method according to one or more of the preceding Expectations, characterized, that with an OR function if only one Input condition is met, all other input conditions should not be interpreted as an error.   9. The method according to one or more of the preceding Expectations, characterized, that when an error is detected, the time when the Error and the link function with the identification of the input conditions not met in a fault memory can be retrieved and stored. 10. The method according to one or more of the preceding Expectations, characterized, that for action modules whose output is not set, an error message is entered in a memory that is available. 11. The method according to one or more of the preceding Expectations, characterized, that the signals at outputs and inputs have symbolic names assigned in a separate comment field are displayed. 12. The method according to one or more of the preceding Expectations, characterized, that if an error is found, it is checked whether only an on gear condition or several input conditions are missing, whereby displayed in the case of several missing transition conditions is how these are linked. 13. The method according to one or more of the preceding claims che, characterized, that if there are several missing AND transition conditions, all of them appear on the display.   14. The method according to one or more of the preceding claims che, characterized, that if several OR conditions are missing, these are displayed and that one of these OR conditions on the tableau to display the information intended for troubleshooting NEN is selectable. 15. The method according to one or more of the preceding claims che, characterized, that is stored in advance for each condition, by which Be actuation of a hand key an action to fulfill the condition can be initiated, and that in the absence of a condition a reference to the manual button to be operated is shown on the display. 16. The method according to one or more of the preceding claims che, characterized, that for each transition condition in addition to the comment an assignment note is saved.