JP6111675B2 - Method, apparatus and program for supporting user program design of safety controller - Google Patents

Description

  The present invention relates to a program development support apparatus for a safety controller, and more particularly to a method, apparatus, and program for supporting design of a user program.

  In recent years, various safety devices have been proposed due to the increasing awareness of occupational safety. The safety device corresponds to a safety controller, a safety I / O terminal, and the like, and is used together with a cutting machine, a cutting machine, a manufacturing robot with an arm, and the like. The safety standard will be described by taking a safety controller as an example. The safety controller incorporates a logic operation function and input / output control function similar to a general programmable controller (PLC), and a self-diagnosis function for safety. Therefore, high reliability is ensured in the control.

  When an abnormality is detected based on the self-diagnosis result of the safety controller, a function (fail-safe function) for forcibly performing safe control is provided so that self-control does not lead to danger. As a result, the operation of the manufacturing machine robot or the like does not lead to danger.

  More specifically, the term “safety” as used herein means that standardized safety standards are included. Standards include, for example, IEC61508 and EN standards. IEC 61508 (International Electrotechnical Commission on Functional Safety of Programmable Electronic Systems) defines the probability of dangerous failure per hour (Probability of Failure per Hour), and this probability determines the level of SIL (Safety Integrity Level). ) Is classified into 4 levels. In addition, the EN standard requires that the risk level of a machine be evaluated and risk reduction measures be taken, and EN 954-1 defines the safety category in five categories. The safety controller or the like of the present invention corresponds to one of such safety standards.

  The safety I / O terminal also has a self-diagnosis function, and has a fail-safe function such that when an abnormality is detected based on the self-diagnosis result, the self-control does not lead to danger. As a result, the operation of the safety controller and the operation of the manufacturing machine robot and the like are prevented from leading to danger. Conventionally, a safety control system in which a safety controller and a safety I / O terminal are connected via a network is known.

  The safety controller has a communication master function for performing network communication with the safety I / O terminal, and is sometimes referred to as a safety master.

  The safety I / O terminal has a network communication function with the communication master function of the safety controller, that is, a communication slave function controlled according to the master. The safety I / O terminal includes a connection terminal, and at least one of a safety input device such as a switch for outputting an on / off signal and a safety output device to which a control signal is output is connected to the connection terminal.

  Examples of the safety input device include an emergency stop switch SW, a light curtain, a door switch, and a two-hand switch. Examples of safety output devices are safety relays and contactors. These safety input devices or safety output devices also comply with safety standards. The safety I / O terminal generates control data based on a signal input from the connected safety application device, and performs network communication of the generated control data to the safety controller.

  As the safety controller, a building block type is known in which a plurality of units such as a CPU unit, a power supply unit, an I / O (input / output) unit, and a communication master unit are connected. Each unit is connected to a common internal bus, and can perform data communication by performing bus communication between the CPU unit that controls the entire safety controller and other units.

  Then, the safety controller inputs the input signal of the safety input device input by network communication from the safety I / O terminal via the communication master unit, and performs a logical operation on / off of the input signal by a logic program stored in advance. An output signal based on the calculation result is output to the safety I / O terminal by network communication via the communication master unit. The safety I / O terminal outputs the output signal to the safety output device. By repeating this series of operations, the entire system including the manufacturing robot is controlled by the safety controller. The communication cycle between the safety controller and the safety I / O terminal may be synchronized with a cycle of repeated execution of the safety controller or may be asynchronous.

  Safety relays and contactors, which are safety output devices connected to the safety I / O terminal, are connected to manufacturing robots, processing machines, cutting machines, etc. The robot or the like is stopped while the robot or the like is operating and the contact is off. Therefore, the safety controller controls the operation of the operation robot or the like to be finally controlled by performing on / off control of the safety output device.

  In a specific example, when the safety controller inputs from the safety I / O terminal by communication that the emergency stop switch SW has been normally operated, a safety output device (relay) Or forcibly control to a safe state and immediately search for necessary safety measures. In addition, when the safety controller inputs a diagnosis result indicating that the emergency stop switch SW or other safety input device has an abnormality, the control target is dangerous regardless of whether the emergency stop switch SW is operated or the safety input device is on or off. Turn off the safety output device to stop its operation so as not to operate, or forcibly control it to a safe state, and immediately search for necessary safety measures.

  Generally, a program development support device (tool device) of a safety controller (PLC) is used to construct the safety control system. Usually, it is configured by incorporating predetermined tool software into a personal computer (see Patent Document 1).

JP-A-9-330250

  Then, in order to be able to process the input signal from the safety input device to the safety controller or the output signal to the safety output device by the user program using the device, an input terminal or an output signal for receiving the input signal is output. It is necessary to execute so-called I / O assignment that assigns variables that can be used by the user program to the output terminals.

  Here, for example, a safety input device for safety use may adopt a duplex structure as an input signal. In this configuration, the safety controller corresponds to two input signals for two input terminals, respectively. Two variables will be assigned respectively.

  For this reason, programming may become complicated in the design of the user program of the safety controller as the number of assigned variables increases.

  The present invention has been made to solve the above problems, and a method, an apparatus, and a device for supporting the design of a user program for a safety controller that can facilitate the design of the user program for a safety controller. The purpose is to provide a program.

  A method for supporting the design of a user program of a safety controller for enabling a user program to process an input signal from a safety input device or an output signal to a safety output device for a safety controller according to an aspect of the present invention, the safety controller Executing I / O assignment for assigning different variable names to input terminals that receive input signals from safety input devices or output terminals that output output signals to safety output devices, respectively, and safety input devices Or the step which acquires the information regarding a safety output device, and the two input terminals which receive two input signals which are duplicated from a safety input device, or safety based on the acquired information about a safety input device or a safety output device Dual output for output devices The two output terminals for outputting the items, and a one step of prohibiting the use of one of the two variable names assigned respectively.

  Preferably, the step of acquiring information related to the safety input device or the safety output device includes a step of receiving data according to a user input related to the safety input device or the safety output device.

  Preferably, the safety input device or the safety output device is connected to the input unit or the output unit that is communicably connected to the safety controller, and the step of acquiring information related to the safety input device or the safety output device is the input unit or the output unit. Receiving data relating to a safety input device or a safety output device.

  Preferably, the safety input device or the safety output device is connected to the input unit or the output unit that is communicably connected to the safety controller, and the input unit or the output unit connected to the safety input device or the safety output device is The method further includes a step of setting a setting parameter corresponding to the safety input device or the safety output device, and the step of acquiring information regarding the safety input device or the safety output device acquires information regarding the setting parameter setting.

  An apparatus for supporting the design of a user program of a safety controller for enabling an input signal from a safety input device or an output signal to a safety output device for a safety controller according to an aspect of the present invention to be processed by a user program. Means for executing I / O assignment for assigning different variable names to the input terminal for receiving the input signal from the safety input device or the output terminal for outputting the output signal to the safety output device, respectively, and the safety input device Alternatively, based on the means for acquiring information related to the safety output device and the acquired information related to the safety input device or the safety output device, two input terminals that receive two duplicated input signals from the safety input device or safety Outputs two output signals that are duplicated to the output device. The two output terminals of is provided with a means for inhibiting the use of one of the two variable names assigned respectively.

  In a computer according to an aspect of the present invention, a function for supporting design of a user program of a safety controller for enabling an input signal from a safety input device to a safety controller or an output signal to a safety output device to be processed by a user program is executed. Each of which corresponds to an input terminal that receives an input signal from a safety input device of the safety controller or an output terminal that outputs an output signal to the safety output device. A step of executing I / O assignment for assigning the information, a step of obtaining information on the safety input device or the safety output device, and duplexing from the safety input device based on the obtained information on the safety input device or the safety output device Two input signals Prohibiting the use of one of the two assigned variable names for the two input terminals that receive the two or two output terminals that output two output signals that are duplicated to the safety output device; Is provided.

  It is possible to easily design a user program for the safety controller.

It is a figure explaining the structure of the safety control system according to this Embodiment. It is a schematic block diagram which shows the internal hardware constitutions of the program development assistance apparatus 10 according to this Embodiment. It is a schematic block diagram which shows the internal hardware constitutions of the safety I / O terminal 3 according to this Embodiment. It is a figure explaining the safety input device (double emergency stop switch) corresponding to a predetermined safety standard. It is a figure explaining the safety input device (double safety light curtain) corresponding to a predetermined safety standard. It is a figure explaining the output device (contactor) corresponding to a predetermined safety standard. It is a figure explaining the flow of the process which sets the parameter of the terminal according to this Embodiment. It is a figure explaining the terminal setting screen according to this Embodiment. It is a figure explaining the table of the terminal parameter regarding the safety input device according to this Embodiment. It is a figure explaining the data output to the safety controller 1 from the safety I / O terminal 3 according to this Embodiment. It is a figure explaining the flow of I / O allocation according to this Embodiment. It is a figure explaining an example of the I / O map of the safety controller. It is a figure explaining the I / O map of the safety controller 1 according to this Embodiment. It is a conceptual diagram of the design of the program of a safety controller. It is a conceptual diagram of the design of the program of the safety controller according to this Embodiment. It is a schematic block diagram which shows the internal hardware constitutions of the safety I / O terminal 3 # according to the modification of this Embodiment. It is a figure explaining the flow which sets the terminal parameter according to the modification of this Embodiment.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals, and description thereof will not be repeated.

FIG. 1 is a diagram illustrating a configuration of a safety control system according to the present embodiment.
Referring to FIG. 1, here, a safety control system is shown in which a bus type network in which a safety controller 1 and a safety I / O terminal 3 are connected by a bus 2 is configured.

  In this example, a plurality of safety input devices 4 and safety output devices 5 are connected to the safety controller 1 and the safety I / O terminal 3, and the PLC of a PLC provided to construct the system is connected to the bus 2. A program development support apparatus 10 is connected.

  The safety controller 1 is a building block type configured by connecting a plurality of units such as a CPU unit, a power supply unit, an I / O (input / output) unit, and a communication master unit. Each unit is connected to a common internal bus, and can perform data communication by performing bus communication between the CPU unit that controls the entire safety controller and other units.

  Then, the safety controller 1 inputs the input signal of the safety input device 4 input from the safety I / O terminal 3 through network communication via the communication master unit, and logically turns on / off the input signal by a pre-stored logic program. Calculate. An output signal based on the calculation result is output to the safety I / O terminal 3 by network communication via the communication master unit. The safety I / O terminal 3 outputs the output signal to the safety output device 5. By repeating this series of operations, the entire system is controlled by the safety controller 1. Note that the communication cycle between the safety controller 1 and the safety I / O terminal 3 may be synchronized with the cycle of repeated execution of the safety controller 1 or may be asynchronous.

  The safety input device 4 includes an emergency stop switch, a light curtain, a door switch, a limit switch, and the like, and the safety output device 5 includes a safety relay, a contactor, and the like.

  The program development support apparatus 10 in the figure is provided so that an interactive support program using an I / O wizard, which will be described later, can be executed. The program development support apparatus 10 is connected not only to the general-purpose notebook personal computer shown in the figure but also to a network. A possible portable information terminal (PDA) or a desktop personal computer may be used.

  In the present example, the configuration in which the safety I / O terminal 3, the safety input device 4, and the safety output device 5 are connected will be mainly described. The present invention can be similarly applied to a system configuration in which the safety input device 4 and the safety output device 5 are connected via an O (input / output) unit. The safety input device 4 and the safety output device 5 are also collectively referred to as a safety input / output device.

  FIG. 2 is a schematic block diagram showing an internal hardware configuration of program development support apparatus 10 according to the present embodiment.

Referring to FIG. 2, the block diagram shown in the drawing represents a typical configuration example.
The program development support apparatus 10 includes at least a CPU 11 that controls and controls the entire program development support apparatus, an input operation unit 12 including a mouse operation and a keyboard operation, and a display on a display screen of an image display provided in the program development support apparatus. A display unit 13 that performs processing, a work RAM 14 that is used for operation input processing, predetermined calculation processing, image processing for a display screen, and the like, a communication unit 16 that controls an external communication interface, and a storage device 15 are included. .

  These are configured in a form connected to the internal bus 17 of the program development support apparatus. Further, an I / O wizard program, which will be described in detail later, is stored in a predetermined storage area of the storage device 15.

  FIG. 3 is a schematic block diagram showing an internal hardware configuration of safety I / O terminal 3 according to the present embodiment.

  Referring to FIG. 3, safety I / O terminal 3 that permits and executes download of an input / output terminal parameter file (terminal setting file) for connecting a safety device, which is supported by an I / O wizard described later. A typical hardware configuration related to is illustrated.

  Here, the communication I / F unit 20 that transmits and receives data to and from the program development support apparatus 10 and the safety master (safety controller) connected to the bus 2, various arithmetic functions, failure diagnosis functions, and the like are executed, and the safety controller For each terminal (24a, 24b) constituting the central processing unit 21 that controls and controls the whole and the input / output terminal units (23a, 23b) to which safety devices are connected, abnormality diagnosis for each terminal is executed. And terminal abnormality diagnosis units (22a, 22b).

  A plurality of safety input devices 4 and safety output devices 5 are connected to the input / output terminals (24a, 24b), respectively.

In addition, in this example, although the structure of the apparatus which can connect a safety input device and a safety output device together as a safety I / O terminal is demonstrated, it is provided not only in the said structure but a safety input device can be connected. It is also possible to adopt a configuration in which the input unit and the output unit provided so that the safety output device can be connected are separated. For example, the configuration of the input unit may be a configuration in which an output system function is not provided, specifically, a configuration in which the terminal abnormality diagnosis unit 22b and the output terminal unit 23b are not provided. Further, the configuration of the output unit may be a configuration in which an input system function is not provided, specifically, a configuration in which the terminal abnormality diagnosis unit 22a and the input terminal unit 23a are not provided.

  Although the configuration of the safety I / O terminal has been described here, the configuration of the I / O (input / output) unit of the safety controller 1 is the same.

<Terminal parameter settings>
Various parameters need to be set for the terminals of the safety I / O terminal connected to the safety input device or the safety output device.

  FIG. 4 is a diagram for explaining a safety input device (double emergency stop switch) corresponding to a predetermined safety standard.

  Referring to FIG. 4, here, the operation signal input from the emergency stop switch is subjected to a double connection process to the wiring input to the terminal, and then the failure of the emergency stop switch or the emergency stop switch / input An example of connection of an emergency stop switch in which a test pulse for abnormality diagnosis for detecting disconnection or short circuit between terminals is set is shown.

  And the item of the various parameters set to the terminal connected with the said safety input device is shown.

  Specifically, “test pulse setting” is “output test pulse”, “test pulse output terminal setting” is “use test terminal 1”, “redundancy setting” is “redundancy” “Yes”, “Timing setting between redundant input devices”, “Allow timing deviation between 100 ms” and the like are set.

  FIG. 5 is a diagram for explaining a safety input device (double safety light curtain) corresponding to a predetermined safety standard.

  Referring to FIG. 5, here, the operation signal input wiring for the double safety light curtain is doubled, but the test pulse for abnormality diagnosis is not set. A connection example is shown.

  And the item of the various parameters set to the terminal connected with the said safety input device is shown.

  Specifically, for “test pulse setting”, “no test pulse output”, “test pulse output terminal setting” “not used”, “duplexing presence / absence setting” “duplexing”, For “timing setting between redundant input devices”, “allow timing deviation for 100 ms” or the like is set.

  FIG. 6 is a diagram for explaining an output device (contactor) corresponding to a predetermined safety standard.

  Referring to FIG. 6, here is shown a connection example of a safety device using a contactor that requires a welding check as a safety output device. In the figure, the object to be controlled is a connection configuration in which contactor contacts KM1 and KM2 subjected to the duplex processing are inserted into a power supply line for driving a three-phase motor to prepare for operation stop. The setting of the input terminal prompts the terminal input connection to the welding check input terminal 1 and the test terminal 1 with respect to the contactor contact surrounded by the one-dot chain line.

  And the item of the various parameters set to the terminal connected with the said safety output apparatus is shown.

Specifically, the "setting of the test pulse" is "outputs a test pulse", "use test terminal 1" for "setting of the test pulse output terminal", the "duplex settings whether" is "duplicated Is set.

  Next, a method for setting parameters of terminals connected to the safety input device will be described.

  In this example, the parameter of the terminal is set using the program development support device 10.

  FIG. 7 is a diagram illustrating a flow of processing for setting terminal parameters according to the present embodiment. This flow is realized by the CPU 11 of the program development support apparatus 10 executing an I / O wizard (tool) stored in the storage device 15. The I / O wizard (tool) is provided with tools for executing various functions, such as a tool for setting terminal parameters, a tool for executing I / O assignment to be described later, and a tool for executing programming. It is possible to selectively execute various functions.

  Here, for example, a wizard is a function that makes it possible to easily perform complicated operations and settings by displaying interactive guidance for the user and selecting the user according to the guide from several options. Includes a display screen. Such a program process only needs to be able to realize the functions of the above-described embodiments by a computer. The program form includes an object code, a program executed by an interpreter, and a script supplied to an OS of a computer on which the program process is mounted and executed. It may have a form such as data.

  Referring to FIG. 7, first, the program development support apparatus 10 is turned on, and after a predetermined initial process is started, the I / O wizard is started, and the program development support apparatus 10 is provided in the storage device 15 composed of an internal HDD or the like. The I / O wizard stored in the storage area is read and executed.

  When the I / O wizard is executed, a search for a safety device is executed (step S2). Specifically, the CPU 11 of the program development support apparatus 10 searches for a safety device (safety controller, safety I / O terminal, etc.) connected to the bus 2 via the communication unit 16. Although not shown in the figure, a list of safety devices is generated by the search.

  In this example, the case where the safety device is connected online with the program development support apparatus 10 is described. However, even when the safety device is offline, the safety device stored in the storage device 15 is searched. Then, information on safety devices (safety controller, safety I / O terminal, etc.) supported by the I / O wizard is read, and a list of safety devices is generated on the display screen of the program development support apparatus 10.

  Here, the safety device is a safety input connected to the input / output terminal of this device in order to ensure the required safety standards, as shown in the typical examples of safety controllers and safety I / O terminals. If the control system constructed from these safety devices has the function that can ensure the operational condition that satisfies the predetermined safety standards based on various diagnostic results Good.

  Next, a safety device is selected (step S4). Specifically, a safety device is selected from the list of safety devices displayed on the display screen of the display provided in the program development support apparatus 10.

  Next, a terminal setting screen is displayed (step S6). Specifically, a terminal setting screen corresponding to the safety device is displayed.

First, terminal setting of a safety device connected to a safety input device will be described.
FIG. 8 is a diagram illustrating a terminal setting screen according to the present embodiment.

  With reference to FIG. 8A, an input terminal setting screen (I / O wizard window 300) displayed on the program development support apparatus 10 is illustrated. In the illustrated example, the I / O wizard window 300 graphically displays the title 301 that displays the name of the process being executed, and the appearance of products that are included in various safety devices that are not shown and that are used to set the terminal that is currently executing the process. It has a device display area 302, a mode comment area 303 corresponding to the number of input terminals of the selected / designated safety device, and a type area 304 for inputting the type of safety device to be wired, and displays various parameter setting screens related to the input terminals. Dialog area 305 to be displayed, an “OK” button 308 for determining the current parameter setting contents by a click operation, etc., and a cursor operation to the Type area 304 are displayed in a sub-window 306 that can be scrolled up and down by a drag method. Input terminal connection with safety devices The “Cancel” button 309 is used to cancel the selected / set contents.

  Also, in the same figure, a simple explanation for various symbols displayed in the Mode Comment area 303 is displayed below the dialog area 305 in the screen.

Here, the meanings of various symbols are as follows.
[E]: Dual Equiv, duplex setting by equivalent input (0/0, 1/1). Switch on when “1/1”, switch off (cut off) when “0/0”.

[C]: Dual Comp, duplex setting with different values (0/1, 1/0).
[P]: Test Pulse, A setting to periodically output a test pulse from the test output terminal in order to detect failure of the safety input device, disconnection / short circuit between the terminal / device.

  [S]: Safety, setting to connect a safety input device without using a test pulse. [ST]: Standard, setting for connecting a non-safety input device.

  The terminal parameter setting corresponding to the safety input device supported by the I / O wizard window 300 shown in the figure is set in the type area 304 in the dialog area 305 which is the configuration of the I / O wizard window 300 screen. When the cursor or the like is operated to match, a list of proven safety input devices that satisfy the safety standards described above is listed in the sub window 306 (a state in which the sub window in the figure is opened).

  Returning to the flowchart of FIG. 7, when a safety input device (connected device) that matches (wiring connection) is selected from the safety input devices listed in the sub-window 306 (step S10), the safety selected in the Type area 304 is displayed. An input device is inserted and set, and a mode comment area 303 corresponding to the type area 304 automatically displays parameters for terminal setting (connection setting to the safety input device) that satisfies safety standards.

  In the illustrated example, for example, when a safety input device that is “emergency stop 2b contact” is selected and set in the Type area 304, “[00]” and “Bit01” in the corresponding Mode Comment area 303 display “[ e] [P] Emergency stop NC ”is displayed. Here, “Bitxx” represents an input terminal of the designated safety device.

  Further, the terminal setting information displayed in the Mode Comment area 303 is based on the table information stored in a predetermined area of the work RAM 14, and the safety standard associated with the safety input device list displayed in the sub-window 306. It is based on a certified operation form. The setting information is uniquely determined corresponding to the selected safety input device.

  That is, the terminal parameters are set based on the table information according to the selected safety input device (step S12).

  Then, it is determined whether or not all the terminal settings have been completed (step S14), and all the input terminals included in the designated safety device are selected from the list displayed in the subwindow 306 continuously for each safety input device. By setting, terminal parameter setting is repeatedly executed (steps S10 to S14).

  When canceling the selection / setting of the safety input device assigned to each terminal of the safety device, by operating the cursor or the like on the Type area 304 where the predetermined information is displayed and pressing the “Cancel” button 309, The setting input is canceled.

  When the setting of the safety input device regarding all the input terminals of the safety device is completed, the user presses the “OK” button 308 in the screen of the I / O wizard window 300 displayed on the program development support apparatus 10 (YES in step S14). To do.

  The I / O wizard being executed corresponds to the input terminals for all input terminals of the safety device currently being processed at the timing when the “OK” button 308 in the screen of the I / O wizard window 300 is pressed. The terminal parameter of the safety input device connected to is stored in a predetermined area of the work RAM 14 as a terminal setting file.

Then, the process ends (END).
FIG. 9 is a diagram illustrating a terminal parameter table related to the safety input device according to the present embodiment.

  Referring to FIG. 9, connection conditions (setting parameters) to be satisfied by the input terminals are stored corresponding to the safety input devices. For example, in the figure, in the setting parameter of the input terminal to which the device number “1” is assigned, the duplex setting by the same value input (0/0, 1/1) is made, and the doubled signal input It is shown that the allowable time for the timing deviation between them is set to “100 ms”. Here, the set time of “100 ms” is a safety input device when one of the duplicated input signals is “OFF” and the other signal input is not “OFF” within “100 ms”. This is a permissible time for determining that a failure has occurred, or that an abnormality such as a disconnection / short circuit of the device / terminal wiring has occurred. In addition, in order to detect failure of this safety input device, disconnection / short circuit between devices / terminals, etc., it indicates that abnormality diagnosis using test pulses is periodically performed. 0/1 "is used as a test source.

  The terminal parameters of each item are included in the terminal setting file and transmitted to a safety device (for example, a safety I / O terminal), and various settings are made for the terminals of the safety device connected to the safety input device. The same applies to safety output devices.

Next, terminal setting of the safety device connected to the safety output device will be described.
With reference to FIG. 8B, an output terminal setting screen (I / O wizard window 400) displayed on the program development support apparatus 10 is illustrated. In the illustrated example, the I / O wizard window 400 graphically displays the title 401 that displays the name of the process being executed, and the appearance of products that are included in various safety devices that are not shown and that are used to set the terminal that is currently executing the process. A device display area 402, a Mode Comment area 403 corresponding to the number of output terminals of the selected / designated safety device, and a Type area 404 for inputting the type of safety output device (safety relay, contactor, etc.) to be connected by wiring are provided. Dialog area 405 for displaying various parameter setting screens related to terminals, “OK” button 408 for determining the current parameter setting contents by a click operation, etc., and a cursor operation to Type area 404 for scrolling up and down by a drag method Possible subwindow 406 A “cancel” button 409 for canceling the selected / set contents regarding the output terminal connection with the safety device displayed inside.

  Also, in the same figure, a simple explanation for various symbols displayed in the Mode Comment area 403 is displayed at the bottom of the screen of the dialog area 405.

Here, the meanings of various symbols are as follows.
[D]: Dual, duplex setting by equivalent output.

  [P]: Pulse test, setting to periodically output test pulses from the output terminal to detect failure of safety output equipment, disconnection / short circuit between terminals / equipment.

[S]: Safety, setting for connecting a safety output device without using a test pulse.
The terminal parameter setting corresponding to the safety output device supported by the I / O wizard window 400 shown in the figure is set in the type area 404 in the dialog area 405 that is the configuration of the I / O wizard window 400 screen. By operating the cursor and the like, a list of proven safety output devices that meet the safety standards described above is listed in the sub window 406 (a state in which the sub window in the figure is opened).

  In this manner, the user can confirm all output devices (related to the selected / designated safety device) supported by the I / O wizard by scrolling the safety output device list displayed in the sub-window 406 in the vertical direction. .

  By providing such a scroll function, it is possible to effectively use a limited screen display area for displaying guidance for creating a terminal setting file, and to display a plurality of safety output devices in a list format. Furthermore, even if the number of safety output devices to be supported in the future increases, the safety output device list can be displayed while keeping the screen display area at a certain size, so it can be handled without changing the screen configuration for guidance display. There are advantages.

  Referring to FIG. 7, steps S2 to S6 are the same. When a safety output device that matches (wiring connection) is selected from the safety output devices listed in the sub-window 406 (step S10), the selected safety output device is set in the Type area 404, and this Type is set. In the Mode Comment area 403 corresponding to the area 404, the terminal setting (connection setting to the safety output device) parameter that satisfies the safety standard is automatically displayed.

  In the example shown in the figure, for example, when a safety output device that is “with two safety relays welded check” is selected / set in the Type area 404, the display fields of “Bit00” and “Bit01” in the corresponding Mode Comment area 403 “[D] [P] Safety relay” is set and displayed. Here, “Bitxx” represents an output terminal of the designated safety device.

  Further, the terminal setting information displayed in the Mode Comment area 403 is based on the table information stored in a predetermined area of the work RAM 14, and is a safety standard associated with the safety output device list displayed in the sub window 406. It is based on a certified operation form. The setting information is uniquely determined corresponding to the selected safety output device.

  That is, the terminal parameters are set based on the table information according to the selected safety output device (step S12).

  Then, it is determined whether or not all the terminal settings have been completed (step S14), and all the output terminals included in the designated safety device are continuously displayed for each safety output device from the list displayed in the sub-window 406. By selecting and setting, the setting for all output terminals of the designated safety device is repeatedly executed (steps S10 to S14).

  When canceling the selection / setting of the safety output device assigned to each terminal of the safety device, by operating the cursor etc. on the Type area 404 where the predetermined information is displayed and pressing the “Cancel” button 409, The setting input is canceled.

  When the setting of the safety output device for all the output terminals of the safety device is completed, the user presses the “OK” button 408 in the screen of the I / O wizard window 400 displayed on the program development support device 10 (YES in step S14). To do.

  The I / O wizard being executed is the output terminal for all the output terminals included in the safety device currently executing the process when the “OK” button 408 in the screen of the I / O wizard window 400 is pressed. The terminal parameter of the safety output device connected to is stored as a terminal setting file in a predetermined area of the work RAM 14.

Then, the process ends (END).
As described so far, if the terminal setting file created with the support of the I / O wizard is stored in the storage device 15 of the program development support apparatus 10, the download setting for the corresponding safety device is performed. Can be executed in various forms (for example, when writing to a storage medium and using a handy tool that supports the storage medium).

  Here, the download execution example in the state where the bus type network shown in FIG. 1 is constructed is shown as data communication between the program development support apparatus 10 and the safety controller 1 to which the safety input / output device (4, 5) is connected. This will be described below using the form.

  In order to execute downloading of the terminal setting file from the program development support apparatus 10, a download process by specifying a destination address, which is common in a data communication method provided in this type of control system, is executed. That is, the program development support apparatus 10 connected to the bus 2 constituting the network is assigned a predetermined node address in order to communicate with the safety devices (safety controller 1 and safety I / O terminal 3) on the network. Therefore, the program development support apparatus 10 sets the node address assigned to the safety device corresponding to the contents of the terminal setting file (here, the safety I / O terminal 3) as the transmission source address, and copes with it. The terminal setting file is downloaded with the node address of the safety device to be set as the destination address.

  Specifically, when the terminal setting file is downloaded and executed in the program development support apparatus 10, the CPU 11 reads the terminal setting file from the storage device 15 in which the terminal setting file is stored and stored, and temporarily stores it in a predetermined storage area of the work RAM 14. Hold. Next, based on the own node address and destination node address information, the terminal setting file stored on the work RAM 14 is converted into a predetermined format (for data transmission), and the transmission data is connected to the CPU 11 via the internal bus 17. Is transmitted to the network via the communication unit 16.

  The communication I / F unit 20 of the safety I / O terminal 3 having the node address corresponding to the terminal setting file detects the destination address of the data transmitted on the bus 2 and executes the reception process. The terminal setting file inserted into the received transmission data is temporarily stored in a predetermined storage area on the RAM provided in the central processing unit 21, and the reception process ends.

  A download file (terminal setting file) stored in the storage area on the RAM of the safety I / O terminal 3 is subjected to data file content confirmation processing by the central processing unit 21. Here, the setting content confirmation processing may include, for example, confirmation of a specific identification number inserted in the terminal setting file, or encryption authentication for preventing change by a third party. May be.

  When the central processing unit 21 of the safety I / O terminal 3 finishes confirming the contents of the downloaded terminal setting file, the setting information of all input / output terminal parameters included in the terminal setting file is set for each terminal. The information is written in a parameter area assigned to a predetermined storage area on the memory 25 in which information is stored.

  Thereby, various settings are made for the terminals of the safety device (safety I / O terminal 3) connected to the safety input device or the safety output device, and the safety input device connected to the safety device (safety I / O terminal 3). Alternatively, the safety output device can be controlled.

  The same processing is performed for the safety device (safety controller 1) connected to the safety input device or the safety output device.

  FIG. 10 is a diagram illustrating data output from safety I / O terminal 3 to safety controller 1 according to the present embodiment.

  Referring to FIG. 10, here, a case where a data signal according to the input signal is output from safety I / O terminal 3 in accordance with an input signal of one input terminal connected to safety input device 4 is shown.

  Specifically, the status based on the diagnosis result in the terminal abnormality diagnosis unit 22a of the safety I / O terminal 3 and the signal value input to the terminal are transmitted together.

  When the status is “1”, it is in a normal state, and when it is “0”, it is in an abnormal state. Further, a case where the signal value is “1/0” corresponding to ON / OFF is shown.

  When the safety input device 4 is duplicated, two input signals are input to the safety I / O terminal 3.

  Therefore, the data signal output from the safety I / O terminal 3 to the safety controller 1 is also output according to each input.

<I / O assignment of terminals>
For the terminal of the safety device connected to the safety input / output device, the terminal parameter corresponding to the safety input / output device is set, and the input signal input to the terminal or the output signal output from the terminal is set to the safety controller 1. In order to enable processing by the user program, each corresponds to an input terminal that receives an input signal from a safety input device provided in the safety controller 1 or an output terminal that outputs an output signal to the safety output device. It is necessary to execute I / O assignment for assigning variable names.

  Then, according to the variable name assigned according to the I / O assignment, it is possible to execute a programming process using the variable name when designing the user program of the safety controller 1.

  In the present embodiment, it is assumed that the program development support apparatus 10 executes the I / O assignment of the terminals of the safety controller 1.

  FIG. 11 is a diagram illustrating an I / O allocation flow according to the present embodiment. This flow is realized based on the function of the CPU 11 of the program development support apparatus 10 executing the I / O assignment of the I / O wizard stored in the storage device 15.

  Referring to FIG. 11, first, CPU 11 assigns a variable to an input or output terminal (step S20). Specifically, different variables are assigned to the input or output terminals provided in the safety controller 1, respectively. The variable is allocated (assigned) automatically according to a predetermined method.

  Next, the CPU 11 acquires information on the safety input / output device to be connected (step S22). Specifically, the CPU 11 acquires information on the terminal setting file for the safety device created by the I / O wizard described above. As the information, for example, information on terminal parameters set for the terminals of the safety I / O terminal 3 is acquired. Based on the information of the terminal parameter, it is possible to acquire information such as whether the safety I / O terminal 3 is connected to a duplicated safety input device or safety output device.

  Next, the CPU 11 determines whether the safety input / output device is duplicated based on the acquired information (step S24).

  In step S24, if the CPU 11 determines that the safety input / output device is duplicated (YES in step S24), it sets one of the two variables assigned to the input or output terminal to be prohibited ( Step S26).

  Then, the process is repeated for all terminals (NO in step S28), and it is determined whether or not all terminals have been completed (step S28).

  If it is determined in step S28 that the process has been completed for all terminals (YES in step S28), the I / O allocation process is terminated (end).

  On the other hand, if it is determined in step S24 that the safety input / output device is not duplicated (NO in step S24), step S26 is skipped and the process proceeds to step S28. The subsequent processing is the same as described above.

  Then, the I / O map indicating the relationship between the terminal and the variable generated according to the I / O allocation processing is downloaded from the program development support apparatus 10 and downloaded to the I / O memory of the safety controller 1.

FIG. 12 is a diagram for explaining an example of the I / O map of the safety controller 1.
Referring to FIG. 12, here, a case where an I / O map generated after the I / O allocation processing of the I / O wizard is used for display is shown.

  In the input side, a case is shown in which variables are respectively assigned to the input terminals of the safety controller 1.

  Specifically, the input terminal “Bitxx” (xx = 00 to 13) represents the input terminal name of the designated safety device (safety controller). A signal input from a safety input device connected via the safety I / O terminal is input to the input terminal.

  A case where variables are assigned (assigned) to each input terminal is shown.

  As described above, two signals are input to the safety I / O terminal 3 in accordance with the safety standard from the safety input device 4 that is duplicated.

  Since the two duplicated input signals are respectively input to the safety controller 1 via the safety I / O terminal 3, variables are assigned to the two input terminals of the safety controller 1, respectively.

  However, the signals input from the duplicated safety input device 4 via the safety I / O terminal 3 have the same value.

  Therefore, if a variable is assigned to each input, the program designer may be at a loss as to which of the two variables should be selected and used. In addition, it causes a programming error.

  Therefore, in the present embodiment, when the safety input / output device is duplicated and connected, use of one of the two assigned variables is prohibited.

  FIG. 13 is a diagram illustrating an I / O map of safety controller 1 according to the present embodiment.

  Referring to FIG. 13, here, a case is shown in which a function for displaying an I / O map generated after the I / O assignment processing of the I / O wizard is used.

  In the same manner as described with reference to FIG. 12, a case is shown in which variables are assigned to the input terminals of the safety controller.

  Compared with the comparative example of FIG. 11, “Bit01” and “Bit03” are grayed out (hatched areas). That is, the state where use of the variable is prohibited is shown.

  Thus, the program designer does not need to hesitate to select which variable to use because one of the variables is prohibited from being used. It is also possible to easily grasp the variables that are permitted to be used.

  In this example, an example of displaying a grayed-out state so that it can be grasped as a state where the use of one of the variables is prohibited has been described. However, the present invention is not limited to this example. It is possible to notify the user, and it is possible to adopt other means, and any form can be used as long as the variable permitted to use and the variable prohibited to use can be distinguished. good.

FIG. 14 is a conceptual diagram of the design of the safety controller program.
Referring to FIG. 14, here, a conceptual diagram of the design of the user program of the safety controller is shown.

  Here, a conceptual diagram in the case where the safety input device is connected to the safety controller via the input unit and is connected to the safety output device via the output unit is shown.

  The input unit corresponds to, for example, a function on the input side of the safety I / O terminal. The output unit corresponds to a function on the output side of the safety I / O terminal.

  And here, the combination in the case of designing the user program of a safety controller using the signal allocated via the input unit using the variable allocated by the I / O map is shown.

  As shown in the figure, when the variables assigned to the two terminals are used in the user program of the safety controller, the variable combination pattern increases in accordance with the number of variables. For example, when the variables A and B and the variables C and D are combined, four ways are conceivable.

  Therefore, it is possible to create a plurality of patterns as a user program, and it becomes necessary for the designer of the program to make a judgment, which makes the judgment difficult and causes an erroneous operation.

FIG. 15 is a conceptual diagram of the design of the program of the safety controller according to the present embodiment.
Referring to FIG. 15, as described in FIG. 14, there is shown a conceptual diagram when the safety input device is connected to the safety controller via the input unit and is connected to the safety output device via the output unit. Has been.

  And here, the combination in the case of designing the user program of a safety controller using the signal allocated via the input unit using the variable allocated by the I / O map is shown.

  As shown in the figure, since one of the variables assigned to the two terminals is prohibited, when used in the user program of the safety controller, the combination pattern of the variables is as shown in FIG. Decrease than if. Here, since use of the variable B and the variable D is prohibited, the combination of the variable A and the variable C is uniquely determined as an example, the design of the user program of the safety controller becomes easy, and the program is simplified. It is possible to In addition, since the combination pattern of variables is reduced, the possibility of making a mistake is reduced, and erroneous operation can be prevented. In addition, since the number of variables is reduced, memory consumption can also be suppressed.

(Modification)
In the above, the method of setting the parameters of the input / output terminals of the safety device according to the I / O wizard of the program development support apparatus 10 has been described. However, the method is not limited to this method, and for example, the safety I / O terminal 3 It is also possible to provide a function for automatically setting the terminal parameters of the input / output terminals provided in the I / O terminal 3.

  FIG. 16 is a schematic block diagram showing an internal hardware configuration of safety I / O terminal 3 # according to the modification of the present embodiment.

  Referring to FIG. 16, the difference from the configuration described in FIG. 3 is that memory 25 is replaced with memory 26.

  The memory 26 includes a terminal setting information DB (database) 27 and a terminal setting program 28.

  In a modification of the present embodiment, the safety I / O terminal 3 # determines the type of the safety input / output device connected to the terminal, and automatically sets the terminal parameter corresponding to the type to the input / output terminal. The method to do is demonstrated.

  FIG. 17 is a diagram illustrating a flow for setting terminal parameters according to a modification of the present embodiment. This flow is executed when the central processing unit 21 reads the terminal setting program 28 stored in the memory 26.

  Referring to FIG. 17, central processing unit 21 first determines whether or not a safety input / output device is connected (step S30). Specifically, it is determined whether or not the safety input / output device is connected to the input terminal portion 23a or the output terminal portion 23b.

  If the central processing unit 21 determines in step S30 that the safety input / output device is connected (YES in step S30), it next determines the type of the safety input / output device (step S32). Specifically, the central processing unit 21 acquires information from the safety input / output device connected to the input terminal unit 23a or the output terminal unit 23b, and classifies the information (for example, emergency stop switch SW, light curtain, door switch). 2 hand switch, safety relay, contactor). The safety input / output device outputs the information when connected to the terminal. Alternatively, the information is output in accordance with an instruction from the central processing unit 21.

  Next, the central processing unit 21 determines whether the determination of the safety input / output device type is OK (step S34). Specifically, the central processing unit 21 determines whether the type of the device can be determined based on information acquired from the safety input / output device. That is, the central processing unit 21 determines whether it is a safe input / output device that can be supported.

  In step S34, if the central processing unit 21 determines that the type of the safety input / output device is OK (YES in step S34), it refers to the terminal setting information DB 27 (step S36). Specifically, the central processing unit 21 reads terminal parameters corresponding to the type determined for the safety input / output device from the terminal setting information DB 27. For example, it is assumed that the terminal setting information DB 27 stores a table of terminal parameters related to the safety input / output device described in FIG. It is possible to acquire a terminal parameter corresponding to the type determined by referring to the table.

  Next, the central processing unit 21 sets the terminal parameter of the corresponding safety input / output device (step S38). Specifically, a terminal parameter is set for each terminal connected to the safety input / output device based on the acquired terminal parameter.

Then, the process ends (END).
On the other hand, if it is determined in step S34 that the type of the safety input / output device is not OK (NO in step S34), the process ends (end). For example, when an unsupported safety input / output device is connected, the process ends without setting a terminal parameter.

  By this processing, the setting information of all input / output terminal parameters is written in the parameter area assigned to a predetermined storage area on the memory 26 in which the setting information for each terminal is stored.

  That is, according to the method, the terminal corresponding to the safety input / output device automatically connected to the input / output terminal of the safety device without using the I / O wizard of the program development support apparatus 10 for the parameter of the input / output terminal of the safety device. It is possible to set parameters.

  The same flow as described in FIG. 11 can be applied to the I / O allocation according to the modification of the present embodiment.

  In this case, regarding the acquisition of the safety input / output device information in step S22, the CPU 11 acquires the information of the safety input / output device connected to the safety device (for example, the safety I / O terminal 3) using the communication unit 16. . Specifically, the CPU 11 accesses the safety I / O terminal 3 using the communication unit 16 and is set to the terminal of the safety I / O terminal 3 stored in the memory 26 of the safety I / O terminal 3. Get information about the selected terminal parameters. Based on the terminal parameter information stored in the memory 26, it is possible to acquire information such as whether the safety I / O terminal 3 is connected to a duplicated safety input device or safety output device. It is.

  Since the other processing is the same as that described with reference to FIG. 11, detailed description thereof will not be repeated.

  In the above, the terminal parameters corresponding to the safety input / output devices to be connected are set for the input / output terminals of the safety device using the I / O wizard of the program development support apparatus 10 for the parameters of the input / output terminals of the safety device. Although the possible methods have been described, the designer directly connects to the input / output terminal of the safety device (for example, the safety I / O terminal 3) via the input operation unit 12 of the program development support apparatus 10 without using the I / O wizard. The terminal setting file may be created by inputting the terminal parameters as shown in FIG. 9 of the safety input / output device to be connected. Then, the terminal setting file can be downloaded to the safety device as described above, and the terminal parameters can be set in each input / output terminal.

  The same flow as that described with reference to FIG. 11 can be applied to the I / O allocation.

  In this case, regarding the acquisition of the safety input / output device information in step S22, the CPU 11 acquires the information of the safety input / output device to be connected according to the terminal setting file created by the designer. Specifically, the CPU 11 acquires terminal parameter information included in the created terminal setting file. Based on the information of the terminal parameter, it is possible to acquire information such as whether the safety I / O terminal 3 is connected to a duplicated safety input device or safety output device.

  Since the other processing is the same as that described with reference to FIG. 11, detailed description thereof will not be repeated.

  The embodiment disclosed this time is an exemplification, and the present invention is not limited to the above contents. The scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  1 safety controller, 2 bus, 3 safety I / O terminal, 4 safety input device, 5 safety output device, 10 program development support device, 11 CPU, 12 input operation unit, 13 display unit, 14 work RAM, 15 storage device, 16 communication section, 17 internal bus, 20 communication I / F section, 21 central processing section, 22a, 22b terminal abnormality diagnosis section, 23a input terminal section, 23b output terminal section, 25, 26 memory.

Claims (6)

A method for supporting the design of a user program for a safety controller for enabling an input signal from a safety input device for a safety controller or an output signal for a safety output device to be processed by a user program,
A step of executing I / O assignment for assigning a different variable name to each of an input terminal for receiving an input signal from the safety input device of the safety controller or an output terminal for outputting an output signal to the safety output device. When,
Obtaining information on the safety input device or the safety output device; and
Based on the acquired information on the safety input device or the safety output device, two input terminals that receive two duplicated input signals from the safety input device or two for the safety output device are duplicated. A method for supporting design of a user program for a safety controller, comprising: prohibiting the use of one of two assigned variable names for two output terminals that output one output signal.   The step of acquiring information related to the safety input device or the safety output device includes a step of accepting data according to a user input related to the safety input device or the safety output device, and supports design of a user program for the safety controller according to claim 1 how to. The safety input device or the safety output device is connected to an input unit or an output unit that is communicably connected to the safety controller,
The user program of the safety controller according to claim 1, wherein the step of acquiring information related to the safety input device or the safety output device includes a step of receiving data related to the safety input device or the safety output device from the input unit or the output unit. How to help design. The safety input device or the safety output device is connected to an input unit or an output unit that is communicably connected to the safety controller,
For the input unit or output unit connected to the safety input device or safety output device, further comprising the step of setting a setting parameter corresponding to the safety input device or safety output device,
The method of supporting design of a user program for a safety controller according to claim 1, wherein the step of acquiring information related to the safety input device or the safety output device acquires information related to setting of the setting parameter. An apparatus for supporting the design of a user program of a safety controller for enabling a user program to process an input signal from a safety input device for a safety controller or an output signal for a safety output device,
Means for executing I / O assignment for assigning different variable names corresponding to input terminals for receiving an input signal from the safety input device of the safety controller or output terminals for outputting an output signal to the safety output device, respectively. When,
Means for obtaining information on the safety input device or the safety output device;
Based on the acquired information on the safety input device or the safety output device, two input terminals for receiving two duplicated input signals from the safety input device or duplexed for the safety output device 2 An apparatus for supporting the design of a user program for a safety controller, comprising means for prohibiting the use of one of two assigned variable names for two output terminals that output one output signal. A program for executing a function for supporting design of a user program of a safety controller for enabling a user program to process an input signal from a safety input device to a safety controller or an output signal to a safety output device in a computer. ,
The program is stored in the computer.
A step of executing I / O assignment for assigning a different variable name to each of an input terminal for receiving an input signal from the safety input device of the safety controller or an output terminal for outputting an output signal to the safety output device. When,
Obtaining information on the safety input device or the safety output device; and
Based on the acquired information on the safety input device or the safety output device, two input terminals that receive two duplicated input signals from the safety input device or two for the safety output device are duplicated. A program for executing processing, comprising a step of prohibiting use of one of two assigned variable names for two output terminals that output one output signal.

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