PLC maintenance support device and PLC maintenance support program

Abstract

PLC (programmable logic controller) maintenance support device, comprising: a signal identification label reader (1) for reading a signal address from a signal identification label (31 to 33) attached to an input and output signal cable (41 to 43) of a PLC (20) to identify the signal address of the input and output signal cable; a transmitter (2) for sending the signal address identified by the signal identification label reader to the PLC; a receiver (3) for receiving from the PLC the on or off state of a signal corresponding to the transmitted signal address; and a monitor (4) for displaying the received on or off state of the signal.

Description

BACKGROUND OF THE INVENTION Area of ​​the invention

[0001] The present invention relates to a PLC maintenance support device and a PLC maintenance support program, and more precisely relates to a PLC maintenance support device and a PLC maintenance support program that are used in an activation operation and a maintenance operation of a system comprising devices controlled by a PLC. Description of the related technique

[0002] Systems comprising devices (controlled devices) controlled by a programmable logic controller (PLC) are sometimes unable to provide the expected actuation. Therefore, to check the connection status of a signal cable, a method is known in which the voltage of a signal cable terminal connected to the controlled device is measured and compared with a value within the PLC (for example, Japanese Patent JP 3,713,387 B2, referred to below as Patent Specification 1). Also known, within the context of verification actuation, is a method in which the actuation of the controlled device is checked while an output signal of the PLC is temporarily and forcibly switched on or off (for example, Japanese Patent JP 3,161,487 B2, referred to below as Patent Specification 2).

[0003] In a generic procedure, the signal name of a signal cable whose connection status is to be checked is identified by a marker tube on which the signal name is printed, and the PLC displays a screen showing the signal's state. Next, the signal's voltage is measured by a test device and compared to the signal's state (on or off) on the PLC. Furthermore, as with an output signal, while the signal is temporarily and forcibly switched on or off by actuating the PLC, an actuation result is verified. This verification actuation must be performed several times to check the signals sequentially until the expected actuation is achieved, thus causing a decrease in efficiency.

[0004] Patents 1 and 2 disclose devices that improve the efficiency of the operation for checking the connection of the PLC. However, the inventions in these documents cannot check the connection of input signals. Likewise, as with output signals, the connections of the output signals cannot be checked unless the correspondences between the signal assignments of the PLC and the devices connected via the cables are identified in advance.

[0005] From publication DE 10 2008 007 230 A1, a method for configuring process control system inputs and outputs is known, in which a tag of a process control device is received from an input / output device and the process control device is assigned to a process control module based on the received tag. A wiring confirmation system and a cable connection management system are known from publications JP 2008-191 874 A and JP 2008-99 407 A. BRIEF SUMMARY OF THE INVENTION

[0006] One object of the present invention is to provide a PLC maintenance support device and a PLC maintenance support program that can quickly and easily determine whether the input and output signals of a PLC each have a value that indicates an on-state or off-state within the PLC during the actuation of the controlled devices.

[0007] A PLC maintenance support device according to an embodiment of the present invention comprises a signal identification label reader for reading a signal address from a signal identification label attached to an input and output signal cable of a PLC in order to identify the signal address of the input and output signal cable, a transmitter for sending the signal address identified by the signal identification label reader to the PLC, a receiver for receiving the on or off state of a signal corresponding to the sent signal address from the PLC, and a monitor for displaying the received on or off state of the signal.

[0008] A PLC maintenance support program according to an embodiment of the present invention comprises the steps of reading a signal address from a signal identification label attached to an input and output signal cable of a PLC in order to identify the signal address of the input and output signal cable, sending the identified signal address to the PLC, receiving the on or off state of a signal corresponding to the sent signal address from the PLC, and displaying the received on or off state of the signal. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The objects, features, and advantages of the present invention will become apparent from the following description of embodiments together with the accompanying drawings. These show: Fig. 1 a configuration diagram of a PLC maintenance support system comprising a PLC maintenance support device according to a first embodiment of the present invention; Fig. 2 a block diagram of the PLC maintenance support device according to the first embodiment of the present invention; Fig. 3 a flowchart of the operation of a PLC maintenance support program according to the first embodiment of the present invention; Fig. 4 a block diagram of a PLC maintenance support device according to a second embodiment of the present invention; Fig. 5 a flowchart of the operation of a PLC maintenance support program according to the second embodiment of the present invention; Fig. 6A an external view of a front face of a PLC maintenance support device according to a third embodiment of the present invention; Fig. 6B an external view of a rear side of the PLC maintenance support device according to the third embodiment of the present invention; Fig. 7 a block diagram of the PLC maintenance support device according to the third embodiment of the present invention; and Fig. 8 a configuration diagram of a PLC maintenance support system comprising a PLC maintenance support device, according to a fourth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] A maintenance support device and a PLC maintenance support program of a programmable logic controller (PLC) according to the present invention are described below with reference to the drawings. First embodiment

[0011] A PLC maintenance support device according to a first embodiment of the present invention is described first. Fig. Figure 1 is a configuration diagram of a PLC maintenance support system comprising the PLC maintenance support device according to the first embodiment of the present invention. Fig. Figure 1 shows an example where a PLC 20 and a device (hereinafter referred to as the "controlled device") 50, which is controlled by the PLC 20, are connected via three input / output (I / O) signal cables, i.e., a first I / O signal cable 41, a second I / O signal cable 42, and a third I / O signal cable 43. However, the number of I / O signal cables is not limited to three, but can be two, four, or more.

[0012] The first to third signal identification labels 31 to 33 are each attached to the first to third input and output signal cables 41 to 43. The number of signal identification labels is three, i.e., the same as the number of input and output signal cables in this embodiment, but is not limited to this. The number of signal identification labels can be two, four, or more, depending on the number of input and output signal cables.

[0013] A maintenance support device 101 emits a radio wave. When the maintenance support device 101 comes within a certain range of the first to third signal identification labels 31 to 33, the radio wave emitted by the maintenance support device 101 causes each of the first to third signal identification labels 31 to 33 to generate a small amount of electrical energy. This electrical energy transmits a radio wave signal containing information about a signal address. The maintenance support device 101 reads the radio wave signal to obtain the information about the signal address of each of the first to third signal identification labels 31 to 33.

[0014] The maintenance support device 101 displays the signal addresses derived from the information on the first to third signal identification labels 31 to 33, and the current signal states specified by the signal addresses within the PLC 20, on a monitor 4 of the maintenance support device 101. For example, the signal addresses of the first to third signal identification labels 31 to 33 are "X1.2", "X1.5", and "Y0.1", respectively. If, in this case, the current signal states within the PLC 20 are "ON", "OFF", and "ON", as shown in Fig. As shown in Figure 1, the signal addresses and signal states are displayed on monitor 4 as "X1.2: ON", "X1.5: OFF", and "Y0.1: ON". It should be noted that the signal addresses and signal states are displayed on monitor 4 when activated by a user at an actuation unit 7.

[0015] Furthermore, it is predetermined that "X- - - " indicates the address of an input signal that is fed into the PLC 20 by the controlled device 50, and "Y..." indicates the address of an output signal that is output from the PLC 20 to the controlled device 50. This preselection makes it possible to determine, based on its signal address, whether a signal sent via the input and output signal cable is an input signal or an output signal.

[0016] Next, the configuration of the PLC maintenance support device according to the first embodiment of the present invention will be described. Fig. Figure 2 is a block diagram of the PLC maintenance support device according to the first embodiment of the present invention. The maintenance support device 101 comprises a signal identification label reader 1, a transmitter 2, a receiver 3, and a monitor 4. The maintenance support device 101 further comprises a first radio communication device 5, a controller 6, and an actuating unit 7. The first radio communication device 5 can comprise the transmitter 2 and the receiver 3. The maintenance support device 101 can be made capable of communication with the PLC 20 via the first radio communication device 5.

[0017] The signal identification label reader 1 reads the signal address from each of the first to third signal identification labels 31 to 33, which are attached to the first to third input and output signal cables 41 to 43 of the PLC 20, in order to identify the signal address of each of the first to third input and output signal cables 41 to 43.

[0018] Transmitter 2 sends the signal addresses identified by signal identification label reader 1 to PLC 20. Receiver 3 receives from PLC 20 the on / off state of each signal corresponding to the sent signal address.

[0019] Monitor 4 displays the on / off states of the received signals. Fig. Figure 1 shows a display example on monitor 4.

[0020] If the maintenance support device 101 is placed near the first to third signal identification labels 31 to 33, which are attached to the first to third input and output signal cables 41 to 43 (see Fig. 1) within the specified range, the signal identification label reader 1 communicates with the first to third signal identification labels 31 to 33 to obtain the signal address of each of the first to third input and output signal cables 41 to 43. The signal identification label reader 1 sends the obtained signal addresses to the controller 6.

[0021] Controller 6 queries PLC 20 via the first radio communication device 5 for the current on / off state of the signal, which is specified by each of the signal addresses obtained from the first to third signal identification labels 31 to 33. Controller 6 also sends a command from the actuator 7. Controller 6 also controls the display on monitor 4.

[0022] An I / O controller 21 of the PLC 20 determines the states of the signals that the maintenance support device 101 has requested via a second radio communication device 22. The PLC 20 then informs the maintenance support device 101 of the signal states via the second radio communication device 22. The I / O controller 21 can also control the activation / deactivation of an output signal according to a command received via the second radio communication device 22.

[0023] Next, a PLC maintenance support program according to the first embodiment of the present invention will be described. Fig. Figure 3 is a flowchart of the operation of the PLC maintenance support program according to the first embodiment of the present invention. First, in step S101, the maintenance support device 101 identifies a signal address of each of the first to third input and output signal cables 41 to 43 from the first to third signal identification labels 31 to 33. In other words, the maintenance support device 101 reads the signal address from each of the first to third signal identification labels 31 to 33, which are attached to the first to third input and output signal cables 41 to 43 of the PLC 20, in order to identify the signal address of each of the first to third input and output signal cables 41 to 43.

[0024] Next, in step S102, the maintenance support device 101 transmits the identified addresses to the PLC 20 and queries the PLC 20 for the status of each signal. More precisely, transmitter 2 of the maintenance support device 101 sends the identified signal addresses to the PLC 20.

[0025] Next, in step S103, PLC 20 determines the state of each signal and informs maintenance support device 101 of the signal state. That is, maintenance support device 101 receives information at receiver 3 about the on / off states of the signals corresponding to the transmitted signal address from PLC 20.

[0026] Next, in step S104, the maintenance support device 101 displays the signal addresses and signal states on monitor 4. That is, monitor 4 displays the received on / off states of the signals.

[0027] The PLC maintenance support program according to the first embodiment of the present invention is preferably provided as a downloadable application.

[0028] As previously described, the PLC maintenance support device and the PLC maintenance support program according to the first embodiment of the present invention can quickly and easily determine whether the input and output signals of the PLC each have a value that indicates an on-state or an off-state within the PLC during the actuation of the controlled device. Second embodiment

[0029] Next, a PLC maintenance support device and a PLC maintenance support program according to a second embodiment of the present invention will be described. Fig. Figure 4 is a block diagram of the PLC maintenance support device according to the second embodiment of the present invention. The difference between a PLC maintenance support device 102 according to the second embodiment and the PLC maintenance support device 101 (see Figure 4) is shown below. Fig. 2) According to the first embodiment, the PLC maintenance support device 102 further comprises a command transmitter 8. If the signals whose on / off states are displayed on the monitor 4 include an output signal, the command transmitter 8 sends a command to the PLC 20 to switch the output signal on or off. The remaining configuration of the maintenance support device 102 according to the second embodiment of the present invention is the same as that of the maintenance support device 101 according to the first embodiment, so a detailed description thereof is unnecessary.

[0030] If the signals read from the first to third signal identification labels 31 to 33 (see Fig. 1) If the output signal includes an output signal, a user can command whether the output signal is switched on or off by the actuator 7. When a command to switch the output signal on or off is issued by the actuator 7, the command transmitter 8 of the maintenance support device 102 transmits the address of the output signal to the PLC 20 and commands the PLC 20 to switch the output signal on or off. Upon receiving the command, the PLC 20 controls the on / off actuation of the commanded signal.

[0031] In the example from Fig. The command transmitter 8 is located in the first radio communication device 5, but this is not the only possible location. The command transmitter 8 can be located outside the first radio communication device 5.

[0032] Next, the PLC maintenance support program according to the second embodiment of the present invention will be described. Fig. Figure 5 is a flowchart of the operation of the PLC maintenance support program according to the second embodiment of the present invention. First, in step S201, the controller 6 determines whether the signals specified by the signal addresses defined by the first to third signal identification labels 31 to 33 include an output signal or not. Note that the monitor 4 indicates whether the signals specified by the signal addresses defined by the first to third signal identification labels 31 to 33 are in an on or off state. If the signals specified by the defined signal addresses do not include an output signal, the operation returns to step S201, and the above determination step is repeated when the signals are updated.

[0033] If the signals specified by the given signal addresses include an output signal, the controller 6 determines in step S202 whether a command to turn the output signal on or off has been issued by the actuator 7. If no command is issued by the actuator 7, the actuator returns to step S202 to wait for a command to turn the output signal on or off.

[0034] When a command to turn the output signal on or off has been issued by the actuating unit 7, the maintenance support device 102 sends the address of the output signal to the PLC 20 in step S203 and commands the PLC 20 to turn the output signal on or off.

[0035] Next, in step S204, the PLC 20 controls the on / off activation of the commanded output signal.

[0036] The PLC maintenance support program according to the second embodiment of the present invention is preferably provided as a downloadable application.

[0037] As previously described, the PLC maintenance support device and the PLC maintenance support program according to the second embodiment of the present invention can quickly and easily control the temporary on / off actuation of the PLC output signal during actuation of the controlled device. Third embodiment

[0038] Next, a PLC maintenance support device according to a third embodiment of the present invention will be described. Fig. Figure 6A is an external view of a front face of a PLC maintenance support device 103 according to the third embodiment of the present invention. Fig. Figure 6B is an external view of a rear side of the PLC maintenance support device 103 according to the third embodiment of the present invention.

[0039] The maintenance support device 103 is equipped with a touch panel 11 on its front and a camera 9 on its rear. The camera 9 is directed towards the first to third input and output signal cables 41 to 43, which are connected to the device 50, which is controlled by the PLC 20, as shown in Fig. Figure 1 shows how to take a picture. However, the signal identification labels are not necessarily attached to the first to third input and output signal cables 41 to 43, but to marking tubes 30 on which signal addresses are printed.

[0040] As in Fig. As shown in Figure 6A, the image captured by camera 9 is displayed on touch panel 11. The markers 60 “ON” or “OFF”, indicating the state of each signal within PLC 20, are displayed near the corresponding marker tubes 30 in such a way that they are superimposed on the captured image. If the signals displayed on a screen of touch panel 11 include an output signal, the level of the output signal can also be reversed relative to a current value, i.e., from “ON” to “OFF” or from “OFF” to “ON”, by tapping the marker tube 30 on touch panel 11.

[0041] For example, a portable device such as a smartphone can be used as a maintenance support device 103.

[0042] Next, the configuration of the PLC maintenance support device according to the third embodiment of the present invention will be described. Fig. Figure 7 is a block diagram of the maintenance support device 103 according to the third embodiment of the present invention. The maintenance support device 103 comprises the camera 9, an image analyzer 10, a controller 6, a first radio communication device 5, and the touch panel 11. The maintenance support device 103 is capable of communicating with the PLC 20 via the first radio communication device 5. An image captured by the camera 9 is sent to the touch panel 11 and displayed on the screen. The image is also sent to the image analyzer 10. When the image analyzer 10 detects an object whose shape matches the shape of the pre-stored marker tube 30, the image analyzer 10 reads a printed signal address and sends the signal address to the controller 6.Controller 6 queries PLC 20 via the first radio communication device 5 for the current on / off state of a signal specified by the signal address obtained by image analyzer 10. An I / O controller 21 of PLC 20 informs maintenance support device 103 via a second radio communication device 22 about the state of the requested signal. Controller 6 of maintenance support device 103 receives the signal state information and displays the marker 60, which indicates the signal state, on touch field 11 near the marker tube 30 of the signal, such that it is superimposed on the image of each of the first to third input and output signal cables 41 to 43.

[0043] If the signals displayed on the touch panel 11 include an output signal when a user taps the image of the marker tubes 30 on the touch panel 11, the touch panel 11 issues a command to the controller 6 to invert the value of the signal. The controller 6 sends the command to the PLC 20 via the first radio communication device 5. Upon receiving the command, the I / O controller 21 of the PLC 20 interrupts a sequential program and inverts the value of the commanded signal relative to its current value.

[0044] A PLC maintenance support program for actuating the PLC maintenance support device according to the third embodiment of the present invention is preferably provided as a downloadable application.

[0045] According to the maintenance support device of the third embodiment of the present invention, tapping the image of the marker tube on the touch field switches the output signal between an on state and an off state, thereby enabling quick and easy control of the on / off actuation of the output signal from the PLC. Fourth embodiment

[0046] Next, a PLC maintenance support device according to a fourth embodiment of the present invention will be described. Fig.Figure 8 is a configuration diagram of a PLC maintenance support system comprising a PLC maintenance support device 104, according to the fourth embodiment of the present invention. The maintenance support device 104 is a data helmet (HMD). An image captured by a camera 9, located outside the maintenance support device 104, is displayed on an internal screen (not shown) of the maintenance support device 104. The signal names of the marker tubes 30 are read from the image, and the signal states requested by the PLC 20 are displayed in the image, as with the maintenance support device 103 according to the third embodiment.Although a procedure for commanding the reversal of the value of an output signal is not described in detail, a user can actually tap the marker tube of the output signal, and the tapping action can be detected by motion capture.

[0047] The present invention can also be combined with a programmable device that is portable and connectable to a PLC. This leads to a further increase in its practicality.

[0048] According to the PLC maintenance support device of the fourth embodiment of the present invention, the image of the marker tubes is displayed on the HMD, and tapping the marker tubes in the image switches the output signal between an on state and an off state, thereby enabling quick and easy control of the on / off actuation of the output signal from the PLC.

[0049] The PLC maintenance support device and the PLC maintenance support program according to the embodiments of the present invention can quickly and easily determine whether the input and output signals of the PLC each have a value that indicates an on-state or an off-state within the PLC during the actuation of the controlled device.

Claims

[1] PLC (programmable logic controller) maintenance support device, comprising: a signal identification label reader (1) for reading a signal address from a signal identification label (31 to 33) attached to an input and output signal cable (41 to 43) of a PLC (20) to identify the signal address of the input and output signal cable; a transmitter (2) for sending the signal address identified by the signal identification label reader to the PLC; a receiver (3) for receiving from the PLC the on or off state of a signal corresponding to the transmitted signal address; and a monitor (4) for displaying the received on or off state of the signal. [2] PLC maintenance support device according to claim 1, further comprising a command transmitter (8) for sending, when the signal whose on or off state is displayed on the monitor (4) is an output signal, a command to turn the output signal on or off to the PLC (20). [3] PLC maintenance support program, comprising the following steps: Reading a signal address from a signal identification label (31 to 33) attached to an input and output signal cable (41 to 43) of a PLC (20) to identify the signal address of the input and output signal cable; Sending the identified signal address to the PLC; Receiving from the PLC the on or off state of a signal corresponding to the transmitted signal address; and Displays the received on or off state of the signal. [4] PLC maintenance support program according to claim 3, further comprising the step of sending, when the signal whose on or off state is indicated is an output signal, a command to turn the output signal on or off to the PLC.

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