Bypass Circuit for Programmable Controller Program Reactivation

Solution Overview

Problem

Existing operation program editing devices for programmable controllers struggle with reactivating SFC language programs that have stopped mid-execution, requiring time-consuming programming operations and making it difficult for third parties to understand the program content.

Innovation Solution

An operation program editing device with a bypass circuit generation unit that allows for the creation of a bypass circuit to skip certain steps during reactivation, along with selection units for choosing the last and first steps within the skipped range, enabling seamless reactivation and clear display of operation content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a ladder program is assigned to each transition with halfway activation flags and activation conditions, then the program can be reactivated after halfway stop, but the programming operation time increases significantly

Engineering Contradiction:

Improvereactivation capabilityVSAvoidprogramming operation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The program is divided into multiple steps with clear segmentation, where each step represents a distinct control process. The bypass circuit is segmented to allow selective skipping of specific steps (from bypass start step to bypass end step) while maintaining the ability to reactivate the program. This segmentation enables simpler programming compared to assigning complex ladder logic to every transition.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A bypass circuit is introduced as an intermediary mechanism to facilitate program reactivation. The bypass circuit includes a bypass start flag and bypass end flag that act as mediators to control the flow of execution. When reactivation is needed, the system sets the bypass start flag to skip from the bypass start step to the bypass end step, avoiding the need for complex ladder program modifications at each transition.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If complex ladder programs with halfway activation flags are used for reactivation, then the program can resume after troubles, but the program content becomes difficult for third parties to understand

Engineering Contradiction:

Improvereactivation capabilityVSAvoidprogram understandability

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The program is divided into multiple steps with clear segmentation, where each step represents a distinct control process. The bypass circuit is segmented to allow selective skipping of specific steps (from bypass start step to bypass end step) while maintaining the ability to reactivate the program. This segmentation enables simpler programming compared to assigning complex ladder logic to every transition.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses SFC (Sequential Function Chart) language to describe the program flow, which provides a visual copy of the program logic that is easily understandable by third parties. The bypass circuit logic is represented in the SFC diagram through graphical elements showing the bypass path, making the reactivation mechanism visible and comprehensible without requiring deep knowledge of underlying ladder logic.

Inventive Principle:

Principle #26Copying

3Ease of operation

If the program executes sequentially from the top as prescribed by SFC language, then the program structure is clear and easy to understand, but reactivation after halfway stop becomes difficult

Engineering Contradiction:

Improveprogram understandabilityVSAvoidreactivation capability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A bypass circuit is introduced as an intermediary mechanism to facilitate program reactivation. The bypass circuit includes a bypass start flag and bypass end flag that act as mediators to control the flow of execution. When reactivation is needed, the system sets the bypass start flag to skip from the bypass start step to the bypass end step, avoiding the need for complex ladder program modifications at each transition.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bypass circuit is pre-configured with designated bypass start steps and bypass end steps before program execution. This preliminary setup allows the system to quickly reactivate by simply setting the bypass start flag, without needing to analyze or modify the program structure at the time of reactivation. The SFC program maintains its sequential clarity while the pre-configured bypass path enables immediate resumption from the appropriate step.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10416641B2Operation program editing device and method for editing operation program

Publication Date: 2019.09.17 JTEKT CORP

AI summary

An operation program editing device includes a program editing portion configured to edit an operation program executable by a programmable controller that controls a facility, and the program editing portion includes a bypass circuit generation unit that generates a bypass circuit including a bypass path for skipping execution of some of the plurality of steps at a time of reactivation of the facility, a first selection receiving unit that receives selection of a last step, from among the plurality of steps, within a range where the execution is skipped by the bypass circuit, and a second selection receiving unit that receives selection of a first step, from among the plurality of steps, within the range where the execution is skipped by the bypass circuit.