Master PLC Ladder Logic for Flexible Robot Cell Reordering
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Solution Overview
Problem
Changing the order of robot cells in a production line requires significant changes to parameter settings and ladder programs, necessitating familiarity with complex parameters and program structures, which is burdensome and inefficient.
Innovation Solution
A controller system with a master PLC that receives input signals indicating the order of robot cell operations and work completion, outputs operation instructions based on a combination of these signals, and stores multiple ladder programs for various operation patterns, allowing for flexible reconfiguration without extensive program rewriting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the order of robot cells is changed, then the production line can adapt to product specification changes, but parameter settings and ladder programs must be changed which requires familiarity with complex parameters and program structures
Solution Approach 1:
The system pre-configures multiple ladder programs corresponding to different robot cell order patterns in advance. When reconfiguration is needed, the system simply selects from these pre-prepared programs rather than creating new ones, eliminating the need for operators to understand complex program structures.
Solution Approach 2:
The invention changes the approach from modifying individual parameter settings to changing a single pattern selection parameter. By selecting a predetermined pattern that matches the desired robot cell order, the system automatically configures all necessary parameters without requiring detailed parameter adjustment.
2Adaptability or versatility
If the order of robot cells is changed, then production line flexibility is improved, but the burden of changing parameter settings and ladder programs increases
Solution Approach 1:
Each predetermined pattern serves multiple functions: it defines the robot cell order, configures I/O address mappings, and sets up the ladder program logic simultaneously. This multi-functionality reduces the reconfiguration burden to a single pattern selection action.
Solution Approach 2:
The system uses template-based predetermined patterns that can be copied and selected. Instead of creating custom configurations each time, operators copy from pre-defined patterns that have been optimized for different production scenarios.
3Reliability
If I/O addresses between PLCs are changed to reflect new robot cell order, then correct communication is maintained, but significant program changes are required
Solution Approach 1:
I/O address mappings for different robot cell orders are predetermined and stored in the system. When reconfiguring, the appropriate pre-mapped addresses are automatically selected rather than manually reconfigured, ensuring communication correctness while minimizing program changes.
Solution Approach 2:
The system abstracts I/O address configuration into pattern-based parameters. By changing the pattern selection parameter, all associated I/O address mappings are automatically updated according to the selected pattern, maintaining communication reliability without requiring detailed address reconfiguration.
Data Source
AI summary
To provide a controller capable of facilitating changing of the order of robot cells, a control system, and a ladder program. A master PLC includes a master input unit that receives a first input signal indicating the order of operation of robot cells, and a second input signal indicating work completion in the robot cells from each of the plurality of robot cells; a master output unit that outputs an output signal for instruction of operation to the robot cell specified on the basis of combination of the first input signals, and the second input signal according to the ladder program; and a storage unit that stores a plurality of the ladder programs corresponding to a plurality of patterns of the order of operation comprising at least some of the plurality of robot cells.