Patent Application
20140309787
The present application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2013-085321, filed Apr. 15, 2013. The contents of this application are incorporated herein by reference in their entirety.
1. Field of the Invention
The present invention relates to a device control system and a controller.
2. Discussion of the Background
Japanese Unexamined Patent Application Publication No. 2011-175351 discloses setting a jog/inching command issuing timing of a switch generated on a display device. The display device is coupled to a Programmable Logic Controller (PLC) and a multi-axis controller through serial communication cables. Specifically, the set jog/inching command issuing timing is when the switch is pressed or released (paragraphs 0029 and 0059).
According to one aspect of the present disclosure, a device control system includes a controller and an operation terminal. The controller is configured to control a device including a motor drive shaft. The operation terminal is communicably coupled to the controller. The operation terminal includes an external instruction synchronized drive command device and a periodic communication device. The external instruction synchronized drive command device is configured to notify the controller of a drive command for external instruction synchronized drive of the motor drive shaft. The periodic communication device is configured to communicate with the controller at a predetermined period at least during the external instruction synchronized drive. The controller includes an external instruction synchronized drive execution device and an external instruction synchronized operation execution stopping device. The external instruction synchronized drive execution device is configured to execute the external instruction synchronized drive based on the drive command. The external instruction synchronized operation execution stopping device is configured to monitor communication from the periodic communication device at least during the external instruction synchronized drive, and is configured to stop the external instruction synchronized drive when the communication from the periodic communication device is interrupted.
According to another aspect of the present disclosure, a device control system includes a controller and an operation terminal. The controller is configured to control a device including a motor drive shaft. The operation terminal is communicatively coupled to the controller. The operation terminal includes a periodic communication device configured to communicate with the controller at a predetermined period. The controller is configured to monitor communication from the periodic communication device, and is configured to stop the motor drive shaft when the communication from the periodic communication device is interrupted.
According to the other aspect of the present disclosure, a controller is used in the above-described device control system.
A more complete appreciation of the present disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The embodiments will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.
As far as the inventors know, in manual operation of a motor drive shaft such as a servo shaft, it is common practice to connect a switch for direct manual operation to a terminal at a controller of the servo shaft, and to operate the motor shaft only when the switch is ON. When the switch is not connected to the terminal, the switch is regarded as being in OFF state. Thus, when the wiring between the switch and the controller is broken, the servo shaft immediately stops its operation.
The connecting wire between the controller and the switch is constantly occupied by a signal indicating the state of the switch. Specifically, a high or low signal indicating that the switch is ON or OFF is constantly applied to the connecting wire. In the following description, such a communication connection is referred to as an occupied communication.
Factory Automation (FA) has become highly sophisticated and complex. This has led to widespread use of unoccupied communication to simplify the communication connection between industrial devices. As used herein, the unoccupied communication refers to a type of communication where various types of information are transmitted through a data connection wire on a time-division basis, instead of the data connection wire being dedicated to a specific type of information. The unoccupied communication includes a wide variety of information communication methods such as serial communication and packet communication. The unoccupied communication also includes wireless transmission. Instead of using physical switches, virtual switches implemented on graphical user interfaces (GUI) such as touch panels are often used.
With the unoccupied communication, it is difficult or impossible to constantly acquire the state of the switch from a connection destination device, as opposed to the occupied communication. An exemplary way of acquiring the state of the switch is to make a notification in the form of information indicating that the state of a switch, physical or virtual, has changed.
Here, using the unoccupied communication to manually operate a motor drive shaft can disable the notification of the switch being turned OFF when communication interruptions occur due to breakage of the communication wire or other causes. This, in turn, can disable the stopping of the operation of the motor drive shaft. Additionally, in using a GUI to manually operate the motor drive shaft, no or minimal consideration has been paid to how to construct the GUI in order to reduce mal-operations caused by human errors and other errors.
In view of this, the inventors studied and developed a device control system that controls a device including a motor drive shaft in an attempt to improve the safety of driving the motor drive shaft. As a result, the inventors conceived of a novel and unique device control system and controller. An embodiment of the unique device control system and controller will be described in detail below.
The controller 2 is what is called a PLC, which controls at least one device based on a control program. As used herein, the term “control program” means information that describes an operation of a device coupled to the controller 2 in terms of a logical relationship or a time axis. Examples of the control program include, but are not limited to, what is called a ladder program and a time chart. Exemplary control targets of the controller 2 include, but are not limited to, input-output devices such as: motor drive shafts, such as the linear slider 5, that are driven through the servo controller 3; the switch 6; and the lamp 7. A program executed by the controller 2 is input into and stored in the controller 2 as electronic data. The controller 2 includes an information communication connector 2a.
The servo controller 3 is a combination of a servo amplifier to control a servo motor and a control circuit of the servo amplifier. The servo controller 3 is provided with an information communication connector 3a and a servo connector 3b. The information communication connector 3a provides connection with other devices such as the controller 2. The servo connector 3b provides connection with servo mechanisms such as the linear slider 5. In this embodiment, the servo connector 3b is connected with the linear slider 5, which is an exemplary motor drive shaft.
The linear slider 5 is a combination mechanism of a servo motor, an encoder, ball screws, and a slide table. The ball screws are coupled to the output shafts of the servo motor. The slide table is guided by a linear guide and driven by the ball screws. The slide table is driven in accordance with the output of the servo controller 3. As used herein, the term “motor drive shaft” refers to a mechanism driven by a drive source that is an electric motor, such as the servo motor, capable of controlling the amount of driving. The term motor drive shaft is thus called when the electric motor is in focus. The electric motor may be other than the servo motor; other examples include, but are not limited to, a step motor. Also the electric motor may not necessarily provide rotative power; it is also possible to use a linear motor.
The I/O unit 4 includes an information communication connector 4a and a plurality of input-output contact points. The information communication connector 4a provides connection with other devices such as the controller 2. The plurality of input-output contact points are where input-output devices are connected. The input-output contact points of the I/O unit 4 include input connectors 4b and output connectors 4c. The input connectors 4b include a plurality of contact points for input use (which will be referred to as input contact points), and the output connectors 4c include a plurality of contact points for output use (which will be referred to as output contact points). The I/O unit 4 transmits input states of the input contact points of the input connectors 4b to the controller 2 through the information communication connector 4a. The I/O unit 4 also controls states of the output contact points of the output connectors 4c in accordance with a command transmitted from the controller 2 through the information communication connector 4a. A function of the I/O unit 4 is to add external input-output contact points to the controller 2. In this embodiment, exemplary input-output devices connected to the I/O unit 4 are the switch 6 and the lamp 7. The switch 6 is a mechanical switch of the normally open (that is, contact the point A) type and connected to the input connector 4b. The lamp 7 is connected to the output connector 4c. As used herein, the term “input-output contact point” refers to a contact point at which information is input or output depending on highness or lowness of impedance. The term input-output device refers to a device coupled to the controller 2 at an input-output contact point.
In this embodiment, as shown in
The operation terminal 8 is a human machine interface (HMI) to operate a motor drive shaft, which is the linear slider 5 in this embodiment, through the controller 2. The driving of the motor drive shaft that the controller 2 controls through the operation terminal 8 needs to be immediate in synchronization with an instruction from an external device (the operation terminal 8), as opposed to the type of control that executes a preprogrammed operation. Such an operation will be hereinafter referred to as external instruction synchronized drive. The external instruction synchronized drive is approximately analogous to what are generally called jogging, inching, and similar operations.
The operation terminal 8 also serves as a control program generation device, which is not directly related to this embodiment and thus will not be elaborated here. The control program generation device generates a control program to be executed by the controller 2. The generated control program is transferred to and stored in the controller 2.
While the operation terminal 8 may be a dedicated apparatus, the example shown is a general-purpose computer. This computer is implemented as the operation terminal 8 by executing a computer program. The computer program may be stored in any of various light discs or a semiconductor memory such as a computer readable information storage medium, and the computer preferably installs the computer program from the medium. The computer may also download the computer program from any of various information communication networks such as the Internet. The computer program may also be implemented using what is called cloud computing; specifically, the function of the computer program may be provided from a server at a remote place through an information communication network. In this embodiment, the function of the operation terminal 8 is implemented as a part of the control program generation device.
For simplified description and illustration, those configuration details and wiring details irrelevant to understanding of this embodiment are omitted from the above description and
The user interface 80 shows information to the user and receives information input from the user. The user interface 80 includes an input receiving device 80a and an image display device 80b. The input receiving device 80a receives information input from the user. The image display device 80b shows information to the user by displaying the information in the form of an image. In this embodiment, the input receiving device 80a corresponds to the input device 8e shown in
The information processing section 81 performs various kinds of information processing in the operation terminal 8. Specifically, the information processing section 81 corresponds to the CPU 8a and the work area RAM 8b shown in
The interface 82 provides electrical communication between the operation terminal 8 and an external device, and corresponds to the I/O 8f shown in
The controller 2 includes interfaces 20, a register 21, an external instruction synchronized drive execution device 22, and an external instruction synchronized drive stopping device 23.
The interface 20 provides electrical communication between the controller 2 and an external device. The controller 2 is coupled to the operation terminal 8 and the motor drive shaft 9 through the interface 20. The motor drive shaft 9 represents a combination of the servo controller 3 and the linear slider 5 shown in
The register 21 is an information storage area, and may be a semiconductor memory such as a general RAM. A predetermined area of the register 21 is used as a drive state holding register 21a, and another predetermined area of the register 21 is used as a communication interruption detection register 21b. The content of the register 21 is rewritable directly by an external device through the interface 20 using a method such as direct memory access (DMA). This means that the operation terminal 8, which is coupled to the controller 2, is able to rewrite the content of the register 21.
The external instruction synchronized drive execution device 22 transmits a signal as a command for the external instruction synchronized drive to the motor drive shaft 9 through the interface 20. In response, the motor drive shaft 9 executes the external instruction synchronized drive. The external instruction synchronized drive stopping device 23 detects a communication interruption that is due to some causes such as physical breakage of the communication line between the operation terminal 8 and the controller 2. Thus, the external instruction synchronized drive stopping device 23 stops the external instruction synchronized drive. The operations of these blocks will be described in detail later.
For simplified description and illustration, the above-described functional blocks of the device control system 1 are only those functions relevant to understanding of this embodiment, and those functions less relevant are omitted from description. Hence, the device control system 1 may have various other functions in addition to those functions shown in
Next, operations of the device control system 1 according to this embodiment will be described. First, in the operation terminal 8, when the input receiving device 80a receives from the user an instruction to start the external instruction synchronized drive, the instruction is transmitted to the external instruction synchronized drive command device 81a. The external instruction synchronized drive command device 81a transmits a signal as a drive command to the controller 2 through the interface 82. The drive command is for the start of the external instruction synchronized drive.
The controller 2 is notified of the drive command by the external instruction synchronized drive command device 81a. Thus, information indicating that the motor drive shaft 9 is in driving state is written and held in the drive state holding resister 21a. This ensures continued indication of the motor drive shaft 9 being in driving state even when the drive command is notified from the operation terminal 8 through the unoccupied communication only once. When the drive state held in the drive state holding resister 21a indicates “driving”, the external instruction synchronized drive execution device 22 transmits a signal to the motor drive shaft 9 through the interface 20. Thus, the external instruction synchronized drive is executed.
In the operation terminal 8, when the input receiving device 80a receives from the user an instruction to stop the external instruction synchronized drive, the instruction is transmitted to the external instruction synchronized drive command device 81a. The external instruction synchronized drive command device 81a transmits a signal as a stopping command to the controller 2 through the interface 82. The stopping command is for stopping of the external instruction synchronized drive.
The controller 2 is notified of the stopping command by the external instruction synchronized drive command device 81a. Thus, information indicating that the motor drive shaft 9 is in stopped state is written and held in the drive state holding resister 21a. When the drive state held in the operation state holding resister 21a indicates “stopped”, the external instruction synchronized drive execution device 22 transmits no signal to the motor drive shaft 9, or transmits a signal (hold signal) to stop the motor drive shaft 9. Thus, the external instruction synchronized drive is stopped.
In the above-described operations, when the communication between the operation terminal 8 and the controller 2 is interrupted after the drive command has been transmitted, the controller 2 is not able to receive the stopping command. In view of this, in the device control system 1 according to this embodiment, upon notification of the drive command, the periodic communication device 81b of the operation terminal 8 communicates with the controller 2 through the interface 82 at a predetermined period. While the predetermined period may be set at any value, an exemplary predetermined period is 100 ms. It may be the user that sets the predetermined period. In this embodiment, the communication performed by the periodic communication device 81b is to write a value into the communication interruption detection resister 21b. The value is changed every time the communication is performed. For example, when the communication interruption detection resister 21b has an eight-bit area, the periodic communication device 81b writes into the communication interruption detection resister 21b a value incremented by 1 (0, 1, 2, 3, . . . ) every time the communication is performed. Upon reaching 255, the value returns to 0. It will be readily appreciated that the value to be written may not necessarily increase by 1 every time the communication is performed. The value may also decrease by 1 or may change under any other rules, insofar as the currently written value differs from the value in the previous communication. The periodic communication device 81b may perform communication regardless of whether the drive command has been made. Still, to avoid unnecessary increase in the communication amount while the motor drive shaft 9 is stopped, the communication is preferably stopped while no drive command is made.
Every time the periodic communication device 81b communicates with the controller 2, a new value is written into the communication interruption detection resister 21b. The value is written at a predetermined period insofar as the communication between the operation terminal 8 and the controller 2 is established. Thus, insofar as the communication between the operation terminal 8 and the controller 2 is not interrupted, the content of the communication interruption detection resister 21b changes at a predetermined period, which is 100 ms in this embodiment.
The external instruction synchronized drive stopping device 23 refers to the content of the communication interruption detection resister 21b at a period equal to or longer than the predetermined period. When the current content of the communication interruption detection resister 21b found in the new reference is different from the content of the communication interruption detection resister 21b found in the previous reference, the external instruction synchronized drive stopping device 23 determines that the communication between the operation terminal 2 and the controller 2 is normal. In this case, the external instruction synchronized drive stopping device 23 performs no processing. When the current content of the communication interruption detection resister 21b found in the new reference is the same as the content of the communication interruption detection resister 21b found in the previous reference, this indicates that the communication between the operation terminal 2 and the controller 2 is interrupted. In this case, the external instruction synchronized drive stopping device 23 writes in the drive state holding resister 21a information indicating that the drive state of the motor drive shaft 9 is “stopped”.
Here, assume that the motor drive shaft 9 is driven under position following control, that is, control to set the current position of the motor drive shaft 9 at a set target position. In this case, the external instruction synchronized drive stopping device 23 writes into the drive state holding resister 21a information indicating that the drive state of the motor drive shaft 9 is “stopped”, and resets the difference between the current position and the target position of the motor drive shaft 9. When the motor drive shaft 9 uses a servo motor, the reset of the difference may be by transmitting a servo-off signal to the servo controller 3 to implement a servo OFF state. It is also possible to simply reset the target position, thereby cancelling the position following control.
In this respect, assume that the motor drive shaft 9 is stopped without reset of the difference between the current position and the target position of the motor drive shaft 9. In this case, the position following control continues through the time when the drive stop state is released. This makes it possible for the motor drive shaft 9 to perform an unexpected operation such as sudden acceleration in an attempt to make up for the difference. In view of this, the external instruction synchronized drive stopping device 23 writes into the drive state holding resister 21a information indicating that the drive state of the motor drive shaft 9 is “stopped”. Then, simultaneously with the motor drive shaft 9 being stopped, the external instruction synchronized drive stopping device 23 resets the difference between the current position and the target position of the motor drive shaft 9. In this manner, the external instruction synchronized drive stopping device 23 prevents an unexpected operation that can occur when the drive stop state is released.
Thus, in the device control system 1 according to this embodiment, the operation terminal 8 is provided with the periodic communication device 81b, and the controller 2 is provided with the communication interruption detection resister 21b and the external instruction synchronized drive stopping device 23. This ensures that the external instruction synchronized drive is immediately stopped when the communication between the operation terminal 8 and the controller 2 is interrupted. The periodic communication from the periodic communication device 81b is detected through the communication interruption detection resister 21b. This is because the operation terminal 8 and the controller 2 are independent devices, and thus it is difficult to synchronize the operations of the periodic communication device 81b and the external instruction synchronized drive stopping device 23 and difficult to provide direct communication between the periodic communication device 81b and the external instruction synchronized drive stopping device 23. Still, it is possible to use a method other than using the communication interruption detection resister 21b described here, insofar as the external instruction synchronized drive stopping device 23 detects the interruption of the periodic communication from the periodic communication device 81b.
The above-described configuration of detecting the interruption of the communication between the operation terminal 8 and the controller 2 is especially effective when the operation terminal 8 and the controller 2 are coupled to one another by the unoccupied communication. Still, the above-described configuration also applies in the case where the operation terminal 8 and the controller 2 are coupled to one another by the occupied communication. Additionally, the detection of the interruption of the communication is also effective for a normal drive command, as well as for use during the external instruction synchronized drive of the motor drive shaft.
Next, description will be made by way of examples with regard to an operation window that the operation terminal 8 displays on its image display device 80b and to operations performed on the window.
A title area 11 is on the top edge of the window 10. Under the title area 11, an area hereinafter referred to as ribbon 12 is disposed. The ribbon 12 contains icons of various commands available to be designated with respect to the operation terminal 8. On top of the ribbon 12, a plurality of kinds of tabs are disposed. The ribbon 12 is switchable among the plurality of kinds of tabs, and in each of the tabs, the ribbon 12 provides different kinds of icons. Since
On top of the operation window 14, tabs 15 are disposed. By selecting among the tabs 15, the user selects any one of a plurality of types of the operation window 14. The window switch device 81c shown in
The operation window 14 shown in
The movement speed of the motor drive shaft during the external instruction synchronized drive is set by making an input into an entry field 103. A field 104 is labeled as “Counter” and serves as a current position counter representing a relative position of the motor drive shaft from an arbitral position. A clear button 105 is used to reset the value of the current position counter, that is, set the value of the current position counter at 0. Thus, the current position counter indicates a relative position of the motor drive shaft from the position at the time when the clear button 105 was last pressed. For example, when the clear button 105 is pressed when the motor drive shaft is 400 mm away from the machine origin and then the motor drive shaft moves to a position 600 mm away from the machine origin, 200 mm is displayed in the current position counter field 104. When the motor drive shaft 9 further moves to a position away from the machine origin by 300 mm, −100 mm is displayed in the current position counter field 104.
A stop button 206 is used to stop the motor drive shaft in the middle of driving. A return button 207 is used to make the motor drive shaft return to a state before the previous operation performed on the motor drive shaft. The return button 207 will be described in more detail. When the external instruction synchronized drive command device 81a makes a drive command, the return operation command device 81d stores the displacement of the motor drive shaft or the pre-movement position coordinates of the motor drive shaft. Then, when the return button 207 is operated, the external instruction synchronized drive command device 81a reverses the positivity or negativity of the displacement that is stored, and makes a command to drive the motor drive shaft in the reverse direction by the same distance, or makes a command to drive the motor drive shaft to move back to the position coordinates that are stored. A command is made for the operation of making the motor drive shaft return to the state before the previous operation performed on the motor drive shaft.
The return button 207 may be deactivated to prohibit operation on the return button 207 until the external instruction synchronized drive is executed. It is also possible to prohibit operation on the return button 207 when a tab 15 is operated to make a switch in the operation window 14, or when the external instruction synchronized drive is performed from the operation window 14 corresponding to a window other than the normal rotation direction displacement setting operation window 200. This eliminates or minimizes an unexpected operation caused by accidental operation on the return button 207.
It is also possible to prohibit operation on the return button 207 when the motor drive shaft is already in return-to-origin set state, or when the origin is not set. The prohibition may be set on the operation terminal 8 side or on the controller 2 side. When the operation on the return button 207 is prohibited on the operation terminal 8 side, it is possible to hold information indicating whether the motor drive shaft is in return-to-origin state or indicating whether the origin is set and to, for example, deactivate the return button 207 based on the information. When the operation on the return button 207 is prohibited on the controller 2 side, it is possible to make an alarm or a similar notification when the return button 207 is operated.
The arrangement of the buttons will be described. In the example shown in
In the reverse rotation direction displacement setting operation window 300, the drive button 305 is on the right side of the stop button 306, and the return button 307 is on the left side of the stop button 306. This order of arrangement is opposite to the order of arrangement in the normal rotation direction displacement setting operation window 200 shown in
This will be described in detail. When the displacement is set to move the motor drive shaft, once an instruction for driving is made, the motor drive shaft automatically continues to move by the set displacement unless the stop button is pressed. In such an operation, if the normal rotation of the motor drive shaft is mistaken as the reverse rotation or when the reverse rotation is mistaken as the normal rotation, an interference between devices or similar situations can occur. In view of this, in this embodiment, the normal rotation direction displacement setting operation window 200 and the reverse rotation direction displacement setting operation window 300 are separate from each other and selectively switchable so that only one of the windows 200 and 300 is displayed. Thus, the drive button 205 for the normal rotation direction and the drive button 305 for the reverse rotation direction are not displayed at the same time. This eliminates or minimizes erroneous selection of the buttons. Furthermore, in this embodiment, the drive button 205 for the normal rotation direction and the drive button 305 for the reverse rotation direction are at on mutually opposite positions. Thus, one drive button is not displayed on the same coordinates of the other drive button, and one return button is not displayed on the same coordinates of the other return button. This eliminates or minimizes such a situation that the normal rotation of the motor drive shaft is mistaken as the reverse rotation, or the reverse rotation is mistaken as the normal rotation even when a wrong tab 15 is selected. This, in turn, improves the safety of driving the motor drive shaft.
Preferably, the displacement input into the entry field 204 in the normal rotation direction displacement setting operation window 200 is set and held independently of the displacement input into the entry field 304 in the reverse rotation direction displacement setting operation window 300. In other words, the displacement input into the entry field 204 in the normal rotation direction displacement setting operation window 200 preferably does not affect the displacement in the reverse rotation direction displacement setting operation window 300. Similarly, the displacement input into the entry field 304 in the reverse rotation direction displacement setting operation window 300 preferably does not affect the displacement in the normal rotation direction displacement setting operation window 200.
Thus, when the drive in the normal rotation direction and the drive in the reverse rotation direction repeat with mutually different displacements, it is not necessary to input the displacements on every drive occasion, which improves operability. For example, assume that a 10-mm movement of the motor drive shaft in the normal rotation direction repeats five times, and then a 50-mm movement of the motor drive shaft in the reverse rotation direction returns the motor drive shaft to its original position. In this case, 10 mm is input into the entry field 204 in the normal rotation direction displacement setting operation window 200, and 50 mm is input into the entry field 304 in the reverse rotation direction displacement setting operation window 300. This eliminates the need for inputting the displacements every time an instruction is made to move the motor drive shaft. For the movement of the motor drive shaft back to its original position (movement in the reverse rotation direction in this embodiment), only a single instruction is necessary. Furthermore, when a displacement is input into the entry field 204 in the normal rotation direction displacement setting operation window 200, this displacement does not unintentionally change the displacement input into the entry field 304 in the reverse rotation direction displacement setting operation window 300. Similarly, when a displacement is input into the entry field 304 in the reverse rotation direction displacement setting operation window 300, this displacement does not unintentionally change the displacement input into the entry field 204 in the normal rotation direction displacement setting operation window 200. This eliminates or minimizes unexpected situations such as the motor drive shaft operating by an unintended displacement.
The stop button 406 is used to stop the motor drive shaft in the middle of driving. The return button 407 is used to return the motor drive shaft to a state before the previous operation performed on the motor drive shaft.
Finally,
In order to set the origin return operations in more detail, it is possible to provide other entry fields than the field shown in
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-085321 | Apr 2013 | JP | national |
