JPH05266290A - Programmable controller - Google Patents

Abstract

PURPOSE:To display exchange time appropriately by performing service life prediction calculation based on an electrical information value printed on a relay circuit with contact, and comparing the number of times of operations of the relay circuit with contact with a count result. CONSTITUTION:A transformer which fetches a voltage value and a current transformer which fetches a current value applied to the relay circuit 6a with contact are provided at an input part 10a. A central arithmetic processing part (CPU) 1 executes a service life prediction calculation program stored in the L area 2a of a system program storage part 2 based on values fetched from them, and stores an input value and a calculation result in the area 4c of the system program storage part 2. The CPU 1 performs automatic count of the number of times of turning on and off operations of a relay 6a with contact by a count program stored in the CA area 2b of the system program storage part 2, and stores it in the area 4c of a data storage part 4. The count value is compared with a service life prediction calculation result, and when the count value goes to a value less than the prescribed range of the service life prediction calculation result, it is displayed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a programmable controller containing a contact relay for driving an external load, and more particularly to a programmable controller suitable for predicting the life of the contact relay.

[0002]

2. Description of the Related Art A programmable controller has a built-in reed relay for driving an external load. Generally, this reed relay has a life, and mechanically it is about 100,000 times. This contact relay is generally 1A
Since the contact capacity is from several A to several A and the service life varies depending on the operating conditions such as the applied voltage value and the current amount, it is necessary to know exactly when it should be replaced and to replace it before it breaks down.

In a conventional programmable controller, as shown in Japanese Patent Laid-Open No. 62-152003, a reference value (the number of times of opening and closing) as life information is input from a program device and stored in a storage unit, and each operation of a contact relay is performed. The reference value stored in 1 is subtracted by one, and when the value becomes zero, the alarm indicates that the reference value has been reached.

That is, as shown in FIG. 25, a conventional programmable controller 100 includes a central processing unit 1, a system program storage unit 2, a sequence program storage unit 3, a data storage unit 4, and an input unit 5. When,
The configuration has the output unit 6, the interface 7 to which the programming device 8 is connected, and the alarm 9. The data storage unit 4 is divided into an area 4a and an area 4b. The area 4a stores an output number input by the program device 8, and the area 4b is a reference as life information input or calculated by the program device 8. The value (opening and closing times) was stored.

Each time the output of the number stored in the area 4a of the data storage unit 4 changes from OFF to ON during operation of the programmable controller and the contact relay operates,
Subtract one from the reference value stored in the area 4b, and when the data stored in the area 4b becomes zero, the alarm 9 outputs the output of the number stored in the area 4a of the data storage unit 4 as a reference. It displayed that the value had been reached.

[0006]

In the conventional programmable controller shown in FIG. 11, in order to obtain the life information of a relay or the like, the program device 8 outputs the output number and the reference value or the output number and the driving condition of the peripheral device. Must be input, which is cumbersome, and when the driving conditions of the peripheral devices are changed when the system related to the programmable controller is changed, the programming device 8 must reset the conditions.

Furthermore, since the history before the change does not remain, the total number of operations up to the present cannot be known. Further, in the conventional programmable controller, since it is subtracted from the reference value, it is not possible to know what the initial setting value was, and it is not possible to display the operation degree up to the present time from the current remaining number. Further, there is a problem that when the remaining number reaches zero, the display remains zero even after passing the remaining number, and the opening / closing number after passing zero is not displayed.

It is an object of the present invention to provide a programmable controller that accurately and automatically predicts the life of a built-in contact relay and displays an appropriate replacement time.

[0009]

The above object is to provide a programmable controller with means for fetching electrical information such as a voltage value and a current value applied to a contact relay circuit built in the output section. And a counting means for counting the number of times of operation of the contact relay, the life prediction calculation means for performing the life prediction calculation based on the value taken in by and the display means for displaying the result of the calculation means, and the counting means. This is achieved by providing a comparing means for comparing the life prediction calculation result and transmitting the result of the counting means to the display means before a predetermined range of the life prediction calculation result.

[0010]

The programmable controller automatically takes in the voltage value and the amount of current applied to the built-in contact relay circuit, and calculates the life prediction of the contact relay. At this time, the fetched value and the calculation result are stored in the data storage unit. Further, the number of times the contact relay is turned on is automatically counted and constantly compared with the calculation result, and the count value is stored in the data storage section. At this time, if the voltage value and current amount applied to the above-mentioned contact relay fluctuates beyond the specified values, the data related to the life prediction immediately before the fluctuation is retained and remains as a history, and a new life prediction calculation is performed. The above series of operations is repeated. Here, when the count value comes before the predetermined range of the life prediction calculation result, the count value is displayed to notify this.

[0011]

Embodiments of the present invention will be described below with reference to the drawings.

A first embodiment of the present invention will be described with reference to FIGS.

The configuration of the programmable controller (PC) in the first embodiment of the present invention will be described with reference to FIG.
The programmable controller 100 is a logical operation
Central arithmetic processing unit (CP that controls arithmetic operations and each part
U) 1, a system program storage unit (ROM) 2 that stores the contents and procedures controlled by the CPU 1, a rewritable sequence program storage unit 3 that stores the user's sequence program, the calculation result of the CPU 1 and the like. A rewritable data storage unit 4 for storing, an input unit 5 for inputting a signal from an external device, an output unit 6 incorporating a contact relay circuit 6a for driving an external load, and an interface 7 to which a programming device 8 is connected. The alarm unit 9 and the input units 10a and 10b for fetching electrical information such as a voltage value and a current value applied to the contact relay circuit 6a built in the output unit 6.

In this embodiment, the system program storage section 2 stores a system program of the CPU 1,
L area 2a in which the life prediction calculation program is stored
And a CA area 2b in which a program for counting the number of operations of the contact relay 6a is stored. Further, the data storage section 4 is divided into a section for storing the calculation result of the CPU 1 and the like, and an area 4c for storing the input values from the input sections 10a and 10b and the calculation result of the life prediction calculation.

The input section 10 is provided with a transformer for taking in the voltage value applied to the contact relay circuit 6a and a current transformer for taking in the current value. The CPU 1 determines the L area 2a of the system program storage unit 2 based on the values fetched from them.
The life prediction calculation program stored in is executed and the input value and the calculation result are stored in the area 4c of the data storage unit 4.
To store. Further, the CPU 1 automatically counts the number of times the contact relay 6a is turned on and off according to the counting program stored in the CA area 2b of the system program storage unit 2 and stores it in the area 4c of the data storage unit 4. This count value is compared with the life prediction calculation result.

FIG. 2 shows a flow chart of a program for fetching the voltage value and the current value, creating the history, and calculating the life prediction. This program is executed when the contact relay 6a with the corresponding output number is turned on. At this time, the electrical information (voltage value, current amount) representing the driving condition of the load connected to the contact relay is taken in, and the history 1 table is displayed when there is no history, that is, when the history is the first. Area 4c of the data storage unit 4 in FIG.
And the final history flag (P flag = 1) is set in the history 1 table.

The state of the area 4c of the data storage unit 4 is shown in FIG. This area has an area for the number of output points, and the area for each point is set wide so that the history remains. In this embodiment, one history table stores a final history flag, a history number, a current value, a voltage value, a power factor value, a life prediction calculation value, and a count value.

Next, the above driving conditions are stored in this table, a calculation formula for life prediction is selected based on this driving condition, a calculation is performed, the calculated values are stored in the above table, and the process ends.

When the history already exists, that is, when the history is the second or later, unless the driving condition that has been taken in exceeds the specified value stored in the final table at the present time, no processing is performed. finish. If there is a fluctuation that exceeds the specified value (for example, if the current changes from 1A to 3A), the final provenance flag of the current final table is cleared, the next provenance table is created, the final provenance flag is set, and driving is performed. The conditions are stored in this table, the life prediction calculation is performed based on this driving condition, the calculated values are stored in the final table, and the process ends.

The life curve of the contact relay is shown in FIG. This curve is represented by an approximate expression using the current value as a parameter.

The life of a contact relay is determined by conditions such as current, voltage, and power factor of a load connected to the relay.
Therefore, when the approximate expression of the life curve of FIG. 5 is obtained, the life prediction calculation of the programmable controller becomes possible.

For example, when the current value I is a variable X and the voltage V = 120 V and the power factor S = 0 of the load, the predicted number L (times) of turning on and off until the contact life is calculated by the following equation (equation 1). ). In (Equation 1), a predetermined calculation is performed for the voltage and the power factor of the load, and the result is described in the same equation as a coefficient or a constant.

[0023]

[Equation 1]

The movement of the CPU 1 at this time is as follows.
Input information Xt such as current is taken in the area 4c of the data storage unit 4, an operation is executed from this input information, and the result is stored in the area 4c of the data storage unit 4.

Next, counting the number of operations of the contact relay from OFF to ON will be described with reference to FIG. The CPU 1 first performs a refresh operation for the corresponding output.

FIG. 6 shows the relationship between the input / output refresh and the counting process. The counting process executes a flow for counting the number of operations of the contact relay from OFF to ON as shown in FIG. 3 at the time of refreshing the output. That is, if the current state is on and the previous scan state is off, counting processing is performed. At this time, as shown in FIG. 6B, the CPU 1 takes in the input information Xt at the beginning of the current scan, executes the calculation based on the input information Xt, and outputs the output information Yt.

On the other hand, the area 4c of the data storage unit 4 is shown in FIG.
As shown in (a), it is divided into an area for storing the input information Xt, an area for storing the output information Yt, and an area for storing the output information Yt-1 by the previous scan.
When the CPU 1 outputs the calculation result of this scan,
Current output information (output information from previous scan) Yt-
1 is moved from the area for storing Yt in the area 4c to the area for storing Yt-1, and the output result is compared with the previous output information Yt-1 as the current output information Yt.

Next, the CPU 1 compares the life prediction calculation value with the count value, and branches according to the judgment condition (301). In the example of FIG. 3, the determination condition is that the count value is 80% or more of the life prediction calculation value, and if this condition is satisfied, an alarm is generated and the process ends.

7, FIG. 8, FIG. 9, and FIG. 10 perform display or monitor operation of the life prediction calculation value, the count value, and the driving condition in the programming device to which the life prediction calculation key as shown in FIG. 11 is added. It is an example of the key reception program stored in the system program in the case.

Key input by this programming device is shown in FIG.
2 is temporarily stored in the data storage unit 4.

An example of key input and display from the program device for the programs shown in FIGS. 7 to 10 will be described with reference to FIGS. In this example, the relay whose lifetime is to be predicted is set to the address 200.

FIG. 13 shows an example of key input and a display example of the program device when the life prediction calculation value and the current count value of the 200th contact relay are monitored. In this case, to explain with the flowchart of FIG. 7, first, "OU
By pressing the "T" key, N of the key input temporary storage storage unit of FIG.
The flag (numerical value input flag), the L flag (“collation” key input flag), and the C flag (“CLR” key input flag) are cleared to zero and initialized.

After that, the "OUT" key information is stored in the storage unit, and when the "2""0""0" key is subsequently input, the N flag (numerical value input flag) is turned on (N flag = 1).
Then, the number 200 is stored. Then "MON"
When the key is entered, the N flag is checked, and if it is off, error processing is performed. If it is on, it is checked whether the number stored in the above storage unit is an output number. If it is not an output number, N, L,
The C flag is cleared and the operation ends normally. When the number stored in the storage unit is the output number, the N, L, and C flags are cleared, the final history search of the output number (P flag = 1 in FIG. 4) is performed, and the life shown in FIG. Display processing of predicted calculation value and count value is performed.

FIG. 14 shows a key input example and a display example of the program device for displaying the driving condition, history number and life prediction calculation value of the 200th contact relay.

The operation in this case will be described with reference to the flow charts of FIGS. 7 to 8. For “OUT”, “2”, “0”, and “0”, FIG.
It is the same as No. 3, and if you press the "Life" key after this, N
If the flag is checked, error processing such as error display is performed if the flag is off, and the process ends. If it is on, the number stored in the storage unit of FIG. If it is not an output number, it ends with error processing. In this case, since it is the output number, the L flag (“collation” key input flag) is subsequently collated. At this point, the L flag is off (L flag = 0), so the L flag is turned on (L flag = 1) in the next process.
Turn off the N and C flags. Next, the final history is searched, and the display processing of the drive condition of the contact relay and the life prediction calculation value is performed.

FIG. 15 shows a key input example and a display example of the program device for displaying the driving condition of the previous history and the life prediction calculation value of the 200th contact relay.

The operation in this case will be described with reference to the flow charts of FIGS. 7 to 8. After the "life" of FIG. 14 is input, the "STEP-" key is subsequently input. Since the "life" key has been input, the L flag is on. At this time, if the history of the driving condition currently displayed is 1, the history is returned to the final history and the output number information stored in the storage unit of FIG. 12 is displayed. If the history is not 1, the previous history information is displayed.

In order to display the next of the currently displayed one, the "STEP +" key in FIG. 9 is input.
At this time, since the "life" key has been input, the L flag is on. If the history of the driving conditions currently displayed is 1, the process returns to the final history and displays the output number information stored in the storage unit of FIG. If the provenance is not 1, the information of the succeeding provenance is displayed.

FIG. 16 shows a key input example and a display example of the program device when the "life" key is input next to FIG. 15 to display the count value of the previous history.

The operation in this case will be described with reference to the flow chart of FIG. When the "STEP-" key is pressed in FIG. 15, the output number information or the previous history information is displayed in this scan as shown in FIG. 8, and this scan ends. Then, the next scan starts, and "STEP
The process corresponding to the "life" key input after the "-" key is performed. That is, in FIG. 8, since the “life” key is input, the L flag is on. At this time, if the history of the driving condition currently displayed is 1, the history is returned to the final history and the output number information stored in the storage unit of FIG. 12 is displayed. If the history is not 1, the previous history information is displayed. As a result, the count value of the previous history is displayed.

FIG. 17 shows an example of key input of the program device when clearing all the history when the 200th contact relay is replaced.

"OUT", "2", "0" and "0" are shown in FIG.
Same as 3. Next, as shown in FIGS. 9 and 10, when the “CLR” key is input, the C flag (“CLR”
Turn on the key input flag) (C flag = 1), and then press the "ENT" key to turn on the C flag ("EN
(The state in which the "CLR" key was entered immediately before the "T" key was entered)
If so, the entire history of the output numbers stored in the storage unit of FIG. 12 is cleared.

According to the present embodiment, the means for taking in the driving condition of the contact relay circuit is added and the life predicting calculation is automatically performed by the taken driving condition. Therefore, the labor for setting the driving condition can be saved and Even if conditions change, you can automatically add up. Further, since the life prediction calculation value and the count value can be monitored by the display, usability is improved in predicting the life.

A second embodiment of the present invention will be described with reference to FIGS.

In this embodiment, electrical information on the driving condition of the contact relay 6a is input from the program device 8 and stored in the area 2a of the system program storage unit 2 under the same condition as that input from the input unit. The life prediction calculation program is executed to predict the life of the contact relay.

Therefore, in this embodiment, as shown in FIG. 19, there are four life calculation keys (“life”) for inputting the drive conditions of the contact relay used in the life prediction calculation in the input key portion of the program device. Key, “A” key, “V” key, “power factor” key).

As shown in FIG. 18, the configuration of the programmable controller main body is such that the input units 10a and 10b for fetching the voltage value and the current value and the alarm unit 9 are removed from the configuration of the first embodiment. The other structure is similar to that of the first embodiment.

FIG. 20 shows an example of key input for inputting the drive condition of the contact relay from the programming device. First, enter the "life" key as the declaration of the start of life prediction, then enter the current value and power factor value, and then start the life prediction calculation.
If there is data for which the driving condition has not been input (not set), the condition value set in advance in the programmable controller is automatically set, and the life prediction calculation is executed.

21 to 23 are examples of a flow chart of a system program for receiving a key input when the driving condition of the contact relay is input from the programming device in this embodiment. In this embodiment, when the keys are input in the order shown in FIG. 20, first, as shown in FIG. 21, when the "life" life key is first pressed, the N flag (numerical value input flag) is zero. Therefore, the process moves to the flow of A (flow of FIG. 22). Next, the output number is input and temporarily stored in the area A of the data storage unit 4. Next, when the "A" key is pressed, the I flag is set to zero, the current value is input, and the current value is temporarily stored in the area B of the data storage unit 4 together with the flag.

Next, when the "V" key is pressed, the V flag is set to zero and the voltage value is input and temporarily stored in area B of the data storage unit 4 together with the flag.

Next, when the "power factor" key is pressed, the S flag is set to zero, the power factor value is input, and is temporarily stored in area B of the data storage unit 4 together with the flag.

In order to clear these data, "D
Press the "CLR" key.

When the input of data such as current, voltage and power factor is completed, the "ENT" key is pressed to start the calculation of the life.

FIG. 24 shows the internal state of the storage units 4 and 4c when the flowchart of FIG. 23 is executed. If the "ENT" key is pressed after data input and the E flag is not set to 1 in this state, it is judged whether the data in area B is normal. If it is normal, the data in area B is transferred to the input address. It moves to A, sets the E flag to 1, and returns to the flow of A (flow of FIG. 22).

According to this embodiment, the input portions 10a and 10b for fetching the voltage value and the current value are not required, and the cost, size and weight can be reduced.

[0056]

According to the present invention, it is possible to obtain a programmable controller capable of automatically predicting the life of a built-in contact relay and displaying an appropriate replacement time.

[Brief description of drawings]

FIG. 1 is a configuration diagram of a programmable controller according to an embodiment of the present invention.

FIG. 2 is a flowchart of a life prediction history creation or life prediction calculation program.

FIG. 3 is a flowchart of an automatic counting program.

FIG. 4 is a state diagram of an area 4c of the data storage unit 4.

FIG. 5 is a characteristic diagram showing a life curve of a contact relay.

FIG. 6 is an operation diagram of a counting process.

FIG. 7 is a flowchart of a key reception program from a programming device related to life prediction.

FIG. 8 is a flowchart of a key reception program from a programming device related to life prediction.

FIG. 9 is a flowchart of a key reception program from a programming device related to life prediction.

FIG. 10 is a flowchart of a key reception program from a programming device related to life prediction.

FIG. 11 is a perspective view of an embodiment of a programming device.

FIG. 12 is a diagram of a storage unit for temporarily storing a key input by the programming device.

FIG. 13 is a diagram showing an example of key input and a display example for life prediction calculation value and monitor operation.

FIG. 14 is a diagram showing a key input example and a display example for a display operation of a driving condition, a history number, and a life prediction calculation value.

FIG. 15 is a diagram showing a key input example and a display example for a display operation of a driving condition of a previous history and a life prediction calculation value.

FIG. 16 is a diagram showing a key input example and a display example for displaying the coefficient value of the previous history.

FIG. 17 is a diagram showing an example of key input in the case of clearing all the histories when a relay is replaced.

FIG. 18 is a configuration diagram of a programmable controller according to a second embodiment of the present invention.

FIG. 19 is a diagram showing an example of input keys of the programming device of the present embodiment.

FIG. 20 is a diagram showing an example of key input for inputting drive conditions for a contact.

FIG. 21 is a flowchart for accepting a key input for inputting drive conditions for a relay.

FIG. 22 is a flowchart for accepting a key input for inputting a drive condition of a relay.

FIG. 23 is a flowchart for accepting a key input for inputting drive conditions for a relay.

FIG. 24 is a diagram showing an internal state of a storage unit.

FIG. 25 is a block diagram of a conventional programmable controller.

[Explanation of symbols]

1 ... Central processing unit, 2 ... System program storage unit,
3 ... Sequence program storage unit, 4 ... Data storage unit,
6 ... Output unit, 8 ... Program device, 9 ... Alarm unit, 10 ...
Drive condition acquisition unit, 100 ... Programmable controller body

Claims (4)

[Claims] 1. A central processing unit for performing an operation according to a control program stored in a control program storage unit, a system program storage unit for storing a system program for controlling the central processing unit, and the central processing unit. In a programmable controller having an output unit that is connected and drives an external load based on the calculation result, and a contact relay that is built in this output unit and that generates a control signal to the external load, the programmable controller is applied to this contact relay. And a display unit for displaying the life of the relay, the system program storage unit stores the relay life prediction calculation program and the operation count program, and the central processing unit Based on the above electrical information according to the life prediction calculation program and the operation count program Life prediction calculation and performs an operation number counting programmable controller a comparison between those count values, characterized in that it is configured to output to the display means. 2. A central processing unit for performing an operation according to a control program stored in a control program storage unit, a system program storage unit for storing a system program for controlling the central processing unit, and the central processing unit. In a programmable controller having an output unit that is connected and drives an external load based on the calculation result, and a contact relay that is built in this output unit and generates a control signal to the external load, the programmable controller is applied to this contact relay. And a data storage unit for storing the calculation result of the central processing unit, wherein the system program storage unit is a relay life prediction calculation program. And a program for counting the number of operations, and the central processing unit stores the life prediction calculation program. Therefore, a life prediction calculation based on the electrical information is performed, the result is stored and held at a predetermined address in the data storage unit, and a new life prediction is performed when the value of the electrical information fluctuates beyond a specified value. The calculation is performed, the address is updated, the result is stored in the data storage unit, the operation count is performed according to the operation count program, and the result of comparison between the new life prediction calculation value and the operation count value is displayed on the display means. A programmable controller configured to output to. 3. An alarm means connected to the central processing unit, wherein the central processing unit provides the alarm means when the operation count value reaches a predetermined rate with respect to the life prediction calculation value. The programmable controller according to claim 1, wherein the programmable controller is configured to operate. 4. A central processing unit for performing a calculation according to a control program stored in a control program storage unit, a system program storage unit for storing a system program for controlling the central processing unit, and the central processing unit. In a programmable controller having an output unit that is connected and drives an external load based on the calculation result, and a contact relay that is built in this output unit and that generates a control signal to the external load, the programmable controller is applied to this contact relay. And a display means for displaying the life of the relay, the system program storage unit stores the relay life prediction calculation program and the operation count program, and the central processing unit According to the life prediction calculation program and operation count program, Programmable controller, characterized in that the comparison result of the life prediction calculated operation number counting was carried out their count values is configured to output to said display means brute.