TWI825666B - A method of replacing a faulty i/o point with a spare point on a device and the device - Google Patents

Abstract

A method of replacing a faulty I/O point with a spare point on a device with spare points is used to continue the transmission function of a control equipment. The control device is provided with at least one transmission point and at least one spare point. The transmission point is electrically connected with a transmission line. The method of replacing a faulty I/O point with a spare point on a device with the spare points includes a one-point fault step, a wire configuration step, and a one-point configuration step. In the point failure step, the transmission point of the control device fails. In the line arranging step, the transmission line is electrically connected to the spare point. In the point configuration step, the control device is controlled to designate the transmission signal of the transmission point to the spare point.

Description

Methods and control equipment for replacing equipment input and output point failures with backup points

The present invention relates to a maintenance method of a data transmission module in a control device, and in particular to a method and control device for replacing a faulty input and output point of the equipment with a spare point.

The main purpose of automated production is to eliminate the conditions for manual production and use automatic control devices to make the controlled objects or processes automatically perform production operations according to predetermined rules. Automated control technology is conducive to freeing humans from complex, dangerous, and tedious labor. It frees up the environment, effectively improves control efficiency and avoids accidents. The biggest benefit of automation is that it can save labor, save energy and material costs, ensure accuracy and precision, and stabilize production quality.

Automated production equipment uses automatic control devices to automatically operate the production of products. Common automatic control devices include programmable controllers (PLC), industrial computers (IPC) or single-chip circuits (such as 8051, Raspberry Pi, etc.) , among which, the automatic control device will set output points (output port, output interface, output port) and input points (input port, input interface, input port) to electrically connect the detection module and actuation module on the device. group, and can control automated production equipment to perform production operations.

Generally speaking, a set of transmission points (including output points or input points) is used to electrically connect with a detection module or actuator module. Only when the signal transmission between the two is correct can the automated production equipment operate normally. When the automatic control device operates for a long time, the internal circuit will gradually be damaged. One of the damage conditions is that the control circuit in the automatic control device is not damaged, but the transmission point fails due to frequent startup or shutdown. , causing the control circuit and the detection module or the actuation module to be unable to transmit information, which leads to the failure of the automated production equipment.

Generally speaking, on-site operators in automated production are only familiar with the operation of automated production equipment. When an equipment failure occurs and the production line is shut down, they can only call technicians to come to the site for repairs. The general maintenance method is to replace spare parts and then perform automatic control. The program is installed so that the automated production equipment can operate normally. However, during actual operation, the following situations will still be encountered:

1. Maintenance time is too long: When the production equipment is damaged, it means that the product cannot be produced. The longer the downtime is, the more losses the company will suffer. When technicians arrive to inspect and find the problem, the warehousing system can retrieve the spare parts and go to the warehouse to pick up the spare parts. When removing the faulty module and installing spare parts, you still need to connect to the computer to install the automatic program. Although some modules do not need to install additional control programs when replacing them, the above maintenance procedures will inevitably consume a lot of time. Therefore, the traditional maintenance method has the disadvantage that the maintenance time is too long.

2. Unable to recover immediately: Generally speaking, the circuits and electronic components used inside the automatic control device are durable and have a long service life. Therefore, when the automatic control device fails, the spare parts in the warehouse may have been used up. If the market fails again, When the same model of machine or module is no longer sold online, repair methods are extremely difficult. You may even need to use a new model of control host and rewrite the control program. This will lead to a situation where the automated production equipment cannot be restored immediately.

3. The cost is too high: Although replacing equipment when it is damaged is a necessary maintenance method, it costs money to replace spare parts or purchase new machines. For small faults, it is necessary to replace the control device with a new one, which also costs money and causes waste.

Therefore, how to quickly restore the operation of the automatic control device is an urgent goal for relevant technical personnel.

In view of this, the object of the present invention is to provide a method for replacing a faulty input/output point of equipment with a backup point.

The method of replacing the failed input/output point with a spare point is used to continue the transmission function of a control device. The control device is provided with at least one transmission point and at least one spare point. The transmission point is connected to a transmission line. Electrical connection.

The method of replacing a faulty input/output point of the equipment with a spare point includes a one-point fault step, a wire configuration step, and a one-point configuration step. In the point failure step, the transmission point of the control device fails. In the wire configuration step, the transmission line is electrically connected to the backup point. In the point configuration step, the control device is controlled to assign the transmission signal of the transmission point to the backup point.

Another technical means of the present invention is that the above-mentioned control equipment is electrically connected to a human-machine device. The human-machine device can display a replacement point block. In the point configuration step, on the human-machine device The switching setting between the transmission point and the backup point is performed in the replacement point block.

Another technical means of the present invention is that the replacement point block of the above-mentioned human-machine device further displays a backup setting area and a replacement setting area corresponding to the backup setting area. The backup setting area displays the Spare point, the replacement setting area is used to set the transmission point replaced by the spare point. In the point configuration step, the replacement transmission area is set in the replacement setting area of the replacement point block of the human-machine device Point.

Another technical means of the present invention is to store a point configuration file in the above-mentioned control device. In the point configuration step, the point configuration file in the control device is set to specify the transmission signal of the transmission point. at this backup point.

Another technical means of the present invention lies in the information connection between the above-mentioned control equipment and a computer device. In the point configuration step, the computer device displays the point setting file and performs the point setting file in the point setting file. Transfer the point replacement settings of the point and the backup point, and then input the set point profile into the control device.

Another technical means of the present invention is that the transmission point and the backup point of the above-mentioned control device are selected from one of the input contact, the output contact, and a combination thereof.

Another technical means of the present invention is that the above-mentioned method of replacing an equipment input/output point failure with a spare point further includes a point setting step before the point failure step. In the point setting step, A point switching program is stored in the control device. The point switching program can switch the transmission signal used for the transmission point to the backup point. In the point configuration step, the control device is controlled to execute the point. Switch program.

Another object of the present invention is to provide a control device.

This control device is suitable for the method of replacing the faulty input and output points of the above-mentioned equipment with backup points. The control device includes a device body, at least one transmission point, and at least one backup point. The transmission point is set on the main body of the device, and the backup point is set on the main body of the device.

Another technical means of the present invention is that the above-mentioned control equipment further includes a data transmission port provided on the main body of the equipment. The data transmission port is used to electrically connect with a human-machine device. The human-machine device displays a replacement point. bit block, the replacement point block has a spare setting area and a replacement setting area corresponding to the spare setting area.

Another technical means of the present invention is that the above-mentioned control device further includes a data transmission module disposed on the main body of the device, and a control module disposed on the main body of the device and electrically connected to the data transmission module. The control module stores a bit configuration file, and the data transmission module is used for information connection with a computer device.

The beneficial effect of the present invention is that the backup point is used to replace the faulty transmission point so that the control device can operate normally again, without the need to spend a lot of time on repairs or the waste of replacing new products.

The relevant patented features and technical content of the present invention will be clearly presented in the following detailed description of the four preferred embodiments with reference to the drawings. Before proceeding to the detailed description, it should be noted that similar components are designated with the same number.

Referring to Figure 1 , a first preferred embodiment of a method of replacing equipment input/output points with spare points with faulty equipment input/output points is shown. The method for replacing equipment input/output points with faulty input/output points with spare points includes a point fault step 901 , a wire configuration step 902, and a point configuration step 903.

Please refer to Figure 2 and Figure 3. The device is a control device 3. In the first preferred embodiment, the control device 3 is a programmable logic controller (PLC). In actual implementation , the control device 3 can be a single-chip control circuit (such as an 8051 control circuit, a Raspberry Pi control circuit, etc.) or other programmable control circuits, and should not be limited to this. The control device 3 includes a device body 31 , a plurality of transmission points 32, and a plurality of backup points 33, the plurality of transmission points 32 and the plurality of backup points 33 are provided on the equipment body 31, wherein the plurality of transmission points 32 and the plurality of backup points 33 They are both data output ports, except that the plurality of transmission points 32 are output ports connected to electronic components, and the plurality of backup points 33 are output ports that are not connected to electronic components and are not in use. Each transmission point 32 is locked. A transmission line 51 is provided so that the transmission point 32 can be electrically connected to electronic components to transmit data to each other. In actual implementation, the plurality of transmission points 32 and the plurality of backup points 33 can be data input ports, and the The number of transmission points 32 and the backup points 33 should be based on actual settings and should not be limited thereto.

In addition, the control device 3 further includes a data transmission module 34 provided on the device body 31. The data transmission module 34 is used to electrically connect with the human-machine device 4. Preferably, the data transmission module 34 The module 34 uses the USB transmission protocol to transmit data with the human-machine device 4. In actual implementation, the data transmission module 34 can use RS232, RS485, or other data transmission technologies, and should not be limited to this.

The human-machine device 4 includes a human-machine body 41. The human-machine body 41 is provided with a touch screen. The touch screen of the human-machine body 41 can externally display the control information of the control device 3. In the first preferred implementation For example, the touch screen of the human-machine body 41 can display a replacement point block 42. Preferably, the replacement point block 42 is linked to a control switch (not shown) on the main menu to display the replacement point. Point block 42, after the user presses the control switch, the human-machine body 41 switches the screen to display the replacement point block 42, because the display screen of the human-machine device 4 can be designed in different ways by the program. Presentation is not the key technology of the present invention and will not be described in detail here.

Among them, the replacement point block 42 can display at least one backup setting area 421 and at least one replacement setting area 422 corresponding to the backup setting area 421. The backup setting area 421 is used to set the required backup point. 33. The replacement setting area 422 is used to set the transmission point 32 that needs to be replaced due to failure. When the parameter settings in the backup setting area 421 and the replacement setting area 422 are completed, the control device 3 can be provided with the backup. Point 33 replaces the transmission point 32 and performs automatic control of the equipment.

In the point failure step 901, the transmission point 32 of the control device 3 fails and can no longer perform automatic control. Among them, the control module 35 in the control device 3 does not fail, and only the transmission point The relevant circuit of bit 32 fails and cannot output or receive data, which in turn causes the control device 3 to no longer be able to run automatic control.

In the wire configuration step 902, the transmission line 51 electrically connected to the transmission point 32 is removed, and then the transmission line 51 is moved to the backup point 33 and electrically connected to the backup point 33, for example. Say, when the transmission point 32 of No. 06 (out06) fails, the transmission line 51 locked on the transmission point 32 of No. 06 (out06) can be removed, and the transmission line 51 can be moved and locked to No. 28 The backup point of (out28) is 33.

In the point configuration step 903, the control device 3 is controlled to assign the transmission signal of the transmission point 32 to the backup point 33. In the first preferred embodiment, the human-machine device 4 can be used to display The switching setting of the transmission point 32 and the backup point 33 is performed in the replacement point block 42. For example, the backup setting area 421 can be displayed on the replacement point block 42 of the human-machine body 4. The backup point 33 with number 28 (out28) is set in the replacement point block 42 of the human-machine body 4, and the transmission point 32 with the number 06 (out06) in the setting area 422 is displayed on the replacement point block 42 of the human-machine body 4, so that the The control device 3 can replace the transmission point 32 with the backup point 33 according to the setting data of the backup setting area 421 and the replacement setting area 422, and continue to execute the automatic control process.

Although in the first preferred embodiment, the wire configuration step 902 is performed first, and then the point configuration step 903 is performed, in actual implementation, the wire configuration step 902 and the point configuration step 902 can also be performed in the same order. The replacement will not affect the purpose of replacing the transmission point 32 with the backup point 33 . In addition, some control devices 3 are not connected to the man-machine device 4 during operation. When the transmission point 32 of the control device 3 fails, in the point configuration step 903, the man-machine device 4 is first connected. Connect the control device 3, and then use the human-machine device 4 to set the transmission point 32 and the backup point 33. After completing the settings, remove the human-machine device 4, and the control device 3 can still use the backup point 33. Continue to execute the automatic control program.

Please refer to Figure 4, which is a second preferred embodiment of a method of replacing equipment input/output points with spare points due to faulty equipment according to the present invention. The second preferred embodiment is substantially the same as the first preferred embodiment. The details will not be described here, but the difference is that the method of replacing the equipment input/output point failure with a spare point further includes a point setting step 904 before the point failure step 901.

In the point setting step 904, a point switching program is stored in the control device 3. The point switching program can switch the transmission signal used for the transmission point 32 to the backup point 33. At this point In the configuration step 903, the control device 3 is controlled to execute the point switching program.

For example, a virtual control switch is set on the touch screen of the human-machine device 4. In step 901 of the fault point, the operator can determine the fault condition from the fault message of the control device 3 or the machine. The damaged transmission point 32 is detected, and the control device 3 is switched to a standby state. Then in the wire configuration step 902 and the point configuration step 903, a backup point 33 is first selected, the transmission line 51 locked on the transmission point 32 is removed, and then locked on the backup point 33, press the control switch simultaneously so that the man-machine device 4 can switch out the replacement point block 42, and then the operator can set the backup point in the backup setting area 421 of the replacement point block 42 33, and set the parameters of the transmission point 32 in the replacement setting area 422 of the replacement point block 42, so that the point switching program can combine the transmission data originally used for the transmission point 32 with the The backup point 33 is linked, so that the backup point 33 can transmit the data of the transmission point 32, and finally the automatic control program of the control equipment 3 is turned on to restore the production capacity of the control equipment 3.

Please refer to Figure 5 and Figure 6 , which is a third preferred embodiment of a method for replacing equipment input and output points with spare points due to faults according to the present invention. The third preferred embodiment is the same as the first preferred embodiment. They are roughly the same, and the similarities will not be described in detail here. The difference is that a computer device 6 is used to electrically connect with the control device 3. Preferably, the computer device 6 is a laptop. In actual implementation, The computer device 6 can use other types of computers that can edit programs, and should not be limited to this.

In the third preferred embodiment, the control device 3 further includes a data transmission module 34 disposed on the device body 31, and a data transmission module 34 disposed on the device body 31 and electrically connected to the data transmission module 34. The control module 35 stores a bit configuration file 351 in the control module 35 of the control device 3. The data transmission module 34 is used for information connection with the computer device 6, and the computer device 6 is used to set the control device 3. The point setting file 351 in is used to assign the transmission signal of the transmission point 32 to the backup point 33. The control module 35 of the control device 3 performs automatic control based on the point setting file 351. The point Generally speaking, the configuration file 351 is the variables received or output, and the setting parameters of the corresponding input port or output port.

In the point configuration step 903, an information transmission line is used to connect the computer device 6 and the data transmission module 34 of the control device 3, so that the computer device 6 can transmit data with the control module 35, and then the computer device 6. Read the point setting file 351 in the control module 35, or open the point setting file 351 stored in the computer device 6. The computer device 6 displays the display screen 61 of the point setting file 351, The point parameters of the transmission point 32 and the backup point 33 are set in the point setting file 351, and then the set point setting file 351 is input and stored in the control module 35 of the control device 3. , so that the control device 3 executes an automatic control program based on the point setting file 351 to achieve the purpose of replacing the transmission point 32 with the backup point 33 .

Please refer to Figure 7, which is a fourth preferred embodiment of a method of replacing equipment input and output points with spare points due to faulty equipment according to the present invention. The fourth preferred embodiment is substantially the same as the first preferred embodiment. The difference will not be described in detail here. The difference is that the control device 3 uses an industrial computer. The control device 3 belonging to the industrial computer is provided with at least one point expansion module 36. Preferably, the point expansion module 36 It is a functional module that can be placed in the control chassis. In actual implementation, the point expansion module 36 can be a control circuit provided on the circuit board (PCB), and should not be limited to this.

The control device 3 that is an industrial computer will be connected to an operation panel or a display screen to control the control device 3 and obtain operation information. The transmission point 32 and the backup point 33 are set on the point expansion module 36 , the human-machine device 4 connected to the control device 3 can quickly set the parameters of the transmission point 32 and the parameters of the backup point 33, so as to provide the control device 3 with the ability to replace the transmission point 32 with the backup point 33. effect.

In the point configuration step 903, a human-machine device 4 or a computer device 6 with a screen can be used to connect to the control device 3 to set the point configuration file 351 stored in the control device 3, so that the The control device 3 uses the backup point 33 to replace the transmission point 32 to perform automatic control. In actual implementation, when the transmission point 32 on the point expansion module 36 fails, a human-machine with a screen can be used. The device 4 or the computer device 6 is connected to the point expansion module 36 and directly performs the replacement setting of the transmission point 32 and the backup point 33 in the point expansion module 36, and the control parameters in the control device 3 Or the control program has not changed. After the setting is completed, the human-machine device 4 or the computer device 6 can be removed from the point expansion module 36, so that the backup point 33 can be used to replace the transmission point 32. The efficacy should not be limited to this.

It can be seen from the above description that the method and control device 3 of the present invention for replacing faulty input and output points of equipment with backup points do have the following effects:

1. Quick recovery: Since the man-machine device 4 has been preset with the function of using the replacement point block 42 to replace the transmission point 32 with the backup point 33, when a fault condition of the transmission point 32 occurs, the operator After changing the position of the transmission line 51, the replacement point block 42 can be used to set the parameters of the backup point 33 and the transmission point 32, so as to quickly use the backup point 33 to restore the automatic control of the control device 3.

2. Avoid downtime: Since the main purpose of the present invention is to replace the transmission point 32 with the backup point 33 to restore the operation of the control device 3 as quickly as possible, there is no need to replace the new product to quickly restore the control of the device, so no troubleshooting will occur. The situation of not having spare parts or being unable to purchase new products can effectively avoid the dilemma of production line downtime.

3. Avoid unnecessary waste: Since the transmission point 32 in the control device 3 will be shut down and started from time to time, it is more likely to malfunction. However, the control circuit-related part of the control device 3 can still operate normally. Therefore, the present invention uses the backup point 33 to replace The method of transmitting the point 32 can effectively extend the use of the control device 3 without the need to replace additional devices, thereby causing no additional waste.

To sum up, when the control equipment 3 fails and it is determined that the transmission point 32 of the control equipment 3 fails, a backup point 33 can be selected and the transmission line 51 corresponding to the transmission point 32 can be The position is changed to the backup point 33, and then the point replacement block 42 shown on the man-machine device 4 is used to set the point parameters, so as to provide the backup point 33 with the function of replacing the transmission point 32. , and can quickly restore the operation of the control device 3, so the purpose of the present invention can indeed be achieved.

However, the above are only four preferred embodiments of the present invention, and should not be used to limit the scope of the present invention. That is, any simple equivalent changes made in accordance with the patent scope of the present invention and the description of the invention are Modifications are still within the scope of the patent of this invention.

3 Control equipment 31 Equipment main body 32 transmission points 33 spare points 34 Data transmission module 35 control module 351 Point configuration file 36 point expansion module 4 Human-machine devices 41 Human-machine body 42 Replace point blocks 421 Alternate setting area 422 Replace setting area 51 transmission line 6 computer equipment 61 Display screen 901 Point fault steps 902 Wire configuration steps 903 Point configuration steps 904 Point setting steps

Figure 1 is a flow chart, which is a first preferred embodiment of a method and control device for replacing equipment input/output points with spare points due to faulty equipment according to the present invention; Figure 2 is a schematic diagram of a device configuration, illustrating the state in which a human-machine device is connected to a control device in the first preferred embodiment; Figure 3 is a schematic diagram of a device configuration, illustrating that in the first preferred embodiment, the human-machine device shows a mode of replacing point blocks; Figure 4 is a flow chart, which is a second preferred embodiment of a method and control device for replacing equipment input and output points with spare points due to failure. Figure 5 is a schematic diagram of a device configuration, which is a third preferred embodiment of a method and control device for replacing equipment input and output points with spare points due to faulty equipment input and output points according to the present invention. It illustrates a device for electrically connecting a computer device to a control device. configuration status; Figure 6 is a device block diagram illustrating the device configuration of the computer device and the control device in the third preferred embodiment; and Figure 7 is a schematic diagram of a device configuration, which is a fourth preferred embodiment of a method and control equipment for replacing equipment input/output points with spare points due to faulty equipment input/output points according to the present invention. It illustrates the use of industrial computer control equipment and one-point expansion modules. The state of electrical connection.

901 Point fault steps 902 Wire configuration steps 903 Point configuration steps

Claims (7)

A method for replacing equipment input/output point failure with a backup point for continuing the transmission function of a control device. The control device is provided with at least one transmission point and at least one backup point. The transmission point is connected to a The transmission line is electrically connected, the control equipment is electrically connected to the human-machine device, the human-machine device can display a replacement point block, and the replacement point block of the human-machine device further displays a backup setting area, and A replacement setting area corresponding to the backup setting area. The backup setting area is used to set the backup point. The replacement setting area is used to set the transmission point. A method for replacing the equipment input/output point failure with the backup point. It includes the following steps: a bit failure step, where the transmission point of the control equipment fails; a wire configuration step, where the transmission line is electrically connected to the backup point; and a bit configuration step, where the control equipment is controlled to transmit the transmission The transmission signal of the point is designated at the backup point, and the switching setting between the transmission point and the backup point is performed in the replacement point block of the human-machine device. Set the replacement point block of the human-machine device. The backup setting area and the replacement setting area are used to enable the control equipment to replace the transmission point with the backup point. The method of replacing equipment input/output points with backup points according to claim 1, wherein a point configuration file is stored in the control device, and in the point configuration step, the point settings in the control device are set File to assign the transmission signal of the transmission point to the backup point. The method of replacing equipment input/output point failure with a backup point as described in claim 2, wherein the control equipment is connected to a computer device information, and the point is configured In the setting step, the computer device displays the point configuration file, and performs point replacement settings for the transmission point and the backup point in the point configuration file, and then inputs the set point configuration file into the point configuration file. in the control device. The method of replacing equipment input/output point failure with a backup point as described in claim 1, wherein the transmission point and backup point of the control equipment are one of input contacts and output contacts. The method for replacing an equipment input/output point failure with a backup point as described in claim 1 further includes a point setting step before the point failure step. In the point setting step, the point setting step is stored in the control device. A point switching program, the point switching program can switch the transmission signal used for the transmission point to the backup point, and in the point configuration step, control the control device to execute the point switching program. A control device, suitable for the method of replacing the faulty input and output points of the equipment described in any one of claims 1 to 5 with backup points. The control device includes: a device body; at least one transmission point, set on the device body on; at least one backup point is provided on the main body of the equipment; and a data transmission port is provided on the main body of the equipment; the data transmission port is used to electrically connect with a human-machine device, and the human-machine device displays a replacement Point block, the replacement point block has a spare setting area and a replacement setting area corresponding to the spare setting area. The control device as described in claim 6, wherein the control device further includes a data transmission module disposed on the device body, and a data transmission module disposed on the device body and connected to the device body. The data transmission module is electrically connected to a control module, the control module stores a bit configuration file, and the data transmission module is used for information connection with a computer device.