Industrial control processor system

• US 4,038,533 A
• Filed: 09/29/1976
• Issued: 07/26/1977
• Est. Priority Date: 09/29/1976
• Status: Expired due to Term

• Current Assignee: Allen-Bradley Company (Rockwell Automation, Inc.)
• Original Assignee: Allen-Bradley Company (Rockwell Automation, Inc.)
• Inventors: Bielawski, Timothy, Dummermuth, Ernst, Donze, William A.
• Primary Examiner(s): Botz, Eugene G.
• Application Number:
  US05/728,000
• Time in Patent Office: 300 Days
• Field of Search: 340/172.5, 235/151.1, 235/151.11
• US Class Current: 700/7
• CPC Class Codes: G05B 19/4147 characterised by using a programmable interface controller [PIC]
• CPC Class Codes: G05B 2219/35262 Macro instruction, canned cycles, subroutines, subprogram
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An industrial control processor is employed in a numerical control system to operate the servo mechanisms on a machine tool in response to a part program stored on a tape. The industrial control processor includes unique hardware and software features which also allow it to operate as a programmable controller to control the discrete digital devices associated with the machine tool. The industrial control processor is programmed with a conventional computer type instruction set to perform numerical control functions and is programmed with a programmable controller type instruction set to perform the machine dependent logic functions. The resulting system maintains the state-of-the-art capabilities of a computer numerical control (CNC) and adds to it the flexibility and programming ease of a programmable controller.

Claims

1. An industrial control processor which comprises:

a read/write memory for storing multi-bit words which include an I/O image table and program instructions;

a multi-lead data processor bus coupled to said read/write memory to convey words which are written into or read out of said read/write memory;

an instruction register connected to said processor data bus and operable to receive and store program instructions read out of said read/write memory;

an arithmetic and logic unit having a first set of inputs connected to the leads in said data processor bus;

an L register having a set of inputs connected to the leads in said data processor bus and a corresponding set of output terminals connected to a second set of input terminals on said arithmetic and logic unit;

a bit pointer circuit having a set of inputs coupled to the instruction register to receive a bit pointer code contained in selected program instructions and having a set of output terminals connected to the respective leads in said processor data bus, said bit pointer circuit being responsive to received bit pointer codes to generate a mask on said processor data bus which is coupled to and stored in said L register;

wherein said mask is logically combined in said arithmetic and logic unit with a word read out of the I/O image table in said read/write memory to perform a logic operation on a selected single bit in said word.

2. The industrial control processor of claim 1 in which said mask is generated by said bit pointer circuit by driving all but a selected one of the leads in said processor data bus to a predetermined logic state and driving said one selected lead to another logic state, and wherein said selected one lead is determined by said bit pointer code.

3. The industrial control processor of claim 1 in which a rung condition storage register has an input coupled to an output terminal on said arithmetic and logic unit to store the result of the logical operation performed on said selected single bit.

4. The industrial control processor of claim 3 which includes

a read-only memory which stores a plurality of micro-programs, each comprised of a set of micro-instructions,

a micro-instruction register coupled to said read-only memory to receive and store a micro-instruction read therefrom,

addressing means coupled to said instruction register and said read-only memory for selecting a micro-routine stored in said read-only memory in response to a code in the program instruction stored in said instruction register and for sequentially reading out the micro-instructions in said selected micro-routine to said micro-instruction register, and

means coupling said micro-instruction register to said arithmetic and logic unit for selecting the logical operation performed by said arithmetic and logic unit from a set of such operations in response to a code in a micro-instruction stored in said micro-instruction register.

5. The industrial control processor of claim 4 which includes a real-time clock having an output terminal which alternately changes logic state and a logic gate which couples the real-time clock output terminal to said processor data bus in response to a selected code in the micro-instruction in said micro-instruction storage register.

6. The industrial control processor of claim 5 in which said read/write memory includes a timer storage portion having a plurality of accumulated time words and a corresponding number of associated preset time words, said industrial control processor including means for selectively reading an accumulated time word out of said read/write memory and comparing the logic state of the least significant bit therein with the logic state of said read-time clock output terminal, and means for reading the associated preset time word out of said read/write memory and arithmetically comparing its value with the value of said accumulated time word.

7. A numerical control system which comprises:

I/o interface rack means including a slot having a plurality of output circuits for driving discrete digital operating devices, a slot having a plurality of input circuits for receiving status signals from a plurality of discrete digital sensing devices, a slot having a command register for storing a position command word to be applied to a servo mechanism, and a slot having an accumulator register for storing a feedback word received from said servo mechanism;

a tape reader for reading a part program and generating blocks of part program data;

an industrial control processor connected to said I/O interface rack means and said tape reader, said industrial control processor including;

a memory which stores

a. background programs, each comprised of a plurality of program instructions;

b. a machine dependent software program comprised of a plurality of controller instructions;

c. an I/O image table comprised of a plurality of multi-bit memory words, each word associated with one of the slots in said I/O interface rack means;

d. a system flag table comprised of a plurality of memory locations;

e. a tape reader driver program comprised of a plurality of program instructions; and

f. a timed interrupt program comprised of a plurality of program instructions;

means responsive to a signal received from said tape reader and program instructions in said tape reader driver program for coupling a block of part program data generated by said tape reader to said memory;

means responsive to part program data stored in said memory and program instructions in one of said background programs for setting a selected memory location in said system flag table to a selected logic state;

means for periodically executing said timed interrupt program including;

a. means responsive to program illustrations in said timed interrupt program for coupling data between said respective I/O image table memory words and their associated slots to update the status of the I/O image table;

b. means responsive to program instructions in said timed interrupt program, responsive to part program data stored in said memory and responsive to the feedback word stored in the I/O image table for calculating a position command word and storing it in the I/O image table memory word which is associated with the I/O interface rack slot containing the command register; and

c. means for executing control instructions in said machine dependent software program to examine the status of selected bits in said I/O image table, to examine the state of selected memory locations in said system flag table, and to set the status of selected bits in said I/O image table.

8. The numerical control system as recited in claim 7 in which said means for executing control instructions includes:

means responsive to a memory address in a control instruction to read a selected multi-bit memory word in said I/O image table from said memory; and

a bit pointer circuit which is responsive to a bit pointer code in a control instruction read from said memory to select a bit in said multi-bit memory word.

9. The numerical control processor as recited in claim 7 which includes a manually operable keyboard connected to said industrial control processor for generating digital characters thereto and said industrial control processor includes means responsive to program instructions in one of said background programs for coupling the digital characters received from said keyboard to the memory to form operation codes for controller instructions in said machine dependent software program.

10. The numerical control system as recited in claim 9 which includes a cathode ray tube display connected to said industrial control processor for receiving digital characters and displaying corresponding symbols, and said industrial control processor includes means responsive to program instructions in one of said background programs to generate a set of digital characters to said cathode ray tube display which correspond to the respective operation codes in a selected set of controller instructions in said machine dependent software program, and wherein said set of controller instructions represent a complete Boolean expression and the corresponding displayed symbols are arranged on the screen of said cathode ray tube to form a rung of a ladder diagram.

11. The numerical control system as recited in claim 10 in which the set of controller instruction operation codes is manually selected by means of said keyboard.

12. An industrial control processor controlling in response to blocks of part program data coupled to it the motion of a cutting tool on a machine tool and for controlling the discrete digital devices associated with the machine tool, the industrial control processor comprising:

means for storing a received block of part program data;

means for storing a position command word for each axis of motion on said controlled machine tool;

I/o image table storage means including a storage location for each discrete digital sensing device associated with the controlled machine tool and for each discrete digital operating device associated therewith;

system flag table storage means including a plurality of storage locations;

means for decoding a block of part program data and in response thereto setting a selected storage location in said system flag table storage means to a logic state which indicates that a specific auxiliary function is to be performed by said discrete digital devices;

means coupled to said data block storage means for calculating a position command word for each axis of motion and coupling each to its respective position command word storage means;

means for coupling said calculated position command words to said controlled machine tool to operate the axis servo mechanisms thereon;

means for storing a plurality of controller instructions which comprise a machine dependent software routine; and

timed interrupt means for periodically interrupting all other functions of the industrial control processor to execute the machine dependent software and to couple data between said discrete digital devices and said I/O image table storage means, said timed interrupt means including;

a. means responsive to selected controller instructions for examining the logic state of selected sensing device storage locations in said I/O image table and responsive to other selected controller instructions for examining the logic state of storage locations in said system flag table; and

b. means responsive to selected controller instructions for setting the logic state of selected operating device storage locations in said I/O image table.

13. The industrial control processor of claim 12 in which said I/O image table storage means is arranged to form a plurality of addressable words, each word containing a plurality of storage locations, and said controller instructions which examine selected storage locations and said controller instructions which set the logic state of selected storage locations each include an address which selects a word in said I/O image table storage means and a bit pointer code which selects a storage location in that word.

14. An industrial control processor comprising:

a read/write memory comprised of a plurality of addressable multi-bit words, said read/write memory storing at a selected set of memory addresses an I/O image table and storing a program comprised of a plurality of controller instructions which each contain a selected one of a set of operation codes;

a processor data bus coupled to said read/write memory for reading words out of and writing words into said read/write memory;

a macro-instruction register coupled to said processor data bus for receiving and storing controller instructions read out of said read/write memory;

a read-only memory for storing a set of addressable micro-routines, each of which corresponds to one of said operation codes in said set and each of which includes a unique set of micro-instructions;

means coupled to said macro-instruction register and said read-only memory for receiving the operation code in a controller instruction stored in said macro-instruction register and in response thereto addressing its corresponding micro-routine in said read-only memory; and

means for sequentially executing the micro-instructions in an addressed micro-routine including;

a. means responsive to a selected micro-instruction and responsive to a memory address code in a controller instruction stored in said macro-instruction register to read out a selected memory word in said I/O image table;

b. a bit pointer which is enabled by a selected micro-instruction and is responsive to a bit pointer code in a controller instruction stored in said macro-instruction register to select a bit in a memory word read from said I/O image table; and

c. means responsive to a selected micro-instruction for performing a logical operation with a selected bit from said I/O image table.

15. An industrial control processor as recited in claim 14 which includes:

a system flag table stored at a selected set of read/write memory addresses; and

means for receiving part program input data which indicates a function to be performed and for setting a bit in said flag table which corresponds to that function;

wherein selected controller instructions include address codes which enable said micro-instruction execution means to read out a memory word from said system flag table and perform a logical operation with a bit therein.

16. An industrial control processor as recited in claim 14 which includes a plurality of I/O slots coupled to said processor data bus, each associated with one memory word in said I/O image table;

I/O slot including a plurality of circuits suitable for coupling to respective external devices, and each circuit associated with a respective single bit in said one memory word.

17. An industrial control processor as recited in claim 16 which includes means for periodically and continuously coupling data between said I/O image table memory words and their associated I/O slots.

18. A numerical control system comprising:

a cabinet which forms an enclosed space and which includes a front door;

a cathode ray tube display mounted to said cabinet door for displaying an image on a screen to an operator disposed in front of the cabinet;

a keyboard mounted to said cabinet door for operation by said operator, said keyboard including a set of keys marked with symbols which represent elements of a ladder diagram;

a tape reader mounted to said cabinet door for operation by said operator, said tape reader being operable to read blocks of part program data from a tape which directs the operation of a machine to be controlled by the numerical control system;

an I/O interface rack mounted to the cabinet and disposed within its enclosed space, said I/O interface rack including;

a plurality of output circuits each connected to drive an associated operating device on the machine to be controlled; and

a plurality of input circuits each connected to receive a status signal from an associated sensing device on the machine to be controlled; and

an industrial control processor mounted to said cabinet within its enclosed space and connected by cables to said cathode ray tube display, said keyboard, said tape reader and said I/O interface rack, said industrial control processor including;

means for generating signals to said output circuits in said I/O interface rack, said generating means being responsive to status signals received from said input circuits, and responsive to part program data received from said tape reader, said generating means including means for storing a machine dependent software program comprised of a plurality of controller instructions;

means responsive to the manual operation of one of said set of keys on said keyboard for loading into said machine dependent software program storage means a digital code which corresponds to the symbol on said key; and

means responsive to the manual operation of one of said set of keys on said keyboard for coupling a digital character to said cathode ray tube display which generates a ladder diagram symbol on the screen that corresponds to the symbol on said one key.

19. The numerical control system as recited in claim 18 in which said I/O interface rack includes means for storing a position command data word and coupling the same to said machine to be controlled, and said industrial control processor includes means for calculating position command data words in response to part program data received from said tape reader.

20. An industrial control processor for controlling in response to blocks of part program data coupled to it the motion of a cutting tool on a machine tool and for controlling the discrete digital devices associated with the machine tool, the industrial control processor comprising:

means for storing a received block of part program data;

means for storing a position command word for each axis of motion on said controlled machine tool;

I/o image table storage means including a storage location for each discrete digital sensing device associated with the controlled machine tool and for each discrete digital operating device associated therewith;

system flag table storage means including a plurality of storage locations;

means for decoding a block of part program data and in response thereto setting a selected storage location in said system flag table storage means to a logic state which indicates that a specific auxiliary function is to be performed by said discrete digital devices;

means coupled to said data block storage means for calculating a position command word for each axis of motion and coupling each to its respective position command word storage means;

means for coupling said calculated position command words to said controlled machine tool to operate the axis servo mechanisms thereon;

means for storing a plurality of controller instructions which comprise a machine dependent software routine;

means for periodically executing said machine dependent software routine to set the logic state of selected operating device storage locations in said I/O image table in response to the logic state of selected sensing device storage locations in said I/O image table and selected storage locations in said system flag table; and

means for coupling data between said I/O image table and the discrete digital devices associated with the controlled machine.

21. The industrial control processor of claim 20 having means for developing and editing said machine dependent software routine which comprises:

keyboard means having a first set of manually operable keys for generating a first set of character table codes which correspond to a set of controller instruction operation codes, a second set of manually operable keys for generating a second set of character table codes which correspond to numeric values, and a third set of manually operable keys for generating a third set of character table codes which correspond to a set of editing functions;

means responsive to said first set of character table codes generated by said keyboard means for selectively generating controller instruction operation codes to said machine dependent software routine storage means;

means responsive to said second set of character table codes generated by said keyboard means for selectively generating binary coded numbers to said machine dependent software routine storage means; and

means responsive to said third set of character table codes generated by said keyboard means for selectively performing editing functions on controller instructions stored in said machine dependent software routine storage means.

22. The industrial control processor of claim 21 in which said means for developing and editing said machine dependent software routine further includes:

display means for generating ladder diagrams in response to a received set of codes; and

means coupled to said display means and said machine dependent software routine storage means for generating a set of codes to said display means which correspond to a selected set of controller instructions that comprise a Boolean expression.