Distributed logic control system and method
First Claim
1. A machine control system which comprises, in combination, a machine including means for producing motion at said machine and means for sensing machine conditions, and control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said motion-producing means, characterized in that said control means comprises:
- means for tabulating said predefined input and output in a combination representative of a preselected set of operation of said machine, each said combination representing an input/output image indicative of a corresponding zone in said preselected set, and said corresponding zone having associated therewith an allowed next zone with at least one of said corresponding zones having associated therewith a plurality of allowed next zones;
means for monitoring said predefined input and output responsive to a change in said predefined input and output to formulate a new input/output image;
means for comparing said new input/output image to an input/output image in said tabulating means indicative of said allowed next zone; and
means for indicating an error condition in the event that said new input/output image does not match that of said next zone in said preselected set.
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Accused Products
Abstract
A system and method for controlling operation of a plurality of elements in an automated process, such as a production process, and indicating error conditions as they occur. Each unique set of input and output conditions of the various system elements defines a unique logic state or zone. Thus, there are defined a multiplicity of valid system logic states or zones, each having a unique input/output image. A predetermined sequence of zones, productive zones representing designed machine operations, is stored in a zone table. All zones not explicitly defined in the zone table are automatically treated as error zones. A zone engine automatically cycles to observe any change in input/output image. Any change in inputs from the various system elements automatically transfer action to the unique zone associated with such inputs, resulting in corresponding changes in control outputs to the system elements and/or display an error message as appropriate.
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Citations
27 Claims
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1. A machine control system which comprises, in combination, a machine including means for producing motion at said machine and means for sensing machine conditions, and control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said motion-producing means, characterized in that said control means comprises:
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means for tabulating said predefined input and output in a combination representative of a preselected set of operation of said machine, each said combination representing an input/output image indicative of a corresponding zone in said preselected set, and said corresponding zone having associated therewith an allowed next zone with at least one of said corresponding zones having associated therewith a plurality of allowed next zones; means for monitoring said predefined input and output responsive to a change in said predefined input and output to formulate a new input/output image; means for comparing said new input/output image to an input/output image in said tabulating means indicative of said allowed next zone; and means for indicating an error condition in the event that said new input/output image does not match that of said next zone in said preselected set. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A machine control system which comprises, in combination, a machine including motion-producing means for producing motion at said machine and condition-sensing means for sensing machine conditions, and control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said motion-producing means, characterized in that said control means comprises:
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means for tabulating said predefined input and output in a combination representative of a preselected set of operations of said machine, each said combination representing an input/output image indicative of a corresponding zone in said preselected set; means for monitoring said predefined input and output responsive to a change in said predefined input and output to formulate a new input/output image; means for comparing said new input/output image to an input/output image in said tabulating means wherein said means for comparing indicates a next zone in said preselected set; means for indicating an error condition in the event that said new input/output image does not match that of a next zone in said preselected set; and means for initiating operation of said machine at each corresponding zone of said preselected set, illumination means associated with each said initiating means, and energizing means for energizing said illumination means at a state of a plurality of illumination states to indicate one of a plurality of available operating modes at said machine. - View Dependent Claims (8, 9)
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10. A method of operating a machine capable of performing a plurality of physical operations in a preselected sequence wherein said machine is controlled through input and output devices, said method comprising the steps of:
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establishing a set of machine operations defined by a set of operating zones, each zone of said operating zones having a corresponding input/output image of inputs and outputs from said input and output devices and each zone having a corresponding allowed next zone with at least one of said operating zones having a plurality of allowed next zones; monitoring inputs and outputs from said input and output devices during a step in said plurality of physical operations and comparing said inputs and outputs to said corresponding input/output image associated with said step; advancing machine operation to a next step in said set of machine operations when a change in said inputs and outputs produces a zone image corresponding to said allowed next zone; and indicating an error condition when a change in said inputs and outputs produces a zone image other than that corresponding to said allowed next zone. - View Dependent Claims (11, 12)
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13. A method of controlling a machine mechanism for obtaining a single non-interfering machine motion through an operating sequence, said method comprising the steps of:
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(a) coupling input/output means to said machine mechanism for providing input/output signals which vary as a function of motion of said machine mechanism through said sequence; (b) establishing a plurality of distinct mechanism operating zones each characterized by a combination of said input/output signals and each having associated therewith an allowed next operating zone, said operating zone including at lest two zones corresponding respectively to one or more operating states of said machine mechanism and an error zone, and at least one of said operating zones is associated with a plurality of next operating zones; (c) monitoring said input/output signals in each of said plurality of distinct mechanism operating zones for the combination of said input/output signals corresponding to said allowed next operating zone; (d) advancing machine operation to said allowed next operating zone upon detection of a corresponding input/output signal combination; and (e) advancing machine operation to said error zone and indicating an error condition upon detection of a combination of an input/output signal other than an input/output signal corresponding to a subsequent mechanism operating zone. - View Dependent Claims (14, 15)
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16. A machine control system which includes a plurality of machine mechanisms for performing operations in a sequence and means for controlling operation of said mechanisms comprising:
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input/output means couples to each of said plurality of machine mechanisms for providing input/output signals in combinations indicative of a plurality of stages of operation associated with said plurality of machine mechanisms; and control means coupled to each of said plurality of machine mechanisms, said control means including means for receiving input/output signals from an associated input/output means, said control means having stored therein a table of predefined operating zones for each of said plurality of machine mechanisms as a function of differing combinations of an associated input/output signal and having associated therewith an allowed next operating zone wherein a least one of said operating zones has associated therewith a plurality of next operating zones, said control means having further stored therein tables of predefined zones in which operation of said plurality of machine mechanisms could interfere with each other, and means for driving each of said plurality of machine mechanisms as a combined function of said associated input/output signal and an indicia stored in said tables. - View Dependent Claims (17)
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18. A machine control system which comprises, in combination, a machine including means for producing motion at said machine and means for sensing machine conditions, and control means responsive to predefined inputs from said condition-sensing means for providing predefined outputs to said motion-producing means, characterized in that said control means further comprises
means for manually initiating operation of said machine at each of a plurality of differing zones in a preselected set of operations at said machine, illumination means associated with each said manually-initiating means, and means for energizing said illumination means at differing illumination states to indicate differing available operating modes at said machine.
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21. An apparatus for controlling a machine comprising:
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memory means for storing at least two input/output images, each input/output image having associated therewith a present zone and an allowed next zone with at least one input/output image having associated therewith a plurality of allowed next zones; monitoring means for receiving an input requiring a change in a present input/output image to a new input/output image; means for comparing an input/output image of said allowed next zone with said new input/output image; means for executing said input and for replacing said present input/output image with said input/output image of said allowed next zone if said new input/output image matches said allowed next none; and means for indicating an error condition when said new input/output image does not match said input/output image of said allowed next zone. - View Dependent Claims (22, 23, 24, 25)
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26. A method for controlling a machine having a present zone, an input/output image of said present zone, and at least two allowed next zones, wherein said method comprises the steps of:
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receiving an input representative of a new input/output image of said machine; comparing an input/output image of a first allowed next zone of said at least two allowed next zones with said new input/output image; changing said present zone to said first allowed next zone if said input/output image of said first allowed next zone matches said new input/output image; and comparing an input/output image of a second allowed next zone of said at least two allowed next zones with said new input/output image if said new input/output image did not match said input/output image of said first allowed next zone.
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27. A method for controlling a machine having a present zone, an input/output image of said present zone, and a plurality of allowed next zones, wherein said method comprises the steps of:
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(a) receiving an input representative of a new input/output image of said machine; (b) comparing an input/output image of a particular allowed next zone of said plurality of allowed next zones with said new input/output image; (c) changing said present zone of said machine to said particular allowed next zone if said input/output image of said particular allowed next zone matches said new input/output image; and (d) repeating steps (b) and (c) if said input/output image of said particular allowed next zone does not match said new input/output image until all of said plurality of allowed next zones have been compared to said new input/output image.
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Specification