Distributed logic control system and method
First Claim
1. A machine control system which comprises, in combination, at least one mechanism including means for actuating said mechanism, means for sensing mechanism conditions, and control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, characterized in that said control means comprises:
- a present zone memory means for storing a present zone of a mechanism of said machine;
an input/output image memory means for storing a table of input/output images associated with said present zone of said mechanism;
an allowed next zones memory means for storing at least one allowed next zone associated with said present zone of said mechanism, at least one of said zones having a plurality of allowed next zones;
means for comparing a new input/output image to an input/output image of said plurality of allowed next zones, wherein if said next zone corresponding to said new input/output image does not correspond to one of said plurality of allowed next zones, an error in processing of said machine exists, anda part processing inhibit table indicative of conditions wherein an operation on a workpiece at said mechanism should be inhibited because said workpiece is not properly prepared for said operation.
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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
40 Claims
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1. A machine control system which comprises, in combination, at least one mechanism including means for actuating said mechanism, means for sensing mechanism conditions, and control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, characterized in that said control means comprises:
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a present zone memory means for storing a present zone of a mechanism of said machine; an input/output image memory means for storing a table of input/output images associated with said present zone of said mechanism; an allowed next zones memory means for storing at least one allowed next zone associated with said present zone of said mechanism, at least one of said zones having a plurality of allowed next zones; means for comparing a new input/output image to an input/output image of said plurality of allowed next zones, wherein if said next zone corresponding to said new input/output image does not correspond to one of said plurality of allowed next zones, an error in processing of said machine exists, and a part processing inhibit table indicative of conditions wherein an operation on a workpiece at said mechanism should be inhibited because said workpiece is not properly prepared for said operation.
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2. A machine control system which comprises, in combination, at least one mechanism including means for actuating said mechanism, means for sensing mechanism conditions, and control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, characterized in that said control means comprises:
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a present zone memory means for storing a present zone of a mechanism of said machine; an input/output image memory means for storing a table of input/output images associated with said present zone of said mechanism; an allowed next zones memory means for storing at least one allowed next zone associated with said present zone of said mechanism, at least one of said zones having a plurality of allowed next zones; means for comparing a new input/output image to an input/output image of said plurality of allowed next zones, wherein if said next zone corresponding to said new input/output image does not correspond to one of said plurality of allowed next zones, an error in processing of said machine exists, and an interference inhibit memory means for storing an interference inhibit table describing at least one zone of one mechanism which inhibits at least one zone of another mechanism. - View Dependent Claims (3)
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4. A method of monitoring the operating of a machine which comprises in combination at least one mechanism including means for actuating said mechanism, and means for sensing mechanism conditions, and control means including memory means, said control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, said method comprising the steps of:
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storing a machine program controlled of at least one mechanism program representing sequences of operation defined by predetermined images of input and output signals stored in a table, monitoring the actual input/output signals, and comparing the image of actual input/output signals with one of the stored means, characterized by; a zone logic method in which each said input/output image is indicative of a zone of said mechanism and each zone having associated therewith a list of corresponding allowed next zones, with at least one of said zones having a plurality of allowed next zones, moving between zones by determining to leave the present zone and by selecting the next zone from among the next allowed zones accommodating interactions between mechanisms by having the current zone of one mechanism prevent the occupation of a predetermined zone of another mechanism, and setting the outputs as prescribed by said selected allowed next zone. - View Dependent Claims (7, 8, 9, 10, 11, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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5. A method of monitoring the operating of a machine which comprises in combination at least one mechanism including means for actuating said mechanism, and means for sensing mechanism conditions, and diagnostic means including memory means, said diagnostic means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, said method comprising the steps of:
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storing a machine program comprised of at least one mechanism program representing sequences of operation defined by predetermined images of input and output signals stored in a table, monitoring the actual input/output signals, and comparing the image of actual input/output signals with one of the stored images, characterized by; a zone logic method in which each said input/output image is indicative of a zone of said mechanism and each zone having associated therewith a list of corresponding allowed next zones, with at least one of said zones having a plurality of allowed next zones, moving between zones by determining to leave the present zone and by selecting the next zone from among the next allowed zones, and using said zone logic method to monitor the input/output conditions of said mechanism without setting outputs, which outputs are set by a control method other than said zone logic method. - View Dependent Claims (6, 12)
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26. A system for monitoring the operating of a machine which comprises in combination at least one mechanism including means for actuating said mechanism, means for sensing mechanism conditions, and control means including memory means, said control means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, said means comprising:
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a stored machine program comprised of at least one mechanism program representing sequences of operation defined by predetermined images of input and output signals stored in a table, means for monitoring the actual input/output signals, and means for comparing the image of actual input/output signals with one of the stored images, characterized by; zone logic means in which each said input/output image is indicative of a zone of said mechanism and each zone having associated therewith a list of corresponding allowed next zones, with at least one of said zones having a plurality of allowed next zones, means for moving between zones by determining to leave the present zone and by selecting the next zone from among the next allowed zones means for accommodating interactions between mechanisms by having the current zone of one mechanism prevent the occupation of a predetermined zone of another mechanism, and means for setting the outputs as prescribed by said selected allowed next zone. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40)
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27. A system for monitoring the operating of a machine which comprises in combination at least one mechanism including means for actuating said mechanism, means for sensing mechanism conditions, and diagnostic means including memory means, said diagnostic means responsive to a predefined input from said condition-sensing means for providing a predefined output to said actuating means, said means comprising:
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a stored machine program comprised of at least one mechanism program representing sequences of operation defined by predetermined images of input and output signals stored in a table, means for monitoring the actual input/output signals, and means for comparing the image of actual input/output signals with one of the stored images, characterized by; zone logic means in which each said input/output image is indicative of a zone of said mechanism and each zone having associated therewith a list of corresponding allowed next zones, with at least one of said zones having a plurality of allowed next zones, means for moving between zones by determining to leave the present zone and by selecting the next zone from among the next allowed zones, and means for using said zone logic means to monitor the input/output conditions of said mechanism without setting outputs, which outputs are set by a control method other than said zone logic method.
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Specification