DE102013010783A1 - Method and control device for testing an automation solution based on a PLC control - Google Patents

Abstract

The invention relates to a method for testing a PLC controller (21), comprising the following steps: - providing a PLC program code for realizing a PLC controller (21); - providing one or more actuator models (22) and one or more application models (23) each in a PLC program code configured to communicate with the PLC controller (21) via a software interface instead of external units; - Reading the PLC program codes of the PLC controller (21), the one or more actuator models (22) and the one or more application models (23) in a PLC control unit (2); - Execute the PLC program codes in the PLC control unit (2).

Description

Technical area

The present invention relates to the testing of automation solutions based on PLCs (Programmable Logic Controllers) or PLCs (Programmable Logic Controllers).

State of the art

Industrial automation applications for modern automation solutions require complex control systems, which are usually implemented as so-called PLC controllers or PLC controllers. Before the PLC controls are used in the application, extensive testing is required to ensure proper operation and avoid damage to the equipment or hazards to personnel.

Damage to the machines used or hazards to persons.

Extensive testing of the automation applications requires that the physical units of the later automation solution be provided in large part already at the test site. This effort is considerable and is therefore often reduced, so that the automation solution before delivery to the end customer is tested only partially, in particular without expensive hardware in a sufficient manner. This often means that extensive adjustments are required at the site, which cause high costs.

In addition, during testing, for example, motion axes of actuators are imaged by very inaccurate approximations, the specific parameter settings and state variables of the actuators, such. B. whose maximum current and the like, do not take into account.

In some cases, the physical systems to be tested can also be virtually created using external modeling tools, such as MATLAB / SIMULINK, to test and optimize the control code and parameters generated for the PLC controller.

The publication DE10248991 (A1) discloses a device for simulating the control and machine behavior of tool or production machines. Axial actual values from axis setpoints are calculated using mathematical models of the drives and the mechanics of the machine. The axis setpoints are output from a numerical controller to a downstream computer, where the actual axis values are calculated and forwarded to a machine model. Condition signals are generated by the machine model and fed back to the numerical controller.

The publication DE 10 2004 033 593 A1 relates to a method for simulating a technical installation with at least two components that are connected to one another via a real interface. Between the components an exchange takes place via the real interface. The exchange is realized in the form of data protocols. Likewise, the control statements are logged as control protocols to the components connected via the real interface. The data and control logs are used to create a virtual image of the real interface. The exchange behavior of the components is then simulated only by means of the virtual interface.

From the DE 10 2004 019 432 A1 a method for virtual commissioning of a technical facility is known, which is a CAD system for creating and displaying a CAD drawing with CAD drawing objects for technical equipment of the plant, a data platform with a library for equipment data, in which at least the attributes of a belonging to technical equipment type associated instrumentation objects, as well as with a controller that executes a control program for the technical equipment includes. A resource type is assigned to a selected CAD drawing object from the resource data library. For each instrumentation object of the resource type, at least taking into account its attributes, CAD motion objects are formed and displayed in the associated CAD drawing object of the CAD drawing.

The publication DE 103 60 530 A1 discloses a method for commissioning a machine in which a numerical set simulated on the machine simulated a set of parameters and the fulfillment of a predetermined commissioning requirement is tested on the basis of the simulated by the simulator machine behavior.

Furthermore, the document shows DE 10 2008 014 153 A1 a method for controlling an automation system. For controlling a control system is used with interconnected control units, wherein in at least one control unit, a control program is stored with a predetermined device function. According to the method, within a runtime environment, a software module having a program function provided, wherein the program function represents a proxy function of the stored in the control unit device function. The device function and the program function are at least partially identical. The device function comprises a first variable function parameter and the program function comprises at least one second variable function parameter assigned to the first function parameter of the device function. The second function parameter is adapted and transmitted from the execution environment via a network to the at least one control unit. The first function parameter is set to the value of the second function parameter.

From the publication DE 10 2009 018 665 A1 is a drive system with a control device for controlling a drive device for driving an element and with a control device for controlling a plurality of operating modes of the drive device known. The multiple modes include a simulation mode in which there is no drive movement of the element to be driven and a response of the drive device to predetermined setpoint values is input to the controller from the controller.

It is an object of the present invention to provide an improved possibility for simulating actuators in a PLC environment, whereby in particular the time to commissioning at the place of use can be shortened and a structure of a complete automation environment at the test location can be dispensed with. Furthermore, the testing of the PLC control should be possible without additional hardware or tools in the developer's usual environment.

Disclosure of the invention

This object is achieved by the method for testing a PLC controller according to claim 1 and by the PLC controller, the automation environment and the computer program product according to the independent claims.

Further advantageous embodiments of the present invention are specified in the dependent claims.

• – Bereitstellen eines PLC-Programmcodes zur Realisierung einer PLC-Steuerung;
• – Bereitstellen eines oder mehrerer Aktuatormodelle und eines oder mehrerer Anwendungsmodelle jeweils in einem PLC-Programmcode, die ausgebildet sind, um über eine Softwareschnittstelle anstelle externer Einheiten mit der PLC-Steuerung zu kommunizieren;
• – Einlesen der PLC-Programmcodes der PLC-Steuerung, des einen oder der mehreren Aktuatormodelle sowie des einen oder der mehreren Anwendungsmodelle in ein PLC-Steuergerät;
• – Ausführen der PLC-Programmcodes in dem PLC-Steuergerät, um eine Funktionsprüfung, ein Test oder ein Debuggen durchzuführen.

According to a first aspect, there is provided a method of testing a PLC controller, comprising the steps of:

• Providing a PLC program code for realizing a PLC control;
• Providing one or more actuator models and one or more application models each in a PLC program code configured to communicate with the PLC controller via a software interface instead of external units;
• - Reading the PLC program codes of the PLC control, the one or more actuator models and the one or more application models in a PLC control unit;
• Execute the PLC program codes in the PLC controller to perform a functional check, test or debug.

One idea of the above method is to implement in the integrated programmable controller in addition to the PLC control code physical models by the actuators and one or more actuated by the actuators, in particular dynamic systems can be simulated so that the drive and application models via PLC functions and function blocks off IEC 61131 libraries or external modeling tools, such as MATLAB or SIMULINK, can be used in the programmable logic controller. These functions and function blocks are configured and parameterized depending on the selected actuators and dynamic systems and their parameters. The application model thus represents the behavior of the process depending on the parameters.

The method combines the PLC program to realize the PLC control on a PLC controller with the virtual models of the actuators and one or more process / application models to test and simulate the PLC program. In other words, the simulation and the test of the entire application are performed virtually on the PLC controller. Physical actuators and process hardware are therefore not required, allowing even the testing of partial aspects of the automation solution.

Furthermore, the execution of the PLC program codes in the PLC control unit can be monitored for proper functioning, in particular by means of a visualization unit.

It may be provided that the execution of the PLC program codes by means of externally provided standard PLC libraries, in particular a IEC 61131 library , is carried out.

• – eine Zustandsmaschine des Aktuators;
• – ein oder mehrere Bewegungsprofile, wie beispielsweise geregelte Positionen, geregelte Geschwindigkeiten, Anfahrpunkte und dergleichen;
• – eine Fehler- und Alarmbehandlung für den Aktuator;
• – eine Schnittstelle zum Triggern von Fehlerzuständen,
• – eine Regelungsschleife, wie z. B. Regelungen für Position, Geschwindigkeit und Moment, einschließend Interpolationen und Profile;
• – ein Motormodell des Aktuators und/oder ein Bremsmodell zur Modellierung des Bremsverhaltens;
• – eine Schnittstelle für die Aktuatorparameter;
• – eine Kommunikationslogik für die Kommunikation zwischen dem Aktuator und dem PLC-Steuergerät, einschließend zyklischen und nicht zyklischen Datenaustausch;
• – eine Visualisierung der Aktuatorzustände, -parameter, -fehler und -alarme;
• – eine lokale IO-Behandlung, wie beispielsweise Endstellungsschalter, Nothalte und dergleichen; und
• – eine CAM-Tabellenausführung.

In particular, the one or more actuator models may include at least one of the following aspects:

• A state machine of the actuator;
• One or more motion profiles, such as controlled positions, controlled speeds, approach points, and the like;
• An error and alarm treatment for the actuator;
• An interface for triggering error conditions,
• - a control loop, such. B. position, velocity and moment controls, including interpolations and profiles;
• A motor model of the actuator and / or a brake model for modeling the braking behavior;
• An interface for the actuator parameters;
• A communication logic for communication between the actuator and the PLC controller, including cyclic and non-cyclic data exchange;
• A visualization of the actuator states, parameters, errors and alarms;
• A local I / O treatment, such as end position switches, emergency stops and the like; and
• - a CAM table execution.

According to another aspect, there is provided a PLC controller having a PLC program code for testing a PLC controller, the PLC program code having a PLC program code for realizing a PLC controller, one or more actuator models, and one or more application models that communicate with each other within the PLC controller via a software interface.

• – das obige PLC-Steuergerät; und
• – eine Visualisierungseinheit zum Ausgeben von in dem PLC-Steuergerät ermittelten Testergebnissen.

In another aspect, an automation environment is provided, comprising:

• The above PLC controller; and
• A visualization unit for outputting test results determined in the PLC controller.

According to a further aspect, there is provided a computer program product including program code for testing a PLC control, the PLC program code having a PLC program code for realizing a PLC control, one or more actuator models, and one or more application models communicate with each other via an internal software interface.

Brief description of the drawings

Preferred embodiments will be explained in more detail with reference to the accompanying drawings. Show it:

1 a schematic representation of a test environment with a PLC controller; and

2 a flow chart illustrating a test method for testing a PLC control in a virtual test environment.

Description of embodiments

1 shows a schematic representation of a virtual automation environment 1 with a PLC control unit 2 , In the PLC control unit 2 it can be a hardware implemented control device or a PLC control device implemented in a virtual PLC environment. The PLC control unit 2 contains, on the one hand, the PLC control to be tested for its function 21 , The PLC control 21 essentially corresponds to a PLC control code that is to be executed in the PLC controller 2 suitable is.

The PLC control 21 stands with at least one actuator model 22 in communication connection. The actuator model 22 contains a virtual representation of a physical actuator, such. B. a drive motor in a robotics application, in a PLC control code, the z. Using standard PLC libraries, such as an external conventional PLC control code IEC 61131 library 3 , is created. By parameter application by means of a suitable external development unit 4 can the actuator model 22 adapted to the application.

The actuator model 22 continues to communicate with at least one application model 23 , which maps the application environment in which the PLC control 21 should be used. The application model 23 forms the application environment z. Using external modeling tools 5 , such as MATLAB or SIMULINK, on the PLC controller 2 executable code and / or the standard PLC library 3 from.

• – die Bewegung von aktuatorbetriebenen Komponenten der Automatisierungsanwendung um eine oder mehrere Achsen;
• – Aktuatorparametereinstellungen;
• – Kommunikationseinstellungen mit dem Aktuator;
• – die gesamte Kommunikation mit dem Prozess- und Anwendungsmodell; und
• – im Falle von Regelungsschleifen deren Leistungsfähigkeit.
• – Fehlerzustände der Automatisierungslösung sowie deren Fehlerbehandlungsroutinen

Aspects that can be tested and simulated using the application environment include:

• The movement of actuator-driven components of the automation application about one or more axes;
• - actuator parameter settings;
• - communication settings with the actuator;
• - all communication with the process and application model; and
• - in the case of control loops, their capacity.
• - Error states of the automation solution and their error handling routines

The availability of models for the simulation of automation applications in the PLC controller 2 can through the IEC 61131 libraries 3 be guaranteed. These allow the simplified use of known Development environments without the need for additional simulation tools.

The PLC control unit 2 can continue with a visualization unit 6 are in communication, in which the results of a in the PLC control unit 2 performed simulation can be displayed. The visualization unit 6 can serve the kinematics of the application model 23 to illustrate.

The PLC control 21 in conjunction with the virtual actuator models 22 and application models 23 can be used after testing without any further change in a real application environment. This allows you to test exactly the PLC control code that is used in the real application environment. The communication of the PLC control 21 An appropriate interface can be ensured by means of communication models.

• – eine Zustandsmaschine des Aktuators;
• – Bewegungsprofile, wie beispielsweise geregelte Position, geregelte Geschwindigkeit, Anfahrpunkte und dergleichen;
• – Fehler- und Alarmbehandlung des Aktuators;
• – Regelungsschleifen und Algorithmen, wie z. B. Regelungen für Position, Geschwindigkeit und Moment, einschließend Interpolationen und Profile;
• – ein Motormodell des Aktuators und/oder ein Bremsmodell zur Modellierung des Bremsverhaltens;
• – eine Schnittstelle für die Aktuatorparameter;
• – eine Kommunikationslogik für die Kommunikation zwischen dem Aktuator und dem PLC-Steuergerät 2, einschließend zyklischen und nicht zyklischen Datenaustausch;
• – Visualisierung der Aktuatorzustände, -parameter, -fehler und -alarme;
• – lokale IO-Behandlung, wie beispielsweise Endstellungsschalter, Nothalte und dergleichen; und
• – eine CAM-Tabellenausführung.

The actuator model 22 may in particular include one of the following aspects:

• A state machine of the actuator;
• Motion profiles such as controlled position, controlled speed, approach points and the like;
• - error and alarm handling of the actuator;
• - control loops and algorithms, such. B. position, velocity and moment controls, including interpolations and profiles;
• A motor model of the actuator and / or a brake model for modeling the braking behavior;
• An interface for the actuator parameters;
• A communication logic for communication between the actuator and the PLC controller 2 including cyclic and non-cyclic data exchange;
• - visualization of actuator states, parameters, errors and alarms;
• Local IO handling, such as limit switches, emergency stops and the like; and
• - a CAM table execution.

The actuator model 22 itself may be generic to a particular family of actuators or specific to a particular actuator. The actuator model 22 can through the engineering software tool 4 can be configured and parameterized, for example via parameter files or within the simulation environment, for example also using the visualization unit 6 ,

The application model 23 can be modeled from a IEC 61131 library 3 , from library modules that can be arbitrarily combined to represent the process or parts thereof, or from other modeling tools 5 , such as MATLAB / SIMULINK, in different code formats, such as C code, IEC 61131 structured Text code and the like, to be imported.

The application model 23 is through the actuator model 22 addressed via (eg standardized) interfaces to ensure that the application models 23 that are provided by external software environments can be easily integrated. Several actuator models 22 can with an application model 23 be connected, for example, to represent independent axes of motion.

Depending on the level of detail of the application model 23 the adaptation and the performance analysis of the automation solution can be carried out in the simulation.

In 2 FIG. 4 is a flow chart illustrating the method of testing a PLC controller. FIG 21 shown.

In step S1, the one by the PLC control 21 Controlled application environment in actuator models 22 and an application model 23 displayed. This model is used in step S2 by suitable libraries, such as the IEC 61131 standard library 3 , additional library modules, or by importing from other modeling tools 5 , with the PLC control 21 combined and suitably in the PLC control unit 2 provided or read into this.

In step S3, the simulation of the thus created virtual application environment in the PLC controller 2 started, with a suitable output on the visualization unit 6 allows you to capture the simulation or test results to decide if the PLC control 21 properly operate the virtualized application environment. Through suitable interfaces, it is now possible with the development unit 4 the one or more actuator models 22 and the application model 23 during simulation, for example, by setting and / or setting variables, log data and the like so as to monitor and track values of variables.

LIST OF REFERENCE NUMBERS

1

automation environment

2

PLC controller

21

PLC control

22

Aktuatormodell

23

application model

3

Standard PLC library

4

development unit

5

modeling tool

6

visualization unit

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 10248991 A1 [0007]
• DE 102004033593 A1 [0008]
• DE 102004019432 A1 [0009]
• DE 10360530 A1 [0010]
• DE 102008014153 A1 [0011]
• DE 102009018665 A1 [0012]

Cited non-patent literature

• IEC 61131 Libraries [0017]
• IEC 61131 library [0020]
• IEC 61131 library [0029]
• IEC 61131 Libraries [0032]
• IEC 61131 Library [0037]
• IEC 61131 structured [0037]
• IEC 61131 Standard Library [0041]

Claims (7)

Method for testing a PLC controller ( 21 ), comprising the following steps: providing a PLC program code for realizing a PLC control ( 21 ); - providing one or more actuator models ( 22 ) and / or one or more application models ( 23 ) each in a PLC program code, which are designed to communicate with the PLC controller via a software interface instead of external units ( 21 ) to communicate; - reading the PLC program codes of the PLC control ( 21 ), one or more actuator models ( 22 ) and the one or more application models ( 23 ) into a PLC control unit ( 2 ); Execution of the PLC program codes in the PLC control unit ( 2 ). Method according to claim 1, wherein the execution of the PLC program codes in the PLC control unit ( 2 ) on a proper function, in particular by means of a visualization unit ( 6 ) is monitored. Method according to claim 1 or 2, wherein the execution of the PLC program codes is carried out by means of provided standard PLC libraries ( 3 ), in particular an IEC 61131 library. Method according to one of claims 1 to 3, wherein the one or more actuator models ( 22 ) includes at least one of the following aspects: a state machine of the actuator; One or more motion profiles, such as controlled positions, controlled speeds, approach points, and the like; An error and alarm treatment for the actuator; - a control loop, such. B. position, velocity and moment controls, including interpolations and profiles; A motor model of the actuator and / or a brake model for modeling the braking behavior; An interface for the actuator parameters; A communication logic for the communication between the actuator and the PLC control unit ( 21 ), including cyclic and non-cyclic data exchange; A visualization of the actuator states, parameters, errors and alarms; A local I / O treatment, such as end position switches, emergency stops and the like; and a CAM table execution. PLC control unit ( 21 ) containing a PLC program code for testing a PLC control ( 21 ), wherein the PLC program code comprises a PLC program code for realizing a PLC control ( 21 ), one or more actuator models ( 22 ) and one or more application models ( 23 ) within the PLC controller ( 2 ) communicate with each other via a software interface. Automation environment ( 1 ), comprising: - a PLC control device ( 2 ) according to claim 5; and a visualization unit ( 6 ) for outputting in the PLC control unit ( 2 ) determined test results. Computer program product containing a program code to control a PLC ( 21 ), the PLC program code being a PLC program code for realizing a PLC control ( 21 ), one or more actuator models ( 22 ) and one or more application models ( 23 ) communicating with each other via an internal software interface.

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