Distributed logic control system and method

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, 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.

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:

• 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.

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:

• 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.

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:

• 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.

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:

• 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.