RSRules, a new concept in fault diagnosis for PLCs

Citation

(1998), "RSRules, a new concept in fault diagnosis for PLCs", Assembly Automation, Vol. 18 No. 4. https://doi.org/10.1108/aa.1998.03318daf.006

RSRules, a new concept in fault diagnosis for PLCs

RSRules, a new concept in fault diagnosis for PLCs

Keywords Defect detection, Programmable logic controller (PLC), Software

Rockwell Automation announces RSRules, from Rockwell Software, a new software productivity tool for automatically diagnosing faults in Allen-Bradley's PLC 5-based control systems.

RSRules reduces training time for support personnel, reduces system downtime and optimises process performance.

RSRules provides a totally new approach to fault finding. When the application is installed, the developer specifies a selection of data bits that are to be used in the fault diagnosis. The application is then run for 30-100 machine cycles, during which time RSRules builds up a set of rules for the normal operation of the application (see Plate 3). In applications that have a variable machine response, it creates a statistical profile to represent normal/abnormal operation. At the end of the training period, it identifies which data points are related and those that are not ­ much as a human operator would.

During the run-time operation of the system. RSRules constantly compares the key data points. When a fault occurs, it identifies the faulty operation and operates an alarm, if required. More important, it is also able to identify the likely cause of the fault.

Plate 3 RSRules, a new concept in fault diagnosis for PLCs

In applications that suffer gradual degradation in performance, RSRules is able to operate an alarm if the process goes outside pre-set limits. The causes of performance degradation can be identified and it will provide process optimisation details if required.

RSRules is easy to set up and requires no additional hardware. It runs on a 486, or better class processor and uses Rockwell's RSLinx32 to communicate with the PLC.

Large industrial control systems can have thousands of sensors and actuators, which can be extremely difficult and time consuming to maintain. RSRules is an effective watchdog that is not only able to instantly diagnose the most complex systems, but it is also able to provide process optimisation.

For further information contact: Rockwell Automation Ltd, Pitfield, Kiln Farm, Milton Keynes MK11 3DR, UK. Tel: +44 (0) 1908 838800; Fax +44 (0) 1908 261917.