Abstract:
A machine programming and control system includes a computer including a processor, memory, a display and a device associated with a process. A flowcharting module executed by the computer generates and edits a flowchart that contains action and decision blocks which define logic for operating the device to further the process. The flowcharting module allows active debugging objects to be added to the flowchart. The active debugging objects provide information relating debugging of flowchart code and/or debugging of a portion of the process that is related to the flowchart code. The active debugging object includes at least one of audio, a movie clip, a link to a website, and text demonstrating the desired operation of the process. The active debugging object includes at least one of audio, a movie clip, a link to a website, and text describing correct values for control variables at a first logical point in the flowchart.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 60/310,387, filed Aug. 6, 2001, which is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to programming and control systems. More particularly, this invention relates to flowchart-based programming and control systems that include active debugging objects. 
     BACKGROUND OF THE INVENTION 
     Programming and control systems are generally used for controlling processes that involve devices such as relays, solenoids, motors, valves, switches, and other electrical and electromechanical devices. The processes that are controlled include machining, drilling, welding, spraying paint, mixing materials, assembling parts, handling materials, and other similar processes. 
     Conventional programming and control systems generally employed ladder diagrams and relay ladder logic (RLL) to control the operation of the devices that are associated with the processes. In practice, however, programmers tend to use a flowchart to initially define the operation of the devices in the process. Then, the programmers manually translated the flowchart into the ladder diagrams. The programmers employ the flowcharts as a first step because the flowcharts emulate human thought processes whereas the ladder diagrams do not. Subsequently, developers created programming and control systems that control the process directly from the flowchart logic. One flowchart-based system is disclosed in “Continuous Flowchart, Improved Data Format and Debugging System For Programming and Operation of Machines”, U.S. Pat. No. 4,852,047, which is hereby incorporated by reference. 
     Flowcharts generally include action blocks that represent an operation or action based on current input and output data. Action blocks generally have one entry point that is usually located at the top and one exit point that is usually located at the bottom. A branching or decision block is a diamond-shaped block that represents a branch in the control path based on the results of a decision. Decision blocks generally have one entry point that is usually located at the top and two exit points that are usually located at the side and the bottom. Using combinations of the action and decision blocks, a programmer creates a flowchart that controls one or more devices that are associated with a process. 
     Programming and control systems generally provide an operating mode and a debugging mode. In the debugging mode, the programmer monitors the flowchart object code as it is executed. In some systems, a currently executing logic block is highlighted in real time while it is executing. Multiple watch windows allow a user to view different flowcharts or different parts of the same flowchart while it is executing. The debugging mode may also include a step-by-step executing mode. In other words, the developer uses a mouse or a keyboard to trigger one logic block to be executed at a time. After each logic block is executed, the developer checks the state of control variables and device operation to determine whether a desired response or logic state is achieved. The debugging process often takes a long time and increases the cost of the project. 
     SUMMARY OF THE INVENTION 
     A machine programming and control system according to the present invention includes a computer with a processor, memory, and a display and a device associated with a process. A flowcharting module executed by the computer generates and edits a flowchart that contains action and decision blocks that define logic for operating the device to further the process. The flowcharting module allows active debugging objects to be added to the flowchart. 
     In other features, the active debugging objects provide information relating to debugging of flowchart code and/or debugging of a portion of the process that is related to the flowchart code. The active debugging objects may include an icon that is added to the flowchart adjacent to related flowchart code to visually identify the active debugging object. 
     In still other features, the active debugging object provides at least one of audio, a movie clip, a link to a website and textual information. The active debugging object includes at least one of audio, a movie clip, a link to a web site and text demonstrating the desired operation of the process. The active debugging object includes at least one of audio, a movie clip, a link to a website and text describing correct values for control variables at a first logical point in the flowchart. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
     FIG. 1 is a functional block diagram of an exemplary process for illustrating the present invention; 
     FIG. 2 is a functional block diagram of a flowchart-based programming and control system according to the invention; 
     FIG. 3 is a more detailed functional block diagram of the flowchart-based programming and control system of FIG. 2; 
     FIG. 4 illustrates a graphical user interface (GUI) screen view of an exemplary flowchart that is generated by the flowchart-based programming and control system and that includes active debugging objects that are added to the flowchart according to the invention; 
     FIG. 5 illustrates a scrolled view of the GUI screen view of the exemplary flowchart of FIG. 4; and 
     FIG. 6 illustrates an exemplary dialog box for setting properties of active debugging objects. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The ensuing detailed description provides preferred exemplary embodiments only and is not intended to limit the scope, applicability or configuration of the present invention. Rather, the ensuing detailed description of the preferred exemplary embodiments will provide those skilled in the art with an enabling description for implementing the preferred exemplary embodiments of the present invention. It being understood that various changes may be made in the function and arrangement of the elements without departing from the spirit and scope of the invention as set forth in the appended claims. 
     A programming and control system according to the invention provides active debugging objects that are added to a flowchart that is created by the programming and control system for operating devices that are associated with a process. The active debugging objects provide audio and/or visual feedback such as help files that include text and images, multi-media content such as audio and video, links to web sites containing relevant information, and other suitable links, information or content that assist a programmer with debugging control logic. The active debugging objects are visible during the debugging process. The active debugging objects are preferably implemented using active components such as ActiveX® components or other suitable components. 
     Referring now to FIG. 1, an exemplary process  10  will be employed to illustrate the invention. The process  10  heats and mixes two materials until their conductivity reaches a pre-selected conductivity. Then, the process delivers the materials to a holding tank. The process  10  includes a supply  12  for a first material and a supply  16  for a second material. A first solenoid valve  20  is positioned in line with a conduit  22  to control the delivery of the first material. A second solenoid valve  26  is positioned in line with a conduit  28  to control the delivery of the second material. The first and second solenoid valves  20  and  26  are operated electronically. A fan  30  includes fan blades  32  and a fan motor  36 . 
     A material container  40  contains the first and second materials  41  that have been delivered by the first and second supplies  12  and  16 . A first mixer  42  includes a first mixer motor  44  and a first mixing device  45  that is located inside the container  40 . A second mixer  46  includes a second mixer motor  48  and a second mixing device  50  that is also located inside the container  40  on an opposite side of the container  40 . A conductivity sensor  54  is located inside the container  40  in fluid contact with the first and second materials  41 . A temperature sensor  56  is likewise located inside the container  40  in fluid contact with the first and second materials  41 . 
     A furnace  60  is positioned adjacent to the container  40  and is connected to a gas supply  64 . The furnace  60  heats the first and second materials. The furnace  60  includes a solenoid valve  66  for supplying gas to the furnace  60 . The furnace  60  includes a pilot  68  and an ignition device  70  that lights the pilot when triggered by an electronic signal. A pilot sensor  72  generates a signal indicating whether a pilot flame is present or absent. A conduit  76  is connected to the container  40  and a finished product container  80 . A solenoid valve  78  controls movement of fluid between the containers  40  and  80 . After mixing and heating the two materials, a finished product is delivered to the finished product container  80  by actuating the solenoid valve  78 . 
     Referring now to FIG. 2, a flowchart-based programming and control system is illustrated at  110 . The programming and control system  110  includes a computer  116 , a display  118 , an input/output card (I/O)  120  and one or more I/O devices such as a keyboard  124  and/or a mouse  126 . The I/O card  120  is connected to a communications network  130 . The I/O card  120  can be an Ethernet card and the communications network  130  can be an Ethernet network. Skilled artisans can appreciate that other I/O cards and communications networks can be employed without departing from the spirit of the invention. 
     The communications network  130  is connected to the first and second mixers  42  and  46  (both of which are identified at  140  in FIG.  2 ). The communications network  130  is similarly connected to the fan  30 , the pilot sensor  72 , the ignition device  70 , the temperature sensor  56 , the conductivity sensor  54 , one or more relays  144 , one or more switches  146 , and the solenoid valves  20 ,  26  and  66  (collectively identified at  148 ). The flowchart-based programming and control system  110  allows a user to create a flowchart  149  that includes active debugging objects as will be described further below. 
     Referring now to FIG. 3, the flowchart-based programming and control system  110  is illustrated in further detail. The computer  116  includes an I/O interface  150  that is connected to a processor  152  and memory storage  154  that can include floppy drives, hard drives, optical storage, etc. Memory  160  is connected to the processor  152  and the I/O interface  150 . The memory  160  includes random access memory (RAM) and read only memory (ROM). When the computer  116  is booted up, the computer  116  loads an operating system (OS) module  170  which is preferably a multi-tasking OS, such as Windows 95®, Windows 98®, Windows 2000®, Windows NT®, and Windows NTE®. 
     After being selected and launched by the user, the computer  116  loads a flowchart module  174  into memory  160 . As a user creates a flowchart, the flowchart module  174  generates flowchart source code  178  that can be stored in memory  160  or memory  154 . When the user validates and debugs the flowchart source code  178 , the user compiles the flowchart source code  178  and generates flowchart object code  180  that is executed by a flowchart run time engine  186  during operation of the process  10 . During creation or editing of the flowchart  149 , the user adds active debugging objects as will be described below. The I/O interface  150  can also be connected to a local area network (LAN)  196 , a wide area network (WAN)  197 , and one or more other I/O devices  198  such as scanners, printers, etc. 
     Referring now to FIG. 4, the exemplary flowchart  149  is created using a pull-down menu  204 , toolbar  210 , and tools  212  and using a cursor  213  that is moved using the keyboard  124  and/or the mouse  126 . Scroll bars  214  and  216  allows a user to navigate a flowchart design window  218 . The exemplary flowchart  149  includes enable blocks, decision blocks, and action blocks. 
     Control begins at enable block  300  where variables are initialized. For example, Flag A and Flag B are set equal to zero. Control continues with decision block  302  where control determines whether a first switch is on. If the first switch is not on, control turns on a flasher at action block  304  and control returns to step  302 . Otherwise, control continues with action block  306  where control turns on a relay associated with the furnace  60  and a relay associated with the mixer  42 . Control waits five minutes at wait block  307  until the furnace  60  is operating and the mixer  42  has had sufficient time to mix the first and second materials. Then, control continues with decision block  310  where control determines whether Flag A is equal to one. If Flag A equals one, control turns on an alarm relay (not shown in FIG. 1) in step  311 . Otherwise, control continues with decision block  312  where control determines if the temperature of the first and second materials  41  is less than 80° F. If the temperature is less than 80°, control continues with decision block  314  where control determines whether a pilot is present by scanning an output of the pilot sensor  72 . 
     If the pilot is not present, control turns on the pilot using the ignition device  70 , waits five minutes at wait block  317 , and then returns to step  310 . Otherwise, control continues with action block  318  where control turns off the furnace  60 , the mixer  42 , and the first switch, sets Flag A equal to 1, and continues with step  310 . 
     If the temperature is greater than 80° F., control continues with decision block  326  where control determines whether the conductivity of the first and second materials  41  is less than 0.8 and a Flag B is equal to zero. If not, control continues with action block  330  where control turns on a relay associated with the second mixer  46 , and sets the Flag B equal to one. In wait block  331 , control waits 2 minutes. Control continues with decision block  334  where control determines whether the conductivity of the materials  41  is less than 0.8. If it is, control continues with step  338  where control turns on the solenoid valve  20  that is associated with the first material supply  12 . Control waits two minutes in wait block  339 . Control turns off the solenoid valve  20  and the relay that is associated with the second mixer  46  in action block  340  and continues with step  310 . Otherwise, control continues with step  341  where control turns off the relay associated with the second mixer  46 . 
     Referring now to FIG. 5, if the conductivity is greater than 0.8 or the flag is equal to zero, control continues from step  326  to step  350  where control determines if the conductivity is less than 0.8 and the flag equals one. If both conditions are met, control continues with step  352  where control shuts down the furnace relay, the mixer relay, and the first switch and continues with step  310 . Otherwise, control continues with step  356  where control determines whether the temperature of the first and second materials  41  is greater than 110° F. If the condition is true, control continues with action block  360  where control turns on a fan relay to start the fan  30  to cool the first and second materials  41  and waits four minutes in wait block  361 . 
     Control continues with decision block  362  where control determines whether the temperature still exceeds 110° F. If not, control turns off the fan relay associated with the fan  30  and continues with step  310 . Otherwise, control continues with step  368 , where control turns off the furnace relay, the mixer relay, and the first switch, sets Flag A equal to one, and continues with step  310 . If the temperature does not exceed 110° F. in step  356 , control continues with decision block  372  where control determines whether the first switch is off. If it is, control continues with action block  376  where control turns off the furnace relay and the mixer relay. Control turns on the fan relay associated with the fan  30 . Control waits five minutes in wait block  377 . Control turns off the fan relay in action block  378  and continues with step  302 . Otherwise, control continues with step  310 . 
     Referring now to FIG. 6, an active debugging object dialog box  500  that is provided by the flowchart module  174  while the flowchart source code is being created is illustrated. The active debugging object dialog box  500  includes a file search interface  502  for locating media such as video, audio, pictures, text or other content. A text window  504  lists file names for a selected directory. Text box  506  and drop down list boxes  508 ,  510  and  512  help a user select content for the active debugging object from files stored on the computer  116  and/or other computers that are connected to the LAN  196  or the WAN  197 . Command buttons  520  and  522  allow a user to apply the content to the active debugging object or to cancel changes. Command buttons  524  and  526  allow a user to initiate a search or to select a new search. Skilled artisans can appreciate that other input formats other than the active debugging dialog box  500  can be employed without departing from the scope of the invention. 
     Referring now to FIGS. 4,  5  and  6 , a user adds active debugging objects  530 ,  532  and  534  in the flowchart design window  218 . The active debugging objects  530 ,  532  and  534  are represented by icons such as an icon representing a picture, an icon representing text, and/or an icon representing a movie clip. Still other icons will be apparent to skilled artisans. The active debugging objects  530 ,  532  and  534  are added using the pull-down menu  204 , the toolbar  210  and/or the tools  212 . The flowchart module  174  automatically creates ActiveX® components that are launched when a user clicks or otherwise selects the active debugging objects  530 ,  532  and/or  534  during the debugging process. 
     The active debugging object properties dialog box  500  is launched automatically when the active debugging objects  530 ,  532  and  534  are added to the flowchart design window  218 . The active debugging object properties dialog box  500  can also be accessed by left-clicking on the active debugging objects  530 ,  532  and  534  or by using the pull-down menu  204 , the toolbar  210 , the tools  212  and/or using hot keys or other keyboard combinations. The active debugging object properties dialog box  500  allows the programmer to associate the active debugging objects  530 ,  532  and  534  with help files that include text and images, with multi-media content such as audio and video, with links to web sites containing relevant information or with other suitable content. The active debugging objects  530 ,  532  and  534  contain content that helps programmers debugging the control logic more quickly. 
     As can be appreciated from the foregoing, the active debugging objects provide audio and/or visual feedback during the debugging process. By providing the audio and/or visual feedback that relates to the flowchart code located near the active debugging objects, the debugging of control logic contained in flowcharts is made easier. Alternately, the audio and/or visual feedback provided by the active debugging object can relate to the part of the process that is impacted by the flowchart code that is located near the active debugging object. For example, the active debugging object can include a movie clip demonstrating the desired operation of the process along with the correct values of the control variables at different logical points in the control logic. The active debugging object can also include a step-by-step troubleshooting guide for eliminating the bug(s). The active debugging object can be a link to the web site of a device that is controlled by the control logic that is near the active debugging object. 
     Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.