JP2002268713A - Controller for batch plant and its method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently and comprehensively retrieve any abnormality processing and exceptional processing in a batch plant, and to automatically generate the abnormality processing, and to express and manage the exceptional processing, and to efficiently manage those abnormality processing and exceptional processing by allowing them make a pair with a normal control logic. SOLUTION: This controller is provided with a program plotting function part 2 for plotting the image diagram of visually expressed equipment as a visual flow sheet, a connecting function part 3 for connecting the plotted image diagrams as an automatic control program, a program animation function part 4 for operating the animation display of the operation of the prepared automatic control program, a control code generating function part 5 for inputting an output from the connecting function part, and for converting it into a control code for operating equipment 7 to be controlled, and a list preparing and command preparing function part 8 for systematically and comprehensively retrieving abnormality processing and exceptional processing, and for preparing those processing as a deviation guide item list.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a control apparatus and a control method for a batch plant, and more particularly to a control apparatus and a control method capable of appropriately coping with abnormal processing and exceptional processing.

[0002]

2. Description of the Related Art In a batch process, changes in operation contents, changes in procedures, and the like occur more frequently than in a continuous process, and the time spent for these changes has conventionally been extremely long. In addition, such a change requires a considerable amount of specialized knowledge, and there is a problem in that there are limitations on the personnel who can respond. Therefore, the emergence of a method and apparatus that allows a system designer or an operator to easily create and change a control program for a batch process has been awaited.

To solve this problem, a description method for control using various expressions has been proposed. For example, there are a flowchart, a ladder chart, a sequential function chart, and the like. However, in these description methods, the expression method for creating the control program is complicated, and is documented and mathematically expressed. Further, in these description methods, even when expressing the same operation, various expression methods may exist depending on the idea of the person who creates the program. This means that there may be a plurality of programs corresponding to one operation, and therefore, errors in program creation often occur. In addition, an expression method capable of easily visually recognizing a change in an operation content, a change in a procedure, or the like has not been realized, and this has also contributed to a frequent occurrence of errors in creating the program.

[0004] In order to solve such a problem, the applicant has already disclosed in Japanese Patent Application Laid-Open No. Hei 10-301768 the creation and change of operation contents required for a batch plant, and the creation and change of procedures and the like. A control device and a control method for controlling a whole plant by executing a control program expressed by this expression method by proposing an expression method that makes it easy for a system designer and an operator to understand the work content of the program. Proposed. This expression is
This is called a visual flow sheet, which makes it easy to grasp the work contents of the control program visually.

The control device disclosed in Japanese Patent Application Laid-Open No. Hei 10-301768 has a drawing function for drawing a visual representation of a device, a connecting function for connecting the drawn data to a program, and a generation function for generating a program. An animation function for the system designer or operator to verify the notation of the programmed program, a control code generation function for inputting the output from the coupling function, and converting this input into a control code for operating a machine or the like, A simulation function for verifying the output converted to the control code. By using this control device, it is possible to control the batch plant.

A general control program is composed of a program describing a normal operation and a program describing an abnormal operation. generally,
Programs that describe normal movements are simple, whereas programs that describe abnormal movements are required to be able to cope with all conceivable abnormalities. Tends to. Therefore, in the program development site, much effort is devoted to picking up all abnormal movements and expressing them.

However, on the other hand, there has been no mechanism for systematically searching for the cause of the abnormality. The development of a program that describes abnormal behavior depends greatly on the experience and knowledge of individuals, and since these experiences and knowledge vary greatly between individuals, the individual differences greatly affect the quality of the completed program. ing. There is no methodology to efficiently summarize the experience and knowledge of these individuals, and even when modifying or remodeling a program later, the designer's ideas and intentions at the time of creation are often documented and remain. At present, a great deal of effort is required to modify and remodel programs.

In the invention described in Japanese Patent Application Laid-Open No. Hei 10-301768, although a program for describing a normal movement can be easily developed, it is not sufficient to deal with abnormal processing or exceptional processing design. .

[0009]

As described above,
In the related art, the handling of the abnormal processing and the exceptional processing in the control program design of the batch plant is not sufficient for the following reasons.

L) There is no mechanism that allows a designer to efficiently and exhaustively search for abnormal processing and exception processing.

2) There is no mechanism for managing the abnormal processing procedure and the exceptional processing procedure created by the designer integrally with the control program without separating them from the control program.

3) There is no mechanism for reusing the abnormal processing procedure and the exceptional processing procedure created by the designer.

It is an object of the present invention to provide the above-mentioned Japanese Patent Application Laid-Open No. Hei 10-30
The invention described in Japanese Patent No. 1769, "Control Device and Control Method for Batch Plant" is further improved, and an expression method capable of efficiently and exhaustively searching for abnormal processing and exceptional processing, and a display by such an expression method. While performing, abnormal processing can be automatically generated, exceptional processing can be expressed and managed by a control device, normal control logic and these abnormal processing,
An object of the present invention is to provide a control device capable of efficiently managing a pair of exceptional processing.

[0014]

The first batch plant control apparatus of the present invention draws a visual representation of the equipment, and incorporates a manually executed operation part into an automatic control program. Program drawing function part,
A flow drawing function unit that draws a control flow to be controlled from a visual representation of a device, a combining function unit that combines the drawn image diagrams into an automatic control program, and a generated automatic control program. Input the output from the program animation function unit that displays the animation of the operation, the flow animation function unit that displays the animation of the flow operation according to the created control flow and the generated automatic control program, and the combined function unit. A control code generation function unit that converts this input into a control code for operating the device to be controlled, a simulation function unit that verifies the output converted to the control code,
Having.

It is preferable that the control device of the batch plant further includes a list creating means for systematically and exhaustively searching for abnormal processing and exceptional processing in the batch plant, organizing and tabulating.

A second batch plant control apparatus according to the present invention includes a program drawing function unit for drawing a visual representation of a device, and a control flow to be controlled from the visual representation of the device. A flow drawing function unit for drawing an image, a combining function unit for combining the drawn image diagrams into an automatic control program, a program animation function unit for displaying an animation of the operation of the generated automatic control program, and the created control. The flow animation function unit that performs animation display of the flow operation according to the flow and the generated automatic control program, and the output from the combination function unit are input, and this input is converted into a control code for operating the device to be controlled. Control code generation function and simulation function to verify the output converted to control code Has a list creation means for abnormality processing and explore the exceptional processing systematically and comprehensively organize tabulated in a batch plant.

In these batch plant control devices, the list creation means has a function of automatically generating an abnormal processing logic in response to the searched abnormal processing, or creates a logic of the searched exception processing. It is preferable to have a function for describing in a table. In the latter case, the exception processing logic is made executable from the tabulation. Further, in the control device of the batch plant, a search means for performing a keyword search on the tabulation is further provided, and the output of the control code generation function unit is supplied to the device to be controlled or supplied to the simulation function unit. It is preferable to further provide a switching function unit for switching between.

In the control device of each batch plant described above, what the program drawing function unit draws is a visual flow sheet as disclosed in Japanese Patent Application Laid-Open No. 10-301768. What the list generating means creates is, for example, a deviation guide item list. The deviation guide item list records the operation result of each deviation guide item indicating a deviation from a normal state for each phase, with the minimum operation unit of the batch plant as a phase, and records the result as a result. This is a list in which measures are recorded, actions for related faces are recorded, and if there is an irregular operation, the operation is recorded.

The first method of controlling a batch plant according to the present invention combines the selected visually represented image diagrams in a specified order to perform drawing, and automatically controls an operation portion that is manually performed. Inserting into a program, drawing a control flow to be controlled from a diagram of the selected visually represented device, and automatically generating an automatic control program by combining the drawn image diagrams And displaying an animation of the operation of the generated automatic control program, and performing an animation display of the operation of the flow according to the generated control flow and the generated automatic control program. Automatically converting a control code for operating a device to be controlled, and It has a step of verifying by Shon, a.

In the batch plant control method, it is preferable to further provide a step of systematically and comprehensively searching for abnormal processing and exceptional processing in the batch plant, organizing and tabulating the abnormal processing and the exceptional processing.

According to a second method for controlling a batch plant of the present invention, a step of combining selected visual representations of images in a specified order to perform plotting, and a step of combining the selected visual representations are performed. Drawing a control flow to be controlled from a diagram of the device, automatically generating an automatic control program by combining the drawn image diagrams, and displaying an animation of the operation of the generated automatic control program Performing an animation display of the operation of the flow in accordance with the created control flow and the generated automatic control program, and automatically converting the generated automatic control program into a control code for moving a device to be controlled Steps, verifying control codes by simulation, and abnormalities in the batch plant It has a step of searching for a physical and exceptional processing systematically and comprehensively organize tabulated, the.

[0022] In these batch plant control methods, it is preferable to further include a step of automatically generating an abnormality processing logic corresponding to the searched abnormality processing. What is created in the drawing step is typically a visual flow sheet as disclosed in Japanese Patent Application Laid-Open No. 10-301768. What is created in the tabulating step is typically a deviation guide item list. In the tabulation step, the deviation guide item list shows, as a phase, the minimum operation unit of the batch plant, the operation result of each deviation guide item indicating a deviation from a normal state for each phase. This is a list that records a countermeasure against this result, records an action for a related face, and records an unsteady operation, if any.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, preferred embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a block diagram illustrating a configuration of a control device according to an embodiment of the present invention.

The control device 1 generates a visual flow sheet, generates a control program for controlling the device 7 to be controlled, and controls the device 7 by the control program. 10-
A flow drawing function for automatically drawing a control flow to be controlled from a visually represented diagram of devices (or supporting drawing by manual input), similarly to the control device disclosed in No. 301768. Unit 11, a program drawing function unit 2 for drawing a visual image of a device as a visual flow sheet, and a connection function unit 3 for combining the image diagrams drawn by the program drawing function unit 2 into an automatic control program. And a flow animation function unit 12 for the user (system designer, operator, etc.) to verify the created control flow, and a program animation function unit 4 for the user to verify the created automatic control program. And a control code for converting an input from the output from the combining function unit 3 into a control code for operating the device 7 and the like. Assimilation functional unit 6 to verify the generation unit 5, was converted to a control code output
And a switching function unit 10 for switching between actually outputting the control code from the control code generation function unit 6 to the device 7 and outputting the control code to the simulation function unit 6.

Further, in order to cope with the abnormal processing and the exceptional processing, the control device 1 generates a deviation guide item list, which will be described later, and also generates a list generation / logic generation for generating the abnormal processing logic and the exceptional processing logic. Function unit 8 and a list storage / keyword search function unit 9 for storing the generated deviation guide item list and enabling a search by keyword.
It has. The list creation / logic generation function unit 8 is provided as a list creation unit, and the list storage / keyword search function unit 9 is provided as a search unit.

Here, the controller 1 is not limited to this, but can be constructed by a computer system such as a personal computer, for example. In the case of building by a computer system, each of the above-described functional units 2
6, and 8 to 12 are each realized as a software component.

The program drawing function unit 2 selects necessary image diagrams from a visually registered image diagram (so-called icon) of a device, for example, a valve diagram or a pump diagram, and arranges them in order. Describe the flow of one operation. The program drawing function unit 2 operates interactively with the user, for example, a CAD (computer aided desig) executed on a personal computer.
n) Perform the same processing as the software. The program drawing function unit 2 of the control device 1 is disclosed in Japanese Patent Application Laid-Open No. 10-3017.
Unlike the drawing function disclosed in Japanese Patent No. 69,
It has the function of partially combining the plots as needed. This function will be described later.

The flow drawing function unit 11 draws a control flow from a pre-registered visual image of a device similar to the case of the program drawing function unit 2. Specifically, the flow drawing function unit 11 draws a manufacturing flow chart as shown in FIG.

The combining function unit 3 is a program drawing function unit 2
And a process of combining and converting the operation flow based on the image diagram created by the flow drawing function unit 11 into a program. The description of this program includes, for example, C ++, JA
An object-oriented language such as VA (registered trademark) may be used.

The program animation function unit 4 and the flow animation function unit 12 allow the creator to view the operation flow based on the image diagrams created by the program drawing function unit 2 and the flow drawing function unit 11, respectively, and create the flow by the combining function unit 3. This is a function to see if the programmed program works correctly in the flow of operation according to the image diagram. In order to realize the program animation function unit 4 and the flow animation function unit 12, software for performing animation display of an image diagram and C for display are provided.
An RT screen or the like is used. More specifically, the program animation function unit 4 animates the created visual flow sheet (see FIG. 2B) to thereby animate the created automatic control program. On the other hand, the flow animation function unit 12
According to the drawn control flow and the automatic control program, for example, opening and closing a valve, turning on / off a pump,
The flow is animated by visually displaying the integration of the flow meter, liquid level fluctuation, and the like.

The control code generation function unit 5 includes the combination function unit 3
Is converted into a control code for operating a machine or the like. The control code is a language for control, such as a G language for a control machine, a ladder language,
Languages such as an instruction language, function blocks, structured text, and sequential function charts, and languages such as C language, C ++, and JAVA are used. Note that a programmable logic controller (hereinafter, referred to as a PLC) is an example of a control device (the device 7 in FIG. 1) that functions with the control code, but the control target is not limited to this.

The simulation function unit 6 is for simulating the created program, that is, executing a simulation to confirm the movement. The simulation result is fed back to the drawing in the drawing function unit 2.

The list creation / logic generation function unit 8 enables a systematic and exhaustive search, organization, and tabulation of abnormal processing and exceptional processing as a deviation guide item list, and inputs data necessary for the tabulation. Then, the error processing logic is automatically generated, and if an abnormal condition occurs in the actual operation and the program stops, the cause can be confirmed in this table, and if there is an exceptional process, the exceptional process will be executed. Logic can be described through this table, and this logic is executed from this table.

The list storage / keyword search function unit 9
The table (deviation guide item list) created by the list creation / logic generation function unit 8 and the associated visual flowchart are stored in pairs, and when these are reused, the visual flow sheet and table required by keywords are stored. Automatic search.

The device 7, which is, for example, a PLC, exchanges signals with instruments at the site and controls the instruments at the site. The situation at the site is sent to the control device 1 via the device 7, so that the driver can grasp the situation at the site. In particular, data relating to the situation at the site is sent from the device 7 to the list creation / logic generation function unit 8 in order to deal with abnormal processing and exception processing.

[0036]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the control device 1 will be described in more detail with reference to embodiments. It goes without saying that the present invention is not limited to the following examples.

<< Embodiment 1 >> An example will be described in which the raw material A is transferred from the first tank TK1 by a predetermined amount to the second tank TK2 through the flow meter F1 by the pump P1. FIG. 2A shows an equipment flow in this case. First tank TK
The amounts of the raw material A in the first and second tanks TK2 are measured by level meters L1 and L2, respectively. Further, a first valve V1 is provided between the bottom outlet of the first tank TK1 and the pump P1, and a flow meter F1 is provided.
Between the second tank TK2 and the second valve V2
Is provided, and a third valve V3 is provided at the bottom outlet of the second tank TK2. Furthermore, the first tank TK
1 has a valve V for injecting nitrogen gas into the tank.
N2 is provided.

First, a procedure for creating an input to the control device 1 when the normal operation procedure is automatically performed will be described. First, in order to clarify the operation contents, a flow diagram as shown in FIG. Here, if it is determined by the start condition determination logic (I / C) that the start condition is satisfied, the first valve V1 is opened to start the pump P1, and after a lapse of a certain time TM1, the second valve V2 Open. During this time, a predetermined amount of the raw material A is measured by the flow meter F1. When the predetermined amount is reached, the first valve V1 is closed, the pump P1 is stopped, and the second valve V2 is closed.

Second, a series of these movements is created using a visual flow sheet. The created visual flow sheet is shown in FIG. In FIG. 2 (b), a white outline indicates an open or operation start state, and a black solid state indicates a closed or operation stop state.

The control program based on the visual flow sheet is created by the program drawing function unit 2 and the combining function unit 3. Then, it is verified using the program animation function unit 4 whether there is any input error in the program created in this way. At the same time, the animation function is verified by the flow animation function unit 12 according to the operation of the visual flow sheet in the flow chart. That is, the input result is displayed on the screen of the display device, and the creator of the program confirms that there is no error in the input.

As described above, the program drawing function unit 2
The program generated by the combining function unit 3 and confirmed by the program animation function unit 4 that there is no error in the input is converted into a control code by the control code generation function unit 5. The control code as an output from the control device 1 is finally output to the device 7 that operates based on the control code, but before that, it is simulated whether or not to operate properly. The verification is performed in the functional unit 6. When the simulation function unit 6 is used, a simulation is selected by the switching function unit 10. That is, the switching function unit 10 displays one of the simulation menus on the screen of the display device,
Since “selection (Y), non-selection (N)” is displayed, the user only has to select “Y”. Note that the control code generation function unit 5 can also be configured by, for example, a PLC.
When the simulation function unit 6 verifies that the program operates properly, the user selects “N” in the above-described simulation menu to send the control code to the device 7 outside the control device 1. Will be output. The simulation function unit 6
Has a function of visually verifying the operation check of the created program offline.

As described above, the control program of the normal operation procedure is completed by using the control device 1. By the way, the program drawing function unit 2 in the control device 1 also has a function of partially combining the drawn ones as necessary, as described above. Hereinafter, this function will be described. "Partially combine the plotted parts as necessary" means to incorporate an operation part that is partially executed manually into the automatic control program.

In the operation of a plant, there are many cases in which some of the operations are performed automatically and some of the operations are performed manually. Until now, manual operations were usually handled by inserting comments. On the other hand, in the control device 1, the same description method as that of the automation part is used for the manually operated part by the drawing function part 2 having a function of partially combining the drawn parts as necessary, The addition of the mark is distinguished from the automation part, thereby expressing the manual operation. For example,
It is assumed that the pump P1 in the equipment flow shown in FIG. 2 (a) is operated and stopped at a site, not an object of automatic control. FIG. 3 shows an example of the visual flow sheet in this case. That is, this can be realized by attaching a manual operation mark (illustrated, palm mark) to the portion of the pump P1 in the automatic control logic shown in the visual flowchart of FIG. 2B. If this part is automated in the future, the control logic can be easily converted to that of an automated control by removing the mark for manual operation.

Further, the control device 1 described here is similar to the control device shown in FIG.
As shown in FIG. 1, a list creation / logic generation function unit 8 is provided.
It has a function to systematically and comprehensively search for abnormal processing and exceptional processing that are indispensable for the control system, organize and tabulate. Hereinafter, the tabulation function by the list creation / logic generation function unit 8 will be described.

As a method for efficiently and comprehensively searching for abnormal processing and exception processing, use of a deviation guide item list is considered. When assessing plant safety, HAZOP (Hazard and Operability Stability) is generally used.
udy) and FMECA (Failure Mode, Effects and Critica)
lity Anarysis) and other techniques are used, which greatly contributes to safety design. This deviation guide item list is also created to effectively, easily and comprehensively search for a safety design of a control system by a method similar to HAZOP, and expresses normal operation control logic. It complements the Visual Flow sheet. In that sense, as shown in FIG.
The visual flow sheet and the deviation guide item list make a pair with one control logic.

FIG. 5 shows an example of the format of a deviation guide item list. Exceptions / abnormalities can be considered as “deviations from normality”, and this deviation is used as a keyword to determine whether there is a control problem in a certain minimum driving operation unit (this is called a phase). Verify. This deviation guide item is used to qualitatively indicate deviation from normal in performing control. In the example shown in FIG.
As shown in the figure, the following ten types are prepared.

[0047] 1. 1. Deviation in phase start condition 2. Deviations from raw materials Deviations from products 4. 4. Deviation of process parameters 5. Deviation of equipment 6. Deviations of instrumentation and electrical components 7. Deviation of manufacturing route 8. Abnormalities from other phases 9. Deviations related to safety interlock As shown in FIG. 5, the deviation guide item list includes, for each deviation guide item, “Result”, “Countermeasure”, “Related phase”, “Action for related phase”, It is a list | wrist of a tabular form which has five columns of "unsteady driving | operation (exception processing)."

Next, a method of using the deviation guide item list will be described.

(1) When an exception / abnormal phenomenon corresponding to a guide item occurs in a corresponding phase, the "result" in the list indicates what kind of operation result will be obtained in that phase.
Record in the column.

(2) What countermeasures are taken as control for this "result" is recorded in the "Countermeasure" column.

(3) During the operation of the plant, "transfer"
There are interrelated phases, such as the phase of “acceptance” and the phase of “acceptance”. In this case, select a phase that is related to your own phase for each guide item, and in the “Related phase” column,
Record the phase of the party involved.

(4) Further, the action for the related partner phase is recorded in the column of “action for related phase”.

(5) If there is an unsteady operation on the guide item, the operation is recorded in the "unsteady operation / process (exception process)" column.

By filling each column in this way, a deviation guide item list is completed.

<< Embodiment 2 >> In this control device 1, the list creation / logic generation function unit 8 has a function of systematically and exhaustively searching for and organizing abnormal processing and exceptional processing indispensable to the control system, and a tabulation function. It has a function to automatically generate abnormality processing logic when data necessary for tabulation is input. Therefore, in this embodiment, a function of automatically generating an abnormality processing logic will be described.

In the equipment flow shown in FIG. 2A, the phase start condition is that the valve V3 at the bottom of the second tank TK2
Are not open and the level L2 of the tank TK2 is not high, these are described in the corresponding columns of the above-mentioned deviation guide item. Since these descriptions correspond to the input of "necessary data", the start condition determination logic (I / C) of the visual flow sheet as shown in FIG. The factor (expressed as a balloon for the I / C unit in FIG. 6) is automatically generated in the unit.

As a deviation of the process parameter, the level L2 of the second tank TK2 is high (Hi).
gh) or when the level L1 of the first tank TK1 is low (Low), the supply logic of the raw material A needs to be interrupted. When these are described in the deviation guide item list, similarly, factors are automatically generated in the interlock determination logic (I / L) section of the visual flow sheet as shown in FIG.

<< Embodiment 3 >> As described above, the list creation / command generation function unit 8 provided in the control device 1 tabulates the cause when an abnormal condition occurs in the actual operation and the program stops. It has a function that can be confirmed with. Therefore, here, this function will be described.

For example, in the batch process shown in FIG. 2A, when the valve V3 at the bottom of the second tank TK2 is opened during the phase start condition, the supply of the raw material A is performed. The logic cannot be executed because the start condition is not satisfied. In such a case, this function is a function of blinking (flickering) the corresponding column of the deviation guide item list and displaying what is the cause of the inability to start. Information on the cause of the inability to start is sent from the device 7 to the list creation / command generation function unit 8. FIG. 7 shows a state in which the cause that cannot be started is displayed in the deviation guide item list and the visual flow sheet.

<< Embodiment 4 >> In this control device 1, the list creation / logic generation function unit 8
It has a function to execute exceptional processing logic from tabulation. Here, this function will be described.

In the normal driving operation, there is often a driving operation for trying to execute the driving as completely as possible, although it is unsteady, in addition to the normal driving operation. For example, in the batch process shown in FIG. 2A, the raw material A is transferred from the first tank TK1 to the second tank TK using the pump P1.
It is assumed that the pump P1 cannot be operated on the way to transfer to P2. In that case, without removing the pump, for example, the first tank TK1 can be
The raw material A can be transferred by applying a pressure with nitrogen gas. Such a case is called an exceptional operation or an exceptional operation.

As described above, when the operation to be executed can be replaced by an exceptional operation, the contents are described in the column of “unsteady operation / processing” in the deviation guide item list. If the contents can be represented by a visual flow sheet, exception handling logic can be described as shown in FIG. If the exception processing logic can be described in the visual flow sheet, the exception processing logic is executed from the column of “unsteady operation / processing” by passing the exception processing logic to the combination function unit 3.

In the example shown here, the first tank TK1
Since the valve VN2 for nitrogen gas installed in the valve is a manual valve, the valve VN2 is opened and closed as a manual operation by using the function "partially connect the drawn ones as necessary" described in the first embodiment. Is expressed.

Fifth Embodiment Next, the function of the list storage / keyword search function unit 9 will be described.

As described above, in this control device 1, FIG.
As shown in (1), the visual flow sheet and the deviation guide item list are created as a pair.
The list storage / keyword search function unit 9 registers and stores a number of pairs of the visual flow sheet and the deviation guide item list as a library.

When creating a new control logic,
Using the list storage / keyword search function unit 9, first, a keyword search is performed from the library as to whether or not similar logic can be used, whereby a set of the corresponding visual flow sheet and deviation guide item list can be extracted. A new control logic is created by modifying the extracted data as needed.

As described above, the control apparatus for a batch plant according to the present invention has been described based on the preferred embodiments and examples.
Can be realized by causing a computer such as a personal computer to read a computer program for realizing the program and executing the program. Specifically, this program is a program for causing a computer to function as each of the functional units 1 to 6 and 8 to 10 in the above-described embodiment. A program for realizing the control device 1 is stored in a recording medium such as a CD-ROM.
Loaded into the calculator. FIG. 10 is a block diagram showing a configuration of a computer system used to realize the control device.

This computer has a central processing unit (CPU) 2
1, a hard disk device 22 for storing programs and data, a main memory 23, an input device 24 such as a keyboard and a mouse, and a display device 25 such as a CRT.
It comprises a reading device 26 for reading a recording medium 27 such as a magnetic tape or a CD-ROM, and a connection interface 28 for transmitting and receiving data and control codes to and from the device 7. Hard disk drive 22, main memory 2
3, the input device 24, the display device 25, the reading device 26, and the connection interface 28
Connected to 1. This computer attaches a recording medium 27 storing a program for functioning as a control device to a reading device 26, reads out the program from the recording medium 27, stores the program in the hard disk device 22, and executes the program stored in the hard disk device 22. Central processing unit 2
1 executes the function of the control device described above.

[0069]

As described above, according to the present invention, the following effects can be obtained.

1) The manual operation and the automatic operation can be expressed by the same logic, and the manual operation can be easily changed to the automatic operation.

2) By using the deviation guide item list, an abnormal process and an exception process can be efficiently and comprehensively searched.

3) The abnormal processing logic is automatically generated by listing the cause of the abnormal processing in the deviation guide item list, so that there is no discrepancy between the document and the logic, and significant efficiency can be expected.

4) The function of saving and retrieving the visual flow sheet and the deviation guide item list as a pair facilitates reuse and achieves a great efficiency.

5) Even a person who is not proficient in computer programming can easily express his intended driving operation and generate actual logic.

6) The abnormal processing and exception processing, which have not been documented so far, are documented in the form of a table, so that future remodeling and correction can be easily performed.

[Brief description of the drawings]

FIG. 1 is a block diagram illustrating a configuration of a control device according to an embodiment of the present invention.

2A is a diagram illustrating a device configuration of a batch process to be controlled, and FIG. 2B is a diagram illustrating an example of a visual flow sheet corresponding to the device configuration illustrated in FIG. 2A.

FIG. 3 is a diagram illustrating an example of a visual flow sheet including a manual operation part.

FIG. 4 is a diagram showing a relationship between a visual flow sheet, a deviation guide item list, and exception handling logic.

FIG. 5 is a diagram illustrating an example of a format of a deviation guide item list.

FIG. 6 is a diagram illustrating a function of automatically generating an abnormality processing logic in a list creation / command generation function unit.

FIG. 7 is a diagram illustrating a function of a list creation / command generation function unit that can confirm the cause of a program stop.

FIG. 8 is a diagram illustrating a function of activating an exceptional processing logic from a table in a list creation / command generation function unit.

FIG. 9 is a block diagram illustrating a computer system used to configure the control device of FIG. 1;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Control device 2 Program drawing function part 3 Combination function part 4 Program animation function part 5 Control code generation function part 6 Simulation function part 7 Equipment to be controlled 8 List creation / command generation function part 9 List storage / keyword search function part 10 Switching Function Unit 11 Flow Drawing Function Unit 12 Flow Animation Function Unit

────────────────────────────────────────────────── ─── of the front page continued (51) Int.Cl. ⁷ identification mark FI theme Court Bu (reference) G06F 19/00 110 G06F 9/06 620B F-term (reference) 5B075 MM11 ND03 ND20 ND23 ND34 PP22 PQ02 PQ13 UU40 5B076 DA00 DB01 DD04 DE05 DE06 EC06 5H220 AA01 BB12 CX06 JJ12 JJ53 KK08 LL06 5H223 AA01 CC03 CC08 DD03 EE19 FF05

Claims (12)

[Claims] 1. A program drawing function unit for drawing a visually represented image of a device and inserting an operation part to be manually executed into an automatic control program, and controlling from a visually represented diagram of the device. A flow drawing function unit for drawing a target control flow, a connection function unit for combining the drawn image diagrams to form an automatic control program, and a program animation function unit for displaying an animation of the operation of the generated automatic control program A flow animation function unit that performs animation display of the operation of the flow in accordance with the created control flow and the generated automatic control program; and inputting an output from the combination function unit and controlling the input to a device to be controlled. A control code generation function unit that converts the control code into a control code for moving; And a simulation function unit for verifying the obtained output. 2. The control apparatus for a batch plant according to claim 1, further comprising a list creation means for systematically and exhaustively searching for abnormal processing and exceptional processing in the batch plant, organizing and tabulating the abnormal processing and the exceptional processing. 3. A program drawing function unit for drawing an image diagram of a device visually represented, a flow drawing function unit for drawing a control flow to be controlled from the device diagram visually represented, A combined function unit that combines the generated image diagrams into an automatic control program; a program animation function unit that performs an animation display of the operation of the generated automatic control program; a created control flow and the generated automatic control program. Therefore, a flow animation function unit that performs animation display of the flow operation, a control code generation function unit that receives an output from the combination function unit, and converts the input into a control code for operating a device to be controlled, A simulation function that verifies the output converted to control codes and a batch plant That abnormal processing and control unit of a batch plant with a list creation means for systematically and comprehensively searched organize tabulated exceptional processing. 4. The control apparatus for a batch plant according to claim 2, wherein the list creation means automatically generates an abnormality processing logic in response to the detected abnormality processing. 5. The list creating means has a function for describing the logic of the searched exceptional processing in a table, and the exceptional processing logic can be executed from the table. 4. The control device for a batch plant according to any one of 4. 6. The control device for a batch plant according to claim 2, further comprising a search unit for performing a keyword search on the table. 7. The batch plant according to claim 1, further comprising a switching function unit that switches between supplying the output of the control code generation function unit to a device to be controlled and supplying the output to a simulation function unit. Control device. 8. A step of combining selected visual representations of images in a specified order for drawing, and incorporating a manually executed driving part into an automatic control program. Drawing a control flow to be controlled from a diagram of a device that is represented in a diagram, a step of automatically generating an automatic control program by combining the drawn image diagrams, and an operation of the generated automatic control program Displaying an animation of the operation of the flow according to the generated control flow and the generated automatic control program; and executing the generated automatic control program to move a device to be controlled. Automatically converting the control code; and verifying the control code by simulation. A method for controlling a batch plant, comprising: 9. The control method for a batch plant according to claim 8, further comprising a step of systematically and exhaustively searching, organizing, and tabulating abnormal processing and exceptional processing in the batch plant. 10. A step of combining selected visually represented image diagrams in a designated order to perform drawing, and controlling a control flow to be controlled from a selected visually represented device diagram. Plotting; automatically generating an automatic control program by combining the plotted image diagrams; displaying an animation of the operation of the generated automatic control program; Performing an animation display of the flow operation in accordance with the generated automatic control program; automatically converting a generated automatic control program into a control code for operating a device to be controlled; and simulating the control code. Verification process and abnormal processing and exception processing in the batch plant. Controlling a batch plant and a step of and exhaustive searched organize tabulated. 11. The batch plant control method according to claim 9, further comprising a step of automatically generating an abnormality processing logic in response to the searched abnormality processing. 12. A tabulation step in which a minimum operation unit of a batch plant is set as a phase, and the operation result is recorded for each deviation guide item indicating a deviation from a normal state for each phase. 13. The method according to claim 9, further comprising recording a countermeasure for the result, recording an action for a related face, and recording an unsteady operation when there is an unsteady operation.
The control method for a batch plant according to any one of the preceding claims.