CN105629923A - Controller and control method thereof - Google Patents

Controller and control method thereof Download PDF

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Publication number
CN105629923A
CN105629923A CN201510784708.5A CN201510784708A CN105629923A CN 105629923 A CN105629923 A CN 105629923A CN 201510784708 A CN201510784708 A CN 201510784708A CN 105629923 A CN105629923 A CN 105629923A
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module
mentioned
cpu
remote
numerical data
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CN105629923B (en
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原直树
畑秀太朗
小野里登
黑泽贤一郎
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Hitachi Ltd
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Hitachi Ltd
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/418Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/4184Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/34Director, elements to supervisory
    • G05B2219/34475Detect abnormality of control system without inverted model, using input command
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Programmable Controllers (AREA)
  • Safety Devices In Control Systems (AREA)
  • Testing And Monitoring For Control Systems (AREA)
  • Numerical Control (AREA)

Abstract

The invention provides a controller for reliably and selectively executing abnormal control operation in a controller formed by a CPU module and remote IO modules so as to achieve high reliability. The controller is provided with the CPU module and multiple remote IO modules. The CPU module is provided with an abnormal state detecting portion for detecting the abnormal action of the CPU module and performing program control on multiple machines in a factory. The remote IO modules is connected with the CPU module via a serial transmission path in a daisy chain way, converts digital data transferred by the CPU module and outputs the digital data to the machines. When detecting the abnormal action, the abnormal state detecting portion notifies the remote IO modules of the CPU anomaly. When notified of the CPU anomaly, the remote IO modules control the machines in stop states on the basis of the digital data.

Description

Controller and control method thereof
Technical field
The present invention relates to the controller that factory (plant) equipment etc. is automatically controlled.
Background technology
As carrying out the controller that automatically controls, there is the system being connected between CPU (CentralProcessingUnit: central processing unit) module with multiple remote I/O (RemoteInput/Output: remote input/output) module by transmission cable. For this structure, CPU module performs the control program the output digital data DO (DigitalOutputdata: digital output data) that automatically control, and the numerical data DO received from CPU module is converted to work plant output signal and it exported to the operation terminal of shop equipment by remote I/O module.
The advantage that the controller of this remote I/O mode exists the control that can realize multiple shop equipment being distributed with save space, low cost.
Such as, the upper and lower water course factory being made up of multiple equipment can apply above-mentioned controller, carries out factory's control. Each equipment of upper and lower water course factory is made up of multiple machines, and, possess operation terminal at each machine. Work plant output signal is exported such that it is able to operation the operation of a machine, stopping externally to this operation terminal. Work plant output signal is suitably exported to operation terminal, thus realizing the operating of machine monomer and the operating that factory is overall from controller or hand-operating device.
The misoperation of the controller of upper and lower water course factory, stopping existence causing tap water cut-off, city flood etc., thus the probability of life-threatening, property. Therefore, controller is required the operating that 24 hours continuous print are stable.
As above, opposite requires high reliability to the controller of upper and lower water course factory.
When controller detects abnormal, in order to prevent the misoperation of factory, and emergent stopping or limit must be implemented and factory's function is maintained detects abnormal front state limit operating, make a part of machine stop and reducing factory and operate functionally or switch to manual operation and carry out operating etc.
Particularly, when the CPU module that the abnormal risk factor detecting controller is the highest is abnormal, it is necessary to avoid CPU misoperation and the risk of numerical data DO output by mistake that causes, and make Plant Emergency stop.
Additionally, upper and lower water course factory is provided with high voltage electric equipment, induction motor, converter etc. and becomes the machine of noise source, therefore, when applying remote I/O module, there is the probability producing that because noise is overlapping, transmission cable CPU module being connected with remote I/O module is produced momentary transmission abnormality.
In the past, in view of the above circumstances, it is proposed that when detecting controller abnormal, the technology (for example, referring to patent documentation 1) of the supply power supply of external loading is controlled.
According to the technology disclosed in patent documentation 1; abnormal by the pulse output exported from mastery routine and the external circuit intervalometer detection being made up of relay and intervalometer; when detecting abnormal, cut off or connect the power supply supply of external loading, thus realizing failure protection function.
Additionally, patent document 2 discloses that following I/O-unit, by arranging the abnormal examination lead-out terminal of MPU11, the state of the output of the lead-out terminal of I/O-unit during abnormal examination becomes the state of the connected IO machine of un-activation such that it is able to detect the presence of failure exception in advance.
Prior art literature
Patent documentation
Patent documentation 1: Japanese Unexamined Patent Publication 9-185403 publication
Patent documentation 2: Japanese Unexamined Patent Publication 2008-310389 publication
Summary of the invention
Invent problem to be solved
According to the technology disclosed in above-mentioned patent documentation 1, carry out watchdog pulse output by the combination of switch on delay intervalometer Yu off delay intervalometer, therefore abnormal to detecting the abnormal abnormality detection waiting time at least needing more than two program loops from producing. Therefore, within the abnormality detection waiting time, there is the problem exported to the mistake of factory that cannot prevent causing because of CPU misoperation.
Additionally, according to patent documentation 1, even if any part at CPU module, remote I/O module, mastery routine, transmission, external circuit produces abnormal, also detection is all identical exception, even if therefore there is the extra high abnormal key factor of risk factor detecting CPU exception etc, the problem that also reliably cannot disconnect numerical data DO immediately when detecting.
Additionally, there are the controller being made up of CPU module and remote I/O module and cannot detect the transmission abnormality of necessity, control action when namely cannot select exception when detecting transmission abnormality and the problem that is set.
According to the technology disclosed in above-mentioned patent documentation 2, though can be tested with in advance without the fault of I/O-unit, exception, but there is fault detect when not considering practice, the problem additionally not considering the fault of the CPU element of PLC, formant.
As above, in the technology disclosed in patent documentation 1,2, it is impossible to realize towards the reliability needed for the controller of upper and lower water course.
For the method solving problem
The present invention completes in view of above-mentioned practical situation, purpose is in that to provide a kind of in the controller being made up of CPU module and remote I/O module, abnormal key element according to CPU exception, transmission abnormality etc., and control action when reliably and optionally performing abnormal such that it is able to realize the controller of high reliability.
In order to solve above-mentioned problem, the controller that the equipment machine to factory of the present invention is controlled possesses: CPU module, and it has the abnormal state detection portion of abnormal operation of detection module, and multiple equipment machines of above-mentioned factory are carried out programme-control; And multiple remote I/O module, they are connected to above-mentioned CPU module by serial transmission paths daisy chain type, and change the numerical data transmitted from above-mentioned CPU module and export to above-mentioned equipment machine, above-mentioned CPU module is when above-mentioned abnormal state detection portion detects abnormal operation, notify that CPU is abnormal to above-mentioned remote I/O module, above-mentioned remote I/O module, when notified above-mentioned CPU exception, differently makes all the said equipment machines be in halted state with the control based on above-mentioned numerical data.
Additionally, there is CPU module and the controller of remote I/O module that the multiple equipment machines for factory are controlled for the present invention, above-mentioned CPU module and above-mentioned remote I/O module are connected by serial transmission paths and CPU state signal, this serial transmission paths daisy chain type connects above-mentioned CPU module and above-mentioned remote I/O module and transmits control information, and this CPU state signal daisy chain type connects above-mentioned CPU module, and with above-mentioned remote I/O module and transmission CPU is abnormal from above-mentioned CPU module to above-mentioned remote I/O module.
Additionally, the present invention has a CPU module and remote I/O module that at least one equipment machine to factory is controlled, and the control method of the controller that multiple equipment machines of factory are controlled has: detects the multiple equipment machines to above-mentioned factory and carries out the abnormal operation of programme controlled CPU module and represent the step of signal of abnormality in the output of CPU state signal; And set, with the numerical data DO notified from CPU module, the step that all of aforesaid operations terminal is set as the state of regulation by the above-mentioned remote I/O module of above-mentioned multiple equipment machine respective operation terminal according to the signal of the expression abnormality of above-mentioned CPU state signal accordingly.
The effect of the present invention is as follows.
In accordance with the invention it is possible to improve the reliability of controller.
Accompanying drawing explanation
The structure chart of the controller of Tu1Shi upper and lower water course factory.
Fig. 2 indicates that the figure of the structure example of CPU module.
The abnormality detection controlling program is processed the sequential chart illustrated by Fig. 3.
Fig. 4 indicates that the figure of remote I/O module and the structure example of equipment machine.
Fig. 5 indicates that the figure of the structure in CPU exception control portion.
Fig. 6 indicates that the figure of the structure in the IO output portion of remote I/O module.
Fig. 7 indicates that the figure of an example of the sequential chart in CPU exception control portion.
Fig. 8 indicates that the figure of the structure of other of remote I/O module.
Fig. 9 indicates that the figure of an example of the sequential chart of the numerical data DO being output from remote I/O transport part.
Figure 10 is flow chart when carrying out routine processes of the action to remote I/O module.
Figure 11 is the flow chart of the CPU abnormality processing non-synchronously carried out.
Figure 12 indicates that water carries the figure of an example of factory.
Wherein:
1 controller; 2 CPU module; 3,3a, 3b, 3c remote I/O module; 4,4a, 4b, 4c, 4d, 4e, 4f, 4g, 4h, 4i equipment machine; 5 serial transmission paths; 6 CPU state signals; 7a, 7b, 7c, 7d, 7e, 7f, 7g, 7h, 7i machine connects cable.
Detailed description of the invention
Hereinafter, with reference to accompanying drawing, embodiments of the present invention are described in detail.
Embodiment 1
Present embodiment is to draw former water from reservoir, rivers and creeks, and carrying out medicine precipitation, sand filters, chlorine injects and manufacture the upper and lower water course factory such as water treatment plant of tap water is that example illustrates.
The upper and lower water course factories such as water treatment plant are made up of raw water pump equipment, high-voltage electric apparatus, the gen-set of emergency, medicine injection device, sedimentation tank equipment, filtering ponds equipment, chlorine injection device, water-delivery pump equipment, drainage equipment etc. And, the detection machine controlling machine and water-level gauge, effusion meter, water quality sensor etc. of pump, motor, valve, chopper, electromotor etc. is comprised at these each equipment.
In above-mentioned control machine, possesses the status contacts for being exported by the operating state of machine to outside. Herein, in the operating state of machine, exist in the operation process of pump or in stopped process, being switched on or switched off of the open and-shut mode such as the standard-sized sheet of valve is fully closed or crack, chopper, machine malfunction.
If the electrical specification of this status contacts such as becomes pump in operation process, then become electric conducting state, if in stopped process, then become the output of the two-value of state of insulation.
It addition, above-mentioned testing machine device possesses the analogue signal that the numerical information that the sensor of electric current, voltage, flow, water level, hydraulic pressure, aperture etc. exports converts to voltage or electric current analog output of outward portion's output.
It addition, in above-mentioned control machine, possess the operation terminal for the action from peripheral operation machine. Operation terminal is formed electric conducting state, state of insulation, thus controlling the break-make etc. of pump, the operating stopping of motor, valve, the opening and closing of valve, chopper, capacitor. Such as, if make the operation terminal of pump be in electric conducting state from outside, then pumping turns, if being in state of insulation, then pump stops. Above-mentioned operation terminal is also for inputting analog input end from outside analogue signal sometimes, now, controls the aperture of machine, rotating speed etc. according to the signal operation of analog input end.
Above-mentioned testing machine also has analog input end sometimes.
Fig. 1 is the structure chart of the controller possessing the upper and lower water course factories such as the above-mentioned water treatment plant controlling machine.
Controller 1 is made up of with multiple remote I/O (RemoteInput/Output) module 3a, 3b, 3c (following, to be generically and collectively referred to as remote I/O module 3) CPU (CentralProcessingUnit) module 2.
Serial transmission paths 5 by multistation modes such as RS-485 of CPU module 2 and multiple remote I/O module 3 and be connected by daisy chain type. And, by the sequential programme in CPU module 2 action, via serial transmission paths 5, access remote I/O module 3, thus controlling to comprise control multiple equipment machine 4a of machine, 4b, 4c ... 4i (following, to be generically and collectively referred to as equipment machine 4).
In the system construction drawing of Fig. 1, it is shown that there is the structure of multiple remote I/O module 3 but it also may be the structure of a CPU module 2 and a remote I/O module 3.
In the following description, the numerical data being transmitted between CPU module 2 and remote I/O module 3 via serial transmission paths 5 is called simulation input data AI (AI:AnalogInputdata) of the numerical data DI (DI:DigitalInputdata) of the input of 1 bit architecture, the numerical data DO (DO:DigitalOutputdata) of output, word or long-word architecture, simulation output data AO (AO:AnalogOutputdata), pulse input data PI (PI:PulseInputdata) etc.
Connect cable 7a via machine respectively at remote I/O module 3,7b, 7c ... 7i (following, to be generically and collectively referred to as machine and connect cable 7) are connected to the status contacts of multiple equipment machine 4, operation terminal, analog input end, analog output. The electrical specification of machine connection cable 7 has the voltage output of AC100V, AC200V, DC24V, DC48V etc., and has conducting or the state of insulation. Or the analogue signal of 4��20mA, 1��5V etc.
The status contacts of equipment machine 4, operation terminal, analog input end, analog output connect cable 7 via this machine and are accessed from remote I/O module 3, and CPU module 2 controls equipment machine 4 by remote I/O module 3.
More specifically, connect, via machine, the state that cable 7 input has the status contacts of equipment machine 4 at remote I/O module 3, as the signal from equipment machine. The state of the status contacts of the equipment machine 4 being transfused to is converted into the numerical data DI transmitted from remote I/O module 3 to CPU module 2. Specifically, if the status contacts of equipment machine 4 becomes conducting state, then DI is converted into " 1 ", if becoming state of insulation, then DI is converted into " 0 ". The numerical data DI of the status contacts of the equipment machine 4 being converted is transferred to CPU module 2 from remote I/O module 3. If it addition, the level of equipment machine 4 output voltage or electric current, then the state of analog output of equipment machine 4 being AD converted and forms simulation input data AI, and transmit to CPU module 2 from remote I/O module 3.
If having numerical data DO from CPU module 2 transmission, then machine is connected cable 7 and is driven to conducting state or state of insulation by remote I/O module 3, thus controlling the operation terminal of equipment machine 4. Specifically, machine is connected for cable 7, if DO is " 1 ", is then driven to conducting state, if DO is " 0 ", is then driven to state of insulation.
It addition, simulation output data AO is carried out DA conversion and forms analogue signal by remote I/O module 3, and export to analog input end of equipment machine 4.
It is connected to three equipment machines 4 in FIG, but 8��64 equipment machines 4 can be connected at a remote I/O module 3. It is connected to multiple I/O module 3 in CPU module 2. Generally, what controller carried out the status contacts of input and output, operation terminal, analog input end and analog output amounts to tens of��thousands of point.
Machine connect cable 7 be layed in each status contacts, operation terminal, analog input end, analog output, and become tens of��thousands of. Particularly in large-scale system, machine connects the laying of cable 7 and becomes difficulty. Therefore, by applying remote I/O module 3, it is arranged around remote I/O module 3 at equipment machine 4, so that the laying that machine connects cable 7 becomes easy, but reply when needing serial transmission paths 5 to misinformate defeated.
In addition, it is necessary to remote I/O module 3 is relative to the reply of the abnormal operation of CPU module 2.
In the controller 1 of the present embodiment, in the following manner, reply error of transmission, CPU abnormal operation.
CPU module 2 performs control program based on numerical data DI, simulation input data AI, as performing result, and output digital data DO, simulation output data AO. Now, CPU module 2 monitoring hardware of the present embodiment, the state of program also detect remarkable action, thus having without exception in CPU state signal 6 output.
It addition, remote I/O module 3 has the error detection mechanism of the serial transmission paths 5 of parity error etc., when detecting error of transmission, the DO of each equipment machine 4 is set to " 0 " (state of insulation) or keeps the state before detecting mistake.
It addition, remote I/O module 3 is when CPU state signal 6 represents that CPU is abnormal, no matter the state of DO, all the operation terminal of whole equipment machines 4 is driven to state of insulation.
Hereinafter, the structure of the remarkable action processing error of transmission, CPU is described in detail.
Fig. 2 indicates that the figure of the structure example of CPU module 2. CPU module 2 has CPU21, memorizer 22, CPU transport part 23, abnormal state detection portion 25 and abnormality output portion 26, and is connected with each other by cpu system bus 24. Memorizer 22 is RAM (RandomAccessMemory: random access memory) etc., and is configured with control program 221, depositor 222.
CPU transport part 23, within the cycle of the regulation corresponding with the process controlling program 221, performs serial communication, and receives and dispatches numerical data DI, numerical data DO etc. via transmission cable 5 and between remote I/O module 3. It addition, numerical data DI, numerical data DO are received and dispatched in CPU transport part 23 via system bus 24 and between depositor 222, so that the numerical data unification (being called refresh process) of remote I/O module 3 and depositor 222.
Control program 221 is the program of the sequential control of equipment machine 4, loop control, stores numerical data DI, numerical data DO, simulation input data AI, simulation output data AO at depositor 222, controls the primary data of program, operational data etc.
It addition, control program 221 is periodically carried out by CPU21, after the Content Transformation of the status contacts of equipment machine 4 being become numerical data DI by remote I/O module 3, it is stored in depositor 222 via CPU transport part 23, becomes the input of control program 221.
The numerical data DI of depositor 222 is performed the sequential operation of logical operations, numerical operation etc. by control program 221 as input, using numerical data DO as performing result output. And, the numerical data DO that controlled processing procedure sequence 221 exports to depositor 222 is sent to remote I/O module 3 via CPU transport part 23, thus within the cycle of regulation the operation terminal of set device machine 4.
Fig. 3 is that the abnormality detection to control program 221 processes the sequential chart illustrated.
Control program 221 performs process repeatedly with the control cycle of such as 50ms, 100ms, 200ms etc.
This place's reason makes remote I/O module 3 constitute with the refresh process of I/O module of numerical data unification of depositor 222, sequential operation. The result of the sequential operation being stored in depositor 222 is sent to remote I/O module 3 in the refresh process of the I/O module in ensuing cycle.
When creating the program exception of CPU21, the abnormal operation of memorizer 22, control program 221, there is sequential operation unclosed situation at the appointed time.
In the process cycle of abnormal state detection portion 25 supervisory control program 221, if the process cycle of control program 221 exceedes the supervision time of regulation, then it is judged to that CPU is abnormal.
More specifically, the watchdog timer overflowed within the supervision time that abnormal state detection portion 25 is arranged on regulation, thus the intervalometer that proceeds by control program 221 initializes the starting with intervalometer. When controlling program 221 normally action, there is not the spilling of watchdog timer. But, when control program 221 processes delay and there occurs the spilling of watchdog timer, then it is judged to the remarkable action of CPU.
It addition, the refresh process of I/O module and control program are as independently executable composition, monitor the refresh process of I/O module and the process cycle controlling program, if the process cycle of any one exceedes the supervision time of regulation, then can also be judged to the remarkable action of CPU. It addition, it can also be multiple for controlling program.
It addition, the abnormal state detection portion 25 of Fig. 2 can also detect the bit-errors etc. of ROM sum mistake, memorizer hardware anomalies, the Exception handling detection OS that performed by illegal instruction is abnormal, control the software anomaly of program exception etc.
The abnormality of the CPU module 2 detected by abnormal state detection portion 25 is informed to multiple remote I/O module 3 by CPU state signal 6 by abnormality output portion 26. Therefore, for CPU state signal 6 identical with serial transmission paths 5 use the differential serial interface that can carry out the RS-485 etc. that multistation is connected.
Serial transmission paths 5 carries out data at a prescribed interval and transfers, if but detect exception, then CPU state signal 6 exports the abnormality of CPU module 2 immediately.
As above, by arranging CPU state signal 6 separately with serial transmission paths 5 such that it is able to the action with the CPU transport part 23 of CPU module 2 independently non-synchronously carries out the communication of the abnormality of CPU, therefore, it is possible to be quickly carried out the abnormal notice of CPU.
It addition, as long as CPU state signal 6 can notify that CPU is abnormal, therefore message capacity can also be less, it is possible to makes traffic rate less than serial transmission paths 5. It is possible to improve the data reliability of the transmission of CPU state signal 6.
It addition, abnormality output portion 26 can also possess CPU state contact, the status data detected in abnormal state detection portion 25 is converted to the signal driving CPU state signal 6 by this CPU state contact, and for exporting to outside. Now, CPU state contact is such as made up of semiconductor relay, electromagnetic relay etc. If status data to be CPU normal, then CPU state contact can also be formed conducting state, if status data to be CPU abnormal, then CPU state contact can also be formed state of insulation.
Now, when stopping supplying power supply to CPU module 2, CPU state contact migrates to state of insulation, and therefore power supply supply stops also being outputted as CPU extremely.
More specifically, there is the voltage of such as AC100V, AC200V, DC24V, DC48V etc., form the contact specification of conducting state or state of insulation, make CPU state signal 6 for such as 2 core cables such that it is able to the presence or absence of the abnormality of CPU is not reliably exported to remote I/O module 3 by the impact ground by external noise from CPU module 2.
Or, it is possible to have the current source of 4��20mA, the stateless that has of electric current is formed contact specification, in the normal situation of CPU, is in the state of electric current.
Fig. 4 indicates that the figure of remote I/O module 3 and the structure example of equipment machine 4.
Remote I/O module 3 has remote I/O transport part 31, IO input portion 36, IO output portion 34, CPU exception control portion 35, and is connected with each other by system bus 33. Being connected it addition, IO input portion 36 connects input cable 7-2 by machine with the status contacts 41 controlling machine 42 of equipment machine 4, IO output mechanism 34 connects output cable 7-1 by machine and is connected with the operation terminal 40 controlling machine 42 of equipment machine 4.
Herein, the structure of 1 size of numerical data is represented by the IO input portion 36 of the dotted line of Fig. 4, IO output portion 34, CPU exception control portion 35, if this remote I/O module 3 is corresponding with the numerical data DI of 16 sizes, DO, then become the structure comprising 16 IO input portions 36, IO output portion 34, CPU exception control portion 35.
Remote I/O transport part 31 performs serial transmission via CPU module 2 and serial transmission paths 5, and receives and dispatches numerical data DI, DO. Herein, by the numerical data of serial transmission by 16 DI are such as set to 1 word, or multiple words that 16 DO are set to 1 word are constituted.
Remote I/O transport part 31 receives the numerical data DI corresponding with the state of status contacts 41 via system bus 33 from IO input portion 36, and the numerical data converting word to is transmitted to CPU module 2.
It addition, the numerical data DO from CPU module 2 transmission is extracted in remote I/O transport part 31, and via the CPU exception control portion 35 being connected to system bus 33, numerical data DO is exported to IO output portion 34.
CPU state signal 6, the normal or abnormal state of notice CPU module 2 it is connected in CPU exception control portion 35. The IO output that CPU exception control portion 35 possesses for remote I/O module 3, carries out computing between the normal or abnormal state of CPU module 2 and the numerical data DO inputted from remote I/O transport part 31, and is exported to IO output portion 34 by operation result.
Specifically being carried out as follows control, when notifying that CPU module 2 is normal state, the state that the output of IO output portion 34 is corresponding with numerical data DO, when notifying that CPU module 2 is abnormal state, IO output portion 34 exports state of insulation.
IO output portion 34 connects output cable 7-1 via machine and is connected with the operation terminal 40 of equipment machine 4, and the operation terminal 40 to equipment machine 4 that sets according to CPU exception control portion 35 notifies conducting state or state of insulation. Thus, equipment machine 4 is controlled.
IO input portion 36 connects input cable 7-2 via machine and is connected with the status contacts 41 of equipment machine 4, thus obtaining conducting state or the state of insulation of status contacts 41. And, when status contacts 41 is conducting state, numerical data DI is set as " 1 ", when status contacts 41 is state of insulation, numerical data DI is set as " 0 ". Set numerical data DI is notified to CPU module 2 via remote I/O transport part 31.
Fig. 5 indicates that the figure of the structure in CPU exception control portion 35.
CPU exception control portion 35 possesses the first input circuit the 351, second input circuit 352 and logical operation circuit 353.
First input circuit 351 is connected to the abnormality output portion 26 of CPU module 2 via CPU state signal 6, thus the signal level of CPU state signal 6 converts to TTL (TransistorTransistorLogic: TTL) level. Such as, convert low level to when CPU state signal 6 represents the abnormality of CPU module 2, convert high level to when representing the normal condition of CPU module 2.
Second input circuit 352 is connected to system bus 33, thus converting the numerical data DO received by remote I/O transport part 31 to Transistor-Transistor Logic level. Such as, convert low level to when numerical data DO is for " 0 ", convert high level to when numerical data DO is for " 1 ".
Logical operation circuit 353 is the logic circuit being such as made up of TTL, and performs the logical operations from the first input circuit 351 and the signal of the second input circuit 352, thus exporting control output signal. Controlling output signal is high level when logic is set up, and is low level when logic is false.
The logical operation circuit 353 of embodiment possesses AND circuit, and as next, output controls output signal.
The normal condition of CPU module 2 is represented at CPU state signal 6, and when numerical data DO is " 1 ", first input circuit 351 be output into high level, the output of the second input circuit 352 also becomes high level, the result of the logic product of logical operation circuit 353, high level output logic set up is for controlling output signal.
The normal condition of CPU module 2 is represented at CPU state signal 6, and when numerical data DO is " 0 ", first input circuit 351 be output into high level, second input circuit 352 be output into low level, the result of the logic product of logical operation circuit 353, by invalid for logic low level output for controlling output signal.
When CPU state signal 6 represents the abnormality of CPU module 2, even if any one that numerical data DO is " 1 " or " 0 ", the result of the logic product of logical operation circuit 353, also by invalid for logic low level output for controlling output signal.
Fig. 6 indicates that the figure of the structure in the IO output portion 34 of remote I/O module 3.
IO output portion 34 is made up of relay circuit 341 and lead-out terminal 342.
Relay circuit 341 is such as made up of semiconductor relay, electromagnetic relay etc., exports signal according to the control in CPU exception control portion 35, carries out the break-make of the circuit of outlet side. Such as, if controlling output signal to become high level, then connecting relay, if additionally controlling output signal to become low level, then disconnecting relay.
Lead-out terminal 342 connects output cable 7-1 by machine and is connected with the operation terminal 40 of equipment machine 4, makes operation terminal 40 in the conduction state or state of insulation by relay circuit 341.
Fig. 7 indicates that the figure of an example of the sequential chart in CPU exception control portion 35, and illustrates CPU state signal, numerical data DO and control the relation of output signal.
When CPU state signal 6 represents normal condition, if numerical data DO is " 1 ", then controls output signal output high level, if numerical data DO is " 0 ", then control output signal output low level. Thus, export the control output signal corresponding with the value of numerical data DO, the operation terminal 40 of equipment machine 4 is controlled as conducting state or state of insulation.
On the other hand, when CPU state signal represents abnormality, no matter numerical data DO is " 1 " or " 0 ", control the output equal output low level of signal. Therefore, when CPU state signal represents abnormality, the operation terminal 40 of equipment machine 4 is controlled as state of insulation.
As mentioned above, it is illustrated with the structure that CPU exception control portion 35 is corresponding with the numerical data DO of 1, but when the structure that remote I/O module 3 is corresponding with the numerical data DO of 16, then become the second input circuit 352 possessing 16 Fig. 5, possesses the AND circuit of 16 AND circuits 353, thus exporting 16 structures controlling output signal from AND circuit 353. And, if notified the abnormality of CPU module 2 by CPU state signal 6, then the operation terminal 40 controlling machine 4 connected is controlled as state of insulation by all 16 IO output portions 34.
As it is shown in figure 1, when controller 1 has multiple remote I/O module 3, CPU state signal 6 is connected to multiple remote I/O module 3 by daisy chain type, therefore the abnormality of CPU module 2 is notified to all of remote I/O module 3. In each remote I/O module 3, carry out above-mentioned process, the operation terminal 40 controlling machine 4 connected is controlled as state of insulation. Thereby, it is possible to all of equipment machine of the control object of stop control 1.
Embodiment 2
Fig. 8 indicates that the figure of other structure of remote I/O module 3.
Remote I/O module 3 has remote I/O transport part 31, transmission abnormality control portion 32, the multiple IO input portions 36 of each equipment machine 4 setting for connecting, IO output portion 34, CPU exception control portion 35, and is connected with each other by system bus 33. Being connected it addition, IO input portion 36 connects input cable 7-2 by machine with the status contacts 41 of equipment machine 4, IO output portion 34 connects output cable 7-1 by machine and is connected with the operation terminal 40 of equipment machine 4.
The situation that remote I/O module 3 shown in Fig. 4 has transmission abnormality control portion 32 from the remote I/O module 3 of the present embodiment is different, below, illustrates centered by difference.
Transmission abnormality control portion 32 monitors the transmission state connecting remote I/O module 3 with the serial transmission paths 5 of CPU module 2 via remote I/O transport part 31 within each control cycle, when detecting transmission abnormality, control remote I/O transport part 31, and change rule changed number data DO according to set in advance.
Herein, transmission abnormality control portion 32 error detection such as the transmission abnormality the detected time-out by the broken string of cable break etc., as the state not terminating transmitting-receiving at the appointed time detects, the crc error of numerical data of transmission, parity error judge.
When detecting transmission abnormality in transmission abnormality control portion 32 within each control cycle, the change rule of changed number data DO is such as be rewritten into by DO " 0 " (zero), maintains (maintenance) and detects abnormal front numerical data DO etc.
This change rule for the position of each numerical data DO, in other words, can set for the equipment machine 4 of each control object. Therefore, in the remote I/O module that the equipment machine 4 with multiple operation terminal connects, for each numerical data DO, carry out instruction setting by CPU module 2 to changing rule.
The numerical data DO changed when transmission abnormality by remote I/O transport part 31 is sent to CPU exception control portion 35.
In CPU exception control portion 35, as it has been described above, the Status Change numerical data DO according to CPU state signal 6, control output signal to the output of IO output portion 34. This control output signal converts conducting state or state of insulation in IO output portion 34, and informs the operation terminal 40 of equipment machine 4.
Fig. 9 indicates that the figure of an example of the sequential chart of the numerical data DO from remote I/O transport part 31 output. The change rule of numerical data during according to the numerical data DO inputted from CPU module 2, the presence or absence of transmission abnormality, transmission abnormality, it is shown that the relation of the output in CPU exception control portion 35.
When not detected the transmission abnormality of transmission cable 5 by transmission abnormality control portion 32, no matter the setting changing rule of numerical data DO, all do not change numerical data DO from remote I/O transport part 31 to CPU exception control portion 35 and output it, if it is abnormal to be absent from CPU, then export with keeping intact.
On the other hand, when detecting transmission abnormality, different because of the setting changing rule of numerical data DO to the numerical data DO of CPU exception control portion 35 output. If rule is for keeping setting, then numerical data DO is altered to the value before detecting transmission abnormality (in fig .9 for " 1 ") and exports. If rule is zero, then numerical data DO is altered to " 0 " and exports. And, if it is abnormal to be absent from CPU, then export the numerical data DO being changed.
As above, for each equipment machine 4, the change rule of numerical data DO is set such that it is able to change corresponding method when making a mistake according to the significance level of equipment machine 4, therefore, it is possible to realize the raising of the reliability of system.
Figure 10 is flow chart when carrying out routine processes of the action to remote I/O module 3. The flow process of Figure 10 carries out action respectively in multiple remote I/O module 3.
First, it is determined whether have received the numerical data DO of this remote I/O module 3 (S901). If do not send the numerical data DO of this remote I/O module 3 from CPU module 2, then etc. (S901's is no) to be received.
When have received above-mentioned numerical data DO (S901 is), it is determined that the presence or absence (S902) of transmission abnormality during reception. Specifically, the judgement of transmission abnormality is undertaken by odd-even check, CRC code, sum inspection etc.
When being absent from abnormal (S902's is no), normally carry out the transmission of numerical data DO, temporarily preserve the DO (S909) received in order to carry out transmission abnormality process described later, enter S906.
When there is transmission abnormality (S902 is), as next, carry out the change of numerical data DO.
First, it is determined that the kind (S903) of set modification rule, if " zero " (" zero " of S903), then numerical data DO is rewritten into zero (S904), enters S906.
If being " maintenance " (" maintenance " of S903) in S903, then numerical data DO is rewritten in S909 the value (S905) of the DO of the normal transmission before temporarily preserving. In other words, after being rewritten into and detecting abnormal front value, S906 is entered.
In S906, it is determined whether detect the abnormal notice of CPU from CPU module 2. When detecting CPU exception (S906 is), numerical data DO is unconditionally rewritten into zero (S907), enters S908.
When not detecting notice abnormal for CPU in S906 (S906's is no), enter S908.
In S908, set numerical data D0 in IO output portion 34, export conducting state or state of insulation according to the value of numerical data DO.
By above-mentioned flow process, detecting the abnormal operation that transmission abnormality and CPU module 2 occur in serial transmission paths 5, changed number data DO, therefore, it is possible to prevent the exception control of controller 1.
It addition, for the abnormal countermeasure promptly carrying out CPU module 2, and non-synchronously carry out process when occurring abnormal of CPU module with the handling process of Figure 10.
Figure 11 is the flow chart of the CPU abnormality processing non-synchronously carried out.
The process of Figure 11 is started by the reception data interruption of CPU state signal 6, it is preferable that improve interrupt priority level as much as possible.
Additionally, the process content of S906, S907, S908 of Figure 11 is identical with Figure 10, therefore omit the description herein.
Embodiment 3
It follows that utilize the concrete example changing rule of the Figure 12 numerical data DO to being processed by transmission abnormality control portion 32 to illustrate.
Figure 12 indicates that the water that stockpiles smoking pump sump 8, and controls to carry from pipe arrangement 9 as the water flowing out water outflow the figure of an example of factory for target flow.
Water carries factory to be made up of pump sump 8, pipe arrangement 9, constant speed pump 42a, adjustment the electrodynamic valve 42b of flow, effusion meter 42c. And, the outflow water discharged by constant speed pump 42a carries out flow measurement by effusion meter 42c, is controlled by electrodynamic valve 42b in the way of becoming constant flow rate.
This water conveying factory connects cable 7a, 7d, 7e, 7g by machine and the equipment machine 4a comprising constant speed pump 42a, the equipment machine 4d comprising electrodynamic valve 42b, the equipment machine 4g that comprises effusion meter 42c is connected to remote I/O module 3a, 3b, 3c, and carries out flow-control by CPU module 2. Remote I/O module 3a, 3b, 3c are connected to CPU module 2 by serial transmission paths 5 and CPU state signal 6 daisy chain type.
Next the function of equipment machine 4a, 4d, 4g is illustrated.
The specification that constant speed pump 42a is invariablenes turning speed of equipment machine 4a, discharges constant flow rate in the running, and delivery flow during stopping is zero. Equipment machine 4a possesses operation terminal 40a, by making operation terminal 40a be in electric conducting state, turns thus continuing pumping, if being in state of insulation, then stops pumping and turns.
The electrodynamic valve 42b of equipment machine 4d regulates starting work and closing action of valve by the forward and reverse of motor, thus controlling the delivery flow from constant speed pump 42a. Valve opening such as carries out action in the scope of the 0��100% of fully closed 0%, standard-sized sheet 100%. The starting of control valve that be set by of this valve opening is made and is closed the movement time of action and carry out.
Specifically, if start work, close action such as in 1 second formed valve opening 5% speed, if then under full-shut position keep start work 20 seconds, then reach standard-sized sheet and stop starting work. On the contrary, under full-gear, if keeping closing action in 20 seconds, then become full-shut position, thus stopping closing action.
Equipment machine 4d possesses operation terminal 40b (starting work) and operation terminal 40c (closing action), by making operation terminal 40b, 40c be in electric conducting state, thus continuing start work or close action, if being in state of insulation, then make to start work or close action to stop.
The valve opening of the electrodynamic valve 42b of equipment machine 4d is by adjusting the time making operation terminal 40b or operation terminal 40c in the conduction state, and can control the aperture for becoming target.
The outflow flow of the effusion meter 42c metered flow water outlet of equipment machine 4g.
The flow value measured is converted to the current signal of 4��20mA by analog output 43 of equipment machine 4g, and exports.
In CPU module 2, input data AI via the outflow flow of remote I/O module 3c acquirement analog output 43 as simulation, in the way of this simulation input data AI becomes target flow, perform to control operating and the stopping of constant speed pump 42a, control starting work and closing the control program of action of electrodynamic valve 42b.
The action instruction of operating or stopping is recorded in numerical data DO by control program by constant speed pump 42a, is set in the operation terminal 40a of equipment machine 4a via remote I/O module 3a, thus indicating operating or stopping.
Electrodynamic valve 42b is recorded in numerical data DO by control program by starting the action instruction made and close action, via remote I/O module 3b, is set in operation terminal 40b, 40c of equipment machine 4d, thus setting valve opening.
As it has been described above, remote I/O module 3a, 3b detection transfers the transmission abnormality of the serial transmission paths 5 of numerical data DO, and based on the change rule changed number data DO of regulation.
In the present embodiment, when detecting transmission abnormality, for constant speed pump 42a and electrodynamic valve 42b, changed number data DO in ensuing change rule.
In remote I/O module 3a, the change forming the settings state controlling the cycle before being remained by the numerical data DO of action of instruction constant speed pump 42a is regular. In other words, operating or the halted state of current constant speed pump 42a are maintained.
In remote I/O module 3b, the numerical data DO made and close action that starts of instruction electrodynamic valve 42b is carried out the change rule of zero setting (do not start and make or close action) by formation. In other words, make electrodynamic valve 42b valve start work, close action stop and standing valve aperture, thus maintaining current flow.
The change of numerical data DO when setting the transmission abnormality of constant speed pump 42a and electrodynamic valve 42b of water conveying factory of the present embodiment as described above is regular, thus not making the water conveying detecting the cycle that controls of transmission abnormality stop, additionally under reverting to the normal situation of transmission, it is possible to easily restart to control.
Above-mentioned change rule is not limited to this, it is possible to utilization specification during according to transmission abnormality suitably determines.
But, carry in the controller 1 of factory at the water of the present embodiment shown in Figure 12, by CPU state signal 6, notify that from CPU module 2 to remote I/O module 3a, 3b, 3c CPU is abnormal.
It is notified of remote I/O module 3a, 3b, 3c abnormal for CPU by CPU state signal 6 to be set to " 0 " by numerical data DO, operation terminal 40a, 40b, 40c are set as state of insulation. In other words, constant speed pump 42a makes pumping turn stopping, and electrodynamic valve 42b makes to start work or close action to stop, and the outflow thus flowing out water stops.
When detecting that CPU is abnormal, exist until the situation restoring spended time of controller. Therefore, in order to carry out flowing out the outflow of water, it is preferable that can manually make constant speed pump 42a and electrodynamic valve 42b action in advance.
It is thus possible, for instance arrange switching device at the machine connection cable 7a of the operation terminal 4a of constant speed pump 42a such that it is able to select the signal from remote I/O module 3a and the signal from hand-operating device.
When constant speed pump 42a stops because CPU is abnormal, by switching device, switch to the operation terminal 4a and hand-operating device that connect constant speed pump 42a. And, manually operate device, making the operation terminal 4a of constant speed pump 42a in the conduction state, turning thus carrying out pumping.
As described above, according to present embodiment, if the fatal state of controller 1 exception detecting CPU module 2 etc, then make machine connect output cable 7-1 and be reliably fitted in state of insulation, it is thus possible to make the action of all of equipment machine stop, therefore, it is possible to prevent the misoperation of factory.
Additionally, according to present embodiment, easy logic circuit is installed by not using the mechanism of high-performance CPU etc. at remote I/O module and only lays the signal cable of the state notifying CPU module, can reliably stop in the operating of CPU exception Shi Shi factory, therefore there is the effect that can improve safety with low cost.
Additionally, if CPU module 2 is normal, then when detecting the transmission abnormality of serial transmission paths 5, continuation or the stopping of the output for controlling machine be can selecting to set, the significance level tackling control object machine neatly and the effect using policy also be able to even if therefore having when occurring abnormal.
Additionally, only when detecting the CPU specifically great abnormal key factor such as abnormal, the all of control the operation of a machine making connection stops, and the operating utilization rate therefore automatically controlled improves such that it is able to expect the minimizing of the burden of the manual operation of operator.
Controller involved in the present invention is not limited to above-mentioned embodiment, it is possible to be properly carried out deformation without departing from the spirit and scope of the invention. Hereinafter, other embodiment of controller involved in the present invention is enumerated.
In the above-described embodiment, although form remote I/O module 3 and possess the structure of 1 DI, 1 DO but it also may form the structure possessing multiple DI, multiple DO, alternatively, it is also possible to form the structure possessing multiple AI, AO, PI.
It addition, in the above-described embodiment, although making status contacts, operation terminal, CPU state contact is a contact but it also may be b contact, c contact.
It addition, the controller 1 involved by above-mentioned embodiment can also apply to the controller of the industrial systems such as the controller of social foundation's construction system of electric power, gas, traffic, reservoir etc., ferrum steel, chemistry, food, logistics.
Additionally, the information such as the program of each function, data that realize are except being stored in RAM (RandomAccessMemory: random access memory), additionally it is possible to be stored in the record medium such as the recording equipments such as SSD (SolidStateDrive: solid state hard disc), IC (IntegratedCircuit: integrated circuit) card, SD (SecureDigital: secure digital) card, DVD (DigitalVersatileDisc: Digital versatile disc).
It addition, the structure in each portion involved by above-mentioned embodiment, function, CPU, memorizer, system bus also are able to all or part by realizing in them with the hardware of IC design.
Additionally, in the accompanying drawing that embodiment is illustrated, illustrate only and be thought of as necessary control line, information wire in explanation, need not necessarily be limited to illustrate all of control line, information wire in goods. It practice, it is also contemplated that be connected to each other for substantially all of structure.

Claims (12)

1. a controller, the equipment machine of factory is controlled by it, and controller noted above is characterised by, possesses:
CPU module, it has the abnormal state detection portion of abnormal operation of detection module, and multiple equipment machines of above-mentioned factory are carried out programme-control; And
Multiple remote I/O module, they are connected to above-mentioned CPU module by serial transmission paths daisy chain type, and change the numerical data transmitted from above-mentioned CPU module and export to above-mentioned equipment machine,
To above-mentioned remote I/O module, above-mentioned CPU module, when above-mentioned abnormal state detection portion detects abnormal operation, notifies that CPU is abnormal,
Above-mentioned remote I/O module, when notified above-mentioned CPU exception, differently makes all the said equipment machines be in halted state with the control based on above-mentioned numerical data.
2. controller according to claim 1, it is characterised in that
Above-mentioned CPU is abnormal to be connected the signal cable of above-mentioned CPU module and above-mentioned remote I/O module by the daisy chain type different from above-mentioned serial transmission paths and informs above-mentioned remote I/O module from above-mentioned CPU module.
3. controller according to claim 1, it is characterised in that
Above-mentioned remote I/O module obtains the abnormal logic product with above-mentioned numerical data of above-mentioned CPU, and to the long-pending operation result of above-mentioned equipment machine output logic.
4. controller according to claim 1, it is characterised in that
Above-mentioned remote I/O module has transmission abnormality control portion, and transmission abnormality the changed number data of above-mentioned transmission cable are detected in this transmission abnormality control portion,
Above-mentioned transmission abnormality control portion is when detecting transmission abnormality, for each of the multiple equipment machines connected, based on the change rule changed number data of regulation.
5. controller according to claim 4, it is characterised in that
Above-mentioned change rule is numerical data to be rewritten into " 0 " namely make zero, or maintain detect transmission abnormality before numerical data namely keep.
6. a controller, it has multiple remote I/O module of CPU module and the multiple equipment machines controlling factory, and controller noted above is characterised by,
Above-mentioned CPU module and above-mentioned remote I/O module are connected by serial transmission paths and CPU state signal,
This serial transmission paths daisy chain type connects above-mentioned CPU module and above-mentioned remote I/O module and transmits control information,
This CPU state signal daisy chain type connects above-mentioned CPU module, and with above-mentioned remote I/O module and transmission CPU is abnormal from above-mentioned CPU module to above-mentioned remote I/O module.
7. controller according to claim 6, it is characterised in that
Above-mentioned serial transmission paths periodically transmits control information,
Above-mentioned CPU state signal and above-mentioned serial transmission paths non-synchronously transmit CPU state information.
8. controller according to claim 6, it is characterised in that
The data volume of above-mentioned CPU state information is fewer than the control information that above-mentioned serial transmission paths is transmitted.
9. a control method, it is the control method of controller, and this controller has multiple remote I/O module of at least one equipment machine of CPU module and control factory and multiple equipment machines of factory are controlled, and above-mentioned control method is characterised by having:
Detect the multiple equipment machines to above-mentioned factory and carry out the abnormal operation of programme controlled CPU module the step of the signal in CPU state signal output expression abnormality; And
With the above-mentioned remote I/O module that the numerical data DO notified from CPU module sets above-mentioned multiple equipment machine respective operation terminal accordingly, the signal of the expression abnormality according to above-mentioned CPU state signal, is set as the step of the state of regulation by all of aforesaid operations terminal.
10. control method according to claim 9, it is characterised in that also have:
Above-mentioned remote I/O module monitors the serial transmission paths connecting above-mentioned CPU module with above-mentioned remote I/O module within the control cycle of regulation, when detecting transmission abnormality, change the numerical data DO notified from above-mentioned CPU module the step being set in aforesaid operations terminal according to the rule that changes of regulation.
11. control method according to claim 10, it is characterised in that
Above-mentioned remote I/O module sets opportunity of aforesaid operations terminal accordingly from the numerical data DO from above-mentioned CPU module and to set opportunity of aforesaid operations terminal according to the signal of the expression abnormality of above-mentioned CPU state signal different.
12. control method according to claim 10, it is characterised in that
With change compared with rule changes the numerical data DO notified from above-mentioned CPU module the step being set in aforesaid operations terminal according to regulation, above-mentioned remote I/O module priority treatment sets the step of aforesaid operations terminal according to the signal of the expression abnormality of above-mentioned CPU state signal.
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