CN105629923B - Controller and its control method - Google Patents

Controller and its control method Download PDF

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Publication number
CN105629923B
CN105629923B CN201510784708.5A CN201510784708A CN105629923B CN 105629923 B CN105629923 B CN 105629923B CN 201510784708 A CN201510784708 A CN 201510784708A CN 105629923 B CN105629923 B CN 105629923B
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mentioned
module
cpu
remote
numerical data
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CN105629923A (en
Inventor
原直树
畑秀太朗
小野里登
黑泽贤郎
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], 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], 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]

Abstract

The present invention provides a kind of in the controller being made of CPU module and remote I/O module, control action reliable according to abnormal element and when selectively performing abnormal, so as to fulfill the controller of high reliability.The controller of the present invention has:CPU module, the abnormal state detection portion of the abnormal operation with detection module, and the multiple equipment machine of above-mentioned factory is controlled into line program;And multiple remote I/O modules, they are connected to above-mentioned CPU module by serial transmission paths daisy chain type, and it converts from the numerical data that above-mentioned CPU module is transmitted and is exported to above-mentioned equipment machine, above-mentioned abnormal state detection portion is when detecting abnormal operation, it is abnormal to above-mentioned remote I/O module notice CPU, all above equipment apparatus controls are differently halted state with the control based on above-mentioned numerical data when being notified above-mentioned CPU exceptions by above-mentioned remote I/O module.

Description

Controller and its control method
Technical field
The present invention relates to the controllers carried out automatically controlling to factory (plant) equipment etc..
Background technology
As the controller carried out automatically controlling, exist CPU (Central Processing through transmission cable Unit:Central processing unit) module and multiple remote I/Os (Remote Input/Output:Remote input/output) connect between module The system connect.For the structure, control program and output digital data DO that CPU module execution automatically controls (Digital Output data:Digital output data), remote I/O module converts the numerical data DO received from CPU module It is exported into factory's output signal and by its operation terminal to shop equipment.
The controller of the remote I/O mode exist can with save space, be realized with a low cost multiple shop equipments being distributed Control the advantages of.
For example, the upper and lower water course factory being made of multiple equipment can apply above-mentioned controller, factory's control is carried out.On Each equipment of sewer factory is made of multiple machines, moreover, having operation terminal in each machine.Externally to the operation terminal Factory's output signal is exported, so as to operate the operation of a machine, stop.From controller or hand-operating device to operating side Son suitably exports factory's output signal, so as to fulfill the operating of machine monomer and the operating of factory's entirety.
The malfunction of the controller of upper and lower water course factory stops in the presence of tap water cut-off, city flood etc. is caused, so as to prestige Coerce the possibility of life, property.Therefore, the 24 hour operating continuously stablized is required controller.
As above, to the controller requirement high reliability for the sewer factory that faces upward.
In the case where controller detects exception, the malfunction of factory in order to prevent, and must implement emergent stopping or Person operates when being maintained factory's function and detecting extremely preceding state, stops a part of machine and reduces factory functionally It operates or switches to manual operation and operate etc..
Particularly, it in the case where detecting the abnormal highest CPU module exception of danger level of controller, needs to avoid The risk that numerical data DO is accidentally exported caused by CPU malfunctions, and stop Plant Emergency.
In addition, upper and lower water course factory, which is provided with high voltage electric equipment, induction motor, frequency converter etc., becomes the machine of noise source Device, therefore in application remote I/O module, there is the biography generated when noise is overlapped to CPU module is connect with remote I/O module Transmission cable generates the possibility of momentary transmission abnormality.
In the past, in view of the above circumstances, it is proposed that in the case where detecting the exception of controller, control external loading Supply the technology of power supply (for example, referring to patent document 1).
According to technology disclosed in patent document 1, by the pulse output exported from main program and by relay and timing The external circuit timer detection that device is formed is abnormal, when detecting abnormal, cut-out or the power supply supply for connecting external loading, So as to fulfill failure protection function.
In addition, following I/O cell is disclosed in patent document 2, it is different by setting the abnormal examination leading-out terminal of MPU11 The state of the output of the leading-out terminal of I/O cell when often checking becomes the state of the connected IO machines of un-activation, so as to Detect the presence of failure exception in advance.
Existing technical literature
Patent document
Patent document 1:Japanese Unexamined Patent Publication 9-185403 bulletins
Patent document 2:Japanese Unexamined Patent Publication 2008-310389 bulletins
Invention content
Problems to be solved by the invention
According to above-mentioned technology disclosed in patent document 1, pass through switch on delay timer and off delay timer Combination carrys out watchdog pulse output, therefore abnormal to detecting abnormal at least to need two abnormal inspections more than program loop from generating Survey the stand-by period.Therefore, within the abnormality detection stand-by period, existing can not prevent caused by CPU is malfunctioned to factory The problem of accidentally exporting.
In addition, according to patent document 1, even if appointing in CPU module, remote I/O module, main program, transmission, external circuit Position of anticipating generates abnormal, is also detected as all identical exceptions, even if therefore existing and detecting that abnormal etc the danger levels of CPU are special Not high abnormal key factor, the problem of also can not reliably disconnecting numerical data DO immediately when detecting.
Additionally, there are the controllers being made of CPU module and remote I/O module can not detect necessary transmission abnormality, that is, exist Detect the subject that control action during exception can not be selected during transmission abnormality and is set.
According to above-mentioned technology disclosed Patent Document 2, though it can be tested with the failure of no I/O cell, different in advance Often, but there is fault detect when not considering practice, in addition do not consider that the CPU element of PLC, the failure of formant are asked Topic.
As above, in the technology disclosed in patent document 1,2, can not realize towards needed for the controller of upper and lower water course can By property.
The method used for solving the problem
The present invention be in view of above-mentioned actual conditions and complete, and it is an object of the present invention to provide it is a kind of by CPU module with it is long-range I/O module form controller in, according to the abnormal element of CPU exception, transmission abnormality etc., and reliably and selectively perform Control action when abnormal, so as to realize the controller of high reliability.
In order to solve the above problems, the controller that the equipment machine of the invention to factory is controlled has:CPU moulds Block, the abnormal state detection portion of the abnormal operation with detection module, and to the multiple equipment machine of above-mentioned factory into stroke Sequence controls;And multiple remote I/O modules, they are connected to above-mentioned CPU module by serial transmission paths daisy chain type, and turn It changes from the numerical data that above-mentioned CPU module is transmitted and is exported to above-mentioned equipment machine, above-mentioned CPU module is examined in above-mentioned abnormality It is abnormal to above-mentioned remote I/O module notice CPU when survey portion detects abnormal operation, above-mentioned remote I/O module be notified it is above-mentioned During CPU exceptions, all above equipment machines is differently made to be in halted state with the control based on above-mentioned numerical data.
In addition, there is CPU module and the remote I/O mould controlled the multiple equipment machine of factory for the present invention For the controller of block, above-mentioned CPU module and above-mentioned remote I/O module by serial transmission paths and CPU state signal and by Connection, the serial transmission paths daisy chain type connect above-mentioned CPU module and above-mentioned remote I/O module and transmit control information, should CPU state signal daisy chain type connects above-mentioned CPU module with above-mentioned remote I/O module and from above-mentioned CPU module to above-mentioned remote I/O Module transfer CPU is abnormal.
In addition, the present invention's has CPU module and the remote I/O mould controlled at least one equipment machine of factory Block, and the control method of controller controlled the multiple equipment machine of factory has:Detection is to the multiple of above-mentioned factory The abnormal operation for the CPU module that equipment machine is controlled into line program simultaneously exports the signal for representing abnormality in CPU state signal The step of;And the numerical data DO with being notified from CPU module accordingly sets the above-mentioned respective operating side of multiple equipment machine The above-mentioned remote I/O module of son is according to the signal of the expression abnormality of above-mentioned CPU state signal and by all aforesaid operations ends Son is set as the step of defined state.
The effect of the present invention is as follows.
In accordance with the invention it is possible to improve the reliability of controller.
Description of the drawings
Fig. 1 is the structure chart of the controller of upper and lower water course factory.
Fig. 2 is the figure for the configuration example for representing CPU module.
Fig. 3 is the sequence diagram to the abnormality detection processing of program is controlled to illustrate.
Fig. 4 is the figure for the configuration example for representing remote I/O module and equipment machine.
Fig. 5 is the figure for the structure for representing CPU exception controls portion.
Fig. 6 is the figure of the structure for the IO output sections for representing remote I/O module.
Fig. 7 is the figure of an example of the sequence diagram for representing CPU exception controls portion.
Fig. 8 is the figure for the other structures for representing remote I/O module.
Fig. 9 is the figure of the sequence diagram of numerical data DO example for representing to be exported from remote I/O transport part.
Figure 10 is the flow chart in the case that the action to remote I/O module is handled into line program.
Figure 11 is the non-flow chart of CPU abnormality processings being synchronously carried out.
Figure 12 is the figure for an example for representing water conveying factory.
Wherein:
1-controller;2-CPU module;3rd, 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 signal;7a, 7b, 7c, 7d, 7e, 7f, 7g, 7h, 7i-machine Device connecting cable.
Specific embodiment
Hereinafter, with reference to attached drawing, the embodiment of the present invention will be described in detail.
Embodiment 1
Present embodiment carries out drug precipitation, sand filters, chlorine is injected and manufactured certainly to draw raw water from reservoir, rivers and creeks It is illustrated for the upper and lower water courses factory such as water treatment plant of water.
The upper and lower water courses factory such as water treatment plant is by raw water pumping unit, high-voltage electric apparatus, the gen-set of emergency, drug The compositions such as injection device, precipitation pool equipment, filtering pool equipment, chlorine injection device, water delivery pumping unit, drainage equipment.Moreover, These each equipment include the control machine of pump, motor, valve, breaker, engine etc. and water-level gauge, flowmeter, water quality sensor Deng detection machine.
In above-mentioned control machine, have for the status contacts by the action state of machine to outside output.Herein, In the action state of machine, there are in the operation process of pump or in stopped process, the standard-sized sheet of valve is fully closed or the opening and closings such as crack State, being switched on or switched off of breaker, the malfunction of machine.
If the electrical specification of the status contacts is for example as pumping in operation process, as electric conducting state, if stopping During only, then as the output of the two-value of state of insulation.
The sensor of electric current, voltage, flow, water level, hydraulic pressure, aperture etc. is exported in addition, above-mentioned detection machine device has Numerical information be converted into voltage or electric current analog signal and outward portion output simulation output terminal.
In addition, in above-mentioned control machine, have for from the operation terminal of the action of peripheral operation machine.It will operation Terminal forms electric conducting state, state of insulation, so as to control pump, the operating stopping of motor, valve, the opening and closing of valve, breaker, electricity Break-make of container etc..If for example, the operation terminal of pump is made to be in electric conducting state from outside, operating is pumped, if in insulation shape State then pumps stopping.Above-mentioned operation terminal is also the simulation input terminal for inputting the analog signal from outside sometimes, this When, aperture, rotating speed of machine etc. are controlled according to the signal operation of simulation input terminal.
Above-mentioned detection machine also has simulation input terminal sometimes.
Fig. 1 is the structure chart for having the controllers of upper and lower water courses factory such as the above-mentioned water treatment plant of control machine.
Controller 1 is by CPU (Central Processing Unit) modules 2 and multiple remote I/Os (Remote Input/ Output) module 3a, 3b, 3c (hereinafter, collectively referred to as remote I/O module 3) is formed.
CPU module 2 is with multiple remote I/O modules 3 by the serial transmission paths 5 of the multistations mode such as RS-485 and by chrysanthemum Chain type connects.Moreover, by the sequential programme acted in CPU module 2, via serial transmission paths 5, remote I/O module 3 is accessed, So as to control include control multiple equipment machine 4a, 4b of machine, 4c ... 4i (hereinafter, collectively referred to as equipment machine 4).
In the system construction drawing of Fig. 1, show the structure with multiple remote I/O modules 3 but it is also possible to be a CPU The structure of module 2 and a remote I/O module 3.
In the following description, it will be transmitted between CPU module 2 and remote I/O module 3 via serial transmission paths 5 Numerical data is known as the numerical data DI (DI of the input of 1 bit architecture:Digital Input data), the digital number of output According to DO (DO:Digital Output data), the simulation input data AI (AI of word or long-word architecture:Analog Input Data), simulation output data AO (AO:Analog Output data), pulse input data PI (PI:Pulse Input Data) etc..
Remote I/O module 3 respectively via machine connecting cable 7a, 7b, 7c ... 7i (hereinafter, collectively referred to as machine connect electricity Cable 7) it is connected with status contacts, operation terminal, simulation input terminal, the simulation output terminal of multiple equipment machine 4.Machine connects The electrical specification of cable 7 has the voltage output of AC100V, AC200V, DC24V, DC48V etc., and the shape with conducting or insulation State.The either analog signal of 4~20mA, 1~5V etc..
Status contacts, operation terminal, simulation input terminal, the simulation output terminal of equipment machine 4 are connected via the machine Cable 7 is accessed from remote I/O module 3, and CPU module 2 passes through 3 control device machine 4 of remote I/O module.
More specifically, there are the status contacts of equipment machine 4 via the input of machine connecting cable 7 in remote I/O module 3 State, as the signal from equipment machine.The state of the status contacts of equipment machine 4 being entered is converted into from remote I/O The numerical data DI that module 3 is transmitted to CPU module 2.If specifically, the status contacts of equipment machine 4 become conducting state, DI is converted into " 1 ", if as state of insulation, DI is converted into " 0 ".The number of the status contacts of equipment machine 4 converted Digital data DI is transferred to CPU module 2 from remote I/O module 3.If in addition, the level of 4 output voltage of equipment machine or electric current, Then the state of the simulation output terminal of equipment machine 4 is AD converted and forms simulation input data AI, and from remote I/O mould Block 3 is transmitted to CPU module 2.
If having numerical data DO from the transmission of CPU module 2, machine connecting cable 7 is driven to conducting shape by remote I/O module 3 State or state of insulation, so as to the operation terminal of control device machine 4.Specifically, for machine connecting cable 7, if DO is " 1 ", then is driven to conducting state, if DO is " 0 ", is driven to state of insulation.
In addition, remote I/O module 3 carries out DA conversions to simulation output data AO and forms analog signal, and to equipment machine 4 simulation input terminal output.
It is connected with three equipment machines 4 in Fig. 1, but 8~64 equipment machines can be connected in a remote I/O module 3 4.Multiple I/O modules 3 are connected in CPU module 2.In general, a controller carries out the status contacts of input and output, operating side Son, simulation input terminal and simulation output terminal amount to tens of~thousands of points.
Machine connecting cable 7 is layed in each status contacts, operation terminal, simulation input terminal, simulation output terminal, and As tens of~thousands of.Particularly in large-scale system, the laying of machine connecting cable 7 becomes difficult.Therefore, pass through Using remote I/O module 3, remote I/O module 3 is set near equipment machine 4, so as to become the laying of machine connecting cable 7 Easily, but reply when needing the serial transmission paths 5 to misinformate defeated.
In addition, it is necessary to reply of the remote I/O module 3 relative to 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 operations.
CPU module 2 is based on numerical data DI, simulation input data AI and performs control program, as implementing result, exports number Digital data DO, simulation output data AO.At this point, the state of 2 monitoring hardware of CPU module of the present embodiment, program and detection operation It is abnormal, it is without exception so as to have in the output of CPU state signal 6.
In addition, remote I/O module 3 has the error detection mechanism of the serial transmission paths 5 of parity error etc., detecting During error of transmission, the DO of each equipment machine 4 is set as " 0 " (state of insulation) or keeps detecting the state before making mistake.
In addition, remote I/O module 3 CPU state signal 6 represent CPU exceptions in the case of, no matter the state of DO, The operation terminal of whole equipment machines 4 is driven to state of insulation.
Hereinafter, the structure of the remarkable action of processing error of transmission, CPU is described in detail.
Fig. 2 is the figure for the configuration example for representing CPU module 2.CPU module 2 have CPU21, memory 22, CPU transport parts 23, Abnormal state detection portion 25 and abnormality output section 26, and pass through cpu system bus 24 and be connected with each other.Memory 22 is RAM(Random Access Memory:Random access memory) etc., and it is configured with control program 221, register 222.
CPU transport parts 23 as defined in corresponding with the processing for controlling program 221 in the period, via transmission cable 5 with Serial communication is performed between remote I/O module 3, and receives and dispatches numerical data DI, numerical data DO etc..In addition, CPU transport parts 23 pass through Numerical data DI, numerical data DO are received and dispatched between register 222 by system bus 24, so as to make remote I/O module 3 with posting The numerical data unification (being known as refresh process) of storage 222.
Control program 221 is the program of the sequential control of equipment machine 4, loop control, and number is stored in register 222 Data DI, numerical data DO, simulation input data AI, simulation output data AO, primary data, the operational data for controlling program Deng.
In addition, control program 221 is periodically carried out by CPU21, by remote I/O module 3 by the shape of equipment machine 4 The Content Transformation of state contact is stored in register 222 into after numerical data DI via CPU transport parts 23, becomes control program 221 Input.
Control program 221 performs logical operation, numerical operation etc. using the numerical data DI of register 222 as input Sequential operation is exported numerical data DO as implementing result.Moreover, controlled processing procedure sequence 221 is exported to the number of register 222 Data DO is sent to remote I/O module 3 via CPU transport parts 23, so as to the behaviour of the set device machine 4 within the defined period Make terminal.
Fig. 3 is the sequence diagram to the abnormality detection processing of program 221 is controlled to illustrate.
Control program 221 performs processing repeatedly with the controlling cycle of such as 50ms, 100ms, 200ms etc..
The processing is by making refresh process, the journey of the I/O module of the numerical data unification of remote I/O module 3 and register 222 Sequence operation is formed.The result of the sequential operation of register 222 is stored in the refresh process of the I/O module in next period It is sent to remote I/O module 3.
Produce CPU21, memory 22 abnormal operation, control program 221 program exception in the case of, there are journeys Sequence operation unclosed situation at the appointed time.
The process cycle of 25 supervisory control program 221 of abnormal state detection portion, if the process cycle of control program 221 is more than The defined monitoring time is then determined as CPU exceptions.
More specifically, the supervision timer overflowed in the monitoring time as defined in being arranged in abnormal state detection portion 25, So as to proceed by timer initialization and the starting of timer in control program 221.It is normally acted in control program 221 In the case of, the spilling of supervision timer does not occur.But supervision timer has occurred in the control processing of program 221 delay Spilling in the case of, then be determined as the remarkable action of CPU.
In addition, the refresh process of I/O module is with controlling program to monitor the refreshing of I/O module as the composition independently performed Processing and the process cycle of control program, if the process cycle of any one is more than the defined monitoring time, can also be determined as The remarkable action of CPU.In addition, control program may be multiple.
In addition, the abnormal state detection portion 25 of Fig. 2 can also detect the hard of ROM sums mistake, the bit-errors of memory etc. Part is abnormal, software anomaly by the way that the Exception handling of execution is illegally instructed to detect abnormal, the control program exceptions of OS etc..
The CPU module 2 that abnormality output section 26 will be detected by CPU state signal 6 by abnormal state detection portion 25 Abnormality notify to multiple remote I/O modules 3.Therefore, for CPU state signal 6 it is identical with serial transmission paths 5 make With the differential serial interface of the RS-485 that can carry out multistation connection etc..
Serial transmission paths 5 carry out data transfer at a prescribed interval, but if it is detected that abnormal, CPU state signal 6 is vertical Export the abnormality of CPU module 2.
As above, by separately setting CPU state signal 6 with serial transmission paths 5, so as to CPU module 2 The action of CPU transport parts 23 independently non-synchronously carries out the communication of the abnormality of CPU, therefore can rapidly carry out CPU Abnormal notice.
In addition, as long as CPU state signal 6 can notify CPU exceptions, therefore message capacity can also be less, can Make traffic rate smaller than serial transmission paths 5.Thus, it is possible to improve the data reliability of the transmission of CPU state signal 6.
In addition, abnormality output section 26 can also have CPU state contact, which will be in abnormality The status data that test section 25 detects is converted into the signal of driving CPU state signal 6, and for being exported to outside.At this point, CPU state contact is formed such as by semiconductor relay, electromagnetic relay.If status data is normal for CPU, can also incite somebody to action CPU state contact forms conducting state, if status data is abnormal for CPU, CPU state contact can also be formed to insulation shape State.
At this point, in the case where stopping supplying power supply to CPU module 2, CPU state contact is migrated to state of insulation, therefore Power supply supply stops also being outputted as CPU exceptions.
More specifically, there is the voltage such as AC100V, AC200V, DC24V, DC48V, form conducting state or exhausted The contact specification of edge state makes CPU state signal 6 for such as 2 core cables, so as to not incited somebody to action with being influenced by external noise The presence or absence of abnormality of CPU is reliably exported from CPU module 2 to remote I/O module 3.
Or, it is possible to have the presence or absence of electric current state is formed contact specification by the current source of 4~20mA, normal in CPU In the case of in there is the state of electric current.
Fig. 4 is the figure for the configuration example for representing remote I/O module 3 and equipment machine 4.
Remote I/O module 3 has remote I/O transport part 31, IO input units 36, IO output sections 34, CPU exception controls portion 35, And pass through system bus 33 and be connected with each other.In addition, IO input units 36 connect input cable 7-2 and equipment machine 4 by machine The status contacts 41 of control machine 42 connect, and IO output mechanisms 34 connect output cable 7-1 and equipment machine 4 by machine The operation terminal 40 of control machine 42 connects.
Herein, digital number is represented by the IO input units 36 of the dotted line of Fig. 4 encirclement, IO output sections 34, CPU exception controls portion 35 According to 1 size structure, if the remote I/O module 3 is corresponding with numerical data DI, DO of 16 sizes, become include 16 IO input units 36, IO output sections 34, CPU exception controls portion 35 structure.
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 for example are set as 1 word or 16 DO are set as 1 word Multiple words form.
Remote I/O transport part 31 receives corresponding with the state of status contacts 41 via system bus 33 from IO input units 36 Numerical data DI, and the numerical data for being converted into word is transmitted to CPU module 2.
In addition, the numerical data DO transmitted from CPU module 2 is extracted in remote I/O transport part 31, and total via system is connected to The CPU exception controls portion 35 of line 33 exports numerical data DO to IO output sections 34.
CPU state signal 6 is connected in CPU exception controls portion 35, notifies the normal or abnormal state of CPU module 2. The IO outputs that CPU exception controls portion 35 has for remote I/O module 3, CPU module 2 normal or abnormal state with from Operation is carried out, and operation result is exported to IO output sections 34 between the numerical data DO that remote I/O transport part 31 inputs.
Specifically it is controlled as follows, in the case where notice CPU module 2 is normal state, IO output sections 34 are defeated Go out state corresponding with numerical data DO, in the case where notice CPU module 2 is abnormal state, IO output sections 34 export absolutely Edge state.
IO output sections 34 are connect via machine connection output cable 7-1 with the operation terminal 40 of equipment machine 4, and according to The setting in CPU exception controls portion 35 notifies conducting state or state of insulation to the operation terminal 40 of equipment machine 4.It controls as a result, Control equipment machine 4.
IO input units 36 are connect via machine connection input cable 7-2 with the status contacts 41 of equipment machine 4, so as to take Obtain the conducting state or state of insulation of status contacts 41.Moreover, in the case where status contacts 41 is conducting states, it will be digital Data DI is set as " 1 ", and in the case where status contacts 41 is state of insulations, 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 is the figure for the structure for representing CPU exception controls portion 35.
CPU exception controls portion 35 has the first input circuit 351, the second input circuit 352 and logical operation circuit 353。
First input circuit 351 is connected to the abnormality output section 26 of CPU module 2 via CPU state signal 6, so as to The signal level of CPU state signal 6 is converted into TTL (Transistor TransistorLogic:Transistor-transistor is patrolled Volume) level.For example, being converted into low level in the case where CPU state signal 6 represents the abnormality of CPU module 2, representing High level is converted into the case of the normal condition of CPU module 2.
Second input circuit 352 is connected to system bus 33, the numerical data so as to be received by remote I/O transport part 31 DO is converted into Transistor-Transistor Logic level.It is " 1 " in numerical data DO for example, being converted into low level in the case where numerical data DO is " 0 " In the case of be converted into high level.
Logical operation circuit 353 is the logic circuit being for example made of TTL, and is performed from 351 He of the first input circuit The logical operation of the signal of second input circuit 352, so as to export control output signal.Output signal is controlled when logic is set up It is low level when logic is invalid for high level.
The logical operation circuit 353 of embodiment has AND gate circuit, as next, output control output signal.
In the case where CPU state signal 6 represents the normal condition of CPU module 2 and numerical data DO is " 1 ", first Input circuit 351 is output into high level, and the output of the second input circuit 352 also becomes high level, logical operation circuit 353 It is logic product as a result, the high level output output signal in order to control that logic is set up.
In the case where CPU state signal 6 represents the normal condition of CPU module 2 and numerical data DO is " 0 ", first Input circuit 351 is output into high level, and the second input circuit 352 is output into low level, logical operation circuit 353 Logic product as a result, by the invalid low level output of logic output signal in order to control.
In the case where CPU state signal 6 represents the abnormality of CPU module 2, though numerical data DO for " 1 " or Any one of " 0 ", logical operation circuit 353 it is logic product as a result, also that the invalid low level output of logic is defeated in order to control Go out signal.
Fig. 6 is the figure of the structure for the IO output sections 34 for representing remote I/O module 3.
IO output sections 34 are made of relay circuit 341 and leading-out terminal 342.
Relay circuit 341 is formed such as by semiconductor relay, electromagnetic relay, according to CPU exception controls portion 35 Control output signal, carry out the break-make of the circuit of outlet side.If for example, control output signal become high level, connect after Electric appliance if in addition control output signal becomes low level, disconnects relay.
Leading-out terminal 342 by machine connect output cable 7-1 connect with the operation terminal 40 of equipment machine 4, by after Appliance circuit 341 makes operation terminal 40 in the conduction state or state of insulation.
Fig. 7 is the figure of an example of the sequence diagram for representing CPU exception controls portion 35, and shows CPU state signal, number Digital data DO and the relationship for controlling output signal.
In the case where CPU state signal 6 represents normal condition, if numerical data DO is " 1 ", control output signal defeated Go out high level, if numerical data DO is " 0 ", output signal is controlled to export low level.Output and the value of numerical data DO as a result, Corresponding control output signal controls the operation terminal 40 of equipment machine 4 for conducting state or state of insulation.
On the other hand, in the case where CPU state signal represents abnormality, no matter numerical data DO is " 1 " or " 0 ", Control output signal exports low level.Therefore, in the case where CPU state signal represents abnormality, by equipment machine 4 The control of operation terminal 40 is state of insulation.
As described above, be illustrated with the structure corresponding with 1 point of numerical data DO of CPU exception controls portion 35, but In the case of the structure corresponding with 16 points of numerical data DO of remote I/O module 3, then become the second input electricity for having 16 Fig. 5 Road 352 has the AND gate circuit of 16 AND gate circuits 353, so as to export the knot of 16 control output signals from AND gate circuit 353 Structure.If moreover, notifying the abnormality of CPU module 2 by CPU state signal 6, all 16 IO output sections 34 are by connection The control of operation terminal 40 for controlling machine 4 is state of insulation.
As shown in Figure 1, in the case where controller 1 has multiple remote I/O modules 3, CPU state signal 6 is by daisy chain type Multiple remote I/O modules 3 are connected to, therefore the abnormality of CPU module 2 is notified to all remote I/O modules 3.Each In remote I/O module 3, above-mentioned processing is carried out, the operation terminal 40 of the control machine 4 of connection is controlled as state of insulation.By This, is capable of all equipment machines of the control object of stop control 1.
Embodiment 2
Fig. 8 is the figure for the other structures for representing remote I/O module 3.
Remote I/O module 3 has remote I/O transport part 31, transmission abnormality control unit 32, for each equipment machine connected Multiple IO input units 36 of the setting of device 4, IO output sections 34, CPU exception controls portion 35, and pass through system bus 33 and be connected with each other. It is connect in addition, IO input units 36 connect input cable 7-2 by machine with the status contacts 41 of equipment machine 4, IO output sections 34 Output cable 7-1 is connected by machine to connect with the operation terminal 40 of equipment machine 4.
The remote I/O module 3 of remote I/O module 3 shown in Fig. 4 and the present embodiment has a case that transmission abnormality control unit 32 Difference, hereinafter, illustrating centered on difference.
Transmission abnormality control unit 32 monitors connection remote I/O module 3 via remote I/O transport part 31 in each control cycle With the transmission state of the serial transmission paths 5 of CPU module 2, when detecting transmission abnormality, remote I/O transport part 31 is controlled, and Become more regular changed number data DO according to preset.
Herein, by the transmission abnormality that transmission abnormality control unit 32 detects by the broken string of cable break etc., be used as and advising Do not terminate the error detections such as crc error, the parity error of numerical data of time-out detection, transmission of the state of transmitting-receiving in fixing time To be judged.
When transmission abnormality control unit 32 detects transmission abnormality in each control cycle, the change of changed number data DO More regular is, for example, to be rewritten into DO " 0 " (zero), and (holding) is maintained to detect abnormal preceding numerical data DO etc..
The more regular position that can be directed to each numerical data DO of the change, in other words, for the equipment of each control object Machine 4 and set.Therefore, in the remote I/O module connected in the equipment machine 4 with multiple operation terminals, for every number Digital data DO carries out instruction setting by CPU module 2 to becoming more regular.
The numerical data DO changed by remote I/O transport part 31 in transmission abnormality is sent to CPU exception controls Portion 35.
In CPU exception controls portion 35, as described above, according to the Status Change numerical data DO of CPU state signal 6, to The output of IO output sections 34 control output signal.The control output signal is converted into conducting state or insulation shape in IO output sections 34 State, and notify to the operation terminal 40 of equipment machine 4.
Fig. 9 is the figure of an example of the sequence diagram for the numerical data DO for representing to export from remote I/O transport part 31.According to The change of numerical data when the presence or absence of numerical data DO, transmission abnormality from the input of CPU module 2, transmission abnormality is more regular, shows The relationship of the output in CPU exception controls portion 35.
In the case where not detecting the transmission abnormality of transmission cable 5 by transmission abnormality control unit 32, no matter numerical data The more regular setting of change of DO is how, do not change numerical data DO from remote I/O transport part 31 to CPU exception controls portion 35 and It outputs it, if abnormal there is no CPU, exports with keeping intact.
On the other hand, in the case where detecting transmission abnormality, to CPU exception controls portion 35 export numerical data DO because The more regular setting of change of numerical data DO and it is different.If rule is keeps setting, numerical data DO is altered to detect to pass The preceding value of defeated exception (being in fig.9 " 1 ") simultaneously exports.If rule is zero, numerical data DO is altered to " 0 " and exports.And And if abnormal there is no CPU, export the numerical data DO being changed.
As above, for each equipment machine 4, the change of setting numerical data DO is more regular, so as to according to equipment machine 4 Significance level change corresponding method when mistake occurs, therefore can realize the raising of the reliability of system.
Figure 10 is the flow chart in the case that the action to remote I/O module 3 is handled into line program.The flow of Figure 10 is more It is acted respectively in a remote I/O module 3.
First, it is determined that whether have received the numerical data DO (S901) of this remote I/O module 3.If it is not sent from CPU module 2 The numerical data DO of this remote I/O module 3, then etc. (S901's is no) to be received.
In the case where having received above-mentioned numerical data DO (S901's be), the presence or absence of transmission abnormality when judgement receives (S902).Specifically, the judgement of transmission abnormality is carried out by odd-even check, CRC code, sum inspection etc..
In the case of there is no exception (S902's is no), the transmission of numerical data DO is normally carried out, after carrying out The transmission abnormality stated handles and temporarily preserves received DO (S909), into S906.
In the case of there are transmission abnormality (S902's be), the change of numerical data DO is carried out as next.
First, it is determined that the type (S903) of set modification rule, if " zero " (" zero " of S903), then by number Digital data DO is rewritten into zero (S904), into S906.
If being " holding " (" holding " of S903) in S903, numerical data DO is rewritten into S909 and is temporarily preserved The value (S905) of the DO of preceding normal transmission.In other words, after being rewritten into and detecting abnormal preceding value, into S906.
In S906, determine whether to detect the notice of CPU exceptions from CPU module 2.In the situation for detecting CPU exceptions Under (S906's be), numerical data DO is unconditionally rewritten into zero (S907), into S908.
In the case of the notice of CPU exceptions is not detected in S906 (S906's is no), into S908.
In S908, IO output sections 34 set numerical data D0, according to the value of numerical data DO export conducting state or Person's state of insulation.
By above-mentioned flow, detect that transmission abnormality and the abnormal operation of CPU module 2 occur in serial transmission paths 5, Changed number data DO, therefore the exception control of controller 1 can be prevented.
In addition, in order to promptly carry out the abnormal countermeasure of CPU module 2, and non-synchronously carried out with the process flow of Figure 10 Processing when being abnormal of CPU module.
Figure 11 is the non-flow chart of CPU abnormality processings being synchronously carried out.
The processing of Figure 11 is started by the reception data outage of CPU state signal 6, and it is excellent preferably to improve interruption as much as possible First grade.
In addition, the process content of S906, S907, S908 of Figure 11 is identical with Figure 10, therefore omit the description herein.
Embodiment 3
Next, utilize specific more regular to the change of the numerical data DO that is handled by transmission abnormality control unit 32 of Figure 12 Example illustrates.
Figure 12 is to represent to smoke the water that stockpiles of pump sump 8, and controls as target flow and flowed out from piping 9 as outflow water The figure of one example of water conveying factory.
Water conveys factory and is made of motor-driven valve 42b, the flowmeter 42c of pump sump 8, piping 9, constant speed pump 42a, adjusting flow. Moreover, flow measurement, the quilt in a manner of becoming constant flow rate are carried out by flowmeter 42c by the outflow water that constant speed pump 42a is discharged Motor-driven valve 42b is controlled.
The water convey factory by machine connecting cable 7a, 7d, 7e, 7g by the equipment machine 4a comprising constant speed pump 42a, packet Equipment machine 4d, the equipment machine 4g comprising flowmeter 42c of the 42b containing motor-driven valve be connected to remote I/O module 3a, 3b, 3c, and pass through CPU module 2 and carry out flow control.Remote I/O module 3a, 3b, 3c are believed by serial transmission paths 5 and CPU state Number 6 daisy chain types are connected to CPU module 2.
Next the function of equipment machine 4a, 4d, 4g are illustrated.
The constant speed pump 42a of equipment machine 4a is the specification of invariablenes turning speed, discharges constant flow rate in the running, row during stopping Outflow is zero.Equipment machine 4a has operation terminal 40a, by the way that operation terminal 40a is made to be in electric conducting state, so as to continue If pump operating in state of insulation, stops pump operating.
The motor-driven valve 42b of equipment machine 4d by the forward and reverse of motor come regulating valve start work with close action, from And control the delivery flow from constant speed pump 42a.Valve opening is for example in the range of the 0~100% of fully closed 0%, standard-sized sheet 100% It is acted.The work that starts for being set by control valve of the valve opening is carried out with closing the actuation time of action.
If it specifically, starts work, close the speed that action forms valve opening 5% for example in 1 second, under full-shut position If holding starts work 20 seconds, reach standard-sized sheet and stop starting work.On the contrary, under full-gear, if keeping closing action in 20 seconds, As full-shut position, so as to stop closing action.
Equipment machine 4d has operation terminal 40b (starting work) and operation terminal 40c (closing action), by making operation terminal 40b, 40c are in electric conducting state, so as to persistently start work or close action, if in state of insulation, make to start make or Action is closed to stop.
The valve opening of the motor-driven valve 42b of equipment machine 4d is in by adjusting making operation terminal 40b or operation terminal 40c The time of conducting state, and can control as the aperture as target.
The outflow flow of the flowmeter 42c measurement outflow waters of equipment machine 4g.
The flow value measured is converted into the current signal of 4~20mA by the simulation output terminal 43 of equipment machine 4g, and Output.
In CPU module 2, the outflow flow of simulation output terminal 43 is obtained as simulation input via remote I/O module 3c Data AI performs the operating of control constant speed pump 42a and stopping, control in a manner that simulation input data AI becomes target flow Motor-driven valve 42b's starts the control program made with closing action.
Constant speed pump 42a is by controlling program that the action instruction for operating or stopping is recorded in numerical data DO, via remote Journey I/O module 3a is set in the operation terminal 40a of equipment machine 4a, so as to indicate to operate or stop.
Motor-driven valve 42b makees to be recorded in numerical data DO with the action instruction for closing action by controlling program that will start, via Remote I/O module 3b is set in operation terminal 40b, 40c of equipment machine 4d, so as to set valve opening.
As described above, remote I/O module 3a, 3b detection transfer the transmission abnormality of the serial transmission paths 5 of numerical data DO, And become more regular changed number data DO based on defined.
In the present embodiment, when detecting transmission abnormality, for constant speed pump 42a and motor-driven valve 42b, in next change More regular middle changed number data DO.
In remote I/O module 3a, the control before the numerical data DO for indicating the action of constant speed pump 42a is remained is formed The change of the setting state in period processed is more regular.In other words, operating or the halted state of current constant speed pump 42a is maintained.
In remote I/O module 3b, formed and starting for instruction motor-driven valve 42b is made to carry out with the numerical data DO for closing action The change of zero setting (without starting work or closing action) is more regular.In other words, make the valve of motor-driven valve 42b start work, It closes action to stop and fix valve opening, so as to maintain current flow.
As described above when the transmission abnormality of the constant speed pump 42a and motor-driven valve 42b of the water conveying factory of setting the present embodiment Numerical data DO change it is more regular, so as to not make to detect that the conveying of the water of the controlling cycle of transmission abnormality stops, in addition extensive Again into the case of transmitting normally, it can easily restart to control.
Above-mentioned change is more regular to be not limited to this, is suitably determined with specification when can be according to transmission abnormality.
However, in the controller 1 of the water conveying factory of the present embodiment shown in Figure 12, by CPU state signal 6, from CPU module 2 is abnormal to remote I/O module 3a, 3b, 3c notice CPU.
Numerical data DO is set as " 0 " by remote I/O module 3a, 3b, 3c that CPU exceptions are notified of by CPU state signal 6, will Operation terminal 40a, 40b, 40c are set as state of insulation.In other words, constant speed pump 42a stops pump operating, and motor-driven valve 42b makes It starts work or closes action and stop, therefore the outflow of outflow water stops.
In the case where detecting CPU exceptions, exist until time taking situation is spent in the recovery of controller.Therefore, in order to The outflow of outflow water is carried out, acts can preferably manually in advance constant speed pump 42a and motor-driven valve 42b.
Thus, for example switching device is set in the machine connecting cable 7a of the operation terminal 4a of constant speed pump 42a, so as to Select the signal from remote I/O module 3a and the signal from hand-operating device.
When constant speed pump 42a stops due to CPU is abnormal, by switching device, it is switched to the operating side of connection constant speed pump 42a Sub- 4a and hand-operating device.Moreover, by hand-operating device, the operation terminal 4a for making constant speed pump 42a is in the conduction state, So as to carry out pump operating.
As described above, according to the present embodiment, controller 1 is if it is detected that the cause of exception of CPU module 2 etc The state of life then makes machine connection output cable 7-1 be reliably fitted in state of insulation, so as to make all equipment machines Action stop, therefore the malfunction of factory can be prevented.
In addition, according to the present embodiment, by not using the mechanism of high-performance CPU etc. in remote I/O module and simple to install Logic circuit and only be laid with notice CPU module state signal cable, can make the operating of factory can in CPU exceptions Stop by ground, therefore there is the effect that safety can be improved with low cost.
In addition, if CPU module 2 is normal, in the transmission abnormality for detecting serial transmission paths 5, can select to set The continuation or stopping of the fixed output for control machine, even if therefore with also can neatly coping with control when being abnormal The significance level of subject machine processed and the effect with policy.
In addition, only make all of connection in the case where detecting the specific great abnormal key factor such as CPU exceptions Control the operation of a machine stop, therefore the operating utilization rate that automatically controls improves, so as to expect that operator's is manual The reduction of the burden of operating.
Controller according to the present invention is not limited to above-mentioned embodiment, can not depart from the purport of the present invention In the range of be suitably deformed.Hereinafter, enumerate other embodiments of controller according to the present invention.
It in the above-described embodiment, can also although forming the structure that remote I/O module 3 has 1 point DI, 1 point DO The structure for having multiple DI, multiple DO is formed, alternatively, it is also possible to form the structure for having multiple AI, AO, PI.
In addition, in the above-described embodiment, although status contacts, operation terminal, CPU state contact is made to be a contacts, Can also be b contacts, c contacts.
In addition, the controller 1 involved by above-mentioned embodiment can also apply to electric power, gas, traffic, reservoir etc. The controller of the industrial systems such as controller, iron steel, chemistry, food, the logistics of social base construction system.
Moreover, it is achieved that the information such as the program of each function, data are in addition to being stored in RAM (Random Access Memory:With Machine accesses memory) other than, additionally it is possible to it is stored in SSD (Solid State Drive:Solid state disk) etc. recording devices, IC (Integrated Circuit:Integrated circuit) block, SD (Secure Digital:Secure digital) block, DVD (Digital Versatile Disc:Digital versatile disc) etc. recording mediums.
In addition, the structure in each portion involved by above-mentioned embodiment, function, CPU, memory, system bus also can All or part in them is realized by the hardware with IC design.
In addition, in the attached drawing illustrated to embodiment, it is necessary control to illustrate only from the aspect of explanation Line, information wire need not necessarily be limited to show all control lines, information wire in terms of product.In fact, it is also contemplated that it is big All structures is caused to be connected to each other.

Claims (10)

1. a kind of controller controls the equipment machine of factory, above controller is characterized in that, is had:
CPU module, the abnormal state detection portion of the abnormal operation with detection module, and to the multiple equipment machine of above-mentioned factory Device is controlled into line program;And
Multiple remote I/O modules, they are connected to above-mentioned CPU module by serial transmission paths daisy chain type, and convert from above-mentioned CPU module transmission numerical data and to above-mentioned equipment machine export,
It is different to above-mentioned remote I/O module notice CPU when above-mentioned CPU module detects abnormal operation in above-mentioned abnormal state detection portion Often,
Above-mentioned remote I/O module differently makes to own when being notified above-mentioned CPU exceptions, with the control based on above-mentioned numerical data Above equipment machine is in halted state,
Above-mentioned remote I/O module has transmission abnormality control unit, which detects the biography of above-mentioned serial transmission paths Defeated exception and changed number data,
Above-mentioned transmission abnormality control unit is when detecting transmission abnormality, for each of the multiple equipment machine connected, base Become more regular changed number data in defined.
2. controller according to claim 1, which is characterized in that
Above-mentioned CPU is abnormal by the daisy chain type connection above-mentioned CPU module different from above-mentioned serial transmission paths and above-mentioned long-range The signal cable of I/O module and notified from above-mentioned CPU module to above-mentioned remote I/O module.
3. controller according to claim 1, which is characterized in that
The abnormal logic products with above-mentioned numerical data of above-mentioned CPU are obtained in above-mentioned remote I/O module, and are exported to above-mentioned equipment machine The operation result of logic product.
4. controller according to claim 1, which is characterized in that
It is that numerical data is rewritten into the digital number before " 0 " is zeroed or maintains to detect transmission abnormality that above-mentioned change is more regular According to i.e. holding.
5. a kind of controller, multiple remote I/O modules of the multiple equipment machine with CPU module and control factory, above-mentioned control Device processed is characterized in that,
Above-mentioned CPU module is connected with above-mentioned remote I/O module by serial transmission paths and CPU state signal,
The serial transmission paths daisy chain type connects above-mentioned CPU module and above-mentioned remote I/O module and transmits control information,
The CPU state signal daisy chain type connects above-mentioned CPU module with above-mentioned remote I/O module and from above-mentioned CPU module to above-mentioned Remote I/O module transmission CPU is abnormal,
Above-mentioned remote I/O module has transmission abnormality control unit, which detects the biography of above-mentioned serial transmission paths Defeated exception and changed number data,
Above-mentioned transmission abnormality control unit is when detecting transmission abnormality, for each of the multiple equipment machine connected, base Become more regular changed number data in defined.
6. controller according to claim 5, which is characterized in that
Above-mentioned serial transmission paths periodically transmit control information,
Above-mentioned CPU state signal non-synchronously transmits CPU state information with above-mentioned serial transmission paths.
7. controller according to claim 6, which is characterized in that
The data volume of above-mentioned CPU state information is fewer than the control information that above-mentioned serial transmission paths are transmitted.
8. a kind of control method, is the control method of controller, which has at least the one of CPU module and control factory Multiple remote I/O modules of a equipment machine simultaneously control the multiple equipment machine of factory, and the feature of above-mentioned control method exists In having:
Detect the abnormal operation of CPU module that control into line program the multiple equipment machine of above-mentioned factory and in CPU state letter Number output represent abnormality signal the step of;
Numerical data DO with being notified from CPU module accordingly sets the above-mentioned of the above-mentioned respective operation terminal of multiple equipment machine According to the signal of the expression abnormality of above-mentioned CPU state signal, all aforesaid operations terminals are set as remote I/O module The step of defined state;And
Above-mentioned remote I/O module monitors the serial of the above-mentioned CPU module of connection and above-mentioned remote I/O module in defined controlling cycle Transmission path when detecting transmission abnormality, becomes the more regular numerical data for changing and being notified from above-mentioned CPU module according to regulation DO and the step of be set in aforesaid operations terminal.
9. control method according to claim 8, which is characterized in that
Above-mentioned remote I/O module and the numerical data DO from above-mentioned CPU module accordingly set aforesaid operations terminal opportunity and The opportunity of aforesaid operations terminal difference is set according to the signal of the expression abnormality of above-mentioned CPU state signal.
10. control method according to claim 8, which is characterized in that
With the change according to regulation is more regular changes the numerical data DO notified from above-mentioned CPU module and be set in aforesaid operations end Son step compare, above-mentioned remote I/O module priority processing according to the signal of the expression abnormality of above-mentioned CPU state signal come The step of setting aforesaid operations terminal.
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