JP2005010915A - Simulator of parallel type controller and parallel type controller system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a parallel type controller for performing the simulation of a control system without changing the control program of a controller and the simulator of the system. <P>SOLUTION: This parallel type controller system is constituted of a parallel type controller 2A having a shared memory constituted of controllers 2m1 and 2m2 connected through a system bus 2mb, an I/O input and output device 2mi and a network module 2mn and a monitor control station 4 and I/O simulator station 3 connected through a network 3mb to the network module 2mn. This system is also provided with a means which sets simulation performance/non-performance flags from the I/O simulator station 3 in each of the simulation program of an object 1 to be controlled and the input/output data of the I/O input and output device 2mi. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to various control systems, and relates to a parallel controller that controls input / output of a controlled object and a simulator of a parallel controller system.
[0002]
[Prior art]
Conventional control systems of various plant facilities are mainly a distributed control system (DCS) based on a microprocessor and are generally used in various processes. This DCS system is intended for comprehensive centralized control of the process to be controlled, and the scale of the system varies from a large scale to a small scale.
[0003]
A controller (hereinafter referred to as a controller) for controlling each control element of the plant, which is the core of the DCS system, is provided by a DCS manufacturer.
[0004]
In recent years, efficient parallel controllers in which a plurality of controllers are connected via a transmission line such as a general-purpose bus have begun to spread as medium-scale plant controllers, and control systems using this parallel controller are known (for example, patents). Reference 1).
[0005]
This Patent Document 1 describes a method of cooperative control when a plurality of controllers are used.
[0006]
Further, there is a description of an improvement proposal for efficiently using an I / O input / output control device that transmits an input / output signal to be controlled by the parallel controller (see, for example, Patent Document 2).
[0007]
In addition, in order to verify the monitoring functions such as controllability and safety of such a control system, verification tests are performed by various simulations at the manufacturing factory that manufactures the control system before moving it in the actual plant. Final adjustments and tests are performed in the process that is the controlled object used in the operation.
[0008]
Here, a conventional verification method performed in a manufacturing factory will be described with reference to FIGS. FIG. 9 is a block diagram illustrating a control model of the control system.
[0009]
In FIG. 9 (a), the controlled object process 11a controls its operation part (for example, a valve) 11b by the operation amount MV which is the output of the controller 12, and the process quantity which is the controlled quantity of the controlled object process 11a. The PV is detected by the detection unit 11c and fed back to the controller 12 as a measurement value of the controlled process 11a.
[0010]
The controller 12 sets the target value SV in the setting unit 12a so that the process amount PV becomes a predetermined value, and the adjustment unit 12b so that the deviation between the target value SV and the process amount PV is controlled within a predetermined range. The optimal control is performed by adjusting the parameters.
[0011]
Such a control system is subjected to a control and safety verification test in advance at the shipping stage of the control system manufacturing factory before the test adjustment performed in the actual process. In this verification test, a method (simulation) is generally performed for modeling and verifying the controlled object 11 including the controlled object process 11a described above.
[0012]
As shown in FIG. 9B, the control system corresponding to the model diagram of FIG. 9A shows the controller 12, the operation amount MV to the controlled object 11 and the signal of the process amount PV from the controlled object 11. It comprises an I / O input / output device 12i that performs signal conversion for taking in the controller 12.
[0013]
Conventionally, as a method of simulating the controlled object 11 of such a control system, a method of simulating a control calculation inside the controller 12 has been mainly used, and process data (process amount PV, operation amount) used in the control calculation is mainly used. For the amount MV), a method of looping back process data inside the controller 12 without using the I / O input / output device 12i has been adopted.
[0014]
As a process data loopback method, as shown in FIG. 10 (a), the operation amount MV is simply turned back as the process amount PV (simple loopback method), and as shown in FIG. 10 (b), There is a method (program loopback) that defines the relationship between the operation amount MV and the process amount PV and incorporates it as one of the programs of the controller 12. In addition, as shown in FIG. 10C, a method of simulating all the control systems including the controller on the computer 10 is known.
[0015]
[Patent Document 1]
Japanese Patent Laid-Open No. 2001-117607
[Patent Document 2]
Japanese Patent Laid-Open No. 2002-82896
[Problems to be solved by the invention]
The simulation by the conventional simple loopback method is a method in which the input / output value of the process to be controlled is set as “process change amount = process operation amount”, and linear processes with limited input / output characteristics or on / off control It could only be used for simulation of the process.
[0018]
In addition, in the case of the program loopback method in which the input / output characteristics of the controlled object are defined and installed and simulated as a program on the controller, the input / output characteristics of the controlled object can be flexibly defined by the program. It was.
[0019]
However, since a new program that will not be run during actual operation is installed in the controller and simulation is executed, it affects the performance of controllability such as responsiveness, and it cannot be evaluated with an actual control system. There's a problem.
[0020]
On the other hand, recently, attempts have been made to simulate the operation of a controller on a computer, but this also does not include an I / O input / output device used in an actual control system.
[0021]
Examples of practical use include a sequence control system using a PLC (programmable controller) or the like, which is also a simulation of limited input / output characteristics.
[0022]
In general, a simulation on a computer and a simulation inside a controller are useful in the design and debugging stages of a process control system.
[0023]
However, at the verification stage of the control system, the controller is operated in a state close to the actual process movement, and the dynamic characteristics of the system including the I / O input / output device are simulated to ensure controllability and safety in advance. It is desirable that it can be verified.
[0024]
The present invention has been made to solve the above-described problems. In a control system configured with a parallel controller, an I / O input / output device can be used without changing the configuration of the control system or the control program of the controller. An object of the present invention is to provide a parallel controller and a system simulator capable of simulating a control system under setting conditions that are actually used by executing programmed input / output data.
[0025]
[Means for Solving the Problems]
To achieve the above object, a parallel controller and parallel controller system simulator according to the present invention is a control system simulator using a controller, and includes a plurality of controllers, I / O input / output means having a shared memory, A parallel controller in which the network module is connected by a bus; a simulator means and a monitoring control means connected by the network module to the network; and a controlled object connected to the I / O input / output means of the parallel controller. The simulator means writes first input / output data having a simulation execution or non-execution flag to the shared memory of the I / O input / output means via the network module,
The I / O input / output means outputs second input / output data from the controlled object based on the simulation execution or non-execution flag attached to the first input / output data written in the shared memory. And the first input / output data written in the shared memory are exchanged and updated, and the simulator means sends the controlled object to the shared memory of the I / O input / output means via the network module. A simulation program for simulating the fluctuation of the second input / output data is written, and the parallel controller executes a simulation of the system by executing the simulation program.
[0026]
Therefore, in a control system composed of parallel type controllers, it is actually used by executing the input / output data programmed in the I / O input / output device without changing the system configuration or the controller control program. It is possible to provide a parallel type controller and a parallel type controller system simulator capable of simulating a control system under the set conditions.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments according to the present invention will be described below with reference to FIGS.
[0028]
FIG. 1 is a configuration diagram showing an embodiment of a control system having a parallel controller of the present invention. In FIG. 1, reference numeral 1 denotes an operation end of a valve or the like that controls the controlled process 1a as a controlled target (output terminal when viewed from the controller) 13, a process amount sensor of the controlled process 1a, and the like. The detection end (when viewed from the controller, it becomes an input end) 14 and the like.
[0029]
The controlled object 1 includes a parallel controller 2A, an I / O simulator station 3 connected to the network module 2mn of the parallel controller 2A via a network 3mb such as a LAN, and a monitoring control station 4.
[0030]
The function of each part of the control system composed of these is as follows. The parallel controller 2A is a device that performs a control calculation of the controlled object 1. In this figure, the parallel controller 2A is configured to be cooperatively controlled by two controllers 2m1 and 2m2. The parallel controller 2A includes controllers 2m1 and 2m2, a network module 2mn, and an I / O input / output device 2mi, which are coupled to each other via a system bus 2mb and controlled via a system bus control circuit described later. Has been.
[0031]
The transmission control circuit 2mt provided in the I / O input / output device 2mi of the parallel controller 2A is connected to the output terminal 13 and the input terminal 14 of the controlled object 1. Furthermore, the network module 2mn is connected to the network 3mb.
[0032]
The I / O input / output simulator station 3 is a device for setting and operating a simulation program including a control model of input / output data of the controlled object 1.
[0033]
The monitoring control station 4 is an apparatus in which an operator of a control system (parallel controller system) using the parallel controller 2A monitors and operates the controlled object 1.
[0034]
As described in the description of the prior art, this configuration is used for any of the simple loopback method (FIG. 10A), the loopback method (FIG. 10B), and the computer simulation (FIG. 10C). A different program for simulating the controlled object 1 shown in FIG. 2 is provided on the I / O input / output device 2mi provided outside the controllers 2m1 and 2m2, and this is installed on the controllers 2m1 and 2m2. The configuration is such that the controllability and safety of this system can be verified without changing the control program of the control system.
[0035]
Based on the concept of such a configuration, the hardware of the parallel controller 2A shown in FIG. 3 is configured. The detailed configuration of the parallel controller 2A will be described below with reference to FIG.
[0036]
The parallel controller 2A includes a plurality of controllers 2m1 and 2m2 connected to a system bus 2mb, a network module 2mn which is an external interface, and an I / O input / output device 2mi.
[0037]
The controllers 2m1 and 2m2 include a CPU 2c, a ROM 2ro, a RAM 2ra, an interface 2if, a system bus control circuit unit 2s, and an internal bus 2ib for connecting them to each other. It has.
[0038]
The ROM 2ro contains a program, and the CPU 2c executes this program. The RAM 2ra stores various data handled by the program.
[0039]
The system bus control circuit unit 2s includes a system bus control circuit 2sb and a shared memory 2sm. The system bus control circuit 2sb connects the system bus 2mb and the internal bus 2ib.
[0040]
The program installed in the CPU 2c includes an operating system that executes a predetermined management function of the parallel controller 2A including cooperative control executed by the two controllers 2m1 and 2m2, and a control system function that the parallel controller 2A performs. An application program to be executed is provided.
[0041]
Next, the I / O input / output device 2mi is configured by a CPU 2c similar to the controllers 2m1 and 2m2, but the external interface includes a transmission control circuit 2mt for performing input / output with the controlled object 1, and this transmission control. The controller 2m1 and 2m2 are different in that the circuit 2mt is connected to the internal bus 2ib of the I / O input / output device 2mi and the shared memory 2sm. The external interface 2if performs data input / output control with the key switch 2k and the like for setting the mode of the control system.
[0042]
Similarly, the network module 2mn is also configured by a CPU 2c similar to the controllers 2m1 and 2m2, but the external interface includes a network control circuit 2mm, and the I / O simulator station 3 and the monitoring control station 4 via the network 3mb. Is different from the controllers 2m1 and 2m2.
[0043]
The data in the shared memory 2sm of the I / O input / output device 2mi can be written and read from the controllers 2m1 and 2m2 via the system bus 2mb, and this control is executed by the system bus control circuit 2sb.
[0044]
Next, the operation of the parallel controller system by the parallel controller 2A configured as described above will be described.
[0045]
First, input / output data processing operations from the I / O input / output device 2mi will be described with reference to FIGS. FIG. 4 is a diagram showing the flow of input / output data handled by the shared memory 2sm of the I / O input / output device 2mi.
[0046]
The input data “DI21, DI22, DI23” from the input terminal 14 of the controlled object 1 and the output data “DO24” of the output terminal 13 are mapped on the shared memory 2sm, and the network module 2mn is connected to the I / O simulator station 3. The input value and output value are displayed via the network 3mb.
[0047]
The broken lines shown in FIG. 4 indicate that the display of the input value and the output value at this time in the I / O simulator station 3 and the monitoring station 4 correspond to each other.
[0048]
The monitoring control station 4 displays the input value and output value at this time via the controllers 2m1, 2m2, the network module 2mn, and the network 3mb.
[0049]
In addition, in the figure, “DI21” and “DI22” are input to the controller 2m1, and “DI23” and “DO24” are input to the controller 2m2 via the system bus 2mb, respectively. Is done.
[0050]
This actual data is, for example, input / output data of the output end 13 such as a valve and input data of the input end 14 such as a temperature sensor.
[0051]
Next, input / output data control by the I / O input / output device 2mi will be described with reference to FIG. FIG. 5 shows actual input and simulation data of the input terminal DI21, and actual output and simulation data of the output terminal DO24.
[0052]
The input / output data mapped to the shared memory 2sm is transmitted to the transmission control circuit 2mt without intervention of the CPU 2c of the I / O input / output device 2mi by a “simulation execution / non-execution” flag to be described later attached to each input / output data. It is selected by its own judgment.
[0053]
The flag “simulation execution / non-execution” accompanying this input / output data is set from the I / O simulator station 3 via the network 3mb and the network module 2mn.
[0054]
That is, if the input / output data set in the I / O simulator station 3, for example, “DI21” and “DO24” are not accompanied by a simulation execution flag, the transmission control circuit 2mt does not involve the I / O input / output device 2mi. The data in the shared memory 2sm is exchanged for actual input / output data.
[0055]
However, if a simulation execution flag is attached to the input / output data “DI21” and “DO24”, the transmission control circuit 2mt does not exchange the data in the shared memory 2sm with the actual input / output data, and uses it as simulation data.
[0056]
The flow of input / output data controlled in this way is shown in FIG. In FIG. 6, it is assumed that a “simulation” request S11 is made from the I / O simulator station 3 to the network module 2mn via the network 3mb.
[0057]
Then, the network module 2mn transmits this request to the I / O input / output device 2mi via the system bus 2mb of the parallel controller 2A. Then, the transmission control circuit 2mt selects the input / output data to be written by the “simulation execution / non-execution” flag of the input / output data mapped from the I / O simulator station 3 to the shared memory 2sm.
[0058]
The original data in the shared memory 2sm at this time is transmitted to a predetermined controller 2m1 or 2m2 via the system bus control circuit 2s and the system bus 2mb.
[0059]
In this way, the simulation data is set in the input / output data, and the input / output data replaced with the shared memory 2sm is used as an input value during the simulation of the controller 2m1 or 2m2.
[0060]
Next, the installation operation of the simulation program for the controlled object 1 that executes the controllability evaluation using the simulation data set in this way and the safety evaluation such as the monitoring function will be described with reference to FIG. To do.
[0061]
The simulation program “SP30” for the controlled object 1 is constructed by the I / O simulator station 3, and the RAM 2ra of the I / O input / output device 2mi via the network 3mb, the network module 2mn, and the system bus control circuit unit 2s. To be downloaded.
[0062]
Since the simulation program “SP30” can define the characteristics of the process amount (input) and the operation amount (output) of the controlled object 1, it is possible to set various changes of the actual process unlike the loopback described above.
[0063]
After the simulation program “SP30” in which one model characteristic of the controlled object is defined is installed, the control programs of the controllers 2m1 and 2m2 are executed.
[0064]
Therefore, the controller 2m1, 2m2 reads the output data (operation amount) in the shared memory 2sm of the I / O input / output device 2mi, and the data (process amount) calculated from the output data by the simulation program is stored in the shared memory 2sm. Written as input data. Then, the controllers 2m1 and 2m2 read this input data and execute an operation according to the control program.
[0065]
Also, alarm information based on self-diagnosis of the devices at the output end 13 and the input end 14 of the controlled object 1 is attached to the input / output data of the I / O input / output device 2mi as data, and this data is also written to the shared memory 2sm. If this is the case, the controllers 2m1 and 2m2 can verify the abnormal processing of the control system based on the alarm information by executing the control program.
[0066]
In other words, by approximating the simulation program to the actual controlled object 1, it is possible to verify the controllability with high accuracy and further the safety of the system without changing the control program of the controllers 2m1 and 2m2. It becomes.
[0067]
A simulation method using the parallel controller system configured as described above will be described with reference to FIG.
[0068]
For example, the parallel controller system shown in FIG. 1 is turned on to start the system (step S31).
[0069]
Then, each part constituting this control system performs initialization processing when the power is turned on, and the parallel controller 2A reads the state of the key switch 2k via the I / O input / output device 2mi (step S32). System mode determination is performed (step S33).
[0070]
As a result, when the simulation mode is selected, this system can be simulated, and a simulation program can be selected from the I / O simulator station 3.
[0071]
For example, when a certain kind of simulation program “A001” of the program “SP30” for evaluating the controllability is selected and input here, this program “A001” is sent from the I / O simulator station 3 via the network 3mb in parallel type. It is installed in the I / O input / output device 2mi of the controller 2A (step S34).
[0072]
When the installation of the program “A001” is completed, the simulation initialization setting process can be performed, and actual input / output data or simulation data according to the flag “execution / non-execution” of each data of the I / O input / output device 2mi. Is selected automatically via the transmission control circuit 2mt (step S35).
[0073]
Here, when a “simulation execution” button is input from the I / O simulator station 3, execution of the control program of the parallel controller 2A is instructed via the network 3mb (step S36).
[0074]
Further, when another simulation is executed, the process returns to step S34 again to select and set a predetermined simulation program from the I / O simulator station 3.
[0075]
In this way, it is possible to verify and controllability and safety by selecting and setting various simulation programs that approximate the characteristics of the actual controlled object 1 without changing the control program of the parallel controller 2A. It becomes.
[0076]
Therefore, since a state close to actual plant operation can be set by such a parallel type controller system, an operator who operates this control system can be efficiently trained.
[0077]
Furthermore, since the input / output data and alarm information of each controlled object 1 can be changed, unnecessary alarm signals can be set in advance during maintenance work in an actual plant, preventing maintenance personnel from confusion with maintenance work. Therefore, safe maintenance inspection work becomes possible.
[0078]
Although the present invention has been described with respect to a parallel type controller, the present invention can be implemented even with a single controller, and this is also included in the scope of the present invention.
[0079]
【The invention's effect】
As described above, according to the present invention, the characteristics to be controlled can be set as the input / output data in the I / O input / output means, so that the settings that are actually used without changing the controller program can be set. The control system can be simulated under certain conditions.
[Brief description of the drawings]
FIG. 1 is a system configuration diagram according to an embodiment of the present invention.
FIG. 2 is an explanatory diagram of a system according to the embodiment of this invention.
FIG. 3 is a hardware configuration diagram of the parallel controller according to the embodiment of this invention.
FIG. 4 is a diagram illustrating a data flow of the parallel controller system according to the embodiment of this invention.
FIG. 5 is a diagram illustrating a data flow during simulation of the parallel controller system according to the embodiment of this invention.
FIG. 6 is a diagram illustrating a method for changing data during simulation according to the present invention.
FIG. 7 is a diagram for explaining the flow of a simulation program and data according to the present invention.
FIG. 8 is an explanatory view of a simulation flow according to the embodiment of the present invention.
FIG. 9 is a model diagram of a control system.
FIG. 10 is an explanatory diagram of a conventional simulation method.
[Explanation of symbols]
1, 11 Control target 2, 12 Controller 2A Parallel controller 2m1, 2m2, 10 Controller 2mb Parallel controller system bus 2mn Network module 2mi, 12i I / O input / output device 2mt Transmission control circuit 2c CPU
2ro ROM
2ra RAM
2s system bus control circuit unit 2sb system bus control circuit 2ib internal bus 2if external interface 2k key switch 2sm shared memory 3 I / O simulator station 3mb control system transmission path 4 monitoring control station 1a, 11a controlled object process 11b operation unit 11c detection Unit 12a setting unit 12b adjusting unit 13 output end 14 input end

Claims (7)

A control system simulator using a controller, a parallel controller in which a plurality of controllers, I / O input / output means having a shared memory, and a network module are connected by a bus,
The network module and the simulator means and the monitoring control means connected by the network, and the controlled object connected to the I / O input / output means of the parallel controller,
The simulator means writes first input / output data having a simulation execution or non-execution flag to the shared memory of the I / O input / output means via the network module,
The I / O input / output means outputs second input / output data from the controlled object based on the simulation execution or non-execution flag attached to the first input / output data written in the shared memory. And updating the first input / output data written in the shared memory,
The simulator means writes a simulation program for simulating the fluctuation of the second input / output data of the controlled object to the shared memory of the I / O input / output means via the network module;
A parallel controller system simulator, wherein the parallel controller performs a system simulation by executing the simulation program. The parallel controller system simulator according to claim 1, wherein the first input / output data to be exchanged and updated is saved in a memory of any one of the parallel controllers before being updated. . 2. The parallel controller system according to claim 1, wherein the simulator means writes alarm information to the first I / O input / output data and writes it to the shared memory of the I / O input / output means. Simulator. The second input / output data written in the shared memory is taken into a memory of any one of the parallel controllers and transmitted to the monitoring control unit via the network module. The parallel controller system simulator according to claim 1. Multiple controllers,
An I / O input / output device having a shared memory that is read or written by the plurality of controllers and external simulator means, and in which real data is written from the controlled object;
A parallel controller comprising a network module connected to the external simulator means and the external monitoring control means,
When the simulation data from the external simulator means is written into the shared memory via the network module, the I / O input / output device transfers the actual data from the controlled object to any one of the parallel controllers. A parallel controller that saves data in the controller's memory. When the simulation program from the external simulator unit is written into the shared memory via the network module, any of the controllers performs a simulation process using the data in the shared memory using the simulation program. 6. The parallel controller according to claim 5, wherein: 6. The parallel controller according to claim 5, wherein actual data saved in the controller is transmitted to the monitoring control means via the network module.

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