JP2009015401A - Distributed control system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To execute restoration of setting information in each of a plurality of PLCs connected to each other through a field network by easy operation without using a tool device, without imposing an excessive software load on a specific controlling device. <P>SOLUTION: By sequentially reading frame configuration data stored in the PLC as a sending station in each receiving station in response to reception of a prescribed starting instruction, creating a restoration request frame, and sending it onto the field network, contents of a setting information storage means of each of the PLCs as the receiving station can be restored by remote control without operating the tool device by only providing the prescribed starting instruction to the PLC as the sending station. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention is configured by distributing a plurality of control devices such as a programmable controller (hereinafter referred to as “PLC”) and a PLC remote I / O terminal and connecting them via a field network. The present invention relates to a distributed control system.

  2. Description of the Related Art A distributed control system configured by distributing a plurality of control devices such as PLCs and PLC remote I / O terminals and connecting them via a field network is conventionally known.

  In this type of distributed control system, each of a plurality of control devices is stored in setting information storage means for storing setting information for defining the operation specifications of the devices, and in this setting information storage means. Restore operation automatically restores the contents of the set information in response to a restore request frame (including the restore request command and data specific to each control device that modifies it) received via the field network Execution means.

  Here, “setting information” includes a user program and various system settings when the control device is a PLC (including both a general-purpose PLC for general control and a safety PLC for safety control). If the control device is a remote I / O terminal, I / O settings can be listed.

  Then, by operating a tool device (generally configured by installing predetermined tool software on a personal computer) connected directly to the field network or indirectly via the PLC, a restore request frame is sent on the field network. By sending it out, the contents of the setting information storage means of the control device that is the transmission destination of the restore request frame can be restored remotely.

  By the way, in this type of distributed control system, in order to restore the setting information in any control device on the network using the tool device, startup of a personal computer constituting the tool device, tool software A series of operations such as starting, selecting a file to be restored, and downloading the selected file must be performed. Further, the procedure of this operation is usually different for each control device to be restored. Therefore, it is not always easy for those who are not familiar with the operation of the tool device to restore the setting information in each of a plurality of control devices existing on the field network.

On the other hand, in a PLC system including a main PLC composed of a plurality of units, one or more extension PLCs connected by bus to the main PLC, and peripheral components connected to the main PLC or extension PLC, Backup information on each PLC and peripheral components is stored in a storage medium provided in the main PLC in a lump and activated by a predetermined switch operation, so that the main PLC can be added without using a tool device. A technique that enables automatic restoration of setting information in the PLC and peripheral components has been known (see Patent Document 1).
JP 2002-297207 A

  However, the batch restoration technology employed in the PLC system described in the above-mentioned patent document is to set the backup data read from the predetermined storage medium of the main PLC as it is to each necessary unit via the data bus. Although it is effective for collective restoration of a group of PLCs (main PLC and expansion PLC) and their peripheral components installed at almost the same location and connected by bus, collective restoration of multiple PLCs distributed over a field network Therefore, it is necessary to convert the backup data read from the storage medium into data that can be received and processed by each PLC on the network, increasing the software load on the main PLC side.

  In addition, when the software on the main PLC side is burdened with processing for converting the backup data read from the storage medium into data that can be received and processed by each PLC on the field network, another data is newly added on the field network. When a PLC is added or an existing PLC is replaced with another model, the software on the main PLC side must be re-installed each time.

  The present invention has been made paying attention to such conventional problems, and the object is to distribute a plurality of control devices such as PLCs and PLC remote I / O terminals. In addition, in a distributed control system configured by connecting them via a field network, a tool device is used to restore setting information in each of a plurality of control devices connected via the field network. In other words, it is possible to execute it with a simple operation and without imposing an excessive software load on a specific control device.

  In addition, the present invention allows such a restore operation to be set by a field worker or the like even in a situation where setting data setting errors are not allowed, such as when a safety control safety PLC is used as a control device. This is to make sure that even those unfamiliar with the operation can execute it.

  Other objects and operational effects of the present invention will be easily understood by those skilled in the art by referring to the following description of the specification.

  The problem to be solved by the above invention can be solved by a distributed control system having the following configuration.

  As a basic premise, this distributed control system is configured by distributing a plurality of control devices such as PLCs and PLC remote I / O terminals and connecting them via a field network. In each of the plurality of control devices, setting information storage means for storing setting information for defining operation specifications of the devices, and contents of the setting information stored in the setting information storage means are And a restore operation automatic execution means for automatically restoring in response to a restore request frame received via the network, thereby operating a tool device connected directly or indirectly to the field network. The restore request frame is sent to the field network. And it is capable restored remotely the contents of the setting information storage means of the control device as a destination.

  As a “control device”. In addition to PLCs and remote I / O terminals, various control devices that are usually placed at this type of control site, such as general-purpose discrete I / O, field adapters, safety network controllers, safety discrete I / O, etc. be able to.

  As the “PLC”, it is sufficient that it has at least a user program execution function and a communication function, and its physical form is that the entire PLC is composed of a plurality of control modules (CPU unit, I / O unit, various high function units). , Communication unit, etc.), or a building block type that includes the functions of these control modules in one housing. The “PLC” may be a general-purpose PLC for general control or a safety PLC for safety control, and these may be mixed as a system configuration.

  “Setting information” is information for defining the operation specifications of the target control device. For example, PLC setting information (user program, system setting, etc.) or remote I / O terminal setting information (IO Setting). However, the “setting information” to be set does not include network setting parameters (field node address, field speed). That is, it is assumed that the network setting parameters are set in advance in each control device by the user as necessary. When the control device is composed of a plurality of units such as a building block type PLC, setting information itself is also prepared corresponding to each unit. In the case of an all-in-one type control device, the setting information is related to the control device.

  In addition to the above basic assumptions, this distributed control system has the following configuration. That is, at least one of the control devices is positioned as a setting information transmitting station, and the other control devices are positioned as setting information receiving stations. The control device positioned as the transmission station is provided with “frame configuration data storage means” and “restore request automatic transmission means”.

  The frame configuration data storage means includes a frame of a restore request frame to be sent out on the field network from the tool device when the stored contents of the setting information storage means of the control device positioned as a receiving station are restored by remote operation. Configuration data is stored. Further, the restore request automatic transmission means sequentially reads out the frame configuration data stored in series in the frame configuration data storage means for each receiving station in response to a predetermined start command being given. And the operation of sending out the restore request frame thus created onto the field network is executed.

  Here, various methods can be considered for giving the “predetermined start command”. As an example, a control switch itself serving as a transmission station may be provided with a start switch, and a restore request automatic transmission process may be started after a manual operation of the start switch. As another example, a flag that is controlled via a user program may be provided, and when the flag is set to “1”, the restoration request automatic transmission process is started. As yet another example, it may be possible to detect that a predetermined activation command has arrived from another control device via the network and start the restore request automatic transmission process.

  With the above configuration, the contents of the setting information storage means of each control device serving as the receiving station can be obtained by operating the tool device only by giving a predetermined activation command to the control device serving as the transmitting station. Can be restored remotely.

  Here, the “frame configuration data” includes a “restore request command” that can be interpreted and executed by each control device, and “command modification data” that modifies the restore request command. The “command modifier data” is restored by the restore request command in addition to the “source node address” that is the source of the restore request command and the “destination node address” that is the destination of the restore request command. At least “setting information” to be included is included.

  In principle, all of the “frame configuration data” is stored in the “frame configuration data storage unit” for each control device. However, if it can be used in common for all control devices, the “restore request command” need not be stored redundantly for each control device. Also, it is not necessary to store known data redundantly for each control device, such as “source node address”.

  Various physical forms of the “frame configuration data storage means” can be employed. As one example, a non-volatile memory package that functions as a frame configuration data storage means is fixedly incorporated on the control device (for example, PLC) side that is positioned as a setting information transmission station, and is fixedly incorporated. It is conceivable that necessary frame configuration data is written on-site to the nonvolatile memory package by connecting a tool device to the device. As another example, a memory package in which frame configuration data is written in advance using a tool device in another location may be built in or externally attached to a control device (for example, PLC) that is positioned as a setting information transmission station. It is possible to incorporate. As still another example, a card slot for mounting a non-volatile memory card is provided on the control device (for example, PLC) side, which is positioned as a setting information transmission station, and a tool device is installed in another place. It is conceivable that a memory card in which frame configuration data is written in advance is inserted into this card slot.

  In the above distributed control system, “restore” means that when some setting information is already stored, when the setting information is updated, and when no setting information is stored, It includes both meanings for storing new setting information.

  According to the distributed control system having the above configuration, as long as a predetermined activation command is given to a control device positioned as a setting information transmitting station, each control device positioned as a receiving station from the control device. A restore request frame is automatically transmitted to each of them, and in response to this, a restore operation is automatically performed in each control device. Even without using a device, anyone can easily restore setting information of other control devices connected via a network.

  In addition, since the frame configuration data itself of the restore request frame to be sent from the tool device to the field network is stored in the frame configuration data storage means, on the side of the control device positioned as the transmission station, The software configuration of the control device positioned as the transmitting station can be realized by automatically transmitting the restore request frame by simply arranging and transmitting the data read from the frame configuration data storage means according to a predetermined format. Is not complicated.

  In addition, information on increase / decrease, change, etc. of control devices on the network is already reflected in the frame configuration data itself when creating a restore request frame for each control device with a separate tool device. Even if there is an increase / decrease or change in the control device on the network, it does not affect the software configuration of the control device positioned as the source station itself. Even if there is a change, there is an advantage that the software on the control device side positioned as the transmission station is not affected.

  In other words, when the function of the tool device is transplanted to a control device positioned as a transmission station, it is incorporated into the control device positioned as a transmission station when a control device newly connected on the network is to be restored. Updated software must be updated. Usually, it is not easy to update the embedded software of a control device (PLC or the like). In contrast, in the present invention, by simply updating the tool software on the personal computer that constitutes the tool device, the embedded software of the control device serving as the transmission station can be used as it is, and the new control device can be restored. it can.

  As a result, according to the distributed control system of the present invention, (1) when the unit is replaced, it is not necessary to reconfigure the system with the PC tool (PC startup ⇒ tool activation ⇒ file selection ⇒ file download sequence unnecessary) Downtime can be reduced, (2) there is no need to provide tool training to field workers, (3) there is no risk of downloading an incorrect configuration file, and (4) configuration tools in safety applications in particular. In order to prevent system setting parameters and programs from being easily changed or operating modes to be changed (program operation), passwords are protected against access to setting files and execution of specific functions. In many cases, there was a problem of password disclosure to field workers. Seward disclosed that becomes unnecessary, in which exhibits the special effect of the like.

  In the above distributed control system, the restore request automatic transmission means on the transmission station side sets the setting information currently stored in the control device as the transmission destination and the setting of the restoration schedule prior to the transmission operation of the restore request frame. Determines identity with information and executes restore request transmission operation for that control device only when identity is denied. If identity is affirmed, restore request transmission operation for that control device is skipped. You may do it.

  According to such a configuration, the setting information already stored and the setting information to be restored in the future are the same, but a waste time due to a wasteful restore operation is saved, and the entire system is reduced. The time required for restoration can be shortened.

  In the above distributed control system, the restore operation automatic execution means on the receiving station side confirms the identity between the password attached to the received restore request and the password stored in its own device prior to the restore operation. Only when the identity is affirmed, the restore operation based on the received setting information is executed, and when the identity is denied, the restore operation based on the received setting information is skipped. It may be structured.

  According to such a configuration, by appropriately incorporating a password in the restore request frame, the start of the restore request automatic transmission operation is left to the site, but the setting information creator's The user can arbitrarily control whether or not restoration is possible.

  Further, in the above distributed control system, the restore request automatic transmission means on the transmitting station side is attached to the device type of the control device as the transmission destination and the control information to be restored prior to the transmission operation of the restore request frame. When the identity is determined and the identity is affirmed, the restore request frame transmission operation for the control device is executed. When the identity is denied, the restore request frame for the control device is executed. The transmission operation may be skipped.

  According to such a configuration, the restore request frame transmission operation for the control device is executed only when the identity is affirmed, and the restore request frame transmission operation for the control device is skipped when the identity is denied. Therefore, if one of the nodes on the communication network accidentally attaches a control device of another device type when replacing the control device, the identity of the device type is denied. Therefore, the system information can be prevented from malfunctioning by restoring the setting information without noticing such a device error.

  Furthermore, in the above-described distributed control system, each of the control devices serving as the receiving stations may be provided with a notification unit for notifying the execution status of the restore operation to the control device serving as the transmitting station. .

  According to such a configuration, there is an advantage that after the restore request automatic transmission operation is activated on the control device serving as the transmission station, the execution status of the restore operation can be confirmed in the control device serving as the reception station.

  According to the present invention, as long as a predetermined activation command is given to the control device positioned as the setting information transmission station, the control device restores each control device positioned as the receiving station. Since the request frame is automatically transmitted and each control device receives the request frame, the restore operation is automatically performed, so that it is not necessary to use a complicated tool device as before. Anyone can easily restore the setting information of other control devices connected via the network.

  In addition, since the frame configuration data itself of the restore request frame to be sent from the tool device to the field network is stored in the frame configuration data storage means, on the side of the control device positioned as the transmission station, The software configuration of the control device positioned as the transmitting station can be realized by automatically transmitting the restore request frame by simply arranging and transmitting the data read from the frame configuration data storage means according to a predetermined format. Is not complicated.

  In addition, information on increase / decrease, change, etc. of control devices on the network is already reflected in the frame configuration data itself when creating a restore request frame for each control device with a separate tool device. Even if there is an increase / decrease or change in the control device on the network, it does not affect the software configuration of the control device positioned as the source station itself. Even if there is a change, there is an advantage that the software on the control device side positioned as the transmission station is not affected.

  Hereinafter, a preferred embodiment of a distributed control system according to the present invention will be described in detail with reference to the accompanying drawings.

  A system configuration diagram showing an example of a distributed control system to which the present invention is applied is shown in FIG. A distributed control system to which the present invention is applied is configured by distributing a plurality of control devices such as PLCs and PLC remote I / O terminals and connecting them via a field network. In the illustrated example, two PLCs 1 a and 1 b and four remote I / O terminals 2 a to 2 d are connected by a field network (hereinafter simply referred to as “network”) 3. Each of the PLCs 1a and 1b is configured as a building block type PLC in this example, and includes a CPU unit 10, a communication unit 11, and two I / O units 12 and 12, respectively. Yes.

  As is well known to those skilled in the art, the CPU unit 10 of the PLC includes a user program memory for storing a user program, and a system program memory for storing a system program for realizing a function as a PLC. In addition, an I / O memory for storing input / output data, a system setting memory for storing various system settings, and the like are provided.

  Further, the system program reads I / O memory output data and sends it to the I / O unit 12, I / O refresh processing that reads the input data of the I / O unit 12 and writes it to the I / O memory, A user program is executed by referring to input / output data of the I / O memory, and a user program execution process for rewriting the contents of the I / O memory by the execution result, acceptance of a user operation, transmission of a display signal, a tool device, And peripheral service processing for performing communication with a remote I / O terminal.

  In this peripheral service processing, by appropriately communicating with the remote I / O terminals 2a to 2d via the communication unit 11, transmission of output data to the remote I / O terminal and input data from the remote I / O terminal are performed. And so on. Further, by communicating with a tool device (not shown) connected to the network 3, various known peripheral service processes such as a user program rewrite process, an edit process, and a monitor process are realized.

  Each of the PLCs 1a and 1b and the remote I / O terminals 2a to 2d constituting the control device responds when a restore request frame transmitted from the tool device (not shown) to the network 3 is received. A function to automatically restore the setting information of the machine is provided. The “setting information” referred to here is, for example, a user program or various system settings in the case of PLC, and in the case of the remote I / O terminals 2a to 2d, I The / O setting corresponds to this.

  In the present invention, in order to restore those “setting information” without the tool device, at least one of the control devices is positioned as a setting information transmitting station, The control device positioned as a station is provided with “frame configuration data storage means” and “restore request automatic transmission means”.

  Here, in the frame configuration data storage means, a restore request frame to be sent from the tool device to the field network when the stored contents of the setting information storage means of the control device positioned as the receiving station is restored by remote control Frame configuration data is stored in series corresponding to each of the control devices positioned as receiving stations.

  Further, the restore request automatic transmission means sequentially reads out the frame configuration data stored in a series in the frame configuration data storage means for each receiving station in response to a predetermined start command, and sends a restore request frame. An operation of creating and sending the restore request frame thus created to the field network is executed. In the case of the example in FIG. 1, the PLC 1a is positioned as a setting information transmitting station, and the other PLC 1b and the four remote I / O terminals 2a to 2d are positioned as setting information receiving stations.

  The PLC 1a holds the frame configuration data of the restore request frame described above. Various methods are conceivable for causing the PLC 1a to hold the frame configuration data of the restore request frame.

  In the example shown in FIG. 2, a card slot 10c is provided on the side of the CPU unit 10, while the frame configuration data 4a is stored in advance in the memory card 4 attached to the card slot 10c. The frame configuration data is held by the CPU unit 10 by mounting it in the card slot 10c.

  In the example of FIG. 3, the connector 10 c is provided on the CPU unit 10 side, and the handy tool 5 is connected to the connector 10 c via a cable, and the frame configuration data for the card slot 5 a provided in the handy tool 5 is provided. By mounting the memory card 4 storing 4a, the CPU unit 10 can hold the frame configuration data.

  In the example of FIG. 4, a nonvolatile memory 6 composed of a package memory is provided on a circuit board in the CPU unit 10 in a fixed or detachable manner. The frame configuration data can be held in the CPU unit 10 by writing the frame configuration data using a tool device at another location.

  As described above, when the control device positioned as the setting information transmitting station is a PLC, various configurations can be adopted as a method for holding the frame configuration data in the PLC. In the following description, it is assumed that the frame configuration data is held by the method shown in FIG.

  1 to 4, reference numeral 10-1 denotes a restore start switch for starting the restore operation, and 10-2 denotes a restore target changeover switch for switching the restore target between the own apparatus and the entire network. The operation of these switches will be described in detail later with reference to a flowchart.

  As is well known to those skilled in the art, a hardware block diagram of the CPU unit 10 and the communication unit 11 is shown in FIG. 13 just in case. As shown in the figure, in the CPU unit 10, a memory card interface 101, a nonvolatile memory 102, a RAM 103, an MPU block 104, a bus control unit 105, a display unit 106, a setting unit 107, and a USB interface 108 are provided. It has been.

  The memory card interface 101 corresponds to the card slot 10c described above. The nonvolatile memory 102 is a general term for a system program memory, a user program memory, an I / O memory, a system setting memory, and the like, and “setting information” noted in the present invention is mainly stored in the nonvolatile memory 102. ing. The RAM 103 is used as a work area. The MPU block 104 includes an MPU and an ASIC, and operates according to the system program read from the nonvolatile memory 102, thereby realizing the functions of IO refresh processing, user program execution processing, and peripheral service processing described above. To do. The bus control unit 105 manages data exchange with the communication unit 11. The display unit 106 controls the operation of a display lamp and a numerical display (not shown) provided on the outer surface of the CPU unit. The setting unit 107 is used for various setting operations, and includes the restore activation switch 10-1 and the restore target changeover switch 10-2 described above in connection with the present invention. The USB interface 108 is provided for connecting a USB cable to the CPU.

  On the other hand, the communication unit 11 includes a nonvolatile memory 111, a RAM 112, an MPU block 113, a bus control unit 114, a display unit 115, a setting unit 116, and a communication physical layer 117.

  The nonvolatile memory 111 stores a system program or the like for realizing a function as a communication unit. The RAM 112 functions as a work area. The MPU block 113 implements a function as a communication unit by reading and executing various system programs from the nonvolatile memory 111. The bus control unit 114 is used for data exchange with the CPU unit 10. The display unit 115 is used for display control of various lamps provided on the outer surface of the communication unit 11. The setting unit 116 includes, for example, a DIP switch and is used for setting a node address and a communication speed. The communication physical layer 117 is provided for realizing communication operation with other control devices (such as a PLC and a remote I / O terminal) via the network 3.

  A system program for realizing processing described later with reference to the flowcharts of FIGS. 6 to 11 is stored in the nonvolatile memory 102 in the CPU unit 10 and executed by the MPU block 104.

  Next, a hardware block diagram of the remote I / O terminal is shown in FIG. As shown in the figure, the remote I / O terminal 2 is provided with an MPU block 201, an I / O circuit 202, a communication physical layer 203, a nonvolatile memory 204, a display unit 205, and a setting unit 206, respectively. Yes.

  The MPU block 201 performs overall control of the entire remote I / O terminal, and implements various functions necessary as a remote I / O terminal by executing a system program stored in the nonvolatile memory 204. The I / O circuit 202 is used for capturing an input signal from an external terminal block and sending an output signal to the external terminal block. The communication physical layer 203 is connected to the network 3 and is used for transmission / reception of input / output data to / from an upper PLC. As described above, the nonvolatile memory 204 stores a system program and is also used as a buffer area for input data fetched from the I / O circuit 202 and output data to be output to the I / O circuit 202. Is done. The display unit 205 is used for display control of a lamp or the like provided on the outer surface of the remote I / O terminal. The setting unit 206 includes, for example, a DIP switch or the like, and is used for setting the node address and communication speed of the remote I / O terminal.

  Next, the data structure of “frame configuration data” stored in the memory card 4 (see FIGS. 2 and 3) or the non-volatile memory 6 (see FIG. 4) will be described with reference to FIG.

  As described above, “frame configuration data” refers to setting information storage means (in the case of FIG. 1, PLC 1b, four remote I / O terminals 2a to 2d) positioned as a receiving station. In the example of FIG. 13, when the stored contents of the nonvolatile memory 102 and the nonvolatile memory 204 in the example of FIG. 14 are restored by remote operation, a restore request to be sent to the network 3 from a tool device (not shown). It means data that constitutes a frame.

  The frame configuration data basically includes a start code, a restore request command, command modification data, an end code, and the like. Then, the memory card 4 (see FIGS. 2 and 3) or the non-volatile memory 6 (see FIG. 4) functioning as the frame configuration data storage means has each control device as shown in FIG. 5 (a). Storage areas are provided, and the above-described frame configuration data is stored in these storage areas.

  Note that at the end of the series of frame configuration data, a check code (for example, a redundancy check code, a hash code, a signature code, etc.) is used to confirm the reliability of the data stored in the memory card 4 or the nonvolatile memory 6. ) Is stored.

  Of course, all the above-mentioned frame configuration data may be stored in the area for each control device shown in FIG. 5A, but for the data such as the start code, end code, and restore request command, Since all the control devices are common or known, in order to save the memory capacity, the data may not be stored in each device.

  In this example, as shown in FIG. 5B, the frame configuration data stored in the memory card 4 or the non-volatile memory 6 includes a start code, as shown in FIG. Only the command modification data excluding the end code and the restore request command is stored. Specifically, this command modification data is composed of “node address”, “device type”, “password”, “setting information”, and “unique ID” corresponding to each control device. .

  Here, the “node address” is an address for uniquely specifying the control device on the network. The restore request frame is transmitted to this node address. As will be described later, when the restoration target is “entire network” and the restoration is performed on the own device, it is recognized by this node address that the restoration target is the own device.

  The “device type” is a code representing the type of control device. For example, it is configured by the type of equipment such as general-purpose discrete I / O, communication adapter, safety network controller, safety discrete I / O, manufacturer, product code, and the like.

  The “password” is a code determined by the creator of the setting information. For example, if this password is set in a hierarchical structure according to the level of the administrator, the automatic restoration process itself is started in the field. However, by appropriately setting the password level, it is possible to select a device on which a restore operation is actually performed.

  The “setting information” is the information body to be restored, and the operation specifications of the control device in which the setting information is set are determined depending on the contents of the setting information. When the control device is composed of a plurality of units such as a PLC, as shown in FIG. 5C, the “setting information” is composed of setting information for each unit, and for each individual unit. The unit-specific ID described later is added to each setting information. In the case of a single configuration in which the control device is not separated into a plurality of units, of course, the “setting information” is also single.

  The “device unique ID” is a unique ID uniquely determined for each version of the “setting information”. Specifically, for example, it can be configured by a redundancy check code, a hash code, a signature code, a time stamp, or a combination thereof. By referring to this “apparatus unique ID”, it is possible to confirm the version of “setting information” currently existing in the control apparatus or the unit in the control apparatus. If the version that is currently being restored is the same as the version that has already been stored, the contents of both are the same, and therefore, it is possible to eliminate the waste of restoring the contents by overlapping them.

  Next, the operation of the system of the present invention based on the hardware configuration and data structure described above will be sequentially described in detail with reference to the flowcharts of FIGS.

  FIG. 6 shows a general flowchart showing the entire processing of the CPU 10 of the PLC 1a serving as the transmission station. In the figure, when processing is started by turning on the power, first, initial setting of various flags and registers necessary for executing normal operation mode processing or restore mode processing is performed (step 101).

  Subsequently, the mounting state of the memory card 4 and the operation state of the restore start switch 10-1 are referred to. Here, even if the memory card 4 is not inserted into the card slot 10c (step 102 NO) or the memory card 4 is inserted into the card slot 10c (step 102 YES), the restore activation switch 10-1 is in the OFF state. If there is (step 103 NO), the normal operation mode processing (step 104) is executed.

  As described above, the normal operation mode processing (step 104) cyclically executes I / O refresh processing, user program execution processing, peripheral service processing, and the like.

  On the other hand, if the memory card 4 is inserted in the card slot 10c (step 102 YES) and the restore activation switch 10-1 is on (step 103 YES), the restore mode process (step 105) is executed. Is done. This restore mode process (step 105) is the main part of the present invention.

  FIG. 7 shows a general flowchart showing the entire restore mode processing in the transmitting station side device. In the figure, when processing is started, a series of “frame configuration data” constituting a restore request frame to be transmitted to each device is read from the storage area in the memory card 4 (see FIG. 5A). (Step 201), the collation match between the data obtained by appropriately processing the read series of data and the check code stored in the memory is confirmed (Step 202).

  Here, if the data obtained by processing a series of “frame configuration data” and the check code do not match (NO in step 203), abnormal processing such as blinking a lamp provided on the outer surface of the CPU unit Is executed (step 207). On the other hand, if it is determined that the data obtained by processing a series of “frame configuration data” matches the check code (YES in step 203), then the operation state of the restore target changeover switch 10-2 is changed. Referenced. If it is determined that the operation state of the restore target changeover switch 10-2 is the own machine (step 204 “own machine”), the process proceeds to step 206 and the restoration process of the own machine is executed. On the other hand, if it is determined that the entire network is present (step 204 “entire network”), the process proceeds to step 205, where the entire network is restored.

  Thus, in the illustrated embodiment, the reliability of the data read from the memory card is automatically checked based on the check code prior to the start of the restore mode process, and is provided in the CPU unit 10. By setting the restore target changeover switch 10-2 to either “own device” or “entire network”, restore processing relating only to the own device and restoring processing of the entire network including the own device are executed alternatively. It can be made to.

  Next, flowcharts (No. 1 to No. 3) showing details of the restoration process of the entire network are shown in FIGS. When the process is started in FIG. 8, first, in step 301, it is determined whether or not the restore process has been completed for all control devices on the network. Here, if it is determined that all the devices have been completed (step 301 YES), an end process is executed and, for example, a lamp (not shown) provided on the outer surface of the CPU unit is displayed in a predetermined manner (step 304). ).

  On the other hand, if it is determined that the restoration process has not been completed for all the devices (NO in step 301), then frame configuration data for one control device is read (step 302). By referring to the node address included in the frame configuration data, it is determined whether it is the data of the own device or the data of another device. Here, when it is determined that the data is from another device (step 303 “other device”), the process proceeds to FIG. 9, and a device type transmission request command is sent to the target device, and based on the response, A device type is acquired from the target device (step 305).

  Subsequently, the device type acquired from the target device and the device type read from the memory card are collated (identity determination) (step 306). Here, when it is determined that the two do not match (step 306), it is estimated that there is a possibility that the control device on the network is mistakenly replaced with another model at the time of replacement. Immediately executing the abnormality process (step 311), the fact is displayed in a predetermined manner on a lamp (not shown) provided on the outer surface of the CPU unit to notify the user.

  On the other hand, when the device type acquired from the target device matches the device type read from the memory card (YES in step 306), subsequently, a transmission request regarding the unique ID of the device is sent to the target device. A unique ID of the target device is acquired by sending a command and acquiring the response (step 307).

  Subsequently, collation (identity determination) between the unique ID of the device acquired from the target device and the unique ID of the device read from the memory card is performed (step 308). If they match (YES in step 308), it means that the version of the new setting information to be restored is the same as the version of the setting information already stored in the device. Since the setting information is not changed before and after, the subsequent transmission processing (step 309) is skipped at all so as not to cause useless restoration processing time.

  On the other hand, if the unique ID of the device acquired from the target device does not match the unique ID of the device read from the memory card (step 308 NO), the version of the new setting information to be restored from now on Means that the version of the setting information already stored is different, so that a restore request frame is immediately created and transmitted to the node address of the target device. The creation of the restore request frame is performed, for example, by sequentially arranging a start code, a restore request command, a transmission source node address, a transmission destination node address, a password, setting information, a device unique ID, an end code, and the like. Those skilled in the art will readily understand.

  Thereafter, the process proceeds to step 310 and waits for a response from the target device. If the response content is abnormal or the response does not arrive within a predetermined time, the process proceeds to step 312 and the abnormality process is executed. Then, a lamp (not shown) provided on the outer surface of the CPU unit is operated in a predetermined manner. On the other hand, if the response from the target device arrives within the predetermined time and it means normal (step 310 “normal”), the process returns to the top of the flowchart of FIG. Until all the devices are determined to be complete (step 301), the process is repeatedly executed.

  On the other hand, if it is determined in the flowchart of FIG. 8 that the frame configuration data read from the memory card is the data of the own device (step 303 “Own device”), the process proceeds to the flowchart of FIG. Restore processing is executed.

  That is, first, in step 313, the device type of the device itself (for example, stored in the nonvolatile memory 102) is checked against the device type read from the memory card. At step 319, the mounting error is estimated and abnormality processing is executed. On the other hand, if the device types match (YES in step 313), the password of the own device (for example, stored in the nonvolatile memory 102) and the password read from the memory card are collated (identity determination). (Step 314). If they do not match (NO in step 314), it is determined that restoration is not permitted, and abnormal processing is similarly executed (step 319). These abnormality processes (step 319) are performed, for example, by operating a lamp (not shown) provided on the outer surface of the CPU unit in a predetermined manner.

  Thus, only when the device type match and the password match are confirmed (steps 313 YES and 314 YES), the unique ID of the own device (for example, stored in the nonvolatile memory 102) and the unique ID read from the memory card Are collated (step 315). Here, if they match (YES in step 315), the version of the setting information already stored and the version of the setting information to be restored are the same. In order to avoid this, the subsequent restore processing is skipped at all.

  On the other hand, if the unique ID of the own device and the unique ID read from the memory card do not match, it means that the versions of both setting information are different. Shift to subsequent processing.

  In this embodiment, since the PLC is composed of a plurality of units, each of all the units can be individually restored as necessary. That is, first, in step 316, it is determined whether or not all the target units have been set. Here, if it is determined that all have been completed (YES in step 316), the process proceeds to step 320 to determine whether or not the restoration of all units has been completed normally. If the normal end is determined here (step 320 YES), the process ends immediately, whereas if any abnormality is determined (step 320 NO), the abnormal process is executed (step 321). A lamp (not shown) provided on the outer surface operates in a predetermined manner.

  On the other hand, if it is determined in step 316 that the setting of the target unit has not yet been completed (NO in step 316), then the unique ID of the target unit (for example, stored in the nonvolatile memory 102) and the memory card are read. Collation (identity determination) with the issued unique ID is performed (step 317). Here, if it is determined that the two match (YES in step 317), it is assumed that the already stored setting information and the setting information to be restored are the same version, so that the contents are also the same. Thus, the restore process is skipped.

  On the other hand, if the two do not match (NO in step 317), the setting information already stored and the setting information to be restored will not match, so the contents of the setting information are not the same. As a result of the estimation, the storage process for the unique ID of the device and the restoration process for the target unit (own apparatus) are immediately performed (step 318).

  In this way, since the unique IDs are always compared (identity determination) prior to the restoration process, even when the restoration process is performed on a PLC having a large number of units, rewriting is performed in those units. Therefore, the restore process can be performed only for units that need to be restored, so that the overall restore time can be greatly reduced.

  Next, processing in the receiving station side device that receives the restore request frame will be described with reference to the flowchart of FIG. The processing shown in the figure is started upon reception of a restore request command. In other words, when a frame arrives at the receiving station side device, the receiving station side device confirms the reception of the restore request command by decoding the command of the frame and starts the processing shown in FIG. It is.

  First, when it is confirmed that the restore request command has been received, the command modification data included in the restore request frame is read and decoded (step 501). Subsequently, in step 502, verification (identity determination) of the own password and the received password is performed. If it is determined that the verification does not match (NO in step 502), the process immediately proceeds to step 509, and an abnormal response is transmitted to the control device serving as the transmission station. As a result, the control device serving as the transmission station can recognize that some abnormality has occurred in the control device to be restored.

  In step 502, if the two passwords match (YES in step 502), at least the restoration is permitted. Then, the process proceeds to step 503, where the unique ID of the own device is compared with the received unique ID. Is called. If they match (YES in step 503), it is presumed that the version of the setting information already stored and the version of the setting information to be restored are the same and the contents are the same. Therefore, the subsequent processing is skipped, and the process immediately proceeds to step 509 to transmit an abnormal response. As a result, the control device serving as the transmission station can immediately recognize that some abnormality has occurred in the control device to be restored.

  If it is determined in step 503 that the two unique IDs do not match (NO in step 503), then the two unique IDs do not match for each unit constituting the control device (for example, PLC). Individual restore processing is executed.

  That is, first, in step 504, it is determined whether or not all of the target units have been set. Here, if it is determined that all the setting of the target unit is completed (YES in step 504), the process proceeds to step 507, and it is determined whether or not the restoration of all the units has been normally completed. Here, in the case of normal end (step 507 YES), a normal response is transmitted to the control device serving as the transmission station, whereas in the case of normal end (step 507 NO), the process proceeds to step 509 and an error is detected. A response is sent. As a result, the control device serving as the transmission station can recognize whether or not the scheduled restoration process has been normally completed in the target control device and each unit within the control device.

  If it is determined in step 504 that the setting of the target unit has not yet been completed (step 504 NO), the process proceeds to step 505, where the unique ID of the target unit is compared with the received unique ID (identity) Determination) is performed. Here, if it is determined that they match (YES in step 505), since the setting information already stored and the setting information to be restored are the same version, the contents are also recognized to be the same. Thus, subsequent processing is skipped in order to eliminate useless restoration processing.

  In contrast, if it is determined in step 505 that the unique ID of the target unit and the received unique ID do not match (NO in step 505), so-called restore processing is executed (step 506). In this restore process, first, a device unique ID storage process and a target unit setting process (a process of rewriting with received data) are executed.

  As described above, in the above embodiment, not only the control device serving as the transmitting station but also the control device serving as the receiving station executes the unique ID matching process in units of devices or units. Even if the unique ID verification process is omitted on the control device serving as the station, the restore process is executed only on the device or unit whose unique ID does not match in the control device serving as the receiving station. When a system program or user program having a relatively large capacity is targeted, it is possible to eliminate the waste of processing time at each receiving station and to perform restoration processing in a short time as a whole.

  Next, details of the restoration processing (step 206) of the own device executed when it is determined that the restoration target is the own device in the flowchart of FIG. 7 will be described with reference to the flowchart of FIG.

  When the processing is started in the figure, first, the setting information of the own device is searched based on the node address of the own device read from the memory card (step 401), and then the setting information of the own device. Is read (step 402). That is, the setting information already stored in the own device is read out.

  Subsequently, in step 403, collation (identity determination) between the device type of the device itself and the device type read from the memory card is performed (step 403). If they do not coincide with each other (NO in step 403), the process proceeds to step 410, where abnormality processing is executed, and a lamp (not shown) provided on the outer surface of the CPU unit, for example, is displayed in a predetermined manner.

  If it is determined in step 403 that the device type of the own device and the device type read from the memory card match (YES in step 403), the process proceeds to step 404, where the password and memory of the own device are stored. The password read from the card is checked (step 404). If the two do not match (NO in step 404), the process proceeds to step 410, and similar abnormality processing is executed.

  If it is determined in step 404 that the two match (step 404 YES), the process proceeds to step 405, where the unique ID of the own device and the unique ID read from the memory card are collated (identity determination). ) Is performed. Here, if it is determined that the two match (YES in step 405), since the setting information versions are the same, the subsequent processing is skipped and the processing proceeds to step 410 in order to eliminate useless restoration processing. A similar abnormality process is executed at.

  In step 405, when it is determined that the unique ID of the own device and the unique ID read from the memory card match (NO in step 405), individual restore processing for each unit is subsequently executed. That is, first, in step 406, it is determined whether or not all target units have been set. Here, when it is determined that all are completed (step 406 YES), a predetermined termination process is performed on the condition that restoration of all units has been completed normally (step 409). In this case, for example, a lamp (not shown) provided on the outer surface of the CPU unit is displayed in a predetermined manner (step 411). On the other hand, if it is determined that the abnormal end has occurred in any unit (NO in step 409), the process proceeds to step 410, and similar abnormality processing is executed.

  If it is determined in step 406 that the setting has not been completed in any unit (NO in step 406), the process proceeds to step 407, where the unique ID of the target unit and the unique ID read from the memory card are set. Verification (identity determination) is performed. If it is determined that the two match (YES in step 407), the setting information has the same version, so it is estimated that the contents are the same, and the subsequent setting processing is skipped.

  On the other hand, if it is determined in step 407 that the two IDs do not match (NO in step 407), the setting information already stored and the setting information to be restored are different in version, and naturally the contents are also included. The original restoration process is executed by assuming that they are different (step 408). In the restoration process (step 408), first, the unique ID of the device read from the memory card is saved, and the necessary setting information rewriting process for the target unit is performed.

  As described above, in the control system of this embodiment, by setting the restore target changeover switch 10-2 provided on the outer surface of the CPU on the side of the PLC positioned as the transmission station, on the own device side. The restore processing based on the information stored in the memory card can be executed only by operating the restore activation switch 10-1 without affecting the other control devices on the network. .

  As described above, according to the distributed control system of this embodiment, the configuration data of the restore request frame corresponding to each of the restore target devices using the tool device or the like in advance in the memory card 4 or the nonvolatile memory 6 separately. If the memory card 4 or the non-volatile memory 6 is incorporated in the control device (for example, PLC) positioned as the transmission station, the restore start switch 10-1 By simply sending the restore request frame to these control devices automatically for the device itself or the entire network, the restore operation for those control devices can be performed without being bothered by complicated operations on the tool device. It can be done automatically.

  For this reason, it is no longer necessary to bring the tool device to the site as before, or to instruct field workers in advance how to use the tool device. Can also be executed by other workers.

  On the other hand, while leaving the restoration operation to the field worker, the setting information creator can automatically restore the unnecessary control equipment or unnecessary units by incorporating a password accordingly. The risk of being done can be prevented beforehand.

  In addition, the control device serving as the transmission station and / or the control device serving as the reception station performs version confirmation (identity confirmation) of the setting information prior to the restore operation. In addition to avoiding unnecessary transmission processing to the station side, unnecessary setting processing is also avoided on the receiving station side. Can be shortened.

  Also, on the control device side that is the source station, not only the restore start switch but also the restore target changeover switch is provided so that the restore target can be selected for the own machine and the entire network. Despite the necessity of restoration, it is possible to restore setting information by narrowing down to an appropriate range according to each case without causing the inconvenience of having to restore the entire network. .

  In addition, when transmitting a restore request frame to the network on the control device side serving as a transmission station, the frame configuration data already stored in the memory card or the non-volatile memory is simply read out to a predetermined format. Therefore, even if such a convenient function is incorporated in one of the control devices, the software does not need to be complicated in the device, and such software is simply read out. Since only the processing and frame configuration processing are executed, even if a new control device is added or changed on the network, the data on the memory card or non-volatile memory will be changed. Therefore, there is no change in the processing on the transmitting station side that processes it. Advantage that there is no need to reinstall the software of the calling station every time their equipment changes on click.

  That is, the point to be noted in the present invention is the difference between the setting information of each device included in the conventional tool device and the configuration information stored in the memory card or the like according to the present invention. That is, since the setting information in the conventional tool device is simply a list of parameters of each device as shown in FIG. 15A, in order to create a restore request frame from now on, In the present invention, for example, the data stored in the memory card is as shown in FIG. 15 (b), while the complicated process for configuring the restore request frame by selecting the necessary parameters is required. In addition, since it is the frame configuration data of the restore request frame for setting the parameters, the restore request frame can be immediately transmitted on the network simply by reading it as it is and rearranging it according to a predetermined format. Even if it is incorporated into the control device that becomes the source station, the software is unnecessarily complicated. It is also of no to.

  In the above embodiment, the restoration process is activated based on the restoration activation switch 10-1 provided on the transmission station side. However, when the control device on the transmission station side is a PLC, for example. The remote I / O unit is provided with a flag controlled by the execution result of the user program in a predetermined memory, and the restore operation is activated by the on / off timing of this flag or connected to the PLC via communication The same effect can be obtained even if the restore operation is started on the PLC side by providing a restore start switch on the side and transmitting an operation signal of this switch to the PLC via communication.

  In the above embodiment, the frame configuration data is stored in the PLC. However, other control devices (for example, a remote I / O terminal, a safety network controller, etc.) connected to this type of industrial network are used. Of course, it may be provided.

  Further, in the above embodiment, the process for executing such an automatic restoration process is incorporated in the CPU unit of the PLC positioned as the transmission station. However, when the control device serving as the transmission station is a PLC, The unit into which such software is to be incorporated is not necessarily limited to the CPU unit, but may of course be provided in the communication unit itself or in various other high-function units.

  According to the present invention, as long as a predetermined activation command is given to the control device positioned as the setting information transmission station, the control device restores each control device positioned as the receiving station. Since the request frame is automatically transmitted and each control device receives the request frame, the restore operation is automatically performed, so that it is not necessary to use a complicated tool device as before. Anyone can easily restore the setting information of other control devices connected via the network.

  In addition, since the frame configuration data itself of the restore request frame to be sent from the tool device to the field network is stored in the frame configuration data storage means, on the side of the control device positioned as the transmission station, The software configuration of the control device positioned as the transmitting station can be realized by automatically transmitting the restore request frame by simply arranging and transmitting the data read from the frame configuration data storage means according to a predetermined format. Is not complicated.

  In addition, information on increase / decrease, change, etc. of control devices on the network is already reflected in the frame configuration data itself when creating a restore request frame for each control device with a separate tool device. Even if there is an increase / decrease or change in the control device on the network, it does not affect the software configuration of the control device positioned as the source station itself. Even if there is a change, there is an advantage that the software on the control device side positioned as the transmission station is not affected.

1 is a system configuration diagram illustrating an example of a distributed control system to which the present invention is applied. It is explanatory drawing (the 1) in the case of making one PLC hold | maintain the frame structure data of the restore request with respect to all the other nodes. It is explanatory drawing (the 2) in the case of making one PLC hold | maintain the frame structure data of the restore request with respect to all the other nodes. FIG. 10 is an explanatory diagram (part 3) in a case where one PLC holds frame configuration data of a restore request for all other nodes. It is explanatory drawing which shows the data structure of the frame structure data stored in a memory card or a non-volatile memory. It is a general flowchart which shows the whole process of PLC (CPU) used as a transmission station. It is a general flowchart which shows the whole restore mode process in a transmission station side apparatus. It is a flowchart (the 1) which shows the detail of the restore process of the whole network. It is a flowchart (the 2) which shows the detail of the restore process of the whole network. 12 is a flowchart (part 3) showing details of a restoration process for the entire network. It is a flowchart which shows the detail of the restore process of an own machine. It is a flowchart which shows the process in the receiving station side apparatus. It is a hardware block diagram of PLC. It is a hardware block diagram of a remote I / O terminal. It is explanatory drawing which shows the difference in setting information with a tool and a memory card.

Explanation of symbols

1a PLC positioned as a source station
1b PLC positioned as receiving station
2a to 2d Remote I / O terminals positioned as receiving stations 3 Network 4 Memory card 4a Frame configuration data 5 Handy tool 5a Card slot 6 Non-volatile memory 6a Frame configuration data 10 CPU unit 10-1 Restore start switch 10-2 Restore target Changeover switch 10a Display unit 10b Operation unit 10c Card slot 11 Communication unit 12 I / O unit 101 Memory card interface 102 Non-volatile memory 103 RAM
104 MPU block 105 Bus control unit 106 Display unit 107 Setting unit 108 USB interface 111 Non-volatile memory 112 RAM
113 MPU block 114 Bus control unit 115 Display unit 116 Setting unit 117 Communication physical layer 201 MPU block 202 I / O circuit 203 Communication physical layer 204 Non-volatile memory 205 Display unit 206 Setting unit

Claims (6)

A plurality of control devices such as PLCs and PLC remote I / O terminals are distributed and connected via a field network.
Each of the plurality of control devices includes
Setting information storage means for storing setting information for defining the operation specifications of the device;
Restore operation automatic execution means for automatically restoring the contents of the setting information stored in the setting information storage means in response to a restore request frame received via a field network,
Thus, by operating a tool device directly or indirectly connected to the field network and sending a restore request frame over the field network, setting information storage means for the control device that is the destination of the restore request frame In a distributed control system that can restore the contents of
Positioning at least one of the control devices as a setting information transmitting station, positioning other control devices as setting information receiving stations,
In the control device positioned as the transmitting station,
When the stored contents of the setting information storage means of the control device positioned as the receiving station are restored by remote operation, the frame configuration data of the restore request frame to be sent out on the field network from the tool device is stored in the receiving station. Frame configuration data storage means stored in series corresponding to each of the control devices positioned as,
In response to a predetermined start command being given, the frame configuration data stored in series in the frame configuration data storage means is sequentially read out for each receiving station to create a restore request frame. A restore request automatic transmission means for executing an operation of sending a restore request frame onto the field network,
As a result, the contents of the setting information storage means of each control device serving as the receiving station can be remotely transmitted without operating the tool device only by giving a predetermined start command to the control device serving as the transmitting station. A distributed control system that can be restored by operation. Prior to the restore request transmission operation, the restore request automatic transmission means determines whether the setting information currently stored in the control device as the transmission destination and the setting information to be restored are identical, and the identity is denied. Only when the restore request transmission operation for the control device is executed, and when the identity is affirmed, the restore request transmission operation for the control device is skipped.
The distributed control system according to claim 1, wherein the distributed control system is structured as described above.   Prior to the restore operation, the restore operation automatic execution means determines the identity between the password attached to the received restore request and the password stored in the own device, and only when the identity is affirmed. The restore operation based on the received setting information is executed, and when the identity is denied, the restore operation based on the received setting information is skipped. 3. A distributed control system according to 1 or 2. Prior to the restore request transmission operation, the restore request automatic transmission means determines whether the device type of the control device as the transmission destination and the device type attached to the control information to be restored are identical. Only when the result is affirmative, the restore request transmission operation for the control device is executed. When the identity is denied, the restore request transmission operation for the control device is skipped.
The distributed control system according to claim 1, wherein the distributed control system is structured as described above.   2. The distributed control system according to claim 1, wherein the predetermined activation command is given by an operation of a switch provided in a control device serving as the transmission station.   The notification device for notifying the execution status of the restore operation to the control device serving as the transmission station is provided in each control device serving as the reception station. Decentralized control system.

Images