JP2009059245A - Control system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a control system equipped with many input/output modules and capable of extracting the maintenance management information of individual input/output modules at optional timing requested by a maintenance person without influencing a control period of the control system under operation. <P>SOLUTION: The control system is equipped with: a maintenance tool 1 for collecting and managing maintenance management information in which serial numbers and maintenance history are made to correspond and stored; a controller 3 for dividing the maintenance management information, receiving the divided maintenance management information and monitoring information as a pair synchronously with a control period at a control period frequency corresponding to a division number and transferring the received information to the maintenance tool 1; an input/output device 6 which comprises input modules 63 for inputting the monitoring information, output modules 64 for outputting the control information and an input/output control section 61 capable of storing the maintenance management information of the input modules 63 and the output modules 64 and controlling the maintenance management information and the monitoring information so that they are transmitted at the control period frequency corresponding to the division number. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a control system for controlling a plant, and more particularly to a control system for managing maintenance management information including a maintenance history of input / output devices constituting the control system.

  The configuration of the conventional control device 11 is shown in FIG. The control device 11 includes a control controller 12, an input / output module unit 13 connected to a control sensor / control operation end 15 a of various controlled objects 15, and a system bus 14 that connects the control controller 12 and the input / output module unit 13. The controlled object 15 such as a plant is controlled.

  The various control sensors / control operation ends 15a of the controlled object 15 are connected to the input / output module 13 such as the analog input module 13a, the digital input / output module 13b, and the digital output module 13c. 13 and the controller 12 perform data communication via a serial transmission line 14 to control the controlled object 15.

  The establishment of a data link for transmission control between the control controller 12 and the input / output module unit 13 is normally performed by a polling / selecting method in which the control controller 12 having a transmission right is a control station and the input / output module unit 13 is a dependent station. Is adopted.

  The setting of the transmission address to each input / output module of the input / output module unit 13 is determined at the system design stage of the control device 11, and is set from the DIP switch on each input / output module in the production process and the adjustment process. Or transmission address data is written in advance in the memory of the transmission interface unit of the input / output module.

  In addition, the transmission address is set to the controller 12 with respect to all input / output modules of the input / output module section 13 controlled by the controller 12 such as the type of input / output signal, the number of input / output signals, and the transmission address. Information is written in advance in the memory of the controller 12 as data.

  In the case of a large system, the number of points of these input / output modules 13 may be a large number of configurations reaching several thousand or more. Therefore, in the setting of the transmission address, an error in setting that cannot be handled by the control controller 12 and the input / output module unit 13 is unavoidable, and when adjusting the control device 11 or replacing the input / output module of the input / output module unit 13 There was a possibility of troubles due to incorrect settings.

Therefore, the tag information for identifying the dependent station and the transmission address of the dependent station corresponding to the tag information are collectively managed by the tag information processing means, written to the IC tag of the dependent station, and the tag information and transmission from the mounted input / output module There is a control device provided with an input / output module equipped with an IC tag capable of preventing an address setting error and a transmission address setting error by transmitting the address to the control station and preventing tag information set in the control station and subordinate stations. reference.).
Japanese Patent Laid-Open No. 2005-135166, P1, FIG.

  In the conventional control device as shown in Patent Document 1, the setting of the transmission address of the input / output module is a mistake in the setting caused by performing the switch operation and the write operation to the memory independently of each other. The problem is solved.

  In a control system having a large number of input / output modules, there is a problem in that the maintenance history of each input / output module is correctly stored and necessary maintenance management information can be extracted quickly, in addition to problems due to erroneous settings.

  That is, the serial number of the input / output module installed at the initially set transmission address, the replacement history of maintenance parts on the input / output module that are not displayed with the serial number, and transient abnormal symptoms recorded by maintenance personnel Maintenance management information is managed by referring to the maintenance history notes recorded by maintenance personnel, so a large amount of maintenance management information is accurately stored, and this maintenance management information corresponds to the installed I / O module. Patent Document 1 does not disclose a technology for accurately storing the information and quickly extracting it even during operation of the control system at an arbitrary timing required by maintenance personnel.

  Also, even if these maintenance management information is stored in the respective input / output modules, a method for extracting a large amount of maintenance management information without affecting the control cycle during operation of the control system is known. Absent.

  The present invention has been made to solve the above-described problems. In a control system having a large number of input / output modules, the maintenance management information of each input / output module affects the control cycle of the operating control system. An object of the present invention is to provide a control system that can perform extraction processing at an arbitrary timing requested by maintenance personnel.

  In order to achieve the above object, a control system according to claim 1 of the present invention comprises a maintenance tool, a controller, and an input / output device, and controls a process and manages maintenance management information of the input / output device. A maintenance system that collects and stores the maintenance management information stored in association with a serial number that identifies each module constituting the input / output device and a maintenance history of the input / output device. The process monitoring information and control information and the maintenance management information are stored in different areas, the monitoring information is received from the input / output device at each preset control cycle, and the first memory is stored in advance. A calculation based on a control program to be executed, and in synchronization with the control cycle, the calculation result is transmitted to the input / output device as the control information, and the maintenance tool When the maintenance management information is requested, the input / output device is requested to transmit the maintenance management information, and the maintenance management information divided by a preset division number and the monitoring information are paired. Synchronously with the control cycle, the controller receives the number of control cycles corresponding to the division number, identifies and stores each information, stores the maintenance management information, and stores the maintenance management information from the controller. When there is a transmission request, the divided maintenance management information and the monitoring information are transmitted at the number of control cycles corresponding to the number of divisions, and when there is no transmission request, only the monitoring information is transmitted. The maintenance management information is divided into the number of control cycles corresponding to a preset division number, and is transmitted in association with the serial number.

  In order to achieve the above object, a control system according to a second aspect of the present invention comprises a maintenance tool, a controller, and an input / output device, and controls a process and manages maintenance management information of the input / output device. A maintenance system that collects and stores the maintenance management information stored in association with a serial number that identifies each module constituting the input / output device and a maintenance history of the input / output device. A first memory for storing the monitoring information and control information of the process and the maintenance management information in different areas; a transmission request for the maintenance management information from the maintenance tool; The maintenance management information corresponding to the request is extracted by referring to the communication interface for returning to the maintenance tool, and the monitoring information is set for each preset control cycle. The calculation is received from the output device and executed based on the control program stored in the first memory in advance, and the calculation result is transmitted to the input / output device as the control information in synchronization with the control cycle, When there is a request for the maintenance management information from a maintenance tool, the input / output device is requested to transmit the maintenance management information, and the maintenance management information divided by a preset division number and the monitoring information are The controller comprising: a CPU that receives the number of control cycles corresponding to the number of divisions in synchronization with the control cycle as a pair, and that identifies each piece of information and stores the information in a different area of the first memory; An input module that inputs the monitoring information for each control cycle, an output module that outputs the control information for each control cycle, the input module, and the output module When there is a request for transmission of the maintenance management information from the second memory for storing the maintenance management information and the controller, the divided maintenance management information and the monitoring information are set to the number of control cycles corresponding to the number of divisions. When there is no transmission request, the input / output device includes an input / output control unit that controls to transmit only the monitoring information, and the maintenance management information corresponds to a preset number of divisions. This is characterized in that it is divided into the number of control cycles to be transmitted and transmitted in association with the serial number.

  As described above, according to the present invention, in a control system having a large number of input / output modules, the maintenance management information of each input / output module can be maintained without affecting the control cycle of the operating control system. It is possible to provide a control system that can perform extraction processing at an arbitrary timing requested by a member.

  A first embodiment of the present invention will be described with reference to FIGS. FIG. 1 shows the configuration of the control system of the present invention. The control system includes a maintenance tool 1, a plurality of controllers 3, an input / output interface 4 that relays each controller 3 and a plurality of input / output devices 6, and a plurality of input / output devices 6.

  Furthermore, a LAN 2 for communicating with the maintenance tool 1 and the plurality of controllers 3 and an input / output bus 5 for connecting the input / output interface 4 and the plurality of input / output devices 6 are provided.

  Next, the configuration of each unit will be described. The maintenance tool 1 stores the LAN 2 for each of the plurality of input / output devices 6 and stores maintenance management information in which serial numbers for specifying individual modules constituting the input / output devices 6 are associated with the maintenance history of the input / output devices. And is processed in accordance with a predetermined maintenance management information processing procedure.

  The serial number represents manufacturing information such as a module manufacturing number and a model. The maintenance management information is, for example, an inspection history with the date and time when maintenance personnel inspected, such as changes in module setting values and recording of abnormal phenomena, and is stored in association with this serial number.

  Maintenance personnel and operators of this control system request maintenance management information by designating the controller 3 from a terminal of the maintenance tool 1 (not shown) at a timing required for plant operation and maintenance. .

  The controller 3 receives the monitoring information from the input / output device 6 and outputs control information to the input / output device 6 to control the process and to obtain maintenance management information of the input / output device 6 from the maintenance tool. Collected from the input / output device 6 by request and sent to the maintenance tool 1.

  The configuration of the controller 3 includes a first memory 32 that stores process monitoring information and control information, and maintenance management information in different areas, and receives a transmission request for maintenance management information from the maintenance tool 1. The communication interface 33 that extracts the maintenance management information corresponding to the request with reference to the memory 32 and sends the monitoring information back to the maintenance tool 1, receives the monitoring information from the input / output device 6, and is stored in the first memory 32 in advance. When calculation based on the program is executed, the calculation result is transmitted to the input / output device 6 as control information in synchronization with a preset control cycle, and maintenance management information is requested from the maintenance tool 1, Request the input / output device 6 to transmit maintenance management information, divide maintenance management information set in advance, and pair the divided maintenance management information and monitoring information in synchronization with the control cycle. Received by the control cycle count that consists Metropolitan CPU31 to be stored in the preset different areas of the first memory 32 to identify the information each.

  At this time, the first memory 32 is configured so that the maintenance management information received in a divided manner can be collectively read from the first memory 32 to the maintenance tool 1 via the communication interface 33. Read time is shortened.

  Each part of the controller 3 is connected by a CPU bus 34, and the CPU bus 34 is connected to the input / output interface 4.

  The input / output interface 4 and the plurality of input / output devices 6 are connected to each other via the input / output bus 5.

  Next, the input / output device 6 includes, for example, a plurality of input modules 63 for inputting monitoring information from a temperature sensor or the like, a plurality of output modules 64 for outputting control information to an actuator such as a valve, and the like, and an input module 63 and the second memory 62 for storing the maintenance management information of the output module 64, and the control corresponding to the number of divisions of the divided maintenance management information and the monitoring information when there is a maintenance management information transmission request from the controller 3. An input / output control unit 61 that controls to transmit only the monitoring information when there is no transmission request when transmitting at the number of cycles.

  At this time, the input / output interface 4 performs control so that requests from the CPU 31 to the input / output device 6 can be collectively controlled when a plurality of input / output devices 6 are configured as shown in the figure.

  Next, the maintenance management information processing operation in this control system will be described with reference to FIGS. FIG. 2 is a time chart for explaining the processing operation of the CPU 31. As shown in FIG. 1, the input / output device 6 may be composed of a plurality of units, but the processing operation is the same, so the case of a single unit will be described.

  As shown in FIGS. 2A and 2B, the CPU 31 receives a maintenance management information transfer request from the maintenance tool 1 through the LAN 2 in the period of the control cycle T0-1 from time t0-1 to t0. To do.

  Next, in the control period T0, the control program stored in the first memory 32 (not shown) is stored in advance based on the monitoring information mt0 received from the input / output device in the previous control period T0-1. Based on the control calculation, the control information is output to the input / output device 6 (FIG. 2C).

  If the time required for the calculation processing of the monitoring information and the control information is Tc, the control cycle T0 is set in advance under the condition of T0> Tc. At this time, in a period excluding the calculation time Tc, that is, after a predetermined delay time Td from the time t0, the monitoring information mt1 and the maintenance management information dt11 in the cycle T0 are sent from the input / output device 6 described later to the first It is transferred to the memory 32.

  That is, the maintenance management information dt11 to dt1n is obtained by dividing the total amount of maintenance management information by a predetermined division number n. From the second memory 62 in n control cycles of control cycles T0 to Tn-1. The data is transferred to the first memory 32 within the period of Ti-Tc (FIG. 2D).

  As shown in FIG. 3, the monitoring information mti and the maintenance management information written in the second memory 62 are divided into maintenance management information dt11 to dt1n for each control period based on a predetermined division number n. Forwarded.

  The control by the input / output control unit 61 can be configured to be controlled by the CPU, but since it is a limited processing function, it can also be configured by a gate array, for example.

  By configuring the input / output control unit 61 with a gate array, the configuration of the input / output device 6 becomes a simple configuration in which processing is implemented as firmware compared to that configured with a CPU.

  The CPU 31 receives the divided monitoring information in the previous control cycle from the input module 63 and outputs the control information in the current control cycle from the output module 64.

  Details of the processing operation of the CPU 31 of FIGS. 2C and 2D are shown in the flowchart of FIG. The CPU 31 monitors whether there is a request for maintenance management information from the maintenance tool 1 (s1). If there is a request, the CPU 31 monitors the current control cycle after a predetermined delay time from the start time of the next control cycle. The information mti and the maintenance management information dt11 divided into n are transferred from the second memory 62 to the first memory 32 (s2, 3, s4).

  Then, the maintenance management information dti1 is transferred for each control cycle until the division number n is reached (s5, 6, 7).

  When the division transfer of all the maintenance management information to the first memory 32 is completed, the maintenance management information stored in the first memory 32 is transferred to the maintenance tool 1.

  Further, as shown in FIG. 2E, the transfer from the first memory 32 to the maintenance tool 1 may be batch transfer or split transfer, and a transfer method in advance so as not to affect the control cycle of the controller 3. Is established.

  That is, if the access control to the first memory 32 is configured to operate in parallel, maintenance information is transmitted to the maintenance tool 1 in a short time by batch transfer.

  Here, the memory storing the control program has been described as the first memory 32, but may be a memory different from the first memory 32 as long as it can be accessed from the CPU 31 via the CPU bus 34. .

  As described above in detail, the maintenance management information of the input / output device in the control system of the present invention is the number of divisions set in advance within the period of a predetermined control cycle when the maintenance management information is requested to be transferred from the maintenance tool. The maintenance management information divided in step (b) can be associated with the serial number of the corresponding input / output module and transmitted to the maintenance tool without affecting the control cycle.

  The present invention is not limited to the above-described embodiment. The memory for storing maintenance management information and monitoring information in the input / output device 6 and the maintenance management information stored in the input / output device 6 are used as control cycles. Any device can be used as long as it can be divided and transferred to the memory of the controller 3 without affecting it, depending on the number of controllers 3 and input / output devices 6 and the request for the transfer rate of maintenance management information to the maintenance tool 1. Various modifications can be made without departing from the spirit of the present invention.

The block diagram of the control system of this invention. The time chart explaining operation | movement of the control system of this invention. Explanatory drawing of the division | segmentation of the maintenance management information of the control system of this invention. The flowchart of the processing operation of the maintenance management information of this invention. Conventional control device

Explanation of symbols

1 Maintenance tool 2 LAN
3 Controller 31 CPU
32 First memory 33 Communication interface 34 CPU bus 4 Input / output interface 5 Input / output bus 6 Input / output device 61 Input / output control unit (gate array)
62 Second memory 63 Input module 64 Output module

Claims (3)

A control system comprising a maintenance tool, a controller, and an input / output device for controlling a process and managing maintenance management information of the input / output device;
The maintenance tool for collecting and storing the maintenance management information stored in association with serial numbers for identifying individual modules constituting the input / output device and maintenance history of the input / output device;
The process monitoring information and control information and the maintenance management information are stored in different areas, and the monitoring information is received from the input / output device for each preset control cycle, and stored in the first memory in advance. In the case where there is a request for the maintenance management information from the maintenance tool, the calculation result is transmitted to the input / output device as the control information in synchronization with the control cycle. The input / output device is requested to transmit the maintenance management information, and the maintenance management information divided by a preset division number and the monitoring information are paired in synchronization with the control cycle and correspond to the division number. The controller that receives the control cycle number of times, and identifies and stores each information;
The maintenance management information is stored, and when there is a transmission request for the maintenance management information from the controller, the divided maintenance management information and the monitoring information are transmitted at the number of control cycles corresponding to the division number, and a transmission request When there is no, comprising the input / output device that transmits only the monitoring information,
The control system according to claim 1, wherein the maintenance management information is divided into control cycle times corresponding to a preset division number and transmitted in association with the serial number. A control system comprising a maintenance tool, a controller, and an input / output device for controlling a process and managing maintenance management information of the input / output device;
The maintenance tool for collecting and storing the maintenance management information stored in association with serial numbers for identifying individual modules constituting the input / output device and maintenance history of the input / output device;
A first memory for storing the process monitoring information and control information and the maintenance management information in different areas; a transmission request for the maintenance management information from the maintenance tool is received, and the first memory is referred to A communication interface that extracts the maintenance management information corresponding to the request and returns it to the maintenance tool; and the monitoring information is received from the input / output device for each preset control cycle, and the first memory A calculation based on a control program stored in advance is executed, and the calculation result is transmitted to the input / output device as the control information in synchronization with the control cycle, and the maintenance management information is requested from the maintenance tool. In this case, the I / O device is requested to transmit the maintenance management information, and the maintenance management information divided by a preset division number and the monitoring information are paired in the control cycle. Synchronize with, and wherein the controller and a CPU that received by the control cycle count corresponding to the division number, and stores identifying information of each said area having the different first memory,
An input module for inputting the monitoring information for each control period; an output module for outputting the control information for each control period; and a second memory for storing the input module and the maintenance management information of the output module; , When there is a transmission request for the maintenance management information from the controller, the divided maintenance management information and the monitoring information are transmitted at the number of control cycles corresponding to the number of divisions, and when there is no transmission request, Including the input / output device including an input / output control unit that controls to transmit only the monitoring information,
The control system according to claim 1, wherein the maintenance management information is divided into control cycle times corresponding to a preset division number and transmitted in association with the serial number.   The control system according to claim 1, wherein the input / output control unit includes a gate array.

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