JP2009294918A - Plant control system - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a plant control system for arbitrarily executing simulation in a state that an actual I/O signal is connected to a process, and for confirming the operation of any equipment other than operation target equipment in the stage of simulation. <P>SOLUTION: This plant control system includes an output signal abnormality decision processing part 3 for determining the abnormality of an output signal from a sequence logic part 1 based on the pattern information of operation equipment and a simulation answer creation part 7 for creating a simulation answer signal. Then, an output signal from a sequence logic part 1 is transmitted to a control process 6 or a simulation answer creation part 7 based on prescribed simulation conditions. Also, an answer signal from a control process 6 or an answer signal from a simulation answer generation part 7 are transmitted to a sequence logic part 1 based on the simulation conditions. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a plant control system having a simulation function and an abnormality determination processing function.

  Conventionally, when performing simulation of plant equipment, a simulation logic of a process signal is created separately from the control device to realize a simulation of the control process (see, for example, Patent Document 1).

JP-A-9-34543

In order to improve the function and confirm the function in the plant control system, the sequence logic is often improved. In the function confirmation after system remodeling, since the actual I / O is connected to the process, it is difficult to perform simulation in an environment that is actually operating in the field. For this reason, in order to confirm the function, it is necessary to prepare a restoration environment not connected to the actual process, incorporate simulation software of the operating device, and operate the sequence logic to confirm. However, it is very difficult to prepare a restoration facility for the entire system regardless of the size of the modification.
Recently, a simulator that can build a control system in a personal computer and conduct tests can be used. However, system construction suitable for the modification on the personal computer has a limit on the number of control devices to be restored. There was also a problem that the performance was difficult.

  In addition, when checking the sequence operation in the simulation environment, the operation target device is checked carefully, but it is almost always determined that the device other than the target device is not operating. I often noticed mistakes in sequence software logic for the first time.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to arbitrarily perform a simulation only with a controller having sequence logic in a state where an actual I / O signal is connected to a process. Furthermore, it is to provide a plant control system capable of confirming the operation of equipment other than the equipment to be operated at the stage of simulation.

  The plant control system according to the present invention includes a sequence logic unit, an operating device pattern setting information unit in which pattern information of devices to be operated from the sequence logic unit is registered, an output signal from the sequence logic unit, and an operating device pattern setting information unit. When the signal for the device that is not registered in the pattern information is output from the sequence logic unit, the output signal abnormality determination processing unit that determines the presence of abnormality and the operating device are simulated. If a simulation signal is input, a simulation answer generation unit that generates an answer signal for simulation of the corresponding operating device for the simulation signal, and an output signal abnormality determination processing unit None is judged A signal switching unit that switches an output signal from the sequence logic unit to a signal to be transmitted to the control process and a simulation signal to be transmitted to the simulation answer generation unit based on the conditions set in the simulation setting unit; An answer signal synthesizing unit that selects an answer signal input from the control process and an answer signal input from the simulation answer generating unit based on conditions set in the simulation setting unit. It is a thing.

  According to the present invention, simulation can be arbitrarily performed only with a controller having sequence logic in a state where the real I / O signal is connected to the process. The operation of the device can be confirmed.

  In order to explain the present invention in more detail, it will be described with reference to the accompanying drawings. In addition, in each figure, the same code | symbol is attached | subjected to the part which is the same or it corresponds, The duplication description is simplified or abbreviate | omitted suitably.

Embodiment 1 FIG.
1 is a configuration diagram showing a plant control system in Embodiment 1 of the present invention. In FIG. 1, the plant control system includes a sequence logic unit 1, an operating device pattern setting information unit 2, an output signal abnormality determination processing unit 3, a signal switching unit 4, an abnormal signal generation unit 5, a control process 6, and a simulation answer generation unit. 7, a simulation setting unit 8 and an answer signal synthesis unit 9 are provided.
In the operating device pattern setting information unit 2, pattern information of devices to be operated from the sequence logic unit 1 is registered in advance. The pattern information is managed in units of sequences, for example.

  The output signal abnormality determination processing unit 3 compares the output signal from the sequence logic unit 1 with the pattern information from the operating device pattern setting information unit 2 to determine whether the signal output from the sequence logic unit 1 is abnormal. It has a function to judge. Specifically, when the output signal abnormality determination processing unit 3 detects that the output signal of the device not registered in the pattern information is turned on by performing the comparison, that is, the device not registered in the pattern information. Is output from the sequence logic unit 1, it is determined that there is an abnormality. As a mechanism of this abnormality determination, for example, all the device output signals output from the sequence logic unit 1 and the registration numbers of the devices that may be operated are aggregated and aligned on the memory in the same order, A logical operation is performed on these two memory states, and whether or not a signal other than the signal that should be output from the sequence logic unit 1 is output from the operation result.

When the output signal abnormality determination processing unit 3 determines that there is an abnormality, the output signal abnormality determination processing unit 3 does not output a signal to the signal switching unit 4 but only outputs a signal to the abnormality signal generation unit 5.
Further, in the abnormal signal generation unit 5, when an abnormality determination signal (abnormal signal) is input from the output signal abnormality determination processing unit 3, the abnormal signal is output to the control logic 6 without performing output to the control process 6. To the sequence logic unit 1 to report the abnormality.

  Further, the output signal abnormality determination processing unit 3 determines that the abnormality is not present by the comparison, that is, when the signal for the device registered in the pattern information is output from the sequence logic unit 1, the sequence logic unit 1 The input signal from is output to the signal switching unit 4.

  The signal switching unit 4 sends an input signal from the output signal abnormality determination processing unit 3 (a signal from the sequence logic unit 1 determined as having no abnormality) to the control process 6 and the simulation answer generation unit 7. A function of switching to a simulation signal to be transmitted is provided. Here, the switching by the signal switching unit 4 is performed based on a predetermined condition set in the simulation setting unit 8. That is, the simulation setting unit 8 is preset with predetermined conditions for performing simulation on the operating device. Then, the signal switching unit 4 determines whether the current state is the actual I / O function or the simulation function of the control process 6 based on the switching signal input from the simulation setting unit 8, and if the actual state is the actual I / O setting. For example, a signal is output to the control process 6, and if it is a simulation setting, a signal is output to the simulation answer generation unit 7.

  The simulation answer generation unit 7 has a function of generating a simulation answer signal of a corresponding operation device for the simulation signal when the simulation signal is input. That is, when the simulation signal is input from the signal switching unit 4, the simulation answer generation unit 7 converts the simulation signal into a signal that assumes the actual operation of the device. For example, in the case of a valve open answer / close answer, a process for delaying on / off of the signal by a specified time is performed in consideration of the valve operation time, and the answer signal is output.

  The answer signal synthesis unit 9 has a function of switching a plurality of input signals and transmitting an appropriate signal to the sequence logic unit 1. Specifically, the answer signal synthesizer 9 receives the actual answer signal from the control process 6 and the simulation answer signal from the simulation answer generator 7. Then, the answer signal synthesis unit 9 selects an optimal one from the two types of input answer signals and transmits it to the sequence logic unit 1. The failure signal is the same as the answer signal. Further, the selection (switching) of the answer signal by the answer signal synthesis unit 9 is performed based on a predetermined condition set in the simulation setting unit 8.

  That is, the answer signal synthesis unit 9 determines whether the current state is the actual I / O function or the simulation function of the control process 6 based on the switching signal input from the simulation setting unit 8, and sets the actual I / O setting. If there is, a real answer signal from the control process 6 is transmitted to the sequence logic unit 1 and a simulation answer signal from the simulation answer generation unit 7 is transmitted to the sequence logic unit 1 if the simulation setting is set.

  According to the first embodiment of the present invention, simulation can be arbitrarily performed only with a controller having the sequence logic unit 1 in a state where the real I / O signal is connected to the process. It becomes possible to confirm the operation of devices other than the device to be operated.

  That is, by switching the signal output destination of the signal switching unit 4 by the switching signal from the simulation setting unit 8, it is possible to create a state in which the control process 6 and the input / output signal are separated without performing software correction. Functional verification of the logic unit 1 can be realized. For this reason, even if the actual plant is in operation, it is possible to switch to simulation when it is desired to perform functional verification, and verification can be performed without preparing a restoration machine or incorporating simulation software into the actual sequence logic. .

  For example, even if normal production at a plant is performed on weekdays and the function can only be confirmed on weekends, switching to simulation enables the actual process equipment to be used in the same environment as normal production at the plant. Function check can be performed without operating. Furthermore, since the relationship between the operation signal and its answer signal (open answer, closed answer, failure signal, etc. for a valve) is clear in the operation of the device, it is easy to add and process the simulation answer generator 7 according to the modification contents. There are also advantages.

  Further, the information on the operating device registered in advance in the operating device pattern setting information unit 2 and the output signal to the device output from the actual sequence logic unit 1 are compared in the output signal abnormality determination processing unit 3, It is determined whether signals other than the operation target device are not turned on. For this reason, even if output to equipment other than the operation target is performed due to a sequence logic error or the like during simulation operation, abnormalities can be noticed at the simulation stage before operating in the actual plant. Can be prevented in advance.

It is a block diagram which shows the plant control system in Embodiment 1 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Sequence logic part 2 Operating device pattern setting information part 3 Output signal abnormality determination process part 4 Signal switching part 5 Abnormal signal generation part 6 Control process 7 Simulation answer generation part 8 Simulation setting part 9 Answer signal synthesis part

Claims (2)

Sequence logic part,
An operation device pattern setting information portion in which pattern information of devices to be operated from the sequence logic portion is registered;
The output signal from the sequence logic unit and the pattern information from the operating device pattern setting information unit are compared. If a signal for a device not registered in the pattern information is output from the sequence logic unit, there is an abnormality. An output signal abnormality determination processing unit for determining
A simulation setting unit in which conditions for performing simulation on the operating device are set;
When a simulation signal is input, a simulation answer generation unit that generates an answer signal for simulation of the corresponding operation device for the simulation signal;
A signal for transmitting an output signal from the sequence logic unit determined to have no abnormality by the output signal abnormality determination processing unit to the control process based on a condition set in the simulation setting unit and the simulation answer generating unit A signal switching unit for switching to a simulation signal to be transmitted to
A signal to be transmitted to the sequence logic unit is selected from an answer signal input from the control process and an answer signal input from the simulation answer generation unit based on conditions set in the simulation setting unit An answer signal synthesizer;
A plant control system comprising: An abnormality signal generation unit that outputs an abnormal signal to the sequence logic unit without performing output to the control process when the output signal abnormality determination processing unit determines that there is an abnormality,
The plant control system according to claim 1, further comprising:

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