JP2012190356A - Data acquisition device, performance reproduction device and facility operating state management system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To execute simulation by preventing occurrence of memory leak even when a unit capacity of a communication frame acquired through high-speed communication is larger than a unit capacity of internally-processable data.SOLUTION: A data acquisition device 30 acquires multiple communication frames consisting of a set of input values, applies data compression processing within the communication frames and data compression processing between the communication frames to each of the acquired communication frames, and records the communication frames after the data compression processing in a first storage part 33. A performance reproduction device 40 restores the recorded communication frames after the compression processing to the set of input values before compression processing in accordance with time information, uses the restored input values to trace a performance state of a facility on the basis of time shown in the corresponding time information, and displays the traced performance state on a screen, separately from the performance state of the facility.

Description

  The present invention relates to a data acquisition device connected to a sequencer that acquires an input value from an input device via an input port and controls the output device by turning the output port on and off under preprogrammed conditions. And an operation reproduction device for reproducing the operation state of the sequencer on the control program based on the history of input values acquired and recorded by the data acquisition device, and the data acquisition device and the operation reproduction device are applied to the equipment system. It is related with the equipment operation state management system which manages the operation state of equipment.

  In the field of FA (Factory Automation), a sequencer such as a PLC (Programmable Logic Array) is used for controlling equipment (hereinafter referred to as equipment system) installed on the site. The PLC incorporates a microcomputer and memory, acquires input signals obtained from input devices such as sensors and switches through the input port, and turns the output port on and off under conditions programmed in advance in the control program. Output devices such as solenoid valves, motors and indicator lights connected to the output port can be freely controlled.

  The control program described above is created using application software of a PC (Personal Computer) and transferred to the PLC via a serial interface such as USB (Universal Serial Bus) or RS-232C. A dedicated language called a ladder program is used as the program language. The ladder program is based on a sequence diagram and makes it easy to visualize the relationship between input and output.

  By the way, the above-described control program often performs an operation check in advance by a virtual test machine called a simulator before being verified by being applied to actual equipment including a control machine. At this time, the operator needs to create a virtual operation model for input / output simulation for each target equipment system. In addition, it is common to perform a simulation by creating a timing chart and examining the operation timing between circuit components and actually repeatedly executing control of the control machine. For this reason, for example, as disclosed in Patent Document 1, history information at the time of operation of the control program is saved, and the operation is traced on the control program using the history information, so that the facility is offline. A debugging method has been proposed that can be used to check the operation.

  According to the technique disclosed in Patent Document 1 described above, it is not necessary to perform the operation of operating the control machine over and over at the time of simulation, so that the debugging work can be easily performed on the data separated from the control machine. become. Further, it is not necessary to create a virtual motion model for each facility, and the reproduction thereof is facilitated, so that the burden on the operator is reduced.

However, in consideration of versatility, when a simulation based on collected history information is performed by a PC or logger connected to a sequencer via a LAN (Local Area Network), the technique disclosed in Patent Document 1 is to be applied. The inconvenience described below occurs. That is, the unit capacity (for example, 100 Mbps) of a communication frame acquired by high-speed communication exceeds the unit capacity (for example, 480 Mbps) of data to be discharged to an external recording medium connected by USB inside the PC. For this reason, data that cannot be processed at a time is accumulated in a memory inside the PC, and as a result, a memory leak or the like occurs and the function as a simulator cannot be performed.

JP 2003-248504 A

  An object of the present invention is to provide a data acquisition apparatus that suppresses the occurrence of a memory leak and enables simulation even when the unit capacity of a communication frame acquired by high-speed communication is larger than the unit capacity of data that can be processed internally, It is another object of the present invention to provide an operation reproduction apparatus and an equipment operation state management system.

The invention according to claim 1 is a data acquisition device including a first storage unit and a second storage unit connected to a sequencer via a communication line, and is assigned to an input device connected to the sequencer. A communication frame consisting of a set of input values obtained from each port for each port is acquired with a first unit capacity via the communication line, and for the acquired communication frame, a data compression process in the communication frame, and a communication frame A communication processing unit that performs a data compression process between the first and second storage units, and a communication frame after the data compression process that is stored in the first storage unit is smaller than the first unit capacity. And a data transfer control unit that transfers data to the second storage unit with a unit capacity of 2.

According to a second aspect of the present invention, in the data acquisition device according to the first aspect, the communication frame acquired by the communication processing unit changes at a first frequency acquired from the first port among the ports. The first input value (A1, A2, A3) and the second and third input values (B1) that change at a second frequency lower than the first frequency acquired from the second and third ports. , B2, B3 and C1, C2, C3), and the communication processing unit at the first time includes a first input value (A1) and a second input value (B1). And a second communication frame (F2) composed of the first input value (A2) and the third input value (C2) at the second time, and the third communication frame (F1). At the time of the third communication frame (F3) composed of the first input value (A3) and the second input value (B3). Each acquired, and characterized by applying data compression processing in said communication frame.

  According to a third aspect of the present invention, in the data acquisition device according to the first or second aspect, each of the first input values (A1, A2,...) Is obtained by performing the data compression processing in the communication frame. A3) and each of the second and third input values (B1, B2, B3, and C1, C2, C3) each time a respective communication frame (F1, F2, F3) is acquired, The communication frame acquired this time is compared with the communication frame acquired last time, and when there is a change, the communication frame acquired this time is selectively held in the first storage unit, and the communication frame And performing data compression processing between the communication frames.

In the invention according to claim 4, the data compression processing in the communication frame and the data compression processing between the communication frames are performed on the communication frame including the set of input values acquired from the sequencer via the communication line, A storage unit in which communication frames after data compression processing are recorded in time series, and a restoration processing unit that restores the communication frames recorded in the storage unit to the set of input values before data compression processing according to time information; An operation reproduction processing unit that generates display information by determining an output value as programmed in advance in the sequencer based on the input value restored by the restoration processing unit, and displays the information on a screen. It is an operation reproduction device.

The invention according to claim 5 is an equipment operation including at least a first storage unit, a second storage unit, and a display unit, wherein a facility including a plurality of input devices and output devices is connected to and controlled by a sequencer. In the state management system, for each port assigned to the input device connected to the sequencer, a communication frame consisting of a set of input values obtained from the port is acquired with the first unit capacity via the communication line, The acquired communication frame is subjected to data compression processing within the communication frame and data compression processing between the communication frames, and is held in the first storage unit, and after the data compression processing held in the first storage unit A data acquisition device for transferring the communication frame to the second storage unit with a second unit capacity smaller than the first unit capacity, and a communication frame recorded in the second storage unit. Is restored to the set of input values before the data compression processing according to the time information, and based on the restored input values, display values are generated by determining output values as programmed in advance in the sequencer, And an operation reproduction device for displaying on the display unit.

  According to the first aspect of the present invention, the communication processing unit performs a data compression process and a communication frame in the communication frame for a communication frame including a set of input values acquired via the communication line with the first unit capacity. The data transfer process is performed and held in the first storage unit, and the data transfer unit transfers the data from the first storage unit to the second storage unit with a second unit capacity lower than the first unit capacity. To do. For this reason, even when the data capacity of a communication frame acquired by high-speed communication is larger than the data capacity that can be processed internally, the occurrence of memory leak can be suppressed and simulation can be enabled.

  According to the second aspect of the present invention, the communication processing unit, for example, by dividing and capturing the input value from the second port having a relatively slow processing speed due to the characteristics of the input device assigned to the port Data compression processing is performed in the communication frame. For this reason, since the size of the communication frame to be acquired at a time is reduced, the time required for data acquisition is shortened, the input value from the first port having a relatively high processing speed is not missed, and the processing is stable. Can be realized.

  According to the invention of claim 3, the communication processing unit sets the communication frame acquired this time as the first only when there is a change in the content of the communication frame after the data compression processing in the communication frame is performed. Data compression processing between communication frames is performed by holding the data in the storage unit. For this reason, only the data compression process between the communication frames is performed and a further data compression effect can be obtained as compared with the case of recording, and the memory resources can be effectively used.

According to the invention of claim 4, the restoration processing unit restores the communication frame compressed and recorded in the storage unit to the set of input values before the compression processing according to the time information, and the operation reproduction processing unit restores the communication frame. The operating state of the sequencer is traced and reproduced on the screen at each time indicated by the corresponding time information using the input value. For this reason, it is not necessary to create a virtual operation model for each sequencer by using a memory recording unit in which input values subjected to data compression processing in communication frames and between communication frames are recorded in time series, In addition, since the contents can be reproduced on the sequencer program, it becomes easy to investigate the cause when an abnormality occurs, and the burden on the operator required for that is reduced.

  According to the invention of claim 5, the data acquisition device acquires a plurality of communication frames including a set of input values, and for each acquired communication frame, between the data compression process in the communication frame and the communication frame. Data compression processing is performed and recorded in the memory recording unit. In addition, the motion reproduction device restores the recorded communication frame after compression processing to a set of input values before compression processing according to time information, and uses the restored input values independently of the operating state of the equipment. The operation state of the equipment is traced and displayed on the screen at each time indicated by the time information. For this reason, even if the data capacity of a communication frame acquired by high-speed communication is larger than the data capacity that can be processed internally by the data acquisition device, it is possible to suppress the occurrence of memory leaks and enable simulation, and The operation reproduction device can further reduce the burden on the operator, and can provide an equipment operation state management system that can be facilitated without moving the control machine that constitutes the equipment system during simulation.

It is a block diagram which shows the structure of the equipment operation state management system which concerns on embodiment of this invention. It is a flowchart which shows operation | movement of the data acquisition apparatus which concerns on embodiment of this invention. It is a flowchart which shows operation | movement of the data acquisition apparatus which concerns on embodiment of this invention. It is a flowchart which shows operation | movement of the motion reproduction apparatus which concerns on embodiment of this invention. It is an image figure of the screen information produced | generated by the motion reproduction apparatus which concerns on embodiment of this invention. It is a schematic diagram of the operation | movement image of the data acquisition apparatus and operation reproduction apparatus which concern on embodiment of this invention.

  An embodiment of the present invention (hereinafter referred to as the present embodiment) will be described below with reference to the accompanying drawings.

(Equipment operation state management system configuration)
FIG. 1 is a block diagram illustrating a configuration of an equipment operation state management system according to the present embodiment. As shown in FIG. 1, an equipment operation state management system 1 according to the present embodiment includes an equipment system 10 including an input / output device (not shown), a sequencer 20, a data acquisition device 30, and an operation reproduction device 40. Composed.

The equipment system 10 is, for example, an automated system installed at a manufacturing site, and includes a control machine in addition to input / output devices. The control machine is in accordance with the contents programmed in advance by a control program by one or more sequencers 20. Be controlled. The sequencer 20 acquires an input signal obtained from an input device such as a sensor or a switch arranged at a key point of the control machine via the input port, and sets the output port according to a condition programmed in a control program built in advance. Turn ON / OFF. Thereby, for example, output devices such as a solenoid valve, a motor, and an indicator lamp connected to the output port can be freely controlled. In FIG. 1, the input port and the output port are collectively referred to as an I / O port 200 without being distinguished from each other.

(Configuration of data acquisition device)
One or more sequencers 20 are connected to the data acquisition device 30 via a communication line 50 such as a LAN. For each I / O port 200 of the sequencer 20, the data acquisition device 30 acquires a plurality of communication frames made up of a set of input values via the communication line 50, for example, at 100 Mbps (Mega bit per sec), and acquires the respective communication Data compression processing within a communication frame and data compression processing between communication frames are performed on the frames, and the frames are stored in the first storage unit 33 in time series. For this reason, the data acquisition device 30 includes a main control unit 31, a communication processing unit 32, a first storage unit 33, a parameter setting unit 34, a data transfer control unit 35, and a second storage unit 36. Composed. All of these constituent blocks 31 to 36 are commonly connected to an internal bus 37 having a plurality of lines for address, data, and control. The data acquisition device 30 is realized by a PC, for example.

  The communication processing unit 32 manages an interface with the LAN, and acquires a communication frame with the sequencer 20 using, for example, a procedure conforming to TCP / IP (Transmission Control Protocol / Internet Protocol) as a unit capacity of 100 Mbps. Here, the communication frame refers to a set of input values of input devices such as sensors and switches acquired via the I / O port 200. In addition, the communication processing unit 32 performs both data compression processing within the communication frame and data compression processing between the communication frames on the acquired communication frame, and the communication frame after the compression processing is transmitted via the internal bus 37. 1 is stored in the storage unit 33.

“Intraframe compression processing” here refers to spatial compression processing performed on input values for each input port assigned to a communication frame, and “interframe compression processing” refers to communication that arrives continuously. This refers to time compression processing in the time axis direction between frames.

By the way, if the size of the communication frame is large, it takes time for the data acquisition device 30 to acquire the communication frame. For this reason, in the intra-frame compression processing, the input value from the input port (hereinafter referred to as high-speed port) where the input value changes rapidly is acquired at high speed by utilizing the fact that the frequency of change of the input value differs for each input port. The input values from other input ports (hereinafter referred to as low speed ports) are divided and captured, thereby reducing the size of the input values captured at one time. This speeds up the acquisition process and stabilizes the process.

  In the inter-frame compression processing, the communication frame captured this time is compared with the communication frame captured last time, and when there is a change, the communication frame captured this time is selectively held in the first storage unit. By doing so, the size of the communication frame stored in the first storage unit 33 is compressed to effectively use the memory mounted in the first storage unit 33. The first storage unit 33 is a work area of a main storage device in which a semiconductor memory such as an SDRAM (Synchronous Dynamic Random Access Memory) is mounted.

The parameter setting unit 34 sets parameters such as the number of divisions and the division unit (size) when the communication processing unit 32 divides and captures the input value from the low-speed port in the intra-frame compression processing. These parameters may be preset as default values, or values may be set dynamically using an input device (not shown).

  The data transfer control unit 35 controls data transfer between the first storage unit 33 and the second storage unit 36. The compressed communication frame held in the first storage unit 33 is transferred to the second storage unit 36 at, for example, 64 Mbps, which is slower than, for example, high-speed communication of 100 Mbps (Mega bit per sec). As the second storage unit 36, a portable recording medium such as an SD (registered trademark) memory card is assumed. Here, since the size of the communication frame acquired by the high-speed communication is compressed, data that cannot be processed is not accumulated in the memory inside the PC, and therefore the occurrence of memory leak can be avoided.

  In addition, the main control unit 31 acquires, for each I / O port 200 of the sequencer 20, a communication frame made up of a set of input values via the communication line 50 with a unit capacity of 100 Mbps. The communication processing unit 32, the first storage unit 33, the data compression process within the communication frame and the data compression process between the communication frames are performed and held in the first storage unit 33. Sequence control of the parameter setting unit 34, the data transfer control unit 35, and the second storage unit 36 is performed.

(Configuration of motion reproduction device)
The motion reproduction device 40 restores the communication frame transferred and recorded in the second storage unit 36 to a set of input values before the data compression processing according to the time information, and preprograms the sequencer 20 based on the restored input values. As described, the output value is determined and display information is generated and displayed on the display unit 46. Therefore, the operation reproduction device 40 includes a main control unit 41, a restoration processing unit 42, a parameter setting unit 43, an operation reproduction processing unit 44, a drawing / display control unit 45, and a display unit 46. Is done. These blocks 41 to 45 are commonly connected to an internal bus 47 having a plurality of lines for address, data, and control.

When the motion reproduction device 40 reproduces the motion, the second storage unit 36 (SD card) in which the communication frame after compression shown in FIG. Shall be connected.

The restoration processing unit 42 restores the communication frame recorded in the second storage unit 36 to a set of input values before the data compression processing according to the time information, and outputs it to the operation reproduction processing unit 44. The parameter setting unit 43 sets an operation reproduction range, an operation reproduction end condition, and the like in the operation reproduction processing unit 44, and controls the operation reproduction processing by the operation reproduction processing unit 44. The motion reproduction processing unit 44 determines an output value as programmed in advance in the sequencer 20 (control program) based on the input value restored by the restoration processing unit 42, and generates display information for reproducing the generated motion. The image is output to the drawing / display control unit 45.

The drawing / display control unit 45 draws the display information generated by the operation reproduction processing unit 44 in the built-in display memory, reads the drawn display information in accordance with the display timing of the display unit 46, and displays it in the display unit 46. Output. The display unit 46 is a display monitor composed of a display device such as an LCD (Liquid Crystal Display Device) or an OLED (Organic Light Emitted Diode), and is synchronized with a display timing signal output from the drawing / display control unit 45. The display information drawn in the display memory is displayed.

  The main control unit 41 causes the motion reproduction device 40 to restore the communication frame recorded in the second storage unit 36 to a set of input values before data compression processing according to time information, and based on the restored input values. The restoration processing unit 42, the parameter setting unit 43, the operation reproduction processing unit 44, the drawing so that the output value is determined as programmed in the sequencer 20 in advance and display information is generated and displayed on the display unit 46. The sequence control of the display control unit 45 is performed.

(Operation of data acquisition device)
2 and 3 are flowcharts showing the operation of the data acquisition apparatus 30 according to the present embodiment. Hereinafter, the operation of the data acquisition apparatus 30 according to the present embodiment shown in FIG. 1 will be described in detail with reference to the flowcharts of FIGS. 2 and 3.

  First, the main control unit 31 initializes the built-in registers X, Y, and i assigned in advance (step S101 in FIG. 2). The registers X and Y are respectively set with the previous input value and the current input value in order to perform inter-frame compression processing as will be described later. The register i is used for counting the order of communication frames acquired by the main control unit 31 via the communication line 50.

Next, when the main control unit 31 shifts control to the communication processing unit 32, the communication processing unit 32 sequentially acquires communication frames from the sequencer 20 via the communication line 50 (step S102). Then, at regular intervals (step S103 “YES”), input values constituting the communication frame are sequentially sampled, and intra-frame compression processing and inter-frame compression processing are performed.

  In performing the intra-frame compression processing, the communication processing unit 32 first determines whether or not the input value is an input value that has arrived from the high-speed port (step S104). Here, if the input value comes from the high speed port (step S104 “YES”), the input value is taken in (step S105), and if the input value comes from the low speed port (step S104 “NO”), The input value is divided according to the number of divisions (n) and the division size (sz) set by the parameter setting unit 34 (step S106). Then, the communication processing unit 32 combines the input value from the divided low-speed port and the input value from the high-speed port that has been captured in advance to assemble the divided communication frame each time and capture this (step) S107).

  The processes in steps S104 to S107 described above are repeatedly executed for the number of divisions n set by the parameter setting unit 34, and the generated divided frames are acquired each time. That is, the communication frame before division includes a first input value (A1, A2, A3) that is obtained from the first port (high-speed port) and changes at a relatively high frequency, and the second and third ports ( Second and third input values (B1, B2, B3 and C1, C2, C3) that are obtained from the low-speed port and change at a relatively low frequency. Then, the communication processing unit 32 performs the first communication including the first input value (A1), the second input value (B1), and the third input value (C1) at the first time (T1). The frame (F1) is acquired, and at the second time (T2), the second communication frame (F2) including the first input value (A2) and the third input value (C2) is acquired, and the first The third communication frame (F3) composed of the first input value (A3) and the second input value (B3) is obtained at time 3 (T3), and data compression processing in the communication frame is performed. Apply.

  The communication processing unit 32 restores each input value from the divided low-speed port to the input value before the division at the timing when the above processing reaches the division number n (“YES” in step S108). Is rearranged in the communication frame before the division by combining with the input value, and the contents are set in the register Y as the currently acquired input value (step S109).

  Subsequently, when performing the inter-frame compression process, the communication processing unit 32 compares the previous input value set in the register X with the current input value set in the register Y (step S110). If there is a change in the input value (“YES” in step S110), the communication frame (the contents of the register Y) captured this time is selectively held in the first storage unit 33 with the time stamp TS (step S110). S111). On the other hand, if there is no change (step S110 “NO”), or after the contents of the register Y are held in the first storage unit 33, the contents of the register X holding the contents of the previously captured communication frame are The taken-in communication frame is updated to the content of the register Y (step S112 in FIG. 3).

  Note that the processing in steps S102 to S112 described above is repeatedly executed by incrementing the register i by +1 every time a communication frame is acquired (step S113) for the unit capacity that can be acquired by one communication. That is, the communication processing unit 32 determines from each of the first input values (A1, A2, A3) and each of the second and third input values (B1, B2, B3, and C1, C2, C3). Each time each communication frame (F1, F2, F3) is acquired, the communication frame Y acquired this time is compared with the communication frame X acquired last time. By selectively holding the communication frame Y in the first storage unit 33, the acquired communication frame is subjected to data compression processing between the communication frames.

Finally, the main control unit 31 activates the data transfer processing by the data transfer control unit 35 at the timing when the processing of the communication frame for the unit capacity is completed (step S114 “YES”). At this time, the data transfer control unit 35 transfers the compressed communication frame stored in the first storage unit 33 to the second storage unit 36 via USB, for example, and records it (step S115).

  The above-described data acquisition operation will be supplementarily described with reference to the schematic diagram shown in FIG. FIG. 6A is a diagram showing a plurality of communication frames formed of a set of input values acquired each time via the communication line 50 in a table format. FIG. 6B shows a communication frame held in the first storage unit 33 and transferred to the second storage unit 36 among the plurality of communication frames. Here, for simplification of explanation, I / O # 1 (first port) is a high-speed port, I / O # 2 (second port), and I / O # 3 (third port) are An example in which the input value acquired from each low-speed port is divided into two (n = 2), stored in the first storage unit 33 at high speed, and transferred to the second storage unit 36. explain.

  According to FIG. 6A, as an input value, a communication frame in which I / O # 1 is OFF and I / O # 2 is OFF at time T1 is I / O # 1 is OFF and I / O # 2 is OFF. Communication frames with / O # 3 OFF are acquired, and communication frames consisting of sets of input values of I / O # 1 to I / O # 3 are acquired at time T1 and time T2. Further, at time T3, a communication frame with I / O # 1 OFF and I / O # 2 is ON, and at time T4, a communication frame with I / O # 1 OFF and I / O # 3 OFF. Acquired, and a communication frame consisting of a set of input values of I / O # 1 to I / O # 3 is acquired at times T3 and T4.

  Further, at time T5, a communication frame with I / O # 1 OFF and I / O # 2 ON, and at time T6, a communication frame with I / O # 1 OFF and I / O # 3 OFF. Acquired, and a communication frame consisting of a set of input values of I / O # 1 to I / O # 3 is acquired at times T5 and T6. At time T7, a communication frame with I / O # 1 OFF and I / O # 2 is ON. At time T8, a communication frame with I / O # 1 OFF and I / O # 3 is ON. Acquired, and a communication frame consisting of a set of input values of I / O # 1 to I / O # 3 is acquired at times T7 and T8.

  In holding the communication frame in the first storage unit 33, the communication processing unit 32 firstly sets the communication frame (OFF) at time T2 when all the input values of I / O # 1 to I / O # 3 are first captured. , OFF, OFF) is set in the register X as the previous communication frame. Next, the communication processing unit 32 sets the communication frame (OFF, ON, OFF) at time T4 at which all the input values of I / O # 1 to I / O # 3 are taken in the register Y as the current frame, Compare with the communication frame (OFF, OFF, OFF) previously set in the register X. Here, since a change is recognized in the input value of I / O # 2, the communication processing unit 32 holds the communication frame (OFF, ON, OFF) acquired at time T4 in the first storage unit 33.

  On the other hand, as a result of comparison with the previous communication frame (OFF, ON, OFF) acquired at time T4, no change in the input value is recognized for the current communication frame (OFF, ON, OFF) acquired at time T6. Therefore, holding the communication frame in the first storage unit 33 at time T6 is prohibited. Further, as a result of comparison with the previous communication frame (OFF, ON, ON) acquired at time T8, the change of the input value is recognized as a result of comparison with the previous communication frame (OFF, ON, OFF) acquired at time T4. Therefore, the communication processing unit 32 holds the communication frame (OFF, ON, ON) acquired at time T8 in the first storage unit 33.

In this way, by detecting the change in the previous input value and the current input value of the acquired communication frame, and performing the operation of holding the communication frame composed of the current input value in the first storage unit 33 only when the change occurs, The number of communication frames held in the first storage unit 33 can be reduced, and the time required for data processing can be shortened by reducing the number of communication frames written to the first storage unit 33. Furthermore, when acquiring communication frames, the input value of the low-speed port is divided and acquired at the timing of acquiring the input value from the high-speed port, so that processing can be performed at high speed without causing the input value of the high-speed port to be lost. Can also be stabilized.

As described above, according to the data acquisition device 30 according to the present embodiment, the communication processing unit 32 performs a communication frame including a set of input values acquired with the first unit capacity via the communication line 50. Data compression processing within the communication frame and data compression processing between the communication frames are performed and held in the first storage unit 33, and the data transfer control unit 35 transfers the first storage unit 33 from the first storage unit 33 to the second storage unit 36. The data is transferred and recorded in a second unit capacity slower than the unit capacity. For this reason, even when the data capacity of a communication frame acquired by high-speed communication is larger than the data capacity that can be processed internally, the occurrence of memory leak can be suppressed and simulation can be enabled.

Also, due to the characteristics of the input device assigned to the port, for example, the data compression processing in the communication frame is performed by dividing and fetching the input value from the second port having a relatively slow processing speed. For this reason, since the size of the communication frame to be captured at a time is reduced, the time required for acquisition is shortened, and the input value from the first port having a relatively high processing speed is not missed and can be stably captured. Further, the communication processing unit 32 records the communication frame acquired this time in the storage unit only when there is a change in the content of the communication frame after the data compression processing in the communication frame is performed. Data compression processing is performed between them. For this reason, only a data compression process between communication frames is performed, and a further compression effect can be obtained as compared with the conventional data acquisition apparatus which has been recorded, and the memory can be effectively used.

(Operation of motion reproduction device)
Next, the operation of the motion reproduction device 40 will be described with reference to the flowchart of FIG. First, the main control unit 41 determines the presence / absence of a reproduction parameter set and acquired by the parameter setting unit 43 (step S201). If the reproduction parameter is set (step S201 “YES”), the main control unit 41 reads out a communication frame (input value) having a size corresponding to the reproduction range from the second storage unit 36, and performs a restoration process. Delivered to the unit 42 (step S202). If the reproduction parameter is not set (step S201 “NO”), a screen for prompting a setting input is displayed on the display unit 46 (step S203).

  Next, the restoration processing unit 42 restores an input value corresponding to the reproduction range. A method of restoring the input value will be described with reference to the schematic diagram of FIG. In FIG. 6, description will be made assuming that the restoration processing unit 42 restores input values at times T1 to T8, for example. At this time, the restoration processing unit 42 receives the input value (OFF, OFF, OFF) at time T2 and the input value (OFF, ON, OFF) at time T4 from the second storage unit 36 via the main control unit 41. The input values (OFF, ON, ON) at time T8 are acquired.

  Based on the input value at time T2 (OFF, OFF, OFF), the input value at time T4 (OFF, ON, OFF), and the input value at time T8 (OFF, ON, ON), Going back to the past, the change of the input value is restored on the time axis, and the processing is handed over to the motion reproduction processing unit 44 (step S204). Specifically, as shown in FIG. 6C, the restoration processing unit 42 is OFF from T1 to T8 at the input port I / O # 1, and OFF from time T1 to T2 at the input port # 2. ON after T3, input port # 3 is OFF from time T1 to T7, and input value on time axis t for each of input ports I / O # 1 to I / O #n so as to be ON at time T8. Restore. That is, the input value shown in the table format shown in FIG.

  When the operation reproduction processing unit 44 acquires an input value corresponding to the reproduction range from the restoration processing unit 42, the operation reproduction processing unit 44 tracks (traces) the operation state of the equipment by the sequencer 20 (ladder program) based on the history, and each time the Display information for reproduction is generated and supplied to the drawing / display control unit 45 (step S205). The drawing / display control unit 45 draws the display information generated by the operation reproduction processing unit 44 in a display memory (not shown) and reads it in synchronization with the display timing of the display unit 46. For example, the screen image shown in FIG. It is displayed (step S206). As illustrated in the screen image in FIG. 5, the operation reproduction processing unit 44 represents the operation timing and change of the input / output device while changing the shape and color of the relay symbol in the ladder program displayed on the screen. Is possible.

  In addition, when the operation reproduction processing unit 44 reproduces the operation state of the equipment based on the history of the input values recorded in the second storage unit 36, the reproduction is limited to a specific input / output device as well as a reproduction range. It is also possible. It is also possible to set the execution of reproduction step by step or the execution speed can be variably set. Therefore, simulation is possible while reducing the burden on the operator, and application to the created program debugging is also conceivable.

  As described above, according to the motion reproduction device 40 according to the present embodiment, the restoration processing unit 42 uses the communication frame compressed and recorded in the recording unit (second storage unit 36) according to time information before the compression processing. By restoring the set of input values, the operation reproduction processing unit 44 tracks the operation state of the sequencer 20 for each time indicated by the corresponding time information using the restored input value and displays it on the screen. For this reason, it is not necessary to create a virtual operation model for each sequencer by using a memory in which input values subjected to data compression processing within and between communication frames are recorded in time series, and Since the contents can be reproduced on the sequencer program, it is easy to investigate the cause when an abnormality occurs, and the burden on the operator required for simulation and program debugging is reduced.

  The facility operation state management system 1 according to the present embodiment is controlled by connecting a facility (equipment system 10) including a plurality of input devices and output devices to a sequencer 20, as shown in FIG. The present invention is applied to an equipment operation state management system including at least a first storage unit 33, a second storage unit 36, and a display unit 46. Then, for each port assigned to the input device connected to the sequencer 20, a communication frame consisting of a set of input values is acquired at the first communication speed via the communication line 50, and a communication frame is obtained with respect to the acquired communication frame. The data compression processing in the network and the data compression processing between the communication frames are performed, recorded in the first storage unit 33, and the communication frame recorded in the first storage unit 33 is the second slower than the first communication speed. The data acquisition device 30 that records in the second storage unit 36 at the communication speed and the communication frame recorded in the second storage unit 36 are restored to a set of input values before data compression processing according to time information, and restored input And an operation reproduction device 40 that generates display information by determining an output value as programmed in advance in the sequencer 30 based on the value, and displays the information on the display unit 46. That.

  According to the equipment operation state management system 1 according to the present embodiment, the data acquisition device 30 acquires a plurality of communication frames including a set of input values, and performs data compression in the communication frame for each acquired communication frame. Processing and data compression processing between communication frames are performed and recorded in the first storage unit 33. Further, the motion reproduction device 40 restores the recorded communication frame after the compression processing to a set of input values before the compression processing according to the time information, and uses the restored input values independently of the operation state of the equipment. At each time indicated by the corresponding time information, the operating state of the equipment is traced and displayed on the screen. For this reason, the data acquisition device 30 can suppress the occurrence of a memory leak even when the data capacity of a communication frame acquired by high-speed communication is larger than the data capacity that can be processed internally, thereby enabling simulation. Can do. Further, the operation reproduction device 40 can further reduce the burden on the operator during the simulation, and can facilitate the simulation without moving the control machine constituting the equipment system.

  In addition, according to the equipment operation state management system 1 according to the present embodiment, the data acquisition device 30 and the motion reproduction device 40 have been described as being configured separately, but are integrated if processing capability permits. The same effect can be obtained.

1 ... equipment operation state management system, 10 ... equipment system, 20 ... sequencer,
30 ... Data acquisition device (31 ... Main control unit, 32 ... Communication processing unit, 33 ... First storage unit, 34 ... Parameter setting unit, 35 ... Data transfer control unit, 36 ... Second storage unit, 37 ... Internal bus) ,
40 ... motion reproduction device (41 ... main control unit, 42 ... restoration processing unit, 43 ... parameter setting unit, 44 ... motion reproduction processing unit, 45 ... drawing / display control unit, 46 ... display unit, 47 ... internal bus), 50 ... communication line, 200 ... I / O port

Claims (5)

A data acquisition device including a first storage unit and a second storage unit connected to a sequencer via a communication line,
For each port assigned to an input device connected to the sequencer, a communication frame consisting of a set of input values obtained from the port is acquired with a first unit capacity via the communication line, and for the acquired communication frame, A communication processing unit that performs data compression processing within a communication frame and data compression processing between communication frames and holds the data in the first storage unit;
A data transfer control unit for transferring the communication frame after the data compression processing held in the first storage unit to the second storage unit with a second unit capacity smaller than the first unit capacity;
A data acquisition device comprising: The communication frame acquired by the communication processing unit is
Among the ports, the first input values (A1, A2, A3) that change with the first frequency acquired from the first port, and the first frequency acquired from the second and third ports. Second and third input values (B1, B2, B3 and C1, C2, C3) that change at a second frequency lower than,
The communication processing unit
At a first time, a first communication frame (F1) consisting of a first input value (A1) and a second input value (B1) is acquired, and at a second time, the first input value ( A second communication frame (F2) consisting of A2) and the third input value (C2) is acquired, and at the third time, the first input value (A3) and the second input value (B3) The data acquisition device according to claim 1, wherein each of the third communication frames (F3) is acquired and data compression processing is performed in the communication frames. The communication processing unit
By the data compression processing in the communication frame, each of the first input values (A1, A2, A3) and each of the second and third input values (B1, B2, B3, and C1, C2, C3), each time each communication frame (F1, F2, F3) is acquired, the communication frame acquired this time is compared with the communication frame acquired last time. 3. The data acquisition apparatus according to claim 1, wherein the communication frame acquired this time is selectively held in the first storage unit, and data compression processing between the communication frames is performed on the communication frame. . A communication frame consisting of a set of input values taken from the sequencer via the communication line is subjected to data compression processing within the communication frame and data compression processing between the communication frames, so that the communication frame after the data compression processing is sometimes A storage unit recorded in the series;
A restoration processing unit that restores the communication frame recorded in the storage unit to the set of input values before data compression processing according to time information;
Based on the input value restored by the restoration processing unit, an output value is determined as preprogrammed in the sequencer to generate display information, and an operation reproduction processing unit for displaying on the screen;
An operation reproduction apparatus characterized by comprising: A facility operation state management system comprising a first storage unit, a second storage unit, and a display unit, wherein a facility including a plurality of input devices and output devices is connected to and controlled by a sequencer,
For each port assigned to an input device connected to the sequencer, a communication frame consisting of a set of input values obtained from the port is acquired with a first unit capacity via the communication line, and for the acquired communication frame, Data compression processing within the communication frame and data compression processing between the communication frames are performed and held in the first storage unit, and the communication frame after the data compression processing held in the first storage unit is A data acquisition device for transferring to the second storage unit with a second unit capacity smaller than one unit capacity;
The communication frame recorded in the second storage unit is restored to the set of input values before data compression processing according to time information, and an output value as programmed in advance in the sequencer based on the restored input value Generating a display information and displaying it on the display unit;
A facility operating state management system characterized by comprising:

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