JP2014182608A - Method for performing parallel operation in control computational system and newly installed control computer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate investigation of a failure and identification of a cause when the failure has occurred after entering into actual operation with a newly installed control computer and a newly installed HMI terminal connected to the newly installed control computer.SOLUTION: In a control computational system where a control computer 51 communicates with a superior system 52 and an inferior system 53, input data from the superior system 52 and the inferior system 53 into the control computer 51 is parallely acquired by a newly installed control computer 1 so as to perform parallel operation when the control computer 51 is replaced with the newly installed control computer 1. In this case, parallel operation is performed by disconnecting an HMI terminal 54 connected to the newly installed control computer 1 and causing communication between a newly installed HMI terminal 2 and the control computer 51 to be performed via the newly installed control computer 1. It means that the system enters into actual operation with the newly installed control computer 1 and the newly installed HMI terminal 2 after performing parallel operation as performing actual operation with the control computer 51 and the newly installed HMI terminal 2.

Description

  The present invention relates to a method for performing parallel operation in a control computer system suitable for use in updating a control computer to a new control computer in a control computer system in which the control computer communicates with an external device, and for new control. Regarding computers.

In a control computer system in which a control computer such as a large-scale manufacturing plant communicates with an upper system or a lower system, an old control computer may be updated to a new control computer. In this case, the processing results in both should be the same as long as no changes have been made to the processing contents of the old and new control computers, but the processing results may differ due to programming mistakes in the newly installed control computer. May end up.
Therefore, the input data from the upper system or lower system to the old control computer is taken to the new control computer and parallel operation (also called pararun) is performed, and the processing results in both are compared, for new control A function verification of a computer has been performed (see Patent Documents 1 to 3 and the like).

JP 2007-80201 A JP 2008-97457 A JP 2012-175343 A

Even when functional verification is performed in parallel operation, there are actually several to several tens of problems after switching to production operation with a new control computer.
The reason is as follows.
(1) There may be a check failure or a check mistake in function verification due to parallel operation.
(2) Since the parallel operation is performed together with the production operation, it is usually limited to a case where normal operation is performed. For this reason, for example, for an abnormal operation case, it is necessary for a person to perform functional verification considering the test case, and a test case leakage may occur.
When a problem occurs in this way, it is necessary to investigate the problem, identify the cause, and take countermeasures. However, investigating the problem and identifying the cause is a large software scale and has a wide impact range, so time is required. Often required.

By the way, an HMI terminal is connected to each of the old and new control computers. In the conventional parallel operation, after performing the parallel operation while performing the production operation with the old control computer and the old HMI terminal connected thereto, the operation is switched to the production operation with the new control computer and the new HMI terminal connected thereto. .
In this case, a failure occurred after switching to the production operation with the newly installed control computer and the newly installed HMI terminal. Actually, this is not a failure of the newly installed control computer, but the operator's operation because he was unfamiliar with the operation of the newly installed HMI terminal. There is also a possibility that it is caused by a mistake or a software defect of a newly installed HMI terminal. Thus, it is necessary to investigate the failure and identify the cause including the cause on the newly installed control computer side or the cause on the newly installed HMI terminal side, which is a time-consuming factor.

  The present invention has been made in view of the above points. When a problem occurs after switching to a production operation by a new control computer and a new HMI terminal connected thereto, investigation of the problem and identification of the cause The purpose is to make it easier to do.

The method for carrying out parallel operation in the control computer system of the present invention is such that when the control computer is updated to a newly installed control computer in the control computer system in which the control computer communicates with an external device, the control device is controlled by the external device. A method for performing parallel operation by taking input data to a computer into the newly installed control computer, the step of releasing the connection of the HMI terminal connected to the control computer, and the newly installed computer And a step of performing parallel operation by performing exchange between the new HMI terminal connected to the control computer and the control computer via the new control computer.
In this case, the new control computer receives the screen display data transmitted from the control computer and, based on the display content information representing the content to be displayed on the screen, included in the received screen display data, Screen control for generating display content information corresponding to the screen display on the new HMI terminal, transmitting it to the new HMI terminal, and instructing it when it is necessary to switch the screen included in the received screen display data Based on the information, screen information corresponding to the screen display on the new HMI terminal is transmitted to the new HMI terminal.
The new control computer receives setting data transmitted from the new HMI terminal, generates setting data that can be handled by the control computer based on the received setting data, and generates the control data. To be sent to the computer.
The new control computer of the present invention is a new control computer that is updated from a control computer that communicates with an external device, the means for receiving screen display data transmitted from the control computer, and the received screen Based on the display content information representing the screen display content included in the display data, display content information corresponding to the screen display on the new HMI terminal connected to the new control computer is generated, and the new HMI terminal And the screen information corresponding to the screen display on the newly installed HMI terminal based on the screen control information included in the received screen display data and instructing the screen switching when necessary. Means for transmitting to a new HMI terminal.
Another feature of the new control computer of the present invention is a new control computer that is updated from a control computer that communicates with an external device, the new control computer being connected to the new control computer. A means for receiving the setting data transmitted from the computer, and a means for generating setting data that can be handled by the control computer based on the received setting data and transmitting the setting data to the control computer. It is in.

In the present invention, when the control computer is updated to the new control computer in the control computer system in which the control computer communicates with the external device, the input data from the external device to the control computer is taken to the new control computer. When performing parallel operation, the exchange between the newly installed HMI terminal connected to the newly installed control computer and the control computer is performed via the newly installed control computer. That is, after performing a parallel operation while performing a production operation with the control computer and the newly installed HMI terminal, the operation is switched to a production operation with the newly installed control computer and the newly installed HMI terminal.
Thereby, it becomes possible to get used to the operation of the newly installed HMI terminal and to confirm the quality of the software of the newly installed HMI terminal during the parallel operation period. Therefore, if a problem occurs after switching to production operation with a new control computer and a new HMI terminal, it may be due to an operator's operation error due to unfamiliarity with the operation of the new HMI terminal or the software of the new HMI terminal software. It is possible to eliminate the possibility that a problem is caused. In other words, it is only necessary to investigate the problem and identify the cause by focusing on the software problem of the newly installed control computer, making it easier to investigate the problem and identifying the cause, reducing the time required for investigating the problem and identifying the cause. Can be made.

It is a figure which shows the structure of the existing control calculation system. It is a figure which shows the state which is implementing parallel operation with the method to which this invention is applied. It is a figure which shows the state which is implementing parallel operation by the conventional method. It is a figure which shows the structure of the computer for new control, and a new HMI terminal. It is a figure which shows the structure of the computer for new control, and a new HMI terminal. It is a figure which shows the state switched to production operation by the new control computer and new HMI terminal after implementing parallel operation.

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 shows a configuration example of an existing control calculation system. A control computer 51 such as a large-scale manufacturing plant performs communication using a modem 55 and a host system 52, which is also called a vidicon, which is an external device. Further, the control computer 51 performs communication using a modem 55 and a lower system 53 such as an electric instrument which is an external device. An HMI (Human Machine Interface) terminal 54 is connected to the control computer 51 via a modem 55. The control computer 51 and the HMI terminal 54 are configured by a computer device including, for example, a CPU, a ROM, a RAM, and the like.

In the following, when the control computer 51 (hereinafter referred to as the old control computer 51) is updated to the new control computer 1 in the control computer system shown in FIG. A case will be described in which input data to 51 is taken by the newly installed control computer 1 to perform parallel operation.
FIG. 2 shows a state in which parallel operation is performed by a method to which the present invention is applied. FIG. 3 shows a state in which parallel operation is performed by a conventional method as a comparative example. In FIG. 2 and FIG. 3, for convenience of explanation, the same components will be described with the same reference numerals.

  As shown in FIGS. 2 and 3, a new control computer 1, a new HMI terminal 2, and a switching hub 3 that relays the connection between the new control computer 1 and the new HMI terminal 2 are installed. The new control computer 1 and the new HMI terminal 2 perform Ethernet (registered trademark) communication. The newly installed control computer 1 and the newly installed HMI terminal 2 are configured by a computer device including, for example, a CPU, a ROM, a RAM, and the like.

  In the conventional method shown in FIG. 3, after the parallel operation is performed while performing the actual operation by the old control computer 51 and the HMI terminal 54 connected thereto (hereinafter referred to as the old HMI terminal 54), the new control computer 1 and the new control computer 1 are installed. Switch to production operation by HMI terminal 2. A range surrounded by a one-dot chain line in FIG. 3 indicates a production operation range when parallel operation is performed.

As shown in FIG. 3, input data from the host system 52 to the old control computer 51 is taken by the new control computer 1. Specifically, input data from the host system 52 to the old control computer 51 is input to the computer 5 for format change via the protocol converter 4a. In the computer 5 for format change, the communication data format corresponding to the old control computer 1 is changed to the communication data format corresponding to the new control computer 1 and transmitted to the new control computer 1.
Similarly, input data from the lower system 53 to the old control computer 51 is taken by the new control computer 1. Specifically, input data from the lower system 53 to the old control computer 51 is input to the computer 5 for format change via the protocol converter 4b. The computer 5 for changing the format changes the collected communication data to a communication data format corresponding to the new control computer 1 and transmits it to the new control computer 1.

  In addition, setting input data from the old HMI terminal 54 to the old control computer 51 is taken to the new HMI terminal 2. Specifically, setting input data from the old HMI terminal 54 to the old control computer 51 is input to the new HMI terminal 2 via the protocol converter 6. In the newly installed HMI terminal 2, the parameterized communication data is changed to a communication data format corresponding to the newly installed control computer 1 and transmitted to the newly installed control computer 1.

  As described above, after performing the parallel operation while performing the production operation (the production operation range surrounded by the one-dot chain line in FIG. 3) by the old control computer 51 and the old HMI terminal 54, the new control computer 1 and the new HMI The terminal 2 is switched to the production operation. Therefore, as described above, it was thought that a problem occurred in the new control computer 1, but in fact, it was not a problem in the new control computer 1 itself, and the operator who was unfamiliar with the operation of the new HMI terminal 2. There is also a possibility that an operation error is a cause or a software defect of the newly installed HMI terminal 2 is a cause.

  On the other hand, in the method to which the present invention shown in FIG. 2 is applied, after performing parallel operation while performing the actual operation by the old control computer 51 and the new HMI terminal 2, the new control computer 1 and the new HMI terminal 2 Switch to production operation. A range surrounded by a one-dot chain line in FIG. 2 indicates a production operation range when parallel operation is performed.

  As shown in FIG. 2, the configuration in which the input data from the higher system 52 to the old control computer 51 and the input data from the lower system 53 to the old control computer 51 are respectively taken by the new control computer 1 is illustrated. Same as 3.

  Further, the old HMI terminal 54 connected to the old control computer 51 is disconnected, and the old HMI terminal 54 is removed. Then, the old control computer 51 and the switching hub 3 are connected via the protocol converter 7 and the new HMI terminal 2 and the old control computer 51 are exchanged via the new control computer 1 in parallel. Perform operation.

Here, in order to perform the actual operation by the old control computer 51 and the new HMI terminal 2, it is necessary to enable screen display on the new HMI terminal 2 based on the screen display data from the old control computer 51. (See arrow A in FIG. 2).
FIG. 4 shows the configuration of the new control computer 1 and the new HMI terminal 2 so that the new HMI terminal 2 can display the screen based on the screen display data from the old control computer 51.

  In the new control computer 1, reference numeral 101 denotes a receiving unit which receives screen display data transmitted from the old control computer 51 and temporarily stores it in the storage unit 102. The screen display data is data created as a result of executing the process according to the operation event in the old control computer 51, and it is necessary to switch the display content information representing the content (various numerical values, etc.) displayed on the screen and the screen. And screen control information for instructing it. Needless to say, the screen display data transmitted from the old control computer 51 corresponds to the screen display on the old HMI terminal 54.

  An analysis / extraction unit 103 analyzes screen display data received by the reception unit 101 and stored in the storage unit 102, and extracts display content information and screen control information. When screen switching is not necessary, the screen control information is not included in the screen display data. The extracted display content information and screen control information are stored in a storage unit (not shown) for comparison of processing results in the old and new control computers 1 and 51.

  Reference numeral 104 denotes a display content information generation / transmission unit. Based on the display content information extracted by the analysis / extraction unit 103, a display corresponding to the screen display on the new HMI terminal 2 having the same content as the display content information. Content information is generated and transmitted to the new HMI terminal 2.

  A screen information acquisition / transmission unit 105 acquires screen information from the screen HTML file 106 based on the screen control information extracted by the analysis / extraction unit 103 and transmits the screen information to the new HMI terminal 2. The screen information is a screen fixed format such as a screen layout, and the screen HTML file 106 stores various screen fixed formats corresponding to the screen display on the new HMI terminal 2 in advance. Although the screen HTML file 106 is illustrated as being in the new control computer 1, the screen control file 1 may be downloaded from the external screen HTML file 106.

  In the new HMI terminal 2, reference numeral 201 denotes a receiving unit which displays display content information transmitted from the display content information generation / transmission unit 104 of the new control computer 1 and screen information transmitted from the screen information acquisition / transmission unit 105. Received and temporarily stored in the storage unit 202.

  A screen output unit 203 displays a screen on the display 2 a based on display content information and screen information received by the receiving unit 201 and stored in the storage unit 202.

In addition, in order to perform the actual operation by the old control computer 51 and the new HMI terminal 2, the old control computer 51 can execute processing based on the setting data set by the operation of the new HMI terminal 2. Needed (see arrow B in FIG. 2).
FIG. 5 shows the configuration of the new control computer 1 and the new HMI terminal 2 for enabling the old control computer 51 to execute processing based on the setting data set by the operation of the new HMI terminal 2. .

  In the new HMI terminal 2, a setting data extraction unit 204 extracts setting data set by operating the input device 2 b such as a keyboard and a mouse, and temporarily stores the setting data in the storage unit 205.

  A transmission unit 206 transmits the setting data extracted by the setting data extraction unit 204 and stored in the storage unit 205 to the new control computer 1.

  In the new control computer 1, 207 is a receiving unit that receives setting data transmitted from the transmission unit 206 of the new HMI terminal 2 and temporarily stores it in the storage unit 208.

  An analysis unit 209 analyzes setting data received by the reception unit 207 and stored in the storage unit 208. The analyzed result is stored in a storage unit (not shown) for comparison of processing results in the old and new control computers 1 and 51.

  210 is a setting data generation / transmission unit that generates setting data that can be handled by the old control computer 51 and has the same content as the setting data based on the setting data analyzed by the extraction unit 209. This is transmitted to the old control computer 51.

  The configurations shown in FIGS. 4 and 5 enable the parallel operation to be performed while the actual operation is performed by the old control computer 51 and the new HMI terminal 2.

  FIG. 6 shows a state in which, after performing parallel operation as shown in FIG. 2, the old control computer 51 is removed and switched to the actual operation by the new control computer 1 and the new HMI terminal 2. As shown in FIG. 6, the old control computer 51 is removed, and accordingly, the modem 55 and the protocol converter 7 that have connected the old control computer 51 and the switching hub 3 are also removed. Thereafter, since the new control computer 1 and the host system 52 directly communicate with each other, the format change PC 5 becomes unnecessary, and therefore the format change PC 5 is also removed.

As described above, after performing the parallel operation while performing the production operation with the old control computer 51 and the new HMI terminal 2, the operation is switched to the production operation with the new control computer 1 and the new HMI terminal 2.
As a result, it becomes possible to get used to the operation of the new HMI terminal 2 and to confirm the quality of the software of the new HMI terminal 2 during the parallel operation period. Therefore, when a problem occurs after switching to the production operation by the newly installed control computer 1 and the newly installed HMI terminal 2, it may be caused by an operator's operation mistake due to unfamiliarity with the operation of the newly installed HMI terminal 2, or the newly installed HMI terminal. It is possible to eliminate the possibility that the second software is caused by a malfunction. In other words, it is only necessary to investigate the problem and identify the cause by focusing on the software problem of the newly installed control computer 1, and it is easy to investigate the problem and identify the cause, reducing the time required for investigating the problem and identifying the cause. It can be made.

As mentioned above, although this invention was demonstrated with various embodiment, this invention is not limited only to these embodiment, A change etc. are possible within the scope of the present invention.
In addition, the present invention supplies software (program) that realizes the function of the new control computer of the present invention to a system or apparatus via a network or various storage media, and the computer of the system or apparatus reads the program. It can also be realized by executing.

  1: new control computer, 2: new HMI terminal, 3: switching hub, 4a, 4b, 7: protocol converter, 5: computer device for format change, 51: old control computer, 52: host system, 53 : Lower system, 54: Old HMI terminal

Claims (5)

When the control computer is updated to a new control computer in a control computer system in which the control computer communicates with an external device, input data from the external device to the control computer is parameterized in the new control computer. To implement parallel operation,
Releasing the connection of the HMI terminal connected to the control computer;
A new HMI terminal connected to the new control computer, and a step of performing parallel operation by performing exchanges with the control computer via the new control computer. Implementation method of parallel operation in a computing system. The new control computer is
Receiving screen display data transmitted from the control computer;
Generating display content information corresponding to the screen display on the new HMI terminal based on display content information representing the content to be displayed on the screen included in the received screen display data, and transmitting the display content information to the new HMI terminal;
Based on screen control information included in the received screen display data and instructing screen switching when it is necessary, screen information corresponding to screen display on the new HMI terminal is transmitted to the new HMI terminal. The method of performing parallel operation in the control computer system according to claim 1. The new control computer is
Receiving setting data transmitted from the new HMI terminal;
3. The control calculation system according to claim 1, wherein setting data that can be handled by the control computer is generated based on the received setting data and is transmitted to the control computer. 4. Implementation method of parallel operation. A new control computer updated from a control computer communicating with an external device,
Means for receiving screen display data transmitted from the control computer;
Generating display content information corresponding to the screen display on the new HMI terminal connected to the new control computer based on the display content information representing the content to be displayed on the screen included in the received screen display data; Means for transmitting to the new HMI terminal;
Based on screen control information included in the received screen display data and instructing screen switching when it is necessary, screen information corresponding to screen display on the new HMI terminal is transmitted to the new HMI terminal. And a new control computer. A new control computer updated from a control computer communicating with an external device,
Means for receiving setting data transmitted from a new HMI terminal connected to the new control computer;
5. The new control according to claim 4, further comprising means for generating setting data that can be handled by the control computer based on the received setting data and transmitting the setting data to the control computer. Calculator.

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