JP2017151646A - Control system, host controller, and mounting/demounting method of sub controller - Google Patents

Abstract

PROBLEM TO BE SOLVED: To safely mount/demount a sub controller.SOLUTION: A host controller 110 includes: a host communication section (a network interface section 218) configured to be communicable with a sub controller 120; and a power supply section (a network power supply section 214) for supplying the sub controller with a network power. The sub controller is operated by any of the network power and a power independent of the network power, and includes a sub communication section (a network interface section 268) configured to be communicable with the host controller. When the communication with the sub communication section is cut off, the host communication section stops supplying the sub controller with the network power and, when the communication with the sub communication section is established, supplies the sub controller with the network power.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a control system in which a plurality of controllers are connected to each other via a network, a higher-order controller among the plurality of controllers, and a method for attaching and detaching a lower-order controller among the plurality of controllers.

  In a large-scale control system such as a programmable logic control system and a distributed control system, a plurality of controllers can be connected to each other and communicate with each other. For example, in a control system in which a master function or a slave function is assigned to a plurality of controllers, a controller that functions as a master (hereinafter simply referred to as a master controller) is a controller that functions as a slave (hereinafter simply referred to as a slave controller). .)), And the slave controller operates in accordance with the control command. In this way, the entire control system operates in an integrated manner.

  In such a control system, especially to increase the number of slave controllers, a daisy chain in which the slave controllers are connected in series (a daisy chain) in order not to unnecessarily increase the number of connection lines between the master controller and the slave controller. A connection may be used. When such a daisy chain connection is used, it is desirable that the network connection between other controllers be maintained even when the main power supply of each slave controller is turned off (including spontaneous and malfunctioning).

  Therefore, in addition to the main power supply, the network interface unit in the controller that relays the network connection is separately supplied with power (hereinafter simply referred to as network power) from a master controller dedicated to the network (hereinafter simply referred to as network power supply). There is known a technique for supplying (for example, Patent Document 1). In such a technique, either the main power supply or the network power supply is selected in the slave controller according to the voltage of the main power supply, and power is efficiently supplied to the network interface unit.

JP 2013-020577 A

  However, the above-described technology for efficiently supplying power to the network interface unit is to continue network communication with lower slave controllers even when the main power of the slave controller is off. The exchange mode is not considered. For example, if the slave controller is replaced without turning off the network power supply from the master controller, an inrush current may occur when a new slave controller is connected. Therefore, the master controller must be stopped when the slave controller is replaced.

  Therefore, in view of such a problem, an object of the present invention is to provide a control system capable of safely attaching / detaching a lower controller, an upper controller, and a method of attaching / detaching a lower controller.

  In order to solve the above-described problem, in the control system of the present invention, which includes a higher-order controller and a lower-order controller that are connected via a network and can communicate with each other, the higher-order controller can communicate with the lower-order controller. And a power supply unit that supplies network power to the lower level controller. The lower level controller operates by either network power or power independent of the network power, and can communicate with the higher level controller. The upper communication unit stops supplying network power to the lower controller if communication with the lower communication unit is disconnected, and establishes communication with the lower communication unit when communication with the lower communication unit is established. It is characterized by supplying network power.

  The power line that supplies network power and the signal line that performs communication may be integrally attached and detached between the upper controller and the lower controller.

  In order to solve the above problems, the upper level of the present invention is connected to a lower level controller including a lower level communication unit that can communicate by receiving power supplied from either network power or power independent of network power. The controller can communicate with the power controller that supplies network power to the subordinate controller and the subordinate controller, and if communication with the subordinate communicator is disconnected, the network power supply to the subordinate controller is stopped. An upper communication unit that supplies network power to the lower controller when communication with the lower communication unit is established.

  In order to solve the above-described problem, a higher-level controller including a higher-level communication unit that can communicate with a lower-level controller and a power supply unit that supplies network power to the lower-level controller, and network power or network power independent In the attaching / detaching method of the present invention in which a lower-order controller that operates by any one of the electric powers and that has a lower-order communication unit that can communicate with the upper-order controller is connected to the network in a control system, When communication with the lower communication unit is disconnected, the upper communication unit stops supplying network power to the lower controller, and when communication with the lower communication unit is established, network power is supplied to the lower controller. It is characterized by making it.

  As described above, according to the present invention, it is possible to safely attach and detach the subordinate controller.

It is explanatory drawing which showed the schematic relationship of each apparatus which comprises a control system. It is the block diagram which showed the schematic structure of the master controller. It is the block diagram which showed the schematic structure of the slave controller. It is explanatory drawing for demonstrating the daisy chain connection of a some controller. It is a flowchart for demonstrating the attachment or detachment method of a low-order controller. It is explanatory drawing for demonstrating operation | movement of the attachment / detachment method. It is explanatory drawing for demonstrating operation | movement of the attachment / detachment method.

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The dimensions, materials, and other specific numerical values shown in the embodiment are merely examples for facilitating understanding of the invention, and do not limit the present invention unless otherwise specified. In the present specification and drawings, elements having substantially the same function and configuration are denoted by the same reference numerals, and redundant description is omitted, and elements not directly related to the present invention are not illustrated. To do.

(Control system 100)
FIG. 1 is an explanatory diagram showing a schematic relationship between devices constituting the control system 100. The control system 100 includes a plurality of master controllers 110 that function as masters, and one or a plurality of slave controllers 120 that function as slaves and are connected to the master controllers 110, respectively. A production execution system (MES: Manufacturing) (Execution System) etc. In the control system 100, the master controllers 110 are connected to each other by, for example, a dedicated connection wiring 130. Further, the master controller 110 and the slave controller 120 are connected through a network wiring 132 made of Giga (G) -based Ethernet (registered trademark) such as RJ45, for example.

  The master controller 110 is composed of a plurality of modules such as a power supply module, a CPU module, an input / output module, and a communication module, and operates according to a control program. Among such modules, for example, the CPU module has a control program for sequence control generated through a ladder diagram and the like, based on the sensor detection result of the slave controller 120 input through the input / output module, etc. An arithmetic process is performed and a control command is transmitted to control the slave controller 120.

  The slave controller 120 includes a sensor that detects various states in FA (Factory Automation), and an electric device such as an electric motor and an encoder that operate according to the detection result of the sensor. Hereinafter, basic structures of the master controller 110 and the slave controller 120 will be described, and then specific connection modes and operations will be described in detail.

(Master controller 110)
FIG. 2 is a block diagram showing a schematic configuration of the master controller 110. In FIG. 2, the flow of power is indicated by a solid line, and the flow of signals is indicated by a broken line. As shown in FIG. 2, the master controller 110 includes a main circuit 210, a main power acquisition unit 212, a network power supply unit 214, a regulator 216, a network interface unit 218, and a network power control unit 220. Composed.

  The main circuit 210 operates by receiving power supply from the main power acquisition unit 212.

  The main power acquisition unit 212 acquires main power of 24V from the main power supply 200 and generates 5V of power through the electrolytic capacitor 212a and the regulator 212b. Since the main power acquisition unit 212 operates by receiving power supply from the main power source 200, the operation stops when the main power source 200 is turned off.

  The network power supply unit 214 obtains 24V main power from the main power supply 200, and generates 5V power through the electrolytic capacitor 214a and the regulator 214b. Then, the network power supply unit 214 supplies network power to the slave controllers 120 connected in a daisy chain (cascade connection) via the network wiring 132 as a network power supply. Like the main power acquisition unit 212, the network power supply unit 214 operates by receiving power supply from the main power source 200. Therefore, the operation stops when the main power source 200 is turned off.

  The regulator 216 acquires 5V power from the main power acquisition unit 212, converts it to 3.3V power, and supplies it to the network interface unit 218.

  The network interface unit 218 receives power supply from the regulator 216 and transmits a control command to the slave controllers 120 connected in a daisy chain.

  The network power control unit 220 includes a relay, a transistor switch circuit, an analog switch IC, and the like, and turns on / off the supply of network power to the slave controller 120 at the lower level (downstream) in accordance with a command from the network interface unit 218.

(Slave controller 120)
FIG. 3 is a block diagram illustrating a schematic configuration of the slave controller 120. Also in FIG. 3, the flow of power is indicated by a solid line, and the flow of signals is indicated by a broken line. As shown in FIG. 3, the slave controller 120 includes a main circuit 260, a main power acquisition unit 262, a network power acquisition unit 264, a power aggregation unit 266, a network interface unit 268, and a network power control unit 270. Consists of including.

  The main circuit 260 operates upon receiving power from the main power acquisition unit 262.

  The main power acquisition unit 262 acquires main power of 24V from the main power supply 250 and generates 5V of power through the electrolytic capacitor 262a and the regulator 262b. Since the main power acquisition unit 262 operates by receiving power supply from the main power supply 250, the operation stops when the main power supply 250 is turned off.

  The network power acquisition unit 264 acquires 5V network power from the network power supply of the host (upstream) controller (master controller 110 or slave controller 120) through the network wiring 132, and supplies 5V power through the electrolytic capacitor 264a and the regulator 264b. Generate. In addition, since the network power acquisition unit 264 operates by receiving power supply from the network power supply, the power consumed for the operation is also consumed from the network power.

  The power aggregating unit 266 is connected to the main power acquisition unit 262 and the network power acquisition unit 264, converts any 5V power to 3.3V power through the regulator 266a, and supplies the converted power to the network interface unit 268. Here, even if the main power supply 250 of each slave controller 120 is turned off (including spontaneous and malfunctioning), network connection with other controllers must be maintained. Therefore, the power aggregating unit 266 supplies main power to the network interface unit 268 from the main power acquisition unit 262 on the side of the main power source 250 with sufficient power while the main power source 250 is turned on. Network power is supplied from the network power acquisition unit 264 on the network power supply side to the network interface unit 268 while in the off state (including voluntary and failure times).

  The network interface unit 268 is daisy chain-connected to the adjacent controller through the network wiring 132, receives a control command from a higher-level controller (master controller 110 or slave controller 120), and sends the control command to a lower-level controller. (Slave controller 120). Further, the network interface unit 268 receives a response from the lower controller and transmits the response to the upper controller.

  The network interface unit 268 is connected to the main power acquisition unit 262 and the network power acquisition unit 264 through the power aggregation unit 266, and at least from the main power acquisition unit 262 on the main power source 250 side while the main power source 250 is turned on. When the main power supply is received and the main power supply 250 is in the off state, the network power supply is received from the network power acquisition unit 264 on the network power supply side. Therefore, as long as the network interface unit 268 is connected to the network wiring 132, the network interface unit 268 can always maintain an operable state, so that the safety of the control system 100 can be ensured.

  Further, the network interface unit 268 is designed so that a control command from a higher-order controller can be bypassed to a lower-order controller when neither main power nor network power can be received. Therefore, even in a situation where power is not supplied to the network interface unit 268, communication connection between the upper controller and the lower controller can be maintained.

  The network power control unit 270 includes a relay, a transistor switch circuit, an analog switch IC, and the like. The network power control unit 270 turns on / off the connection of network power between the upper controller and the lower controller according to a command from the network interface unit 268.

(Daisy chain connection of multiple controllers)
FIG. 4 is an explanatory diagram for explaining daisy chain connection of a plurality of controllers. Here, an example in which the master controller 110 and the three slave controllers 120 are connected by the network wiring 132 is given, and network power and control commands are transmitted from the master controller 110 to each slave controller 120. In FIG. 4, the solid line arrows indicate the flow of electric power, and the broken line arrows indicate the flow of control commands.

  Each of the master controller 110 and the slave controller 120 has two connectors 132a and 132b, and the network wiring 132 is established through the connectors 132a and 132b. However, the connector 132a of the master controller 110 and the connector 132b of the lowest slave controller 120 are not connected. Here, when the upper controller and the network wiring 132 are connected via the connector 132b and the lower controller and the network wiring 132 are connected via the connector 132a, the upper controller is connected via the power line 132c of the network wiring 132. The network power is supplied from the controller (for example, the network power supply unit (power supply unit) 214 of the master controller 110) to the lower level controller (for example, the network power acquisition unit 264 of the slave controller 120). The power line 132c is assigned to an empty terminal of RJ45.

  In addition, regarding the signal line 132d of the network wiring 132, the upper controller and the lower controller are connected in a daisy chain, thereby enabling bidirectional communication. Therefore, the control command issued from the network interface unit 218 of the master controller 110 circulates all the connected slave controllers 120. Each slave controller 120 decodes a header or the like in the control command, and if the header indicates that it is a control command for itself, takes the control command and reflects it in its control processing.

  The power line 132c and the signal line 132d are arranged in parallel in the network wiring 132 and are integrally attached to and detached from each controller through the connector 132a or the connector 132b. Therefore, the power line 132c and the signal line 132d are simultaneously connected and disconnected by attaching / detaching the connector 132a or the connector 132b. However, it is sufficient that the power line 132c and the signal line 132d are connected and disconnected at the same time, and it is not necessary to form both the connecting lines in an integrated connector.

  In this embodiment, by using daisy chain connection, the master controller 110 and all of the slave controllers 120 can be all connected by one signal line 132d for unidirectional communication and two signal lines 132d for bidirectional communication. it can. With this configuration, even if the number of slave controllers 120 is increased, the number of signal lines 132d in the daisy chain connection does not change, which is advantageous in all maintainability, maintenance cost, and occupied area.

  However, simply supplying network power from the upper controller to the lower controller may cause the following problems when replacing (removing) the lower controller with the control system 100 turned on. That is, when a new lower controller is connected, an inrush current may occur due to a potential difference from the network power supply and an inflow of electric charge to the electrolytic capacitor 264a provided in the network power acquisition unit 264. Therefore, all the controllers including the master controller 110 have to be stopped when replacing the lower controller.

  Therefore, in the present embodiment, the upper controller monitors the communication state with the lower controller, and turns on / off the supply of network power to the lower controller depending on whether the communication connection is valid. In this way, the lower controller can be safely attached and detached. Hereinafter, a method for attaching and detaching the lower controller will be described together with specific operations.

(How to attach and detach the lower controller)
FIG. 5 is a flowchart for explaining a method of attaching / detaching the lower controller, and FIGS. 6 and 7 are explanatory views for explaining the operation of the attaching / detaching method. 6 and 7, the solid line arrows indicate the flow of electric power, and the broken line arrows indicate the flow of control commands. A solid line indicates that power is effectively supplied or communication is established, and a white line indicates that power or communication is invalid. Here, an example will be described in which the slave controller 120 is replaced (detached) with the master controller 110 as a higher controller and the slave controller 120 positioned one step lower than the master controller 110 as a lower controller.

(Step S300)
When attempting to replace the slave controller 120, the worker first turns off the main power supply 250 of the slave controller 120.

(Step S302)
Subsequently, the worker disconnects the connector 132 a of the slave controller 120 and removes the slave controller 120 from the network wiring 132. Thus, as shown in FIG. 6A, the connection state of the signal line 132d of the network wiring 132 is released, and the network interface unit (upper communication unit) 218 of the master controller 110 and the network interface unit (lower communication of the slave controller 120). Part) Communication connection with 268 is interrupted. Any order of processing in step S300 and step S302 may be performed first. At this time, the supply of network power from the network power supply unit (power supply unit) 214 of the master controller 110 is effectively maintained.

(Step S304)
The network interface unit (upper communication unit) 218 of the master controller 110 always monitors the communication state with the slave controller 120 positioned one step lower, and if it is determined that the communication connection has been lost, the connector 132a of the lower controller As shown in FIG. 6B, the supply of network power to the lower controller is stopped through the network power control unit 220 as shown in FIG.

(Step S306)
The operator attaches a new slave controller 120 to the network wiring 132. At this time, since no network power is supplied to the power line 132c from the master controller 110 as shown in FIG. 6B, that is, since it is disconnected from the network power supply, no inrush current occurs.

(Step S308)
Subsequently, when the operator turns on the main power supply 250 of the slave controller 120, main power is supplied from the main power supply 250 to the network interface unit 268 of the slave controller 120, and as shown in FIG. The communication unit) 268 resumes communication with at least the network interface unit (upper communication unit) 218 of the upper master controller 110. Any order of processing in step S306 and step S308 may be performed first.

(Step S310)
The network interface unit (upper communication unit) 218 of the master controller 110 always monitors the communication state with the slave controller 120 positioned one step lower, and determines that the communication connection has been resumed. It is assumed that 132a is connected, and the network power supply to the lower controller is resumed through the network power control unit 220 as shown in FIG. 7B.

  Here, the master controller 110 as the upper controller, the slave controller 120 as the lower controller, the network interface unit 218 as the upper communication unit, the network interface unit 268 as the lower communication unit, and the network power supply unit 214 as the power supply unit. However, any of the upper and lower controllers may be the slave controller 120. In any case, it is sufficient that the controller is connected to the network wiring 132 and the network power supply relationship is the upper and lower relationship, and the network power is directly supplied from the upper controller to the lower controller.

  In this case, the network interface unit of the upper controller functions as the upper communication unit, the network interface unit of the lower controller functions as the lower communication unit, and supplies network power to the lower controller. For example, network power control The unit 270 functions as a power supply unit.

  Also provided are a program that causes the computer to function as the control system 100 or a higher-level controller, and a storage medium such as a computer-readable flexible disk, magneto-optical disk, ROM, CD, DVD, or BD on which the program is recorded. . Here, the program refers to data processing means described in an arbitrary language or description method.

  According to the control system 100 described above, when a lower controller is replaced, an inrush current is not generated due to a potential difference from the network power supply and an inflow of electric charge to the electrolytic capacitor. Therefore, the lower controller is safely attached and detached. It becomes possible.

  As mentioned above, although preferred embodiment of this invention was described referring an accompanying drawing, it cannot be overemphasized that this invention is not limited to this embodiment. It will be apparent to those skilled in the art that various changes and modifications can be made within the scope of the claims, and these are naturally within the technical scope of the present invention. Is done.

  For example, in the above-described embodiment, the programmable logic control system has been described as the control system 100. However, the controller is connected to the network wiring 132, the network power supply relationship is the upper and lower relationship, and the upper controller. If the network power is directly supplied from the controller to the lower controller, the present invention can be applied to a distributed control system. Further, the controller can be applied to a substrate or an integrated circuit regardless of a unit such as an electric device.

  Further, in the above-described embodiment, the example of replacing the lower controller with a new controller has been described as the method for attaching and detaching the lower controller. However, the lower controller is removed, and some setting change or maintenance is performed. It can also be applied to simple attachment / detachment.

  It should be noted that the steps in the controller attaching / detaching method in the lower part of this specification do not necessarily have to be processed in time series in the order described in the flowchart, but are executed in parallel or individually (for example, parallel processing) Alternatively, processing by an object) may be included.

  INDUSTRIAL APPLICABILITY The present invention can be used for a control system in which a plurality of controllers are connected via a network, a higher controller among the plurality of controllers, and a method for attaching / detaching a lower controller among the plurality of controllers.

100 Control system 110 Master controller (upper controller)
120 Slave controller (subordinate controller)
132 Network Wiring 214 Network Power Supply Unit (Power Supply Unit)
218 Network interface unit (upper communication unit)
268 Network interface part (lower communication part)

Claims (4)

A control system including an upper controller and a lower controller that are connected via a network and can communicate with each other,
The upper controller is:
An upper communication unit capable of communicating with the lower controller;
A power supply for supplying network power to the lower controller;
With
The lower controller is:
Operated by either the network power or power independent of the network power, and comprising a lower communication unit capable of communicating with the upper controller,
The upper communication unit stops the supply of the network power to the lower controller when communication with the lower communication unit is disconnected, and when communication with the lower communication unit is established, the lower controller A control system for supplying the network power to the network.   The control system according to claim 1, wherein the power line that supplies the network power and the signal line that performs the communication are integrally attached and detached between the upper controller and the lower controller. An upper controller connected via a network to a lower controller having a lower communication unit capable of communicating by receiving power supplied from either network power or power independent of the network power;
A power supply for supplying the network power to the lower controller;
If communication with the lower-level controller is possible and communication with the lower-level communication unit is cut off, the supply of the network power to the lower-level controller is stopped, and communication with the lower-level communication unit is established. An upper communication unit that supplies the network power to the lower controller;
A host controller characterized by comprising: A higher-level controller including a higher-level communication unit capable of communicating with a lower-level controller and a power supply unit that supplies network power to the lower-level controller, either the network power or power independent of the network power In a control system connected via a network with a lower-level controller having a lower-level communication unit that can operate and communicate with the higher-level controller, a method for attaching and detaching the lower-level controller,
The upper communication unit is
If communication with the lower communication unit is disconnected, the supply of the network power to the lower controller is stopped,
A method for attaching and detaching a lower controller, wherein when the communication with the lower communication unit is established, the network power is supplied to the lower controller.

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