JP2023125352A - Simulation system, method and simulation program - Google Patents

Abstract

To communicate information related to a simulated control process to an information processor.SOLUTION: A controller includes a first connector that connects a first network to which a control target belongs and a second connector that connects a second network to which an information processor belongs; and executes a user program for performing a control process and a communication program for performing a communication process for communicating information related to the control process to the information processor. A simulation system 1 includes: a simulator 338 for the control process; and a communication unit that performs a communication process for communicating information related to a simulated control process to the information processor according to predetermined settings.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to a technology for providing an environment for developing a program for controlling FA (Factory Automation) equipment.

FA systems for automating production processes are becoming widespread at various production sites. The FA system includes equipment to be controlled in the production process and a control device such as a PLC (Programmable Logic Controller) that executes a control program.

In a control program development environment, a designer can usually use a simulator. Regarding such simulations, for example, Japanese Patent Laid-Open No. 2004-5431 (Patent Document 1) describes how to appropriately create multiple virtual resources that model physical entities to be simulated (machine tools, assembly machines, conveyors, process control). This section describes how to complete a simulation model by combining them.

Japanese Patent Application Publication No. 2004-5431

The diversity of production sites is increasing. For example, in a PLC, target control processing and communication processing for communicating information related to the control processing with an information processing device via a network are implemented. Therefore, even in the development of control programs, there has been a demand for an environment in which such communication processing can be performed. However, Patent Document 1 does not propose a mechanism that enables such communication processing.

An object of the present disclosure is to provide an environment for simulating control processing of a controller in which information related to the simulated control processing can be communicated with an information processing device.

In the simulation system for simulating processing of a controller according to the present disclosure, the controller includes a first connector that connects a first network to which a controlled object belongs, a second connector that connects a second network to which an information processing device belongs, and a second connector that connects a second network to which an information processing device belongs; The simulation system includes a user program for performing processing, and an execution unit that executes a communication program for performing communication processing for communicating information related to control processing with an information processing device. The information processing apparatus includes a simulator that simulates processing, and a communication unit that performs communication processing that communicates information related to the control processing to be simulated with the information processing device according to predetermined settings.

According to the above disclosure, the simulation system can provide an environment for simulating a control process to perform a communication process for communicating information related to the simulated control process with an information processing device.

In the above disclosure, the above information processing device includes a DB device that manages a DB (database).

According to the above-mentioned disclosure, the simulation system provides an environment for simulating control processing to perform communication processing for communicating information related to the simulated control processing with a DB device.

In the above disclosure, the communication process includes a process of issuing a DB operation command to the DB device to operate the DB.

According to the above disclosure, the communication process for communicating information related to the control process to be simulated with the DB device can include issuing a DB operation command.

In the above disclosure, the predetermined setting items include designation of the target to be operated by the DB device according to the DB operation command.

According to the above disclosure, the setting unit can specify the target to be operated by the DB device according to the DB operation command.

In the above disclosure, the specification of the target to be operated by the DB device includes an identifier of the data to be accessed in the DB, and the information related to control processing includes the data to be accessed.

According to the above disclosure, information related to control processing can be set as an identifier of data accessed in the DB.

In the above disclosure, the predetermined setting items include parameters related to communication processing.

According to the above disclosure, parameters related to communication processing for communicating information related to control processing with an information processing device can be set in a simulation of control processing.

In the above disclosure, the parameters related to the communication processing include parameters for establishing communication with the information processing device.

According to the above disclosure, parameters for establishing communication with the information processing device can be set in order to implement communication processing.

In the above disclosure, the parameters related to communication processing include parameters of communication processing time.

According to the above disclosure, it is possible to set parameters for communication processing time with an information processing device, which are used to perform communication processing.

In the above disclosure, the communication processing time is based on the communication speed of the second network. According to this disclosure, the communication processing time can be set based on the communication speed of the second network to which the information processing device belongs, that is, the network used for communication by the controller.

In the above disclosure, the controller includes a multitask execution unit that executes a plurality of tasks including a control task for implementing control processing and a related processing task for implementing processing related to the control processing, Communication with the information processing device is performed in the related processing task, the multitask execution unit executes the control task in the first cycle, the multitask execution unit executes the related processing task in the second cycle, and the communication The processing time is based on the second cycle.

According to the above disclosure, when the controller executes related processing including control processing and communication with an information processing device using multi-task control, in the simulation system, communication processing is performed based on the execution cycle of such tasks. You can set the communication processing time with the information processing device, which is used to implement the process.

According to other aspects of this disclosure, a method of simulating processing of a controller is provided. The controller includes a first connector that connects a first network to which the controlled object belongs, a second connector that connects a second network to which the information processing device belongs, a user program for implementing control processing, and a program related to the control processing. an execution unit that executes a communication program for communicating information with the information processing device; the method includes the steps of simulating control processing; and performing communication processing to communicate with the information processing device according to the method.

In the above-mentioned disclosure, when the method is implemented, it is possible to provide an environment for simulating a control process to perform a communication process for communicating information related to the simulated control process with an information processing device.

According to still another aspect of this disclosure, a simulation program for causing a computer to execute a method of simulating processing of a controller is provided. The controller includes a first connector that connects a first network to which the controlled object belongs, a second connector that connects a second network to which the information processing device belongs, a user program for implementing control processing, and a program related to the control processing. an execution unit that executes a communication program for performing communication processing for communicating information with an information processing device; the method includes the steps of simulating control processing; and information related to the simulated control processing. and a step of performing communication processing to communicate with the information processing device according to predetermined settings.

In the above disclosure, when the simulation program is executed, it is possible to provide an environment for simulating a control process to perform a communication process for communicating information related to the simulated control process with an information processing apparatus.

According to the present disclosure, it is possible to provide an environment in which information related to the simulated control processing can be communicated with the information processing device for simulation of the control processing of the controller.

1 is a diagram schematically showing the configuration of a simulation system 1 according to the present embodiment. FIG. 1 is a schematic diagram showing a system configuration of a control system 10 according to the present embodiment. FIG. 1 is a schematic diagram showing a hardware configuration showing the main parts of a PLC 100 according to the present embodiment. FIG. 1 is a schematic diagram showing the software configuration of PLC 100 according to the present embodiment. It is a schematic diagram showing an example of periodic control in PLC100 concerning an embodiment. FIG. 3 is a schematic diagram showing the hardware configuration of a support device 300 according to the present embodiment. FIG. 3 is a schematic diagram showing the software configuration of support device 300 according to the present embodiment. 1 is a diagram schematically showing the configuration of a program development environment according to the present embodiment. 3 is a diagram schematically showing a code example of a user program 186 related to DB access processing according to the present embodiment. FIG. It is a diagram showing an example of a settings file 345 according to the present embodiment. FIG. 3 is a diagram illustrating a setting tool 339 according to the present embodiment. 1 is a diagram showing a configuration in which a simulation system 1 according to the present embodiment is implemented in a cloud environment. 3 is a flowchart of simulation according to the present embodiment.

Embodiments according to the present invention will be described below with reference to the drawings. In the following description, the same parts and components are given the same reference numerals. Their names and functions are also the same. Therefore, detailed explanations thereof will not be repeated.

<A. Application example＞
An application example of the present invention will be explained. The simulation system 1 according to the present embodiment can be applied to an environment for developing user programs including programs for controlling field devices such as drive devices that drive machines and equipment on a production line. In this embodiment, a PLC that controls field devices will be described as a typical example of a controller. However, the controller according to the present invention is not limited to PLC, and can be applied to various control devices.

FIG. 1 is a diagram schematically showing the configuration of a simulation system 1 according to the present embodiment. In FIG. 1, the configuration of a simulation system 1 is shown in association with the configuration of an actual PLC 100. Referring to FIG. 1, the PLC 100 includes a fieldbus connector 158 that connects the fieldbus 110, which is an example of a communication network to which the field device 95 belongs, and an upper network to which a DB device 400 that manages a DB (abbreviation for database) belongs. 112 is connected to the upper communication connector 168. The DB device 400 is an example of an information processing device that communicates information related to control processing with the PLC 100.

In this embodiment, fieldbus 110 may include the concept of a communication network in a narrow sense. It is preferable that the field bus 110 employs a bus or network that performs fixed-cycle communication in which data arrival time is guaranteed. EtherCAT (registered trademark), EtherNet/IP (registered trademark), DeviceNet (registered trademark), CompoNet (registered trademark), and the like are known as buses or networks that perform such periodic communication. On the other hand, the upper network 112 may employ general network protocols such as Ethernet (registered trademark) or EtherNet/IP (registered trademark).

Further, the PLC 100 includes an execution unit 189 that provides an environment for executing a user program 186 (in the figure, the user program is abbreviated as “UPG”) for implementing control processing for the field device 95. The execution unit 189 is configured as a platform including a system program 188 for executing application programs including a user program 186. The system program 188 includes an OS (Operating System), various libraries, and various communication programs including a DB communication program 192. By executing the DB communication program 192, the PLC 100 performs communication processing to communicate information related to control processing with the DB device 400.

In the control process, a control calculation for calculating a control command is performed using the state value received from the field device 95, and the calculated control command is transmitted to the field device 95. The field device 95 operates according to the control command, and transmits the state value of the field device 95, which is the operation result, to the PLC 100. In the PLC 100, the UPG 189 is executed periodically. As a result, the field device 95 continues to operate based on the control command calculated in synchronization with the period. Further, the PLC 100 executes the DB communication program 192 at a cycle synchronized with the execution cycle of the UPG 189. Such periodic control allows the PLC 100 to periodically communicate information related to control processing with the DB device 400.

As the DB device 400, a known configuration that provides a database can be adopted. Any configuration such as a relational data type or an object data type can be adopted as such a database. Since the DB device 400 is configured according to a general-purpose computer architecture, its detailed description will not be repeated here. The DB device 400 performs access processing on the DB based on information received from the PLC 100, and transmits a response based on the processing result to the PLC 100. More specifically, the DB device 400 receives a connection request or an access request (for relational data type, an instruction code defined in an SQL statement, which is a type of database operation language) from the PLC 100, and executes a request based on the request. It executes necessary data processing and responds to the PLC 100 with the processing results.

In the communication processing of the DB communication program 192, connection requests and access requests output in the control processing are converted into a format that can be processed by the DB device 400, for example, SQL statements, and DB operations including the converted connection requests and access requests are performed. A command is transmitted (issued) to the DB device 400. In the communication process, a response of the processing result based on the DB operation command is received from the DB device 400 and passed to the execution unit 189.

The simulation system 1 is configured on a support device 300 that includes a general-purpose computer. The simulation system 1 includes a simulator 338 that constitutes a simulation section that mainly simulates control processing, a DB connection system 351 that constitutes a communication section that executes communication processing of the PLC 100, and a setting tool 339. The DB connection system 351 includes an executable communication module configured to include at least one instruction code of the DB communication program 192. The DB connection system 351 is provided as a module independent of the simulator 338. More specifically, the simulator 338 and the DB connection system 351 are configured to be able to call each other or operate independently without being called.

The setting tool 339 is configured as a setting unit that performs settings for causing the DB connection system 351 to perform communication processing with the DB device 400 regarding information related to the control processing simulated by the simulator 338. That is, the setting tool 339 performs settings for realizing the exchange of information between the simulator 338 and the DB connection system 351, which are independent from each other, and the processing for the DB connection system 351 to communicate with the DB device 400. It is configured as a setting section that performs. The information exchanged between the simulator 338 and the DB connection system 351 is information related to the control processing simulated by the simulator 338, and includes, for example, the control commands and status values described above, but is not limited to these. Not done.

In the simulation system 1, when the simulator 338 is started, the DB connection system 351 is also started. The control processing is simulated by the simulator 338 by executing the user program 186. More specifically, for example, a simulation is repeatedly executed so that the state value becomes the target value, so that the state value and the control command are acquired in time series. The DB connection system 351 performs communication processing according to the settings of the setting tool 339. More specifically, according to the settings, the DB connection system 351 acquires information related to the control processing of the status value or control command from the simulator 338, and uses the acquired information to respond to the DB connection request or access request. Along with the DB operation command, communication processing is performed with the DB device 400 on the network 112 via the communication IF (abbreviation for interface) 318 of the support device 300 . The DB device 400 executes data processing based on the DB operation command from the support device 300, and transmits a response of the processing result to the support device 300 (DB connection system 351).

The DB connection system 351 receives a response from the DB device 400 in communication processing, and outputs the response to the simulator 338 according to the settings of the setting tool 339. The simulator 338 uses the response for simulation or outputs it on a UI (user interface) or the like. By providing such a UI, the user (program developer) is provided with information for analyzing the response. Based on the analysis of the response, the user can debug the user program 186, for example, the instruction code that constitutes the DB access process.

In this way, the user program 186, which has been debugged and developed using the simulation system 1, is converted into an executable program and transferred from the support device 300 to the actual PLC 100. The data is stored in a non-volatile storage unit such as a disk drive. When the PLC 100 is started, the user program 186 is read from a non-volatile storage section and expanded into a volatile memory work area including a RAM (Random Access Memory). The PLC 100 performs control processing by interpreting and executing the expanded program, and communicates information related to the control processing with the DB device 400.

Note that in FIG. 1, the information processing device with which the simulation system 1 communicates is not limited to the DB device 400. For example, other devices on the network 112 that achieve the same performance and operation as the DB device 400 may be used. Further, the network to which this other device belongs is not limited to the network 112, but may be any other network as long as it has the same performance as the network 112.

Further, the configuration of the support device 300 in FIG. 1 may be built into the PLC 100. In this case, the PLC 100 may be realized by, for example, an industrial personal computer (IPC).

A more specific application example of this embodiment will be described below.
<B. System configuration>
FIG. 2 is a schematic diagram showing the system configuration of the control system 10 according to this embodiment. Referring to FIG. 2, control system 10 includes PLC 100, a support device 300 connectable to PLC 100, and a DB device 400 that receives access from PLC 100. PLC 100 executes user program 186 periodically or on an event basis. The user program 186 can include instructions regarding database access, and the PLC 100 can access the DB device 400 in accordance with the instructions. The PLC 100 and the DB device 400 are configured to be able to exchange data with each other via a network 112 such as Ethernet (registered trademark). Further, the information processing apparatus belonging to the network 112 further includes a data server 500 that manages collected data 512 collected from the PLC 100 and a web server 600.

The support device 300 is configured to be connectable to the PLC 100. The support device 300 provides an environment for the simulation system 1, and also provides functions such as setting various parameters, programming, monitoring, and debugging with the PLC 100. The support device 300 is connected to the PLC 100 via the connection cable 114, and the PLC 100 and the support device 300 are typically configured to be communicable according to the USB (Universal Serial Bus) standard. Note that the support device 300 may be configured such that the connection cable 114 is detachable, and may also be operated stand-alone without the connection cable 114 being connected.

PLC 100 includes a CPU unit 104 that executes control calculations and one or more IO (Input/Output) units 106. These units are configured to be able to exchange data with each other via the PLC system bus 108. Further, power of appropriate voltage is supplied to these units by the power supply unit 102.

In the control system 10, the PLC 100 exchanges data including control commands and status values with various field devices 95 via the IO unit 106 and/or the field bus 110. These field devices 95 include actuators provided in the production line, sensors for acquiring various information from the production line, and the like. FIG. 1 includes a detection switch 11, a relay 20, and a servo motor driver 30 that drives a motor 32 as an example of such a field device 95. Further, the PLC 100 is also connected to a remote IO terminal 200 via a field bus 110. The remote IO terminal 200 basically performs general input/output processing similarly to the IO unit 106. More specifically, remote IO terminal 200 includes a communication coupler 205 for processing data transmission on fieldbus 110 and one or more IO units 204. These units are configured to be able to exchange data with each other via remote IO terminal bus 208 .

<C. Configuration of PLC100>
Next, the configuration of PLC 100 according to this embodiment will be explained. FIG. 3 is a schematic diagram showing the hardware configuration of the main parts of the PLC 100 according to the present embodiment. FIG. 4 is a schematic diagram showing the software configuration of PLC 100 according to this embodiment.

The hardware configuration of the CPU unit 104 of the PLC 100 will be described with reference to FIG. 3. The CPU unit 104 includes a processor 120, a chipset 122, a system clock 124, a main memory 126, a non-volatile memory 128, a USB connector 130, a PLC system bus controller 140, a field bus controller 150, and upper level communication. It includes a controller 160 and a memory card interface 170. The chipset 122 and other components are coupled via various buses.

Processor 120 and chipset 122 are typically configured according to a general purpose computer architecture. That is, the processor 120 interprets and executes instruction codes sequentially supplied from the chipset 122 according to the internal clock. The chipset 122 exchanges internal data with various connected components and generates instruction codes necessary for the processor 120. The system clock 124 generates a system clock with a predetermined cycle and provides it to the processor 120. The chipset 122 has a function of caching data obtained as a result of execution of arithmetic processing by the processor 120.

The CPU unit 104 has a main memory 126 and a nonvolatile memory 128 as storage units. The main memory 126 is a volatile storage area that holds various programs to be executed by the processor 120 and is also used as a working memory when executing various programs. The nonvolatile memory 128 nonvolatilely stores system programs, user programs 186, data definition information, operation log information, and the like.

The USB connector 130 is an interface for connecting the support device 300 and the CPU unit 104. Typically, executable programs and the like transferred from the support device 300 are loaded into the CPU unit 104 via the USB connector 130.

The CPU unit 104 includes a PLC system bus controller 140, a fieldbus controller 150, and an upper communication controller 160 as communication circuits. These communication circuits transmit and receive data.

PLC system bus controller 140 controls data exchange via PLC system bus 108. More specifically, the PLC system bus controller 140 includes a buffer memory 142, a PLC system bus control circuit 144, and a DMA (Dynamic Memory Access) control circuit 146. PLC system bus controller 140 is connected to PLC system bus 108 via PLC system bus connector 148.

Fieldbus controller 150 includes a buffer memory 152, a fieldbus control circuit 154, and a DMA control circuit 156. Fieldbus controller 150 is connected to fieldbus 110 via fieldbus connector 158. Upper communication controller 160 includes a buffer memory 162, an upper communication control circuit 164, and a DMA control circuit 166. Upper communication controller 160 is connected to network 112 via upper communication connector 168.

A memory card interface 170 connects a memory card 172 that is removable to the CPU unit 104 and the processor 120 .

Next, with reference to FIG. 4, a software configuration for realizing various functions provided by PLC 100 according to the present embodiment will be described. The instruction codes included in these software are read out at appropriate timing and executed by the processor 120 of the CPU unit 104.

Referring to FIG. 4, the software executed by CPU unit 104 has three layers: OS 180, system program 188, and user program 186.

OS 180 provides the basic environment for processor 120 to execute system program 188 and user program 186. The system program 188 is a software group for providing the basic functions of the PLC 100. Specifically, the system program 188 is a multitask execution program having a sequence instruction program 190, a DB communication program 192, a file transfer program 193, an input/output processing program 194, a tool interface processing program 196, and a scheduler 198. 199. The OS 180 and the system program 188 cooperate to form an execution unit 189.

On the other hand, the user program 186 is a program arbitrarily created according to the purpose of controlling the controlled object. That is, the user program 186 is arbitrarily designed depending on the line (process) to be controlled using the control system 10.

User program 186 cooperates with sequence instruction program 190 to implement control objectives at the user. That is, the user program 186 implements programmed operations by using instructions, functions, functional modules, etc. provided by the sequence instruction program 190. Therefore, the user program 186 and the sequence instruction program 190 can constitute a control program.

The data definition information 182 includes definitions for handling referenced data (input data, output data, internal data) as unique variables when the user program 186 and the like are executed. The operation log 184 shows information to be logged by the PLC 100 as the field device 95 is controlled (operated). The operation log 184 includes a log including status values or control commands outputted with the execution of the normal user program 186, a log of information (requests and responses) related to communication with the DB device 400, and the like. Note that the logs collected by the PLC 100 may include logs output when a program fails to execute or a hardware malfunction occurs, and logs whose locations and contents are arbitrarily specified in the user program 186. Further, the operation log 184 has a file format in which log information during operation is stored in association with time information.

The DB communication program 192 includes a group of instruction codes for implementing the processing necessary to access the DB device 400 as the user program 186 is executed. The DB communication program 192 includes execution codes corresponding to instructions that can be specified in the user program 186.

The file transfer program 193 is a program that edits the operation log 184 into a file in a transferable format, for example, and transfers the edited file via the network 112. The input/output processing program 194 is a program for managing acquisition of input data and transmission of output data between the IO unit 106 and various field devices. The Tool interface processing program 196 provides an interface for exchanging data with the support device 300.

The scheduler 198 generates threads and procedures for executing the control program and the user program 186 according to predetermined priorities, system timer values, etc. under multitasking control.

As described above, the user program 186 is created according to the user's control purpose (for example, target line or process). User program 186 is typically in the form of an object program executable by processor 120. The user program 186 is generated by compiling a source program written in a ladder format or a function block format in the support device 300 or the like. The generated user program 186 in the object program format is then transferred from the support device 300 to the CPU unit 104 and stored in the nonvolatile memory 128 or the like.

<D. Periodic control>
FIG. 5 is a schematic diagram showing an example of periodic control in the PLC 100 according to the embodiment. The PLC 100 constitutes a multitask execution unit that allocates resources such as the processor 120 on a task-by-task basis by executing a multitask execution program 199. The multitask execution unit executes a plurality of tasks including a control task for implementing control processing 45 and a related processing task for implementing related processing 46 related to the control processing 45. The tasks of the related processing 46 include the DB connection service 47 task, which is a task based on the DB communication program 192, and the file transfer service 185, which is an ask based on the file transfer program 193. The related processing 46 tasks may further include other types of tasks.

The multitask execution unit uses the scheduler 198 to switch tasks to which resources should be allocated in synchronization with a predetermined period, for example, a control period T, according to the priority of the task. For example, as shown in FIG. 5, the task of the control process 45 with the highest priority is guaranteed to be executed in the first cycle of the control cycle T, and the task of the related process 46 with the lowest priority is It is executed during the free time of the resource (processor 120) in the control period T. Although not limited to this, the tasks of the related processing 46 are executed, for example, at a cycle that is an integral multiple of the control cycle T. In the embodiment, the task of the DB connection service 47 is executed, for example, every cycle 2T, that is, twice the control cycle T, and the task of the file transfer service 185 is executed, for example, every cycle 4T, that is, every four times the control cycle T. executed. In this way, the multitask execution unit executes control processing and communication processing with the DB device 400 in parallel in the PLC 100.

<E. Configuration of support device 300>
Next, support device 300 according to this embodiment will be explained. FIG. 6 is a schematic diagram showing the hardware configuration of support device 300 according to this embodiment. FIG. 7 is a schematic diagram showing the software configuration of support device 300 according to this embodiment.

Referring to FIG. 6, the support device 300 includes a CPU 302 that executes various programs including the OS, a ROM (Read Only Memory) 304 that stores the BIOS and various data, and data necessary for the CPU 302 to execute the programs. It includes a RAM 309 that is a memory that provides a work area for storage, and an HDD 308 that non-volatilely stores programs and the like that are executed by the CPU 302. More specifically, the HDD 308 stores various programs and data including a support program 335 for realizing the functions provided by the support device 300.

The support device 300 further includes a keyboard 310 and a mouse 312 that accept operations on the support device 300 from the user, and a monitor 314 that presents information to the user. Furthermore, the support device 300 includes a communication IF (abbreviation for interface) 318 for communicating with information processing devices belonging to the network 112 such as the DB device 400, data server 500, and web server 600, and a USB connector for communicating with the PLC 100. Contains 319.

The support program 335 and the like executed by the support device 300 are stored in the optical disk 332 or the memory card 333 and distributed. The program stored in the optical disc 332 is read by the optical disc reader 316, and the program stored in the memory card 333 is read by the memory card I/F 334 and stored in the HDD 308 or the like. Alternatively, the program may be configured to be downloaded to the support device 300 from an upper host computer or the like via the network 112. In support device 300, these components communicate with each other via internal bus 320.

Referring to FIG. 7, the support device 300 stores the OS 330, the support program 335, the user program 186 to be developed, a configuration file 345 that stores the settings of the configuration tool 339, and an operation log obtained by simulation in the HDD 308. DB connection system module 350 in an executable format corresponding to DB connection system 351 , and file transfer module 360 . DB connection system module 350 is a module in executable form that includes at least one instruction code of DB communication program 192 . Alternatively, the file transfer module 360 is an executable module that edits the collected data of the log file 346 into, for example, a CSV (Comma Separated Value) file and transfers the file to the data server 500 via the network 112.

Support program 335 includes development program 336 and PLC interface program 340. The development program 336 includes programming tools (editing, compiling, converting to an executable format (build), etc.) for designing various programs including the user program 186 to be developed, a simulator 338 for testing the designed programs, It includes various programs constituting a setting tool 339, a tool for debugging a designed program, and the like. The PLC interface program 340 manages data exchange between the support device 300 and the PLC 100.

The support program 335 provides tools that support user operations in program development, tools that support user operations related to communication with the PLC 100, and the like. Such support tools include a GUI (Graphical User Interface) or a UI (User Interface). In this embodiment, a simulator 338 is provided by executing a development program 336 under the OS 330, and a DB connection system 351 is provided by executing a DB connection system module 350.

<F. Module configuration of program development environment>
FIG. 8 is a diagram schematically showing the configuration of a program development environment according to this embodiment. As shown in FIG. 8, the simulation system 1 in the support device 300 includes a programming tool 337, a simulator 338, a setting tool 339, and a DB connection system 351.

(f1. Configuration of programming tool 337)
The programming tool 337 controls the development of the user program 186 and the execution of the simulator 338 by accepting user operations. The programming tool 337 includes a GUI section 41, a program management section 43, a communication section 44 that exchanges data with the simulator 338, and a simulation IF (abbreviation for interface) section 42.

The GUI unit 41 has a function of accepting user operations on the support device 300 and exchanging various information regarding simulation, debugging, etc. (for example, start, stop, etc. of simulation) with the user based on the accepted user operations.

The program management section 43 has a function of creating and editing programs. The program management section 43 performs processing according to instructions given by the user via the GUI section 41. Specifically, the program management unit 43 has functions such as reading a program from the HDD 308 via the communication unit 44 or writing a program. The communication unit 44 has a communication interface with the communication unit 54 of the simulator 338.

The simulation I/F unit 42 has a function of exchanging various information regarding simulation, debugging, etc. (for example, starting and stopping the simulator 338) with the simulator 338.

(f2. Configuration of simulator 338)
The simulator 338 operates based on user operations and performs simulations in cooperation with the DB connection system 351. For this cooperation, the simulator 338 exchanges data with the DB connection system 351. The details will be described later.

The simulator 338 starts or stops in response to a command to start or stop the simulator from the programming tool 337. The simulator 338 includes a program control section 51, a stop condition holding section 52, a program execution section 53, a communication section 54, and a storage section 301 that stores information for program execution by the program execution section 53.

The storage unit 301 stores the user program 186 created by the programming tool 337 and data 306 for simulation. Data 306 includes target values for simulation, variable table 307, log file 346, and the like. The storage unit 301 may include storage areas of an HDD 308 and a RAM 309. The variable table 307 includes, for each variable defined by the data definition information 182 of the PLC 100, a set of an identifier, for example, a variable name, and a value set for the variable. When the user program 186 is executed by the simulator 338, the values of each variable acquired by the execution (internal data such as input data status values, output data control commands, intermediate values, and responses of DB access processing) are Set.

In response to being given a predetermined activation/stop command, the program execution unit 53 reads out and executes the user program 186 from the storage unit 301, and reads and writes data 306 along with the execution. The user program 186 and data 306 held in the storage unit 301 can be monitored by the programming tool 337 via the communication unit 54. Furthermore, the data 306 can also be read or written from the DB connection system 351 via the communication unit 54.

The communication unit 54 has a function of reading and writing data. The communication unit 54 also provides an interface for exchanging data with the DB connection system 351. By using the communication unit 54, the DB connection system 351 can read and write variable values of the data 306 that the simulator 338 reads and writes during execution.

The program control unit 51 has a function of controlling the start and stop of execution of the user program 186 by the program execution unit 53 in response to a start and stop command given from the programming tool 337. Further, the program control unit 51 has a function of responding to the stop condition setting given from the programming tool 337 and causing the stop condition holding unit 52 to set and hold the “stop condition” included in the stop condition setting.

The program control unit 51 constantly monitors whether the “stop condition” set and held in the stop condition holding unit 52 is satisfied, and if it is determined that the “stop condition” is satisfied, the program execution unit 53 It has a function to immediately stop the execution of the user program 186. Therefore, by setting and holding a desired "stop condition" in the stop condition holding unit 52, the simulation is stopped at an arbitrary timing. This makes it possible to debug the user program 186 while simulating it.

(f3. Configuration of setting tool 339>
The setting tool 339 configures settings to enable communication processing with the DB device 400 (that is, communication processing performed by the PLC 100 by executing the DB communication program 192) regarding information related to the control processing to be simulated. to support. Configuration tool 339 provides UI tool 341 for such support. Settings are managed in the setting file 345 by setting items in the setting file 345 based on user operations received via the UI tool 341 . In the configuration file 345, items are set for causing the DB connection system 351 to communicate information related to the control processing simulated by the simulator 338 with the DB device 400. The setting file 345 includes, for example, variable names of values in the variable table 307 (for example, addresses of the storage unit 301), which are information related to control processing, time parameters related to communication processing, etc., but the setting items are Not limited.

(f4. Configuration of DB connection system 351>
The DB connection system 351 includes a communication section 352 and an execution section 353. The communication unit 352 has a function in which the DB connection system 351 exchanges control-related information with the simulator 338, and a function in which the DB connection system 351 communicates with the DB device 400 via the network 112.

The execution unit 353 operates according to a predetermined program 354 corresponding to the DB connection system module 350. The program 354 is configured to include at least one instruction code of the DB communication program 192, and when executed, can carry out a process of communicating information related to the control process to be simulated with the DB device 400. It is configured as follows. The program 354 implements a code for writing or reading a value to a corresponding variable in the variable table 307 of the storage unit 301 of the simulator 338, and DB access processing for the read value, according to the settings of the configuration file 345. The code for generating the DB operation command (SQL statement) for the DB operation, the code for issuing (sending) the DB operation command to the DB device 400, and the response of the execution result of the DB operation command received from the DB device 400 are stored in a variable table. It includes multiple instruction codes such as codes to be written to 307. The DB operation command includes a DB connection request and an access request command to write a value read from a variable table into the DB. The DB device 400 processes (operates) the DB according to such a DB operation command, and transmits a response of the processing result to the requesting support device 300.

The DB connection system 351 searches the configuration file 345 for a variable name to be subjected to DB access processing, and searches for data (value) from the variable table 307 based on the searched variable name. The retrieved data is sent to the DB device 400 along with the DB operation instruction, and the DB device 400 processes the data according to the DB operation instruction and responds with the processing results. In this way, the DB connection system 351 operates according to the configuration file 345 to perform DB access processing and communication processing with the DB device 400 regarding information related to control processing acquired in the simulated control processing. I can do it.

<G. Example of user program 186>
The above DB access processing is written as code in the user program 186 by the programming tool 337. FIG. 9 is a diagram schematically showing a code example of the user program 186 regarding DB access processing according to the present embodiment.

In FIG. 9, sections 90 to 93 of the user program 186 show an instruction (INSERT) for writing information related to control processing into the DB and peripheral DB operation instructions. These instructions are executed in the order of sections 90, 91, 92, and 93.

More specifically, an execution start flag "DBconnectionTrigger" is defined as an execution start condition, and when this flag is turned on, the DB connection process is executed. As this DB connection processing, a DB connection command block 910, a DB connection map selection block 911, and an INSERT/SELECT DB map generation block 914 are described. In the DB connection map selection block 911, a value (variable name "lightVar") 9A to be written to the DB is set as an input. Block 912 shows instructions to convert the value to a data type that can be written to the DB. Block 912 converts "lightVar" with value 9A to "lightVar.LightValue" with value 9B having the converted data type.

In section 93, block 913 is executed when flag 9C to start writing the converted value to DB is turned on. Block 913 outputs (sets) the processing time of communication processing to variable 9F. More specifically, when the flag 9C is turned on, the block 913 calculates the time from the current time indicated by the input 9D, that is, the start time of the communication process until receiving the response from the DB device 400 that executed the write command. That is, the time up to when the flag 9E in block 914 turns on is measured, and the measured time is set in the variable 9F. Block 914 is also configured to detect a timeout of processing time based on the input variable "TimeOut." Further, block 914 obtains a response from the DB device 400 using the variable “SendStatus”.

Through the simulation of the simulator 338, the value of the variable "lightVar" is stored in the variable table 307, and the code shown in FIG. 9 in the user program 186 is executed. At this time, the DB connection system 351, which is running in parallel with the simulator 338, searches for the value of the variable "lightVar" from the variable table 307 based on the variable "lightVar" set in the configuration file 345. The calculated value is sent to the DB device 400 together with the DB operation command. Such DB operation commands include commands such as DB connection, map selection, and inserting (writing) the value of the variable "lightVar" into the DB. The DB device 400 executes processing based on the DB operation command. The DB connection system 351 sets the response of the processing result received from the DB device 400 in the corresponding variable of the variable table 307. In the simulator 338, control processing is continuously performed based on the responses set in the variable table 307.

The simulator 338 uses a timer to periodically perform the control processing and communication processing described above so as to simulate the multitasking of the PLC 100.

In FIG. 9, the DB operation instructions are described using function blocks made into components in the library, that is, instructions defined within the function blocks, but the description is not limited to the method using function blocks. A method using ladder logic or a ladder language may also be used.

<H. Settings file 345>
The DB connection system 351 refers to the configuration file 345 when exchanging data regarding information related to control processing with the simulator 338 and the DB device 400. FIG. 10 is a diagram showing an example of the settings file 345 according to this embodiment. FIG. 11 is a diagram illustrating the setting tool 339 according to this embodiment.

Referring to FIG. 10, configuration file 345 includes targets to be operated by DB device 400 according to the DB operation command. For example, the object to be operated includes an identifier 71 of data processed (read or written) by the user program 186. The target of such DB operation may include designation of a DB map to be accessed.

Further, the configuration file 345 includes parameters related to communication processing with the DB device 400. For example, the parameters related to communication processing include parameters for the DB connection system 351 to establish communication with the DB device 400, such as a communication session or a communication connection. More specifically, it includes a parameter 70 that specifies the host on which the simulator 338 is running (the support device 300 that is the source of the DB operation command) and a parameter 73 that specifies the DB device 400 that is the destination.

Further, the parameters related to communication processing include processing time (“Interval_ms: 10”). The configuration file 345 includes a variable name designation 74 in which a response from the DB device 400 is set, and a variable 72 in which a processing time is set. Further, the configuration file 345 may include the type of DB operation command issued to the DB device 400. The DB connection system 351 generates a code corresponding to the type of DB operation command set in the configuration file 345 and issues it to the DB device 400.

(h1. Setting tool 339)
The settings file 345 in FIG. 10 allows the user to set items by operating the UI tool 341 provided by the settings tool 339. Referring to FIG. 11, UI tool 341 displays a screen on monitor 314 that accepts user operations. The screen in FIG. 11 includes a slider 741 that can be slid by the user and accepts a user operation to set, for example, a processing time for communication processing, and data 75 indicating a time corresponding to the amount of operation of the slider 741. Data 75 indicates, for example, 10 seconds. The value of the data 75 is set to the processing time of the configuration file 345.

When the DB connection system 351 receives a response from the DB device 400, it retains the response in an internal buffer, and when the processing time (10 seconds) of the configuration file 345 has elapsed from the time of response reception, the retained response is saved. is set in the variable table 307 of the simulator 338. Since the processing time can be set in this way, it is also possible to change the processing time to the one required in the environment of the actual machine, and it is possible to simulate the performance (communication speed) of the network 112 to which the LC 100 is connected. Further, the processing time may be set regardless of user operation. More specifically, the setting tool 339 may detect the communication speed of the network 112 to which the actual PLC 100 is connected, and set the processing time based on the detected communication speed.

Further, the processing time may be set based on the periodic control time performed in the PLC 100. More specifically, the DB connection service 47 including communication processing is executed as the related processing 46 during the free time of the processor 120 in the control period T, as shown in FIG. That is, if the processing load of the control process 45 is high and the idle time of the processor 120 is insufficient in the control cycle T, the tasks of the related process 46 will not be executed until the next execution cycle. In this case, as shown in FIG. 5, the execution interval of the DB connection service 47 including communication processing is a cycle of 4T. In order to simulate such a case, the processing time may be set by the setting tool 339 based on the execution cycle of the task of the related processing 46. Note that the processing time may be set based on a combination of communication speed and execution cycle.

<I. Cloud environment＞
The simulation system 1 is not limited to the support device 300, and may be implemented in a cloud-based environment. FIG. 12 is a diagram showing a configuration in which the simulation system 1 according to the present embodiment is implemented in a cloud environment. In FIG. 12, the simulation system 1 is installed on a web server 600. The user can exchange data for operating the programming tool 337, simulator 338, and setting tool 339 with the simulation system 1 of the web server 600 using the web browser included in the support device 300. Note that the programming tool 337 may be installed in the support device 300, and the simulator 338, DB connection system 351, and setting tool 339 may be installed in the Web server 600.

<J. Flowchart>
Next, the processing procedure of the simulator 338 and the DB connection system 351 will be explained. FIG. 13 is a flowchart of simulation according to this embodiment. Each step shown in FIG. 13 is realized by the CPU 302 executing the user program 186 by the simulator 338, and by the CPU 302 executing the connection system module 350 that realizes the DB connection system 351.

Referring to FIG. 13, CPU 302 starts simulator 338 and DB connection system 351 (step S10). Thereby, the CPU 302, as the simulator 338, executes the instructions included in the user program 186 and simulates the processing (control processing, etc.) according to the instructions. Information related to control processing (control commands, state values, etc.) derived in the simulated control processing is set in the variable table 307.

It is detected that the timing for executing the DB access processing command (function block command in FIG. 9) in the execution of the user program 186 is reached (step S12). More specifically, the CPU 302, as the DB connection system 351, acquires the variable name (address) to be processed from the configuration file 345, searches the variable table 307 based on the acquired variable name, and applies the search results to the variable table 307. Based on this, it is detected that a value has been set for the variable name. By searching the variable table 307 in this way, it is detected that it is time to execute the DB access process (step S12).

The CPU 302 performs processing equivalent to the communication processing performed by the actual PLC 100. Specifically, the CPU 302, as the DB connection system 351, searches for (obtains) a value (that is, information related to control processing) from the variable table 307 according to the settings of the configuration file 345, and uses the DB device for the obtained value. 400, i.e., generates and issues a DB operation command to the DB device 400 in order to perform DB access processing, and outputs the response from the DB device 400 to the simulator 338, i.e., writes it into the variable table 307. (Step S14). The response received from the DB device 400 is set (written) in the corresponding variable of the variable table 307 after a period of time according to the processing time parameter set in the configuration file 345 has elapsed.

<K. Modified example>
In this embodiment, the information processing device for which the PLC 100 performs the communication processing via the network 112 among the related processing of the control processing is the DB device 400, but such an information processing device is limited to the DB device 400. Not done. For example, the PLC 100 may communicate the operation log 184 in the CSV file format with an FTP (File Transfer Protocol) server, which is an example of the data server 500, in the file transfer service 185 by executing the file transfer program 193. In such a case, the support device 300 can utilize a system for connecting the FTP server and communicating the log file 346 with the FTP server by activating the file transfer module 360. Such an FTP connection system issues operation commands to the FTP server, such as obtaining a list of files in the FTP server (FTPGetFileList), uploading a file (FTPPutFile), and deleting a file (FTPRemoveFile), and receives the responses. It is configured as follows.

Further, for example, in the control process, the PLC 100 may communicate information with an NTP (Network Time Protocol) server on the network 112 in order to obtain time information regarding the control cycle. In such a case, the support device 300 uses a system that connects an NTP server. Such a connection system is configured to issue an operation command to get the status (GetNTPStatus) to the NTP server and receive the response.

Although FIG. 13 shows an example in which a development environment is realized by the processor 120 executing a program, some of the processing and functions necessary to realize the development environment are implemented using an ASIC (Application Specific Integrated Circuit). Alternatively, it may be implemented using a circuit such as an FPGA (Field-Programmable Gate Array).

Further, in this embodiment, the simulation environment of the support device 300 may be configured from the simulator 338, the setting tool 339, and the DB connection system 351, and in that case, the programming tool 337 is not an essential component.

<L. Program＞
Program modules and data for realizing a development environment such as the simulator 338, setting tool 339, and DB connection system 351 provided in this embodiment may be downloaded to the HDD 308 via the communication IF 318 and the network 112. . Alternatively, the information may be downloaded to the HDD 308 via a recording medium (for example, the memory card 333 or the optical disc 332). Such recording media are used to store information such as programs and data electrically, magnetically, optically, mechanically, or chemically so that computers, other devices, machines, etc. can read the recorded programs and other information. It is a medium that accumulates due to physical action. A program for realizing a development environment can be executed by a processor or by a combination of a processor and a circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field-Programmable Gate Array).

(advantage)
In this embodiment, it is possible to provide the simulator 338 with an environment in which DB access processing, including processing for communicating information related to the control processing to be simulated, with the DB device 400 can be performed. That is, even if the user program 186 includes instructions for DB access processing, by configuring the simulation system 1 to include the DB connection system 351 and operating the DB connection system 351 according to the settings in the configuration file 345, the environment can be adjusted. can be provided. Further, since such an environment can be provided without inserting special code into the user program 186 (without modifying the program), costs (time and money) related to the development of the user program 186 can be saved.

Furthermore, even if the conditions for DB access processing including communication processing are changed, for example, even if the user program 186 is changed, the settings in the configuration file 345 can be reset to match the changed conditions. , similar simulation environments can be used (or reused).

<M. Additional notes＞
This embodiment as described above includes the following technical idea.
[Configuration 1]
A simulation system (1) that simulates processing of a controller (100),
The controller includes:
a first connector (158) connecting a first network (110) to which the controlled object (90) belongs;
a second connector (168) that connects a second network (112) to which the information processing device (400, 500, 600) belongs;
It has an execution unit that executes a user program (186) for implementing control processing and a communication program (192) for implementing communication processing for communicating information related to the control processing with the information processing device. death,
The simulation system includes:
a simulator (338) that simulates the control process;
A simulation system comprising: a communication unit (351) that performs communication processing to communicate information related to a control process to be simulated with an information processing device according to predetermined settings (345).
[Configuration 2]
The simulation system according to configuration 1, wherein the information processing device includes a DB device (400) that manages a DB (database).
[Configuration 3]
The simulation system according to configuration 2, wherein the communication process includes a process of issuing a DB operation command for operating the DB to the DB device.
[Configuration 4]
The predetermined setting items are:
The simulation system according to configuration 3, including designation of a target to be operated by the DB device according to the DB operation instruction.
[Configuration 5]
The designation of the target to be operated by the DB device includes an identifier of data to be accessed in the DB,
The simulation system according to configuration 4, wherein the information related to the control processing includes the data to be accessed.
[Configuration 6]
The predetermined setting items are:
The simulation system according to any one of configurations 1 to 5, including parameters related to the communication processing.
[Configuration 7]
The simulation system according to configuration 6, wherein the parameters related to the communication processing include parameters for establishing communication with the information processing device.
[Configuration 8]
8. The simulation system according to configuration 6 or 7, wherein the communication processing-related parameters include a communication processing time parameter.
[Configuration 9]
9. The simulation system according to configuration 8, wherein the communication processing time is based on a communication speed of the second network.
[Configuration 10]
The controller includes a multi-task execution unit (45) that executes a plurality of tasks including a control task (45) for carrying out the control process and a related processing task (47) for carrying out processes related to the control process. 199), wherein communication with the information processing device is executed in the related processing task,
The multitask execution unit executes the control task in a first cycle (T),
The multitask execution unit executes the related processing task in a second cycle (2T, 4T),
The simulation system according to configuration 8 or 9, wherein the communication processing time is based on the second cycle.
[Configuration 11]
A method of simulating processing of a controller (100), the method comprising:
The controller includes:
a first connector (158) connecting a first network (110) to which the controlled object (95) belongs;
a second connector (168) that connects a second network (112) to which the information processing device (400, 500, 600) belongs;
It has an execution unit that executes a user program (186) for implementing control processing and a communication program (192) for implementing communication processing for communicating information related to the control processing with the information processing device. death,
The method includes:
simulating the control process;
A method comprising: implementing a communication process for communicating information related to a control process to be simulated with the information processing device according to predetermined settings (345).
[Configuration 12]
A simulation program for causing a computer (302) to execute a method of simulating processing of a controller (100),
The controller includes:
a first connector (158) connecting a first network (110) to which the controlled object (95) belongs;
a second connector (168) that connects a second network (112) to which the information processing device (400, 500, 600) belongs;
It has an execution unit that executes a user program (186) for implementing control processing and a communication program (192) for implementing communication processing for communicating information related to the control processing with the information processing device. death,
The method includes:
simulating the control process;
A simulation program comprising: implementing a communication process for communicating information related to the control process to be simulated with the information processing apparatus according to predetermined settings (345).

The embodiments disclosed this time should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is indicated by the claims rather than the above description, and it is intended that all changes within the scope and meanings equivalent to the claims are included.

1 simulation system, 10 control system, 11 detection switch, 20 relay, 30 servo motor driver, 32 motor, 43 program management section 44, 54, 352 communication section, 45 control processing, 46 related processing, 47 DB connection service, 51 program Control unit, 52 Stop condition holding unit, 53 Program execution unit, 90, 91, 92, 93 Section, 95 Field device, 110 Field bus, 112 Network, 114 Connection cable, 120 Processor, 122 Chip set, 124 System clock, 126 Main memory, 128 Nonvolatile memory, 148 System bus connector, 158 Fieldbus connector, 168 Upper communication connector, 170 Memory card interface, 184 Operation log, 185 File transfer service, 186 User program, 188 System program, 192 Communication program, 193 File transfer program, 198 Scheduler, 199 Multitask execution program, 300 Support device, 307 Variable table, 400 DB device, 335 Support program, 336 Development program, 337 Programming tool, 338 Simulator, 339 Setting tool, 345 Setting file, 350 DB Connection system module, 351 DB connection system, 354 Program, 360 File transfer module, 500 Data server, 600 Web server, 741 Slider, S10, S12, S14 Step, T Control cycle.

Claims (12)

A simulation system that simulates processing of a controller,
The controller includes:
a first connector connecting a first network to which the controlled object belongs;
a second connector connecting a second network to which the information processing device belongs;
an execution unit that executes a user program for implementing control processing; and a communication program for implementing communication processing for communicating information related to the control processing with the information processing device;
The simulation system includes:
a simulator that simulates the control processing;
A simulation system comprising: a communication unit that performs communication processing to communicate information related to the control processing to be simulated with the information processing device according to predetermined settings. The simulation system according to claim 1, wherein the information processing device includes a DB device that manages a DB (database). 3. The simulation system according to claim 2, wherein the communication process includes a process of issuing a DB operation command for operating the DB to the DB device. The predetermined setting items are:
The simulation system according to claim 3, further comprising designating a target to be operated by the DB device according to the DB operation instruction. The designation of the target to be operated by the DB device includes an identifier of data to be accessed in the DB,
The simulation system according to claim 4, wherein the information related to the control processing includes the data to be accessed. The predetermined setting items are:
The simulation system according to any one of claims 1 to 5, comprising parameters related to the communication processing. The simulation system according to claim 6, wherein the parameters related to the communication processing include parameters for establishing communication with the information processing device. The simulation system according to claim 6 or 7, wherein the parameters related to communication processing include a parameter of communication processing time. The simulation system according to claim 8, wherein the communication processing time is based on a communication speed of the second network. The controller includes a multitask execution unit that executes a plurality of tasks including a control task for implementing the control processing and a related processing task for implementing processing related to the control processing, communication with is performed in the related processing task,
The multitask execution unit executes the control task in a first cycle,
The multitask execution unit executes the related processing task in a second cycle,
The simulation system according to claim 8 or 9, wherein the communication processing time is based on the second period. A method for simulating processing of a controller, the method comprising:
The controller includes:
a first connector connecting a first network to which the controlled object belongs;
a second connector connecting a second network to which the information processing device belongs;
an execution unit that executes a user program for implementing control processing; and a communication program for implementing communication processing for communicating information related to the control processing with the information processing device;
The method includes:
simulating the control process;
A method comprising: implementing a communication process to communicate information related to the control process to be simulated with the information processing apparatus according to predetermined settings. A simulation program for causing a computer to execute a method of simulating processing of a controller,
The controller includes:
a first connector connecting a first network to which the controlled object belongs;
a second connector connecting a second network to which the information processing device belongs;
an execution unit that executes a user program for implementing control processing; and a communication program for implementing communication processing for communicating information related to the control processing with the information processing device;
The method includes:
simulating the control process;
A simulation program comprising: implementing a communication process for communicating information related to the control process to be simulated with the information processing apparatus according to predetermined settings.

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