JP4569838B2 - Controller system setting method and controller system monitoring method - Google Patents

Description

The present invention relates to a controller system setting method and a controller system monitoring method.

  A programmable controller (hereinafter referred to as “PLC”) used in FA (factory automation) is a sequence program written in ladder language or the like by inputting ON / OFF information from an input device such as a switch or sensor connected to the PLC. Execute logical operation according to the (user program), and output ON / OFF information for the relay output connected to the PLC or drive / stop information for output devices such as valves and actuators based on the operation result The control is executed by outputting the above signal. Such PLC control is executed by repeating so-called cyclic processing.

  By the way, the connection form between the PLC and the input device and the output device may be connected to a terminal of the PLC or a terminal of the I / O unit, or may be connected via a network. When constructing a network system connected by such a network, the ON / OFF information is transmitted and received via the network. At this time, information is normally transmitted in a master-slave system in which the PLC side is a master and the device side is a slave. This master-slave method is also called a remote I / O method, and is used with a communication master unit attached to a PLC and a communication slave unit connected to the communication master unit via a network line. Then, a plurality of input devices or output devices are connected to the terminals of the communication slave unit. Communication between the master and the slave is performed by serial communication transmission at a predetermined cycle. In the transmission, the master makes a data request to the slave, and the slave receives the request and returns ON / OFF information (I / O information) of each input or output device connected to the slave as a serial signal. That is, the master controls the communication right of the network, and the slave performs transmission processing toward the network according to the control of the communication right.

  Note that communication between the master and the slave may be performed in synchronization with the cyclic processing of the PLC, or may be performed asynchronously. The exchange of information between the PLC CPU and the master may be performed by PLC I / O refresh processing or by peripheral processing. In addition, a plurality of slaves can be connected to one master and communicate with each other.

  On the other hand, recently, there is a control based on PLC that assumes applications such as robot machines, press machines, cutting machines and the like where safety requirements are high. For example, robot control is being introduced in what is called a safety system or a safety net system so that a robot arm does not come into contact with a human body due to an abnormality or failure of a control system, resulting in a personal injury. In that case, it is composed of a PLC as a control system element, each device itself, and a network in which a safety function is incorporated. Here, the “safety function” refers to a function that confirms safety and performs output. In addition, the “safety system”, for example, duplicates the CPU and other processing units, detects a mismatch between the two and determines that the processing unit is abnormal, and causes an abnormality in the network for some reason (normal communication is not possible). When the emergency stop switch of the mechanical system is pressed, or when the entrance of a person (part of the body) is detected in the dangerous area by a multi-optical axis photoelectric sensor such as a light curtain In this case, it is a function for reliably operating the mechanical system in a safe state, or a function for forcibly stopping the operation of the mechanical system in a safe state due to fail-safe operation. In other words, it is a system that outputs only when safety is stored by the safety function and moves the machine. Therefore, the machine stops when safety cannot be confirmed.

  When constructing a safety system or a safety network system having the above-described safety function, all devices connected to the network (PLC, slave, and devices connected to the slave, etc.) must be equipped with safety functions. It was. This is because if even one device without a safety function is incorporated, the failsafe does not work for the control including the device and the data communication with the device, and the safety function of the entire system cannot be guaranteed. .

  By the way, in the control by PLC, the safety function is not necessarily required for the entire system. However, if even a part of the safety function needs to be guaranteed, a safety system will be used, and thus a device without a safety function cannot be included therein. In that case, the safety PLC and the safety device are also used in a place where the safety function is not originally required. Since a device with a safety function is more expensive than a normal device, the cost of the entire system becomes high.

  In addition, if you intend to introduce additional devices or safety PLCs with partial safety functions into an environment where a network system based on a conventional PLC that already has no safety functions has been constructed, the safety functions will be added to the existing conventional equipment. Even if I tried to mix the devices I had, I couldn't do it well. In other words, it is necessary to completely separate the existing part having no safety function and the part having the safety function, and the two cannot be mixed in the same environment. Of course, it is conceivable to discard the existing equipment and newly install a safety network system, but a great number of replacement steps are required.

  On the other hand, in view of the above points, there is also an idea that a safety network is to be constructed only for a portion where a safety function is required. However, as described above, the safety system and the non-safety system are separated, and it becomes difficult to exchange data between them. Furthermore, since a safety system and a non-safety network system are provided separately, not only two types of setting / management tools are required, but the two types of such tools must be used separately, which is cumbersome. .

The present invention monitors the control information and controller status using a common tool for the non-safety system and the safety system, as well as for the controller system in which the safety system and the non-safety system coexist. It is an object of the present invention to provide a controller system setting method and a controller system monitoring method in which both settings can be performed with a common tool .

As an example of a safety unit that constitutes a controller system to which the present invention is applied, it can be connected to a non-safety controller configured by linking a plurality of non-safety units including a CPU unit, and executes safety function processing. is there. A CPU bus for linking to the CPU unit and a safety dedicated bus for linking to another safety unit are provided.

Further, as another example , a safety unit that can be connected to a non-safety controller configured by connecting a plurality of non-safety units including a CPU unit, the CPU bus for linking to the CPU unit, and a safety And a processing unit that executes functional processing, and can be configured to transmit and receive data to and from the CPU unit via the CPU bus.

  The safety unit includes, for example, a safety controller, a safety bus master, a safety I / O, and a combination of these functions. Further, the safety dedicated bus corresponds to the safety dedicated bus 11 in the embodiment. That is, the “dedicated safety bus” is a bus for transmitting and receiving information (data) for realizing safety function processing, and only the safety unit is connected. However, as long as a closed world can be constructed within the safety unit, it may be used to send and receive other non-safety information. It is only necessary that it is not directly accessible from the non-safety unit. In addition, the “safety function” is a so-called fail-safe function. When an abnormality occurs in the control of the controller or when a communication abnormality occurs, the control is stopped. This function allows the control device to maintain a safe state. Also, the control itself does not run away. As an example of when control stop is necessary, if the controller CPU or other processing units are duplicated and a mismatch between the two is detected, or if an abnormality occurs in the network for some reason, the emergency stop switch of the mechanical system When the button is pressed, there may be a case where a dangerous state occurs, such as when a person (part of the body) has entered the dangerous area by a multi-optical axis photoelectric sensor such as a light curtain. In the above case, the safety function ensures that the machine system to be controlled is operated in a safe state, or is stopped in a safe state in addition to the operation, or a fail safe is activated to make the machine system safe. The operation is forcibly stopped in a stable state.

  According to the present invention, since the safety dedicated bus is provided, the reliability of the safety system can be ensured. In other words, even if the non-safety unit and the safety unit that make up the non-safety system are connected and the non-safety system and the safety system are mixed, at least the data for safety function processing can be obtained by using the safety dedicated bus. Reliability is obtained.

  Thereby, the controller which mixed the non-safety system and the safety system can be formed. Therefore, space can be saved and the safety unit can be managed as a high-function unit of a non-safety controller (PLC).

  In addition, by preparing appropriate units (safety units) for places where safety functions are required and places where safety functions are not required, and connecting them together, it is possible to install the right material in the right place and prevent unnecessary costs from increasing. Is done. If a non-safety controller has already been installed, the system can be replaced only in places where a safety function is required by connecting the safety unit of the present invention to the existing controller. -Effective use of resources can be achieved. Therefore, it is possible to easily add a safety system to an environment in which a non-safety controller (PLC) is already used.

  Moreover, it is good to provide the safety system configuration management information storage means which memorize | stores safety system configuration management information, and to provide the master function which manages and collates all the safety units. In the embodiment, the master function is realized by the MPU 12 of the safety unit 1d. This safety unit becomes a master for managing the transmission and reception of data between safety units when a plurality of safety units are connected. And it is good to provide the setting means which sets whether it is the main safety unit (master) which controls a safety system among several safety units. The setting means corresponds to the user interface 21 in the embodiment. By providing the setting means in this way, the user can easily set which safety unit is the master and can confirm later.

  Furthermore, a tool interface is provided, and a function of acquiring information held in the other safety unit or the non-safety unit via the CPU bus according to a request from a connected tool can be provided.

  Further, the controller system of the present invention can be configured by connecting the safety unit of each invention described above to a non-safety controller configured by connecting a plurality of non-safety units including a CPU unit. In this case, the CPU unit may be capable of reading data via the CPU bus regardless of the safety unit or the non-safety unit.

  According to the present invention, since all of the safety units have the CPU bus controlled by the CPU unit, the CPU unit can pass through the CPU bus regardless of whether it is a safety unit or a non-safety unit. Data can be read out. Conversely, the safety unit can read data from the non-safety unit via the CPU unit.

  Therefore, when a tool is connected to the CPU unit, it is possible to acquire the configuration information of the safety system unit as well as the non-safety system. Similarly, when a tool is connected to the safety unit, it is possible to acquire the configuration information of the non-safety unit as well as the safety unit.

The connection method between the non-safety controller and the safety controller in the present invention will be described. Each of the plurality of safety units constituting the safety controller is connected by a dedicated safety bus so that information can be exchanged between the safety units. In addition, the CPU bus of the non-safety controller is connected to each safety unit of the safety controller. At this time, the CPU bus is branched to each safety unit (so-called multidrop). That is, the CPU bus is extended and connected to the safety controller. Data is transmitted and received and information is exchanged between the CPU unit of the non-safety controller and the safety unit via the CPU bus.

  As a control method according to the present invention, a non-safety controller and a safety controller are configured as a controller system, and the CPU bus of the non-safety controller is extended and connected to the CPU unit of the safety controller. At this time, a safety unit other than the CPU unit of the safety controller may be connected via the CPU bus. As control of the non-safety controller, in addition to passing I / O information to each unit of the non-safety controller via the CPU bus, I / O for safety control handled by the safety controller via the CPU bus is used. The non-safety controller inputs O information. Furthermore, as a safety function control of the safety controller, the controller system is controlled by passing I / O information to each safety unit via a safety dedicated bus.

  When the non-safety controller inputs safety control I / O information, the I / O information storage area in the system memory (corresponding to the system RAM 14 of the embodiment) of the CPU unit of the safety controller or via the network What is necessary is just to make it take in from the I / O information storage part (equivalent to the I / O information storage part 22 of embodiment). Instead, the CPU bus is connected to another safety unit, and the I / O information of the device connected to the unit and the unit are stored directly from the safety unit without going through the safety CPU unit. Existing I / O information may be captured. In addition, if the safety controller captures the I / O information for the non-safety controller and uses it for control, the safety function cannot be guaranteed, so the information by the control of the non-safety controller is not captured. This is because the safety unit (CPU unit or each unit) may refuse to input control information from the non-safety unit (controller, CPU unit), or the non-safety unit may be a safety unit. The control information may not be output toward. That is, the non-safety controller may prohibit transmission of control information and I / O information to the safety unit based on the configuration management information.

Here, the monitoring method of the controller system according to the present invention includes a non-safety controller configured by connecting a plurality of units including a CPU unit by a CPU bus and a plurality of safety units including a CPU unit having a safety function. A controller configured to extend and connect the CPU bus of the non-safety controller to the safety controller, the CPU unit of the non-safety controller includes a tool interface, and a tool is provided. In accordance with a request from the connected tool, the CPU unit of the non-safety controller acquires information held in the safety controller via the CPU bus, and the acquired information is transmitted via the tool interface. To send to external tools The process and the process of transmitting information held by the non-safety controller to an external tool via the tool interface, and according to a request from the connected tool, the CPU via the CPU unit of the non-safety controller I / O data related to safety function control cannot be written to the CPU unit of the safety controller.

In the controller system setting method of the present invention, a non-safety controller configured by connecting a plurality of units including a CPU unit by a CPU bus and a plurality of safety units including a CPU unit having a safety function are connected. A controller system in which the CPU bus of the non-safety controller is extended to the safety controller and connected to the CPU unit of the non-safety controller with a tool interface, and a tool is connected. A process in which the CPU unit of the non-safety controller acquires predetermined information to the safety controller via the CPU bus and transmits the predetermined information to the tool via the tool interface in accordance with an instruction from the tool, Non-safety controller non-safety Control information related to the processing of safety functions, to the CPU unit of the safety controller via the CPU unit of the non-safety controller according to the request from the connected tool. Can not be rewritten.

In another controller system monitoring method according to the present invention, a non-safety controller configured by connecting a plurality of units including a CPU unit by a CPU bus and a plurality of safety units including a CPU unit having a safety function are connected. A controller configured to extend the CPU bus of the non-safety controller to the safety controller and connect the tool to the CPU unit of the safety controller with a tool interface. In accordance with a request from the connected tool, the information stored in the non-safety controller is acquired via the CPU bus by processing of the CPU unit of the safety controller, and the acquired information is used for controlling the safety function Without the tool interface The information held in the safety controller is acquired by processing of the CPU unit of the safety controller in accordance with a request from the connected tool, and the acquired information is externally transmitted via the tool interface. It was sent to the tool of.

As described above, according to the present invention, the control information and the state of the controller can be monitored while the safety function is secured by using a common tool for the non-safety system and the safety system, or both the non-safety controller and the safety controller can be set. Can be done with a common tool.

  The present invention will be described in more detail with reference to the accompanying drawings. FIG. 1 shows an example of a network system to which the present invention is applied, and FIG. 2 shows an example of the internal structure of a PLC 1 that is a controller. As shown in FIG. 1 and FIG. 2, in the present embodiment, a plurality of (six in this example) units 1a, 1b, 1c, 1d,. The PLC 1 according to the present embodiment includes a unit (non-safety unit) for constructing a non-safety network system having no safety function and a unit (safety unit) having a function for constructing a safety network system unlike the conventional one. Are connected in a mixed state.

  Specifically, three non-safety units 1a to 1c and three safety units 1d to 1f are provided. The non-safety unit 1a is a so-called CPU unit, 1b is an I / O unit, and 1c is a communication master unit. A non-safety network 3 is connected to the communication master unit 1c, and various devices 2 such as input devices and output devices are connected to the network 3. Thereby, PLC1 constructs | assembles the non-secure network system generally used conventionally with the apparatus 2 normally. The device 2 performs serial communication with the communication master unit 1c and is called a slave unit. The CPU unit 1a performs so-called cyclic processing. The cyclic process is a process that repeatedly performs an I / O refresh process, a user program execution process, and a peripheral process. The I / O refresh process is a process of taking ON / OFF information of the input device into the memory of the CPU of the PLC, and a process of outputting the result of executing the user program in the previous cycle to the output device as a signal. . The input / output device is connected to the I / O unit 1b or the device 2. The user program execution process is a process for performing an operation based on input information from the input device in accordance with the conditions of the user program. Peripheral processing is processing for performing communication through a network line connected to the PLC. Communication partners include tools, host computer terminals, and remote I / O slaves.

  The safety unit 1d is equivalent to a CPU unit capable of supervising the units 1d to 1f having safety functions, and in addition to performing cyclic processing in the same manner as the CPU unit 1a, the safety unit 1d is configured to realize a safety function. ing. A safety network 7 is connected to the safety unit 1d, and a safety device 6 is connected to the safety network 7. Specific examples of the safety device 6 include input devices or output devices such as a light curtain sensor, a safety switch, and a safety application actuator. If the safety unit 1d has a communication master function, the safety device 6 may be equivalent to a slave unit or equivalent to an I / O terminal, and a remote I / O can be constructed on the safety network. The safety device 6 is connected to a plurality of input devices, output devices, or input / output devices, and exchanges I / O information with the master through serial communication. The safety unit 1e is equivalent to a safety I / O unit, and can be directly connected to a safety device (input device or output device) without going through a network, and an input signal is sent at the timing of the I / O refresh processing of the safety CPU unit 1d. Captures and outputs an output signal. The safety unit 1f functions as one of the safety units, such as a safety high-function unit, a safety analog unit, and a safety motion control unit.

  As shown in the figure, a CPU bus 10 is provided across all the units 1a to 1f. The CPU bus 10 is a communication bus line that enables data transmission / reception between units. The control of data transmission / reception on the CPU bus 10 is managed by the non-safety CPU unit 1a. That is, the CPU unit 1a performs arbiter control for transferring the bus right. The safety units 1d to 1f are provided with another safety dedicated bus 11 independent of the CPU bus 10, and the safety units are connected by a bus. Then, transmission / reception of safety data between the safety units 1d to 1f is performed via the safety dedicated bus 11. Control of the bus right of the safety dedicated bus 11 cannot be performed by the CPU unit 1a, but is performed by any one of the safety units 1d to 1f. One of the units may have a bus master function.

  That is, since the CPU bus 10 for connecting all the units 1a to 1f and the safety dedicated bus 11 for connecting the safety units 1d to 1f are provided separately, a non-safety unit is included in a series of PLCs. When it is desired to exchange the data held by the safety unit with the data held by the safety system, communication can be performed using the CPU bus 10. For example, the I / O information possessed by the safety unit 1d is passed to the CPU unit 1a, the various setting information of the safety unit group possessed by the safety unit 1d is passed to the CPU unit 1a, or the safety units 1d to 1f from the CPU unit 1a. Various setting information can be passed to. It is better not to pass the I / O information of the CPU unit 1a to the safety unit. This is because if the I / O information having no safety function is mixed in the safety device, the safety device may not be able to secure the safety function.

  On the other hand, safety-related data for which a safety function is to be secured can be communicated in a closed world using the safety dedicated bus 11. That is, the transmission and reception of data for performing the safety function can be reliably performed in the safety units 1d to 1f, and a safety function such as fail-safe can be realized with certainty. In short, a series of PLCs have a configuration in which a safety system and a non-safety system are mixed and have an independent relationship with each other.

  A tool 5 can be connected to the PLC 1, and a user program can be created or edited by the tool 5 and downloaded to the PLC 1, or network system information stored in the PLC 1 can be collected. In addition to the collected information, PLC configuration management information, I / O information (control status of each contact, etc.), I / O information of each unit, status of each input contact, status of output contact, I / O of CPU unit / O data, buffer memory information of I / O unit, etc.), setting information of each unit (initial setting information, node number, communication setting of communication unit, etc.), safety information (I / O information of safety unit, each unit) Operating time information, lifetime information, abnormality history information, etc.), configuration management information of each unit, and the like.

  Next, a specific configuration of each unit will be described. First, the non-safety unit 1a is a CPU unit 1a in this embodiment, and controls the non-safety system, that is, executes a user program created by a ladder or the like, becomes a master of the CPU bus 10, and has an overall configuration of the PLC 1. Or manage. As described above, the CPU unit 1a performs so-called cyclic processing, and repeatedly performs I / O refresh processing, user program execution processing, and peripheral processing.

  In this process, the MPU 12 reads the system program stored in the system ROM 13 and further the user program stored in the user program storage unit 15 and uses the memory area (I / O information storage area) of the system RAM 14 as appropriate. Execute. Furthermore, it has a configuration management information storage unit 16 and stores information (configuration management information) about all the units constituting the PLC 1 and manages the entire configuration based on the stored configuration management information. The data structure of the configuration management information storage unit 16 is a table in which slot numbers, IDs, product types, and serial numbers are associated as shown in FIG. 3, for example. The slot number is a number assigned to each connected unit in order, and the ID is information specifying the type. As is apparent from the figure, this slot No. is assigned to all the units 1a to 1f regardless of the safety system or the non-safety system. This configuration management information is used when various items are set from the tool 5 to the units 1a to 1f.

  Furthermore, it has a tool interface 17, and by connecting the tool 5 to this tool interface 17, it is possible to download a user program, collect information, and set the PLC 1. The MPU 12 connected to the tool interface 17 via an internal bus is linked to the CPU bus 10 via the interface 18 so that the tool 5 and the units 1b to 1f can transmit and receive signals. For example, the setting target unit is specified by the slot number (corresponding to the unit number) on the tool 5 side, the setting information of the specified unit is input on the tool 5 side, and the setting information is downloaded to the specified unit. This download reaches each unit via the path of the tool 5, the tool interface 17, the MPU 12, the interface 18, and the CPU bus 10.

  The non-safety units 1b and 1c execute non-safety functions. The MPU 12 is connected to the CPU bus 10 via the interface 18 and transmits / receives data to / from the CPU unit 1a and the like. The MPU 12 accesses the system ROM 13 and the system RAM 14 and executes predetermined processing for realizing the function of each unit.

  In this embodiment, the non-safety unit 1b is a non-safety I / O unit including an I / O interface 19, and a predetermined I / O device is directly connected to the I / O interface. The non-safety unit 1 c is a non-safety communication unit including the communication interface 20. Accordingly, the communication interface 20 of the non-safety unit 1c (communication unit) is connected to the network 3, and together with the device 2 connected to the non-safety network 3, a non-safety network system is constructed.

  This non-safety network system is a network system based on PLC that has been generally used in the past, and the contents thereof are conventionally known although they are referred to as “non-safety”. In some cases, it is an existing facility.

  On the other hand, the safety units 1d to 1f perform safety functions and are connected to the safety dedicated bus 11. The safety dedicated bus 11 is connected to only the safety units 1d to 1f, is suitable for realizing a safety function, and is provided independently of the conventional CPU bus 10. Further, the safety units 1d to 1f are also connected to the CPU bus 10 so that necessary data can be transmitted to and received from the non-safety unit via the CPU bus 10. As shown in the figure, each of the safety units 1d to 1f is also provided with an MPU 12, a system ROM 13 storing a program for executing the function, and a system RAM 14 used at the time of executing the operation in order to execute each function. Each MPU 12 is connected to the CPU bus 10 via an interface 18 and is connected to the safety dedicated bus 11 via a safety interface 24.

  Furthermore, one of the plurality of safety units 1d to 1f becomes the master of the safety dedicated bus 11 (reference numeral 1d in the example in the figure), and the safety system configuration management information storage unit 25 includes the configuration of the safety units 1d to 1f. Stores management information. The data structure of the safety system configuration management information storage unit 25 is, for example, as shown in FIG.

  As is clear from comparison between FIG. 4 and FIG. 3, the types of information to be stored are the same (slot No, ID, product model, serial No), but are stored in the configuration management information storage unit 16 in FIG. Is the configuration management information for all units, but the safety system configuration management information shown in FIG. 4 is different in that it is only for the safety units 1d to 1f constituting the safety system. And slot no. (Safety slot No.) is also reassigned. That is, the safety unit 1d has a slot No. Becomes “4” and the safety slot No. becomes “1”. Similarly, each of the safety units 1e and 1f has a slot No. Becomes “5” and “6”, and the safety slot numbers become “2” and “3”.

  Furthermore, the safety unit 1d includes a tool interface 17 and a communication interface 20, and can be connected to the tool 5 and the safety network 7 through these interfaces. In addition, by performing serial communication with the safety device 6 connected to the safety network 7, the I / O information of each safety device 6 is captured and stored in the I / O information storage unit 22. The data structure of the I / O information storage unit 22 is as shown in FIG. In other words, the safety unit 1d is equivalent to a remote I / O communication master unit, and the safety device 6 operates as a communication slave. Devices, actuators and other output devices). The safety device 6 itself may be an input device or an output device, and each device may have an interface unit that directly outputs to the network 7. Further, one safety device 6 connects a plurality of input or output devices, and may be a so-called slave unit or terminal unit. In this case, I / O information of a plurality of devices is parallel / serial converted and transmitted or received to the network.

  Furthermore, a user interface 21 is provided in the safety unit 1d. The user interface 21 is composed of various switches and performs various settings. As an example, it is used to set whether or not it is a master unit. The safety unit 1d is a safety master and also constitutes a communication unit, but it is of course possible to divide these functions and configure them as separate units.

  The safety unit 1e and the safety unit 1f also have a CPU bus 10 and a safety dedicated bus 11, and the MPU 12 is connected to the buses 10 and 11 via the interface 18 and the safety interface 24. Furthermore, the safety unit 1e constitutes an I / O unit. That is, the I / O interface 19 is provided, and the safety information of the I / O safety device connected to the I / O interface 19 is acquired and stored in the I / O information storage unit 23. An example of the data structure in the I / O information storage unit 23 is shown in FIG. The MPU 12 performs data transmission / reception with these safety devices, storage in the I / O information storage unit 23 and other processing while accessing the system ROM 13 and the system RAM 14.

  Next, functions of the MPU 12 provided in the CPU unit 1a serving as a non-safety master will be described. First, when the power is turned on (ST1), the configuration management information and the actual unit are checked to determine whether or not they match (ST2). That is, it is determined whether or not each unit (safety system, non-safety system) connected to the CPU bus 10 is correctly connected. If they do not match, the configuration is abnormal and the operation is stopped (ST3, ST4).

  On the other hand, when the configuration check is OK, the operation start command is waited (ST5), and when the start command is received, the operation shifts to a normal cyclic control operation. That is, first, a CPU bus refresh process is executed (ST6). This is called I / O refresh, and the I / O data stored in the system RAM 14 of the CPU unit 1a and the system RAM 14 of other units 1b and 1c (1d to 1f as required) is rewritten. This is a process of updating to the latest I / O data. Then, the user program is executed based on the latest input data obtained by this I / O refresh process (ST7). The execution result is written in the system RAM 14 as the latest output data. This execution result is sent as output data to another unit during the next I / O refresh process. Then, it is determined whether or not there is a processing request from the tool interface of the CPU unit 1a (ST8). If there is no request, the refresh process and the execution of the user program are repeated. When there is a processing request from the tool 5 connected to the CPU unit 1a (Yes in ST8), the tool processing is executed. This processing is the peripheral processing described above. After the peripheral processing is completed or the peripheral processing is performed for a predetermined time, the process returns to Step 6. Thereafter, the normal cyclic execution process is repeated. As peripheral processing, for example, monitoring (reading) of I / O information and processing for rewriting I / O information can be performed. The reading of I / O information may be a non-safety system or a safety system, but writing is not allowed for the safety system. In addition, the user program may be taken out, and the configuration management information may be read out and updated. The peripheral processing is also described later.

  When this non-safety PLC processing is performed by the CPU unit 1a, safety-related I / O information may be used as necessary. In that case, I / O allocation is performed based on the configuration management information as to which I / O information of which safety device is connected to which safety unit. The I / O assignment is to associate the I / O information area in the system RAM 14 with the previous safety device. By making this assignment, the MPU 12 of the CPU unit 1 a acquires I / O information of the safety device of the specific safety unit via the CPU bus 10. Specifically, the safety unit 1d (corresponding to the CPU unit) is stored in the I / O information of each safety unit stored in the system RAM 14 or the I / O information storage unit 23 of the device on the network. There is a method of acquiring data via the CPU bus 10 by processing of the MPU 12 of the CPU unit 1a. However, the I / O information may be acquired from the safety units 1e and 1f.

  Next, the function of the MPU 12 of the safety units 1d to 1f will be described. As shown in FIG. 8, when the power is turned on (ST11), it is determined whether or not it is a safety system master (ST12). This determination is made based on the setting of the user interface 21. The user interface 21 is not used for setting whether or not the safety master is used. For example, the safety master is assigned a safety unit number. Is set to “1”, the branch determination in step 12 is the safety unit No. This is done by checking.

  In the case of a safety system master, the result of step 12 is Yes, and the process proceeds to step 13, where it is recognized as a safety bus master, and the safety system configuration management information and the actual unit configuration are checked to determine whether they match (ST14). . That is, it is determined whether or not each safety unit 1d to 1f connected to the safety dedicated bus 11 is correctly connected. If they do not match, the configuration is abnormal and the operation is stopped (ST23, ST24).

  On the other hand, when the safety system bus configuration is OK, the operation shifts to a normal cyclic control operation. That is, the refresh process for the safety dedicated bus 11 is executed (ST15). This execution is a process of exchanging the I / O data stored in both the system RAM 14 of the safety master 1d and the system RAM 14 of the other units 1e and 1f to update to the latest I / O data. By this process, the safety master 1d takes in the input information from the other units 1e and 1f, updates the input information to the latest one, passes the output information to the other unit, and updates the output information on the other unit side. Will be updated to the ones. Next, safety function processing is executed based on the latest input data obtained by this I / O refresh processing (ST16). This safety function process is a user program execution in the safety master 1d, which processes a predetermined logical operation in accordance with input information and obtains the operation result as output information for operating the safety device. Say. Thereafter, it is determined whether or not there is a processing request for the tool 5 via the CPU bus 10 or from the tool interface of the safety unit 1d (ST17). If there is no request, the process returns to the refresh process in step 15 and the normal cyclic process is repeated. On the other hand, if there is a processing request from the tool 5 connected to the CPU unit 1a or the safety unit 1d (Yes in ST17), the processing returns to step 15 to perform normal cyclic processing after executing tool processing as peripheral processing. . In addition, as a tool process, for example, the state of the safety device or the entire safety device may be monitored. Of course, the I / O information in the system RAM 14 of the safety master 1d may be rewritten via a tool, but in that case, password management is required. Tool processing performed via the CPU bus 10 is limited to a monitor or the like, and it is preferable that safety device information and control information related to the safety device cannot be rewritten. The reason is that if safety information processing is performed, information is taken from a non-safety route, and if the taken information is used for safety purposes, the safety function cannot be secured.

  Explain safety data exchange. Data transmission / reception is performed between the units 1d to 1f via the safety dedicated bus 11, but the data transmission is duplexed as a safety function at that time. For example, if the sending safety unit sends the same data twice to the safety dedicated bus 11 and validates the data capture on condition that the two data received by the receiving safety unit match Good. As another method, the transmission-side safety unit includes the actual data information and a signal obtained by processing the actual data information in one frame (for example, a digitally inverted signal) and sends it to the safety dedicated bus 11 to receive the data. Check the match between the actual data part of the frame received by the safety unit and the signal that restored the processed signal (in this example, the signal that was digitally inverted again and returned to the state before the inversion). The received data may be regarded as valid.

  On the other hand, if it is not a safety master (No in step 12), it is recognized as a safety bus slave (ST19), and the presence or absence of a safety bus interface processing request is determined (ST20). If there is a request, a safety bus refresh process is performed, and after a predetermined data is returned to the safety master, a safety function process is executed (ST22). If there is no request, the safety function process is executed as it is.

  Next, tool processing, that is, processing for calling (acquiring) data stored in different units will be described. First, FIG. 9 shows a processing procedure when information held by the safety unit is read from the tool 5 connected to the CPU unit 1a. Information read out from the safety unit 1d, which is a safety system master, includes the safety system configuration management information stored in the safety system configuration management information storage unit 25 and the I / O information storage unit 22, and the network device I / O. O information, which is I / O information stored in the I / O information storage unit 23 from the safety unit 1e, which is a safety I / O unit.

  First, the tool 5 makes a read request (ST30). The MPU 12 of the CPU unit 1a waits for a request from the tool 5 (ST31), and when receiving the request through the tool interface 17, analyzes the content of the request and requests the safety unit holding the data to be read out (ST32). This read request is made via the CPU bus 10.

  On the other hand, the MPU 12 of the safety unit also waits for a request sent via the CPU bus 10 (ST33), and when the request is accepted, information (data B & C, data D) that it manages and holds via the internal bus is received. The read information (data B & C, data D) is transmitted to the MPU 12 of the CPU unit 1a via the CPU bus 10 (ST34).

  When the MPU 12 of the CPU unit 1a receives a response from the requesting safety unit, the MPU 12 sends the received data (B & C, D) to the tool 5 via the internal bus → tool interface 17 (ST35). Thereby, since the tool 5 can receive data (B & C, D) (ST36), the received data is displayed on the monitor of the tool 5 (ST37).

  As a result, data held by the safety system safety unit can be collected from the non-safe system CPU unit 1a. Although not specifically shown, it goes without saying that the tool 5 connected to the CPU unit 1a can monitor the data held by the CPU unit 1a as in the prior art.

  Next, the information (management configuration information: data A stored in the configuration management information storage unit 16) held by the non-safety CPU unit 1a is read from the tool 5 connected to the safety unit 1d, which is the safety master. A processing procedure in this case will be described. As shown in FIG. 10, the tool 5 makes a read request (ST40). The MPU 12 of the safety unit 1d waits for a request from the tool 5 (ST41), receives a request (specifies data to be read) via the tool interface 17, analyzes the content of the request, and sends the request to the CPU unit 1a. Then, a read request is made (ST42). This read request is made via the CPU bus 10.

  On the other hand, the MPU 12 of the CPU unit 1a also waits for a request sent via the CPU bus 10 (ST43). When the request is received, the request content is analyzed and the configuration management information (data A) held by itself is analyzed. Is read out, the information (data A) managed and held by itself is read via the internal bus, and the read information (configuration management information) is sent to the MPU 12 of the safety unit 1d via the CPU bus 10. (ST44).

When receiving the response from the CPU unit 1a that issued the request, the MPU 12 of the safety unit 1d sends the received data to the tool 5 via the internal bus → tool interface 17 (ST45). Thereby, since the tool 5 can receive information (data A) (ST46), the received data is displayed on the monitor of the tool 5 (ST47).

  As a result, data held by the non-safety CPU unit can be collected from the safety unit 1d which is a safety system. Although not specifically shown, it goes without saying that the tool 5 connected to the safety unit 1d can monitor the data B & C held by the safety unit 1d as in the conventional case.

  Furthermore, a procedure for reading data held by another safety unit of the same safety system from a tool connected to the safety unit 1d will be described. As shown in FIGS. 11 and 12, first, the tool 5 makes a read request (ST50). The MPU 12 of the safety unit 1d waits for a request from the tool 5 (ST51), and when receiving the request via the tool interface 17, makes a read request to the CPU unit 1a (ST52). This read request is made via the CPU bus 10.

  On the other hand, the MPU 12 of the CPU unit 1a also waits for a request sent via the CPU bus 10 (ST53). When the request is received, the request content is analyzed, and the unit number. If it is determined that the I / O information (data D) held by the safety unit 1e of No. 5 is a read request, the data D is requested to be read from the safety unit 1e via the CPU bus 10 (ST54).

  The MPU 12 of the safety unit 1e waits for a request sent via the CPU bus 10 (ST55) as in the case of reading from the tool connected to the CPU unit 1a described above (ST55). The information (data D) managed and held by itself is read, and the read information (data D) is transmitted to the MPU 12 of the CPU unit 1a via the CPU bus 10 (ST56). Note that the MPU 12 of the safety unit 1e has nothing to do with the request source tool, and only receives the request from the CPU unit 1a and returns the necessary data.

  Then, the MPU 12 of the CPU unit 1a transmits the data D received via the CPU bus 10 to the MPU 12 of the safety unit 1d that issued the original read request via the CPU bus 10 (ST58).

  Upon receiving the response from the CPU unit 1a, the MPU 12 of the safety unit 1d sends the received data to the tool 5 via the internal bus → tool interface 17 (ST59). Thereby, since the tool 5 can receive information (data D) (ST60), the received data is displayed on the monitor of the tool 5 (ST61).

  Of course, the MPU 12 of the safety unit 1d can also acquire the data D from the safety unit 1e directly via the safety dedicated bus 11. However, according to the processing procedure described above, data can be sent and received between units via the CPU bus 10, and the safety dedicated bus 11 can be dedicated to sending and receiving information for the safety processing function. preferable.

  By adopting the above-described configuration, the safety units 1d to 1f can be managed as high functions of the conventional PLC. Further, since it can be integrated with a conventional non-safety PLC, for example, only one power supply unit or the like can be used, so that space can be saved. Furthermore, a safety system can be easily added to an environment that already uses a non-safety PLC.

  Further, by connecting the non-safety units 1a to 1c and the safety units 1d to 1f and connecting them by bus, they are electrically and mechanically connected and integrated, thereby reducing wiring. In addition, having a safety dedicated bus not only optimizes safety and non-safety processing (high speed), but also has a safety dedicated bus to ensure safety reliability. it can. Therefore, a safety system can be constructed at a relatively low cost.

  Further, since the CPU bus 10 that can be controlled by the PLC CPU (the MPU 12 of the CPU unit 1a) is provided in all of the safety units 1d to 1f, the MPU 12 of the CPU unit 1a is connected to the safety unit and the non-safety unit via the CPU bus. Regardless of the data, all units can be read. Further, the safety unit can read data of the non-safety unit via the CPU unit.

1 is a diagram showing a preferred embodiment of a safety network system according to the present invention. It is a figure which shows the principal part of suitable one Embodiment of the controller (PLC) based on this invention. 4 is a diagram illustrating an example of a data structure of a configuration management information storage unit 16. FIG. 4 is a diagram illustrating an example of a data structure of a safety system configuration management information storage unit 25. FIG. 4 is a diagram illustrating an example of a data structure of a / O information storage unit 22. FIG. 4 is a diagram illustrating an example of a data structure of an I / O information storage unit 23. FIG. It is a flowchart explaining the function of MPU of CPU unit 1a. It is a flowchart explaining the function of MPU of the safety unit 1d which is a safety system master. It is a flowchart explaining the effect | action which MPU of CPU unit collects the information which a safety unit holds. It is a flowchart explaining the effect | action which MPU of a safety unit collects the information which a CPU unit holds. It is a part of flowchart explaining the effect | action which MPU of the safety master unit which is a safety system master collects the information which another safety unit holds. It is a part of flowchart explaining the effect | action which MPU of the safety master unit which is a safety system master collects the information which another safety unit holds.

Explanation of symbols

1a CPU unit 1b, 1c unit (non-safety unit)
1d, 1e, 1f unit (safety unit)
10 CPU bus 11 Safety dedicated bus

Claims (3)

A non-safety controller configured by connecting a plurality of units including a CPU unit by a CPU bus, and a safety controller configured by connecting a plurality of safety units including a CPU unit having a safety function, In a controller system in which the CPU bus of a non-safety controller is extended and connected to the safety controller,
A tool interface is provided to the CPU unit of the non-safety controller, a tool is connected,
In accordance with a request from the connected tool, the CPU unit of the non-safety controller acquires information held in the safety controller via the CPU bus, and the acquired information is externally transmitted via the tool interface. While performing the process of transmitting to the tool and the process of transmitting the information held by the non-safety controller to the external tool via the tool interface,
According to a request from a connected tool, I / O data related to control of safety functions cannot be written to the CPU unit of the safety controller via the CPU unit of the non-safety controller. To monitor the controller system. A non-safety controller configured by connecting a plurality of units including a CPU unit by a CPU bus, and a safety controller configured by connecting a plurality of safety units including a CPU unit having a safety function, In a controller system in which the CPU bus of a non-safety controller is extended and connected to the safety controller,
A tool interface is provided to the CPU unit of the non-safety controller, a tool is connected,
A process in which the CPU unit of the non-safety controller acquires predetermined information to the safety controller via the CPU bus and transmits it to the tool via the tool interface in accordance with a command from a connected tool; and While performing the processing to rewrite the control information regarding the processing of the non-safety function of the non-safety controller,
According to a request from a connected tool, control information related to safety function processing cannot be rewritten to the CPU unit of the safety controller via the CPU unit of the non-safety controller. How to set up the controller system. A non-safety controller configured by connecting a plurality of units including a CPU unit by a CPU bus, and a safety controller configured by connecting a plurality of safety units including a CPU unit having a safety function, In a controller system in which the CPU bus of a non-safety controller is extended and connected to the safety controller,
A tool interface is provided to the CPU unit of the safety controller, a tool is connected,
According to the request from the connected tool, the information stored in the non-safety controller is acquired via the CPU bus by the processing of the CPU unit of the safety controller.
Without using the acquired information to control the safety function, send it to an external tool through the tool interface,
According to the request from the connected tool, the information held in the safety controller is acquired by processing of the CPU unit of the safety controller, and the acquired information is transmitted to the external tool via the tool interface.
And a controller system monitoring method.

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