JP6314937B2 - How to update process computers - Google Patents

Description

  The present invention relates to a process computer update method for updating an existing process computer connected to an upper device and a lower device via an input / output device to a new process computer (hereinafter also abbreviated as a process computer). .

  The process computer controls the entire production line in cooperation with a host device such as a business computer and a host device such as a PLC (Programmable Logic Controller). Since it is an important device responsible for operational automation and product quality, when the process computer stops, the production line often stops.

  When updating the computer control, it is necessary to confirm all the cases that may occur in the operation, such as the product specifications instructed by the host device and the control mode of the slave device. However, in order to switch to a new process computer and check all cases, the production line must be stopped for a long time.

  For this reason, when updating the computer control, the necessary input information is input to the new computer together with the existing computer, and the operation of the new computer is checked while simultaneously moving the existing computer and the new computer (abbreviated as "Parallan"). It is essential to do. In many cases, necessary input information has been acquired in parallel from the upper apparatus and the lower apparatus by the method described below.

<High-level device>
Most of the existing process computers exchange signals via a host device and a modem device (a modulation / demodulation device for a modem analog signal and a digital signal). In this case, the input signal is obtained in parallel by providing a distributor excluding the output signal transmission pin. In the case of Ethernet (registered trademark) transmission, the method described later is used.

<Lower device>
Information input from the lower-level device is classified into three types: a modem device, a PIO (Programmed Input / Output) signal, and a manufacturer-dedicated network. When the modem device is used, the acquisition is performed in the same manner as the host device. When the PIO signal is used, only important signals are often acquired in parallel via a signal amplifier such as a relay. When using a manufacturer-dedicated network, it is often acquired in parallel through a gateway device.

  As a technique for performing the process control update while acquiring necessary input information in parallel and performing a pararun, there is a technique disclosed in Patent Document 1, for example. In this technology, when acquiring a PIO signal in parallel with communication with a lower-level device, the PIO signal is received by a control device such as a PLC instead of being amplified by hardware as in the method described above. This is performed by software processing in which one of the data is generated by copying. Compared to the conventional hardware processing, the process control can be updated economically without degrading the reliability.

JP-A-8-328607

  The technique disclosed in Patent Document 1 is a technique for performing a parallax between an existing procon and a new procon before updating the existing procon, but does not include a pararun in a state after switching to the new procon.

  However, in the update of the process computer, the time that can be used for the function check as the switching test during the period of switching to the newly installed process computer can be limited due to production convenience.

  For this reason, indispensable functions are identified and confirmed within a limited time. However, the process control that controls the entire line has a wide variety of confirmation items. A situation in which a line is stopped due to an abnormality of the apparatus due to a communication shift of several seconds often occurs.

  When the line is stopped, whether the cause of the error is a data problem, a data communication protocol problem, a switching timing problem, an operator error, etc. There are various causes, and they must be crushed one by one.

  In order to investigate the cause of this abnormality, there has been a problem that cases where test run time having a limited time is consumed frequently occur.

  In addition, the quality information sent from the process control to the host device may exceed several thousand items, and the information obtained from each single device is edited by the process control. There was also a problem that soft bugs remained and there were cases where it was delayed to notice a serious quality defect.

  The present invention has been made in view of the circumstances as described above, and provides a process computer update method capable of finding a defect early in a short period of time and surely switching to a new process computer. It is for the purpose.

  In order to solve the above problems, the present invention has the following features.

[1] A process computer update method for updating an existing process computer connected to an upper device and a lower device so as to allow input / output and controlling a production line in cooperation with a new process computer,
Install a new process computer
While continuing to operate the production line under the control of the existing process computer, the new process computer is used together.
While automatically comparing the operations of the existing process computer and the new process computer, replacing the operation of the existing process computer partly with the operation of the new process computer,
A new process computer startup step for starting up a new process computer based on the operation of the existing process computer;
Even after switching the existing process computer to the new process computer and operating the production line, the operation of the new process computer and the operation of the existing process computer are automatically verified as a result of using the existing process computer together. If there is a difference, the operation modification step of the new process computer that corrects the operation of the new process computer with reference to the operation of the existing process computer,
A process computer update method characterized by comprising:

[2] In the process computer update method according to [1] above,
In performing the startup process of the new process computer,
Connect a parallax computer between the host device and the existing process computer, enabling output from the host device to the pararun computer, and output from the existing process computer to the pararun computer, respectively.
A new process computer is connected between the parallax computer and the lower-level device, enabling output from the para-run computer to the new process computer and output from the lower-level device to the new process computer. Set up a new process computer,
After that, in performing the operation modification step of the new process computer,
Input / output is possible with the existing process computer and the parallax computer connected.
Enables output from the lower level device to the existing process computer while the lower level device and the existing process computer are connected.
Disconnect the connection between the host device and the existing process computer, and connect the host device and the new process computer to enable input and output.
Allows output while connected to the new process computer from the lower level device, and enables output by connecting to the lower level device from the new process computer.
Enables output from the new process computer to the pararun computer.
A method of updating a process computer, wherein the operation of the new process computer is corrected with reference to the operation of the existing process computer via the pararun computer.

  According to the present invention, during the switching test to the new process computer, the operation of the existing process computer that is used in combination with the new process computer is collated, the collation result is accumulated, and the malfunction of the new process computer is corrected, so that the discovery is difficult. It is possible to detect and correct defects in a short period of time.

  In addition, even if a serious problem occurs in the new process computer, the movement of the existing process computer can be referred to immediately, reducing the time previously spent investigating the cause of the problem, and the problem after switching to the new process computer. Can be reduced, and measures and measures can be quickly taken even when a quality defect occurs.

It is a figure which shows the example of a process process in process computer update. It is a figure which shows the system configuration example before the update of a process computer. It is a figure which shows the system configuration example at the time of starting of a newly installed process computer. It is a figure which shows the example of a system configuration | structure at the time of operation correction of a new process computer.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

  FIG. 1 is a diagram showing an example of processing steps in process computer update. FIG. 2 is a diagram illustrating a system configuration example before the process computer is updated. FIG. 3 is a diagram showing an example of a system configuration when starting up a new process computer. FIG. 4 is a diagram showing an example of a system configuration at the time of correcting the operation of the new process computer.

  In the figure, 1 is an upper apparatus, 2 is an existing process computer, 3 is a lower apparatus, 4 is a pararun computer, and 5 is a new process computer.

  The processing will be described with reference to the system configuration examples shown in FIGS. 2 to 4 according to the processing steps in the process computer update shown in FIG. In the present invention, the system configuration is changed in order from FIG. 2 to FIG. 4, and the process computer is reliably updated in a short time.

  First, as shown in FIG. 2, at the start of FIG. 1, the existing process computer 2 to be updated is connected between the upper device 1 and the lower device 3, and performs data communication with each other and cooperates with each other. The state before the update which controls a production line (not shown) is represented.

  Next, in the start-up step of the new process computer in Step 01, the new process computer is set up in a parallax state in which the existing process computer and the new process computer are run in parallel while the operation of the production line continues under the control of the existing process computer. increase. FIG. 3 shows an example of the system configuration.

  That is, a pararun computer 4 is connected between the host device 1 and the existing process computer 2 to enable output from the host device 1 to the pararun computer 4 and output from the existing process computer 2 to the pararun computer 4. The new process computer 5 can be connected between the parallax computer 4 and the subordinate apparatus 3 so that output from the parallax computer 4 to the new process computer 5 and output from the subordinate apparatus 3 to the new process computer 5 are possible. And

  In order to perform a parallel run in which the existing process computer 2 and the new process computer 5 are run in parallel, the same output sent to the existing process computer 2 is sent from the host device 1 to the parallel run computer 4, and the sent output is sent to the parallel run. By transferring from the computer 4 to the new process computer 5, the new process computer 5 can perform a parallax. The data transfer function in the pararun computer 4 enables a pararun in the next operation modification step of the newly installed process computer.

  As described above, the host device 1 and the existing process computer 2 may perform modem transmission or Ethernet (registered trademark) transmission used in a LAN (local area network). When modem transmission is performed, if a bifurcated cable in which the transmission pin is not used is used, it can be input to the new process computer 5 in parallel. Further, when Ethernet (registered trademark) transmission is performed, if a HUB which is a concentrator capable of mirror port transmission (transmission capable of mirroring (copying) all traffic of a transmission source) is used, a newly installed process computer 5 is used. Can also be entered in parallel.

  In Step01, while continuing to operate the production line under the control of the existing process computer, the new process computer is used together, and the operations (output contents and output timing) of the new process computer combined with the existing process computer are compared. Establish a new process computer based on the operation of the process computer.

  The above is for starting up a new process computer while performing a pararun of the new process computer before updating the existing process computer, and the technique disclosed in Patent Document 1 is one of them.

  In the present invention, as a new method, in the operation correction step of the new process computer in Step 02, the operation process is switched from the existing process computer to the new process computer whose operation has been completed, and the operation of the production line is continued under the control of the new process computer. In addition, the operation of the new process computer will be confirmed in a parallax state in which the existing process computer is also used.

  The operations of the existing process computer and the new process computer are automatically collated, and the operation of the new process computer is corrected by referring to the operation of the existing process computer.

  FIG. 4 shows an example of a system configuration for automatically collating the operations of the existing process computer used together and the new process computer whose operation has been confirmed.

  That is, input / output is possible while the existing process computer 2 and the pararun computer 4 are connected, and output from the lower apparatus 3 to the existing process computer 2 is possible while the lower apparatus 3 and the existing process computer 2 are connected. Leave.

  Then, the host device 1 and the existing process computer 2 are disconnected, and the host device 1 and the new process computer 5 are connected to enable input / output, and the lower device 3 can output while being connected to the new process computer 5. The new process computer 5 is connected to the subordinate apparatus 3 to enable output, and the new process computer 5 can output to the parallax computer 4.

  When the operation of the new process computer 5 is corrected, the new process computer 5 communicates with the upper apparatus 1 and the lower apparatus 3. At this time, the parallax computer 4 operates as a virtual host device, and communicates with the existing process computer 2 and the parallax computer 4. The output from the existing process computer 2 to the pararun computer 4 includes an output to the virtual upper apparatus (a in the figure) and an output to the lower apparatus 3 (b in the figure).

  In addition, input data from the host device 1 is transmitted from the new process computer 5 via the pararun computer 4 to data transmitted from the pararun computer 4 to the existing process computer 2 in order to perform a pararun in the existing process computer. Data is also included.

  The pararun computer 4 automatically collates the operations of the existing process computer 2 and the new process computer 5, and corrects the operation of the new process computer by referring to the operation of the existing process computer (c in the figure).

  After performing the operation correcting step of the new process computer, the control of the production line may be temporarily returned from the new process computer to the existing process computer. While the production line is operating on the existing process computer, the final new process computer may be corrected and adjusted, such as a new process computer that could not be corrected in the operation correction step of the new process computer. it can.

  In step 03, the existing process computer is removed and switched to the new process computer only, and the update of the process computer is completed.

  According to the present invention, it has become possible to reduce the time that has been spent on investigating the cause of defects so far, to reduce defects after the switchover, and to quickly take measures and countermeasures even when quality defects occur. It is also possible.

  Note that, for example, the effectiveness of applying the present invention is confirmed also in the incorporation of a quality control function performed by a quality control computer into a process controller. In the present invention, the update of the process control includes the case of incorporating the function into the process control.

  By applying the present invention, it has been possible to complete the renewal of the process computer in a short period of 2 months, which previously required an average of 6 months for the renewal of the process computer.

  This early process computer update reduces the manpower involved in work, enables process computers to be updated in a limited time, and eliminates soft bugs after switching to a new process computer, resulting in poor quality. The deterrence was realized.

DESCRIPTION OF SYMBOLS 1 High-order apparatus 2 Existing process computer 3 Low-order apparatus 4 Pararun computer 5 New process computer

Claims (1)

A process computer update method for updating an existing process computer connected to an upper device and a lower device so that input / output is possible and controlling a production line in cooperation with a new process computer,
Install a new process computer
While continuing to operate the production line under the control of the existing process computer, the new process computer is used together.
While automatically comparing the operations of the existing process computer and the new process computer, replacing the operation of the existing process computer partly with the operation of the new process computer,
A new process computer startup step for starting up a new process computer based on the operation of the existing process computer;
Even after switching the existing process computer to the new process computer and operating the production line, the operation of the new process computer and the operation of the existing process computer are automatically verified as a result of using the existing process computer together. If there is a difference, the operation modification step of the new process computer that corrects the operation of the new process computer with reference to the operation of the existing process computer,
I have a,
In performing the startup process of the new process computer,
Connect a parallax computer between the host device and the existing process computer, enabling output from the host device to the pararun computer, and output from the existing process computer to the pararun computer, respectively.
A new process computer is connected between the parallax computer and the lower-level device, enabling output from the para-run computer to the new process computer and output from the lower-level device to the new process computer. Set up a new process computer,
After that, in performing the operation modification step of the new process computer,
Input / output is possible with the existing process computer and the parallax computer connected.
Enables output from the lower level device to the existing process computer while the lower level device and the existing process computer are connected.
Disconnect the connection between the host device and the existing process computer, and connect the host device and the new process computer to enable input and output.
Allows output while connected to the new process computer from the lower level device, and enables output by connecting to the lower level device from the new process computer.
Enables output from the new process computer to the pararun computer.
A method of updating a process computer, wherein the operation of the new process computer is corrected with reference to the operation of the existing process computer via the pararun computer .

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