JPH09114689A - Plc test support system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a PLC test support system which saves trouble of test preparation and specification change and has a reproducibility and a general usefulness by providing a PLC emulator. SOLUTION: An operation console 1 consisting of a personal computer implements and operates various test programs purposing to effectively support the PLC test and displays the test result. A logging console 2 consisting of a personal computer always scans values of various monitor data, which are mounted on a PLC, at a high speed and arranges and stores data. A PLC emulator 3 consisting of a personal computer transmits/receives data to/from a personal computer group in an object system and emulates the data storage function instead of the PLC. A printer 4 records the test result. Preparation and adjustment for the test are easily performed as text editing on the CRT picture of the personal computer.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a personal computer, FA computer, WS (WORK STATION), PLC (PROGRAMA).
BLE LOGIC CONTROLLER) is a main component, and it is related to the test (including debug) support system in software development work related to various target systems of the distributed system configuration, especially PLC test including PLC simulation test and PLC emulation. Regarding support system.

[0002]

2. Description of the Related Art A conventional technique will be described with reference to FIG. FIG. 13 is a block diagram showing a schematic configuration when a conventional PLC test support system is applied to a distributed control system.

Conventionally, the sequence logic design of the PLC 131 and the creation and testing of the ladder program (especially the interface portion) are usually carried out as shown in FIG.
A test operation display panel 13 called a switch panel 132A or a lamp panel 132B as shown in FIG.
It was common to use 2.

This is a kind of instrumentation panel equipped with many small operation switches A or indicator lamps B. By connecting it to various input / output boards of PLC131 by cables, it can be used as a field instrument or a control device in an actual plant. The input / output signal of is simulated and the result is displayed.

P actually using the operation display panel 132
In the LC test, the switch panel 132A in FIG.
Turn on / off the small switches A lined up above one by one to P
Generates a pseudo input signal to the LC 131 to advance the sequence logic inside the PLC, and also to the lamp panel 132.
The test is executed by a method of adjusting the value of the output signal from the PLC 131 by observing the ON / OFF status of the LED lamps B arranged on the B side.

In addition, the control logic of the personal computer 134 and FA computer 135 is tested, and the personal computer 134 and F
In order to perform a connection test between the A computer 135 and the PLC 131, it was often necessary to newly develop a dedicated test program for each project.

Originally, an instrumentation equipment maker that produces PLCs or distributed instrumentation control systems (DCS) usually prepares various test tools and support programs for its own equipment. . Recently, other than that, we have miniaturized the switch panel and lamp panel to sell the test equipment packaged by incorporating the DIP switch and the indicator lamp, or to our own specific PLC that incorporates some test functions. There are also examples of providing corresponding test programs.

[0008]

In the method of utilizing the switch panel or lamp panel as described above, an attempt was made to simulate many input / output data used in a large-scale batch plant or the like. In this case, the following problems will occur.

1. A large amount of connection cables need to be wired and inspected, which requires a lot of time and effort for preparation, and the possibility of wiring mistakes is very high. In the actual test work, the test personnel proceed with the test while manually operating the switch and checking the lighting of the lamp, so there are many mistakes in recording the operation itself and the test result, and the switch operation also takes time, It is also difficult to set and adjust the timing.

2. According to this method, after all the test wiring work is completed once during the system development, the operation display panel is in a state in which the connection cables are extremely complicated and it is difficult to remove the operation display panel. It is difficult to change or add output data.

3. Before the target system is shipped to the site for installation work, all the cable wiring with the operation display panel is removed, so that the subsequent PLC test by the developer becomes impossible. Also, even when considering the system maintenance work after inspection and delivery to the customer, it is rare that a sufficient amount of test equipment such as PLC is left at hand, and the original development environment is used. It will be very difficult to reproduce.

On the other hand, all of the test hardware and software intended for a specific PLC or the like can be used only for the purpose of an extremely simple signal test determined in advance.

5. The test tools provided by each manufacturer for their own systems are limited to simple test functions, the types are considerably small, and the usage conditions and environment are considerably limited. ing.

An object of the present invention is to provide a PLC test support system which is reproducible and versatile in view of the above-mentioned drawbacks of the prior art and which does not require test preparation and specification change.

[0015]

In order to solve the above problems, the present invention provides a personal computer, a workstation, a programmable logic controller and a communication interface which are connected on a communication network and constitute a distributed system. PLC for etc.
A test support system, which is a test program section for the purpose of PLC testing, an operation console including a means for displaying and recording a test result upon request, and various monitoring data values mounted on the PLC. Logging console to scan data constantly and at high speed to organize and store data according to the test items and methods specified by the request, and to send and receive data to and from the target PC group instead of the PLC on the communication network. A PLC test support system including a PLC emulator for simulating a data storage function.

The logging console has a simulated data output area, and the target PLC has a data buffer area for transferring the simulated data.
A PLC test support system having a function of echoing back an input signal to the PLC.

The logging console has a PLC monitoring program for monitoring the target data area of the PLC and a recording table for writing change information of the target data, and the operation console searches for a sequence display program and change information of the target data. A PLC test support system characterized by having functions.

Further, the above-mentioned operation console further comprises a program for PLC data simulation and a data file for rewriting PLC data, which is a PLC test support system.

The PLC test support system is characterized in that the PLC emulator has a program for emulation, a pointer table, and a pseudo PLC data area in place of the PLC.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described with reference to the drawings. FIG. 1 is a block diagram showing a schematic configuration when the PLC test support system of the present invention is applied to a distributed control system.

In the figure, 1 is an operation console (hereinafter abbreviated as O / C) consisting of a personal computer.
This is for loading and operating various test programs for the purpose of effectively supporting the C test, and displaying the test results obtained according to the test program function upon request. 2 is a personal computer logging
A console (hereinafter abbreviated as L / C) that constantly scans the values of various monitoring data mounted on the PLC at high speed, and organizes and stores the data according to the test items and methods specified by the request. It is a thing. Reference numeral 3 is a PLC emulator composed of a personal computer for simulating (emulating) the data transmission / reception and data storage functions with the personal computer group in the target system instead of the PLC. A printer 4 is for recording the test results obtained according to the test program function upon request. The PLC test support system 10 is composed of these. Further, 5 is a PLC which is one of the test targets, and a personal computer 7 which is one of the test targets through the dedicated LAN 6.
It is connected to the FA computer 8 etc. to construct a distributed control system.

If this distributed control system is, for example, a batch plant control system, the manufacturing management computer (FA controller, WS) has manufacturing management functions such as performance management, manufacturing information management, and data transfer. On-site end and automatic warehouse end (both PCs) are plant monitoring,
It has process control functions such as reporting, line control, lot control, etc., and sequencer (PLC) also has equipment control functions such as sequence control and interlock, and these control functions are subject to testing. .

The "PLC test" described in the present invention means P
This is a general term for all tests in the target system that includes LC as a component, but especially tests for control logic inside the personal computer / FA computer, tests for connection interfaces between the personal computer / FA computer and PLC, and P
It applies to each stage of testing the sequence logic inside the LC.

The types of test functions and programs of the present invention will be described in detail.

The relationship between the test function and the test program included in the PLC test support system is shown in FIG. 2, the types of the test function and their relationships are shown in FIGS. 3A and 3B, and the output examples of some data display functions are shown. 4A, B to 5
Shown in A and B.

As can be seen from FIGS. 2 and 3A and 3B, the PLC
The program structure of the test support system consists of various tests.
In the collection of programs, there is a main menu at the top, and submenus for each test function unit underneath it, and below that there are tests for display and settings associated with concrete PLC data. -It has a hierarchical structure in which programs are arranged.

The PLC test support system is originally shown in FIG.
A test program that realizes advanced PLC test functions such as various data collection, display, recording, printing, search, setting, and simulation shown in A and B is included as standard.
Most of them consist of "framework program" for test control and "processing program" for test execution.

Next, the selection of test functions and the activation of the processing program based on the test menu will be briefly described.
Once a particular PLC test function is selected from the main menu, the corresponding framework program runs.

The framework program corresponds to the submenus (1-1 to 5 and 2-1 to 6) shown in FIGS. 3A and 3B, and after displaying the submenu specific to the selected test function, the user It accepts the setting of execution parameters and the selection of test cases from, and then starts the processing program corresponding to the selected test function.

In the processing program, the "standard module" which describes the processing logic of the general test describes individual test conditions and test data in, for example, the simplified language ALMIGHTY (SOFTIC registered) developed by us. It reads the "data file" and interprets and executes it in steps.

As described above, since the program part and the data part of the processing program are separated, even if it is necessary to change or add some test functions, the corresponding simple language data file is commercially available. It only needs to be modified with an editing program (editor), and does not require time-consuming recompilation and relinking of the entire system.

The test functions of FIGS. 3A and 3B all display and set the values of various data / registers inside the PLC on the O / C, and the specific contents are as follows. -Bit data display: Real-time display and data setting of bit data in normal mode-High-speed bit data display: Real-time display and data setting of bit data in high-speed mode-Bit trend display: Real-time trend display of bit data-Event bit Trend display: Trend display that progresses only when a bit data event occurs (change in target data) -Sequence display: Search / display / record of target data change combined with L / C PLC monitoring program-Analog data display: Analog data Real-time display and data setting of-Analog trend display: Real-time / trend display of analog data-Analog data list 1: Simplified real-time display of analog data (medium capacity) -Analog data list 2: Simplified analog data list Real-time display (large capacity) -Analog data logging: Data change monitoring and data retrieval / display / recording by O / C alone-Data load: Data input / processing / output in PLC data area by simple language Execution of Logic Next, the implementation of the test function of the present invention will be specifically described. A) Test function by L / C The PLC test support system has the following two types of test functions by the logging console L / C in addition to those shown in FIGS. 3A and 3B.

One is, as shown in FIG. 6, a simple echo back function (simulated data) for generating input signals from various instrumentation devices (not shown) on site via the I / O board. Setting function).

FIG. 6 is a diagram for executing the echo back function by the logging console L / C.

The L / C 61 has a PLC monitoring program 6 for constantly monitoring the target data area 623 of the PLC 62.
11 and a bit change recording table 612 and a simulated data output area 613 for recording bit changes of the PLC.

In the data area of the PLC 62 for which the L / C 61 performs the echo back function, the input / output data channel 625, which is a data transfer place with various I / O boards 64 for interfacing with external signals, and , A communication area 625 for storing data of a communication function with another PLC 63, and the like, which are directly connected to the hardware function. Apart from that, PLC output data area 621 and PL
Like the C input data area 623, a data buffer area 624 having the same size as the corresponding input / output data channel / communication area 625 is prepared in advance, and the sequence logic 628 which is a PLC control program externally For signal input / output, the data buffer area 624 is accessed instead of the input / output data channel / communication area 625.

PLC is a field device / instrument or other PLC 63
When the connection 626 with the
There is a sequence between the corresponding data areas of the channel / communication area 625 and the data buffer area 624.
The same contents are held by a series of block transfer instructions 627 by the logic 628.

The echo back function is used when the field equipment / instrument or other PLC 63 is not connected.
By preparing a data buffer area 624 of the same size corresponding to each input / output data channel / communication area 625 of the PLC 62 on a bit-by-bit basis in the PLC in advance, data input / output operation with an actual hardware environment can be performed. Instead, it is realized by writing the simulated data 613 designated by the program on the personal computer into the data buffer area 623 of the PLC. This is because the PLC monitoring program 611 of the L / C 61 constantly scans the PLC output data area 621 of the control signal to various devices (not shown) connected to the I / O board 64 and sets it in the bit change recording table 612. If there is a data change, the simulated data 613 is converted into a PLC as an echo back signal from the device with a specified time delay.
The data is written in the input data area 623.

The sequence logic is separated from the actual hardware environment by switching the PLC logic corresponding to this environmental change.

Secondly, as shown in FIG. 7, there is a function of monitoring / recording a large amount of changes in bit data and retrieving.

FIG. 7 is a diagram for executing the monitoring / searching function by the logging console L / C.

The L / C 71 has a PLC monitoring program 7 for constantly monitoring the target data area 721 of the PLC 72.
11 and a record table 712 in which the information of the change bit is written. On the other hand, C in O / C73
There is a sequence display function program including an RT screen display / print output function 733, which operates according to designated parameters 734 given to them. L / C71 and O /
Data transmission during C73 is performed by the L / C recording table 71.
2 to the file data 731 in the O / C 73 via the logging file stored in the file memory 722 in the PLC 72 or the floppy disk 723.
Read in.

This monitoring / retrieval function is performed by the PL of L / C71.
When the C monitoring program 711 constantly scans the designated data area 721 of the PLC 72 and detects PLC bit data different from the data value input by the previous scan, the recording table 712 resident in the L / C 71 together with the time stamp. To write to. The data in the recording table 712 will be recorded later in the logging file (PLC7
2 is transferred to the O / C 73 via the file memory 722 or the floppy disk 723) in the No. 2 memory.

The sequence display function of the O / C 73 utilizes this data to retrieve data according to designated parameters, and display the result on the CRT screen / print output function 73.
Perform 3rd grade. B) PLC data simulation function In the data load function of the PLC test support system, P
The contents of various data areas and register areas inside the LC are sequentially rewritten. This corresponds to simulating the flow of the PLC control program and the behavior of the actual plant in real time using the change in the PLC data value as an intermediary (interface). As a result, even in the pre-shipment test stage in the office environment, the test can be realized under the condition similar to the actual system operation status.

FIG. 8 shows the operation console O /
It is a figure which performs the simulation by C.

In the O / C 81, there is a group of test programs for realizing the PLC data simulation function. The test program called from the sub menu 812 corresponding to the data load function is composed of a framework program 813 for test control and a processing program 814 (standard module) for test execution. The input data of the processing program 814 is a data file 815 described in a simple language, which is associated with each test case (simulated scenario), and the data of the PLC according to the simulated scenario specified there. Data is sequentially written in the area.

In a control / monitoring / management system of a certain scale, there are various plant operation scenarios due to requests from the operating side. In the PLC test support system, data files 8 corresponding to the names of many simulation scenarios 821
A mechanism for designating 15 names is prepared to provide a means for the tester to easily select a test case. The main body (data file) of the simulation scenario specified there is created as another text file described in a simple language, which is executed by the standard module of the data load function.

In the simple language, in addition to the basic function of simply reading and writing various PLC data, a large number of program functions (operators) are prepared so that flexible and sophisticated processing logic can be described. For example, there are scale conversion of PLC data, data operation such as four rules, bit / data processing, internal register control, destination control, screen display, external file input, time waiting, etc. You can also set breakpoints and manually enter data to allow confirmation of execution results and data changes during the test. Further, if some simulation scenarios have different reference data but almost the same execution logic, a part of an arbitrary program function is used for the purpose of realizing this by a relatively short simulation program loop (repetition). (index,
Special instructions for rewriting reference data, PLC channel numbers, etc.) are also prepared. In creating a text file for simulation, the above-mentioned program function groups are freely combined to create a required simulation scenario.

Using this simulation function, it is confirmed that the personal computer, FA computer, PLC, etc. of the target system operate normally according to the originally assumed operating conditions, and in addition, a plant abnormality or trouble occurs. In order to simulate, it is easy to intentionally add wrong logic or input error data to a part of the simulation program.

Normally, sequential processing (sequential)
In most cases, it is sufficient to use the simulation logic of, but if there is a complicated operation scenario that is essentially realized only when multiple simulation logics operate in parallel in time, the multitasking OS (operating system)
It is sufficient to execute each of the simulation scenarios as separate tasks under [1] while synchronizing with each other for synchronization. C) PLC emulation function Separate from the program body of the PLC test support system,
An independent program called a PLC emulator is prepared. This is a program that executes various data transmission / reception functions with a plurality of personal computers / FA computers connected to the network of the target system, instead of a plurality of PLCs. If you use a PLC emulator, you can easily communicate the contents of communication data and data even if only the personal computer / FA computer is available and the PLC hardware does not exist after the target system is shipped.
It is possible to carry out a sequence confirmation test.

Network control of the PLC emulator is realized by the following method. When performing data communication via a network, communication messages between the components are assembled according to the standard communication protocol provided by each manufacturer. To describe the contents of the message in more detail, the message body (the data itself you want to send)
Besides, it consists of a header part (source / destination address etc.) and a trailer part (error check etc.) that is added to the purpose of communication control and referred to by the driver software. Normally, each device such as PLC connected to the network has a unique network (port) address, so it is logical that one PC receives communication messages for multiple PLCs. It should not be possible, but rewrite the destination PLC address of the source PC / FA computer (specified by a part of the header part mentioned above) to specify the network address of the PLC emulator. . In addition, the unused area of the same header portion is used or borrowed, and the original destination address is added as a comment. Since the PLC emulator side also performs the same address modification operation when transmitting the response data, the sender personal computer / FA computer can recognize from which PLC the received response data originally should have come. These address modification and remodification are executed as part of the process of assembling and disassembling the message in the processing routine of the corresponding communication protocol (a part of the PLC test support system), so the communication driver and application function Has no effect on

FIG. 9 is a block diagram showing the internal structure of the PLC emulator.

A communication driver 901, which is a connection interface with a network, is installed in a personal computer provided with a PLC emulator.

The online program constituting the PLC emulator includes environmental condition setting 902 for setting environmental conditions, and a communication protocol routine 90 corresponding to the communication system of the connection interface.
3. LAN that retrieves received message and creates reply
Link unit software 904, command interpretation / execution 905 that analyzes / executes messages (updates PLC data area), trace data storage 906 that performs data trace processing, displays contents of pseudo PLC data area on CRT screen / There is a real time display 908 / data area setting 909 to be set.

In addition to the above, various definition functions 910 such as data initialization, configuration definition, and data area setting, and a trace
There is a trace function 912 that performs a data search function.

Tables used by these programs /
The files include a pointer table 913 on the main memory that expresses the setting conditions of the PLC to be emulated,
Huge data area table 914 to which the specified pseudo PLC data area is allocated, trace on main memory
There are a trace table 907 that stores data, a trace file 911 that moves it to a disk device, and the like.

Communication driver with network (I /
F) Upon receiving a message from the 901, the communication protocol routine 903 corresponding to the environment setting condition (confg) 902 is first executed. Here, address modification / remodification according to the communication method is performed. Next, after the message portion is taken out by the LAN link unit software 904, the command interpretation / execution routine 905 analyzes the contents of the message, checks for errors, and executes the pseudo PLC data area 914 according to the designation.
To update. On the other hand, the entire communication message is sent from the LAN link unit software 904 to the trace data storage routine 906 and sequentially stored in the trace table 907 resident in the main memory. In addition, in parallel with these, the contents of the pseudo PLC data area are displayed 908 on the CRT screen in real time, and manual data setting 909 is also permitted by the user's designation. Besides this,
There are various definition functions 910 such as data initialization, configuration definition, and data area setting. All communication data is dynamically and sequentially stored in the trace table 907 on the main memory, but later moved to the trace file 911 on the disk device by designation, and offline search according to various designated keys. Used in process 912.

The above-mentioned functions are based on the real-time multitasking OS, the communication driver group 901, the communication protocol 903, the LAN link unit 904, the command interpretation /
Task groups such as execution (including error processing), pseudo PLC data area update 905, data area display 908 and input 909, and trace data storage 906 operate in parallel while cooperating with each other. The data used by these tasks are the PLCs that you want to emulate in advance.
If you freely set the type and size of the data area of, the pointer table 913 on the main memory and the huge data area table 914 are
The data area of the designated size is allocated.

Next, other features of the PLC test support system described above will be described. 1) Communication interface for network connection The PLC test support system was originally developed with the goal of supporting various control, monitoring and management systems with a wide range of system configurations. It is designed for network connection.

First, the PLC test support system has a hierarchical module structure. Especially, in the data communication processing part, from the lower level, three layers of physical layer support (driver), communication protocol support, and test function support are provided. It is designed separately. Normally, one type of physical layer is determined according to the manufacturer and type of communication hardware to be used, but some manufacturers may provide two or more types of communication protocols. Also, the test function has almost no relation to communication hardware, and prepares a program for the purpose and function required for each project. In an actual project, the program modules required for each of these support levels are used by incorporating them into the PLC test support system. In particular, if there are two or more types of choices for a given layer, pre-install all the corresponding modules in the PLC test support system and use a different configuration setting file.
Parameterize which module to use at runtime.

Next, since the test function included in the PLC test support system is very general, it hardly depends on the manufacturer or model of the PLC adopted in the target system. However, the names of various data areas inside the PLC are unique to the manufacturer and model, so if you want to use a specific data area name, etc., for ease of viewing, put that name in another text file. Respond by registering. 2) Setting of test conditions P that is a test target by adopting an easy-to-use simple language
Various parameters such as LC data type, address / data processing method, screen display logic, data simulation logic, program logic, etc. at the test execution level are stored in a text file as needed (instead of changing the program logic). It can be specified easily and flexibly by editing.

On the other hand, it is concerned with the control of the whole PLC test support system such as network addresses of various devices, data communication / input / output execution availability, debug method / output destination specification, processor speed specification, logging file name, etc. General processing parameters are stored in a text file other than the program itself.
It is set when the LC test support system is started. This file can be changed freely by modifying it with a commercially available editing program (editor). If there are several combinations of frequently used processing parameters, prepare them as text files with different names in advance and specify the file name you want to use before starting the PLC test support system. Good.

[0063]

EXAMPLES The PLC test support system described here has a very flexible system structure, so that various application operations are possible depending on the purpose of use for each project. Specific application examples of the present invention will be described below. As an “application example 1”, consider a simple reaction system as shown in FIG. Items 1 & 2 below show the general specifications of the actual reaction system.

1. Main system components-Raw material tanks (A, B): R-101, R-102-Flow meter: FI-101, FI-102-Solenoid valve (inlet side): V-101, V -102-Reaction tank: R-201-Weigh scale: W-201-Level gauge: LI-201 (HH, H, M, L, LL levels) -Agitation motor: M201-Temperature control unit: CW, HW-Electromagnetic Valve (outlet side): V-201-Pump: P-202, main unit operation (unit operation) -Preparation of raw material A (R-101 → R-201) -Preparation of raw material B (R-102 → R-201) -Stirring (M-201) -Temperature control (Temperature control unit) -Transfer of intermediate product (R-201 → downstream process) -Cleaning of reaction tank 3. Test example of "transfer of intermediate product" operation And verification method Each of the above Among the unit-based operations, the "transfer of intermediate product" operation is taken up here to briefly explain how various test functions of the PLC test support system can be used.

3-1 Example of PLC data allocation related to "transfer of intermediate product" (Note) Described in the order of output (command) and input (status / numerical value), respectively.・ V-201 (ON / OFF): RL-0100, RL-0200 ・ P-201 (ON / OFF): RL-0101, RL-0201 ・ LI-201 (LL) ・ ・ ・ ・ ・ ・ ・ ・, RLー 0500 ・ Transfer start: RL-0600, RL-0700 ・ Transfer stop: RL-0601, RL-0701 ・ W-201 ・ ・ ・ ・ ・ ・ ・ ・, DT-0100 ・ Agitation timer: RL-0615, TM-0100 (RL-0615 is a timer reset)

3-2, Test function generally available

(1) Bit data display The bit data RL-xxx of item 3-1 is assigned to an arbitrary bit data display screen in advance. If you select this screen during execution of any PLC test, you can monitor that the ON / OFF status of these bit data is always displayed in real time, and compare and confirm with the expected normal test result. I can.

(2) Analog data display Analog data TM-xxx of the item 3-1 in advance.
Allocate x, DT-xxxx to any analog data display screen. If the screen is selected during execution of any PLC test, it is possible to monitor the numerical values of these analog data displayed in real time and compare / confirm with the expected normal test result.

(3) Event Bit Trend Display The bit data RL-xxx of item 3-1 is assigned to an arbitrary event bit trend display screen in advance.
If you want to know the change order of the bit data in a specific control sequence, select the screen and the ON / OFF change order of these bit data will be recorded automatically on the screen as a graphic display. You can compare and confirm with the expected normal time sequence.

(4) Analog data logging All bits / analog data (word unit) of the item 3-1 to be monitored are allocated in advance to the logging data setting file. If you want to know the order of ON / OFF change of bit data or numerical value change of analog data and the data value, select the screen and the change status of the set bit / analog data will be automatically displayed with the time stamp. It is sequentially recorded in the logging table in C. After the data collection period, PLC number, data type,
By specifying the data address and other keywords and searching the logging table in the O / C to obtain the change record of the target PLC data (word unit), the expected normal time sequence and data value You can compare and confirm.

3-3, PLC simulation using "data load" function

(1) Outline of data load function This function does not display or record PLC data, but creates a simulated flow of logic inside the PLC in the O / C using a simple language. Run as a result, and as a result P
Data values having specified contents are sequentially written in various bit / analog data areas in the LC in accordance with a specified order / logical condition. As a result, even in the development environment where the sequence logic corresponding to the PLC is not included or the PLC is not connected to the measuring instrument or control device in the field, various data areas in the PLC are simulated. Can be changed in real time to enable interface testing with other PLCs and personal computers.

(2) Example of control sequence of "transfer of intermediate product" operation-Check of initial conditions (equipment interlock, liquid level of reaction tank, equipment status, status of process operation etc.)-Solenoid valve V- 201 Open ・ Pump P-201 start ・ Lack check (LL) check of reaction tank ・ Solenoid valve V-201 closed (Note) All operation instructions are echo back signal ・ Check pump P-201 stop.

(3) PLC simulation procedure. Define and register the following control logic in a simple language as one of the data files used in the "data load" function.・ Set the data pattern that matches the initial conditions: (B) Set the initial conditions ・ Set RL-0100: (A) Open solenoid valve V-201 ・ Set RL-0200 after a time delay: (B) Same as above Echo back signal ・ Set RL-0101: (A) Pump P-201 start ・ Set RL-0201 after a time delay: (B) Echo back signal same as above ・ W-201 value is incremented to 0 Decrease: (B) Decrease the contents of the reaction tank ・ Set RL-0500: (B) Blank inspection (LL) on ・ Reset RL-0100: (A) Solenoid valve V-201 closed ・ RL after a time delay -Reset 0200: (B) Echo back signal same as above-Reset RL-0101: (A) Pump P-201 stop-RL-020 after time delay The To reset: (B) Same as above echo back signal

By executing the above control logic with the data load function, the PLC sequence logic is sequentially advanced under the same conditions as if signals are exchanged with the equipment / equipment on the plant side in the actual project. As a result, bit / analog data corresponding to the I / 0 signal is set in various data areas of the PLC. Utilizing this, other components (personal computer or PLC) belonging to the target system can perform an arbitrary PLC test under almost the same environment as a field test of an actual plant.

The step described as (A) in the comment section above is an output signal originally generated by the control logic inside the PLC, and the step described as (B) is
It is an input signal to be returned to the PLC as a result of equipment operation on the actual plant side. Therefore, depending on the execution environment of the PLC test (for example, whether signals from the site can be received),
Which part of the PLC data needs to be generated by the data load function changes, and as a result (A),
The control logic of (B) or both of them will be incorporated in the data load function.

In order to realize a more advanced PLC test, it is possible to make the following sequence logic. -In order to check the influence of the signal generation timing, insert an appropriate time delay for each step of the sequence logic described above. -Change the flow of some sequences to intentionally create an error condition. -Define a break point (point to pause) on the way, and the tester specifies an arbitrary sequence step from the O / C keyboard. As an example of "Application 2", the development of a physical distribution control system for a large-scale assembly / processing plant physical distribution / transportation system is taken up,
An example of PLC data simulation will be described with reference to FIG.

In such a logistics / transportation project,
In many cases, the schedule of equipment installation / testing work on the site is significantly delayed, making it impossible to connect to actual equipment for a long time on-site to perform an online test of the physical distribution control system. In such a case, consider delaying the shipment timing of the physical distribution control system from the office as an alternative, and virtually conducting a connection test (interface test) with various physical distribution equipment that should have been done on site. .

In an actual plant, raw materials of products, semi-finished products,
Processed products are sequentially processed by various assembling / processing machines while being conveyed on a long belt conveyor. Further, for the convenience of collectively processing a large number of semi-finished products, a number of sets of transfer equipment including a palletizer and a depalletizer are installed in the middle of the transfer route.

In order to control the actual plant, as shown in FIG. 11, a large number of device control PLCs 111 are connected to the LAN, and normally, the PLCs receive the actual signals from various physical distribution devices on site. While transmitting and receiving various signals such as work instructions and interlocks in real time, a series of logistics operations are carried out. In addition, the computer end (WS) 112, which is the core of the physical distribution control system,
The signals between the PLCs are fetched to give operation instructions relating to the entire physical distribution control system and perform data management.
An automatic warehouse is installed in the actual plant for temporary storage of semi-finished products, and is controlled by a dedicated automatic warehouse management controller (personal computer) 113.

However, in the case assumed here, since no real physical distribution equipment can be prepared for the connection test in the office, the PLC data simulation function (data load) of the PLC test support system is used instead. Function).

In this embodiment, a large number of expected factory operation scenarios and PLC control logic are organized and summarized to create a simulated scenario for testing.
Using the data load function 115 on the O / C 114 of the PLC test support system, process signals according to the simulated scenario are automatically generated sequentially and written in the data area of the corresponding device control PLC 111. On the other hand, the analog data logging function and the analog data list function of another O / C 116 are used to confirm the order and contents of the process signals captured by the computer terminal. Further, by partially modifying the simulation data, it becomes possible to easily simulate abnormal states and various exceptional states of the assembly processing system. As another example of "Application 3", a control system for a typical large-scale batch plant based on a personal computer in the field of fine chemicals is taken up, and based on FIG.
An example of LC emulation will be described.

The data management / processing of the entire actual plant is FA
The computer 121 is in charge, and a plurality of personal computers 122 perform actual daily plant monitoring and operation. A large number of PLC groups 123 execute sequence control of various devices such as an agitator, a reaction tank, and a transport system that constitute the plant.

Normally, such a control system, once delivered to a customer, continues to operate for operation / monitoring of the customer's plant for many years without changing the hardware configuration or the system function. However, in some cases, customers may be required to modify or add some of the system functions (PC part) many years later due to operational requirements. No software remains, and in many cases there is a constraint that it is virtually impossible to stop the customer's plant for on-site testing. In such a case, as an alternative measure, P
We will consider connecting 1: 1 with another PC equipped with an LC emulator and using the emulation function to perform a connection test.

In this method, as shown in FIG. 12, one PLC emulator 124 simulates the data communication functions of all the PLCs 123. Production PC 1
The modified application program is run on 22, the output data is received by the PLC emulator 124, the data is read and written in the simulated data area for the target PLC 123, and the contents are confirmed and searched. On the contrary, the simulated PLC data for the test can be sent online to the PLC emulator 12
Manually enter 4 to check whether the production personal computer 122 can correctly receive and process. In this way, it becomes possible to easily test the program modification portion of the production personal computer 122.

[0086]

As described above, P according to the "prior art" is used.
Compared with the LC test performed by the instrument panel and manually, the computerized test by using the PLC test support system on the personal computer has the following remarkable effects.

1. Since the test logic and test data are completely separated and prepared in the form of computer program and text data respectively, preparations and adjustments for the test are made on the CRT screen of the personal computer. Easy to edit as text. Also, since the setting and recording of test data is automated, the labor of testing can be greatly saved and reliable test records can be easily left.

2. For the same reason as above, the test logic and the test data can be arbitrarily changed / added during the system development, so that it is possible to flexibly deal with the specification change of the target system. . Further, even if there is no development environment after shipping the target system, a test environment for follow-up, maintenance, and modification work can be provided as software.

3. Since it is a general-purpose open platform that adopts general hardware and software widely recognized in the latest system fields such as personal computers and LANs, many manufacturers and It can easily and flexibly connect to target systems such as personal computers, FA computers, PLCs, LANs, etc.

4. Since high-level PLC test functions such as various data collection, display, recording, printing, retrieval, setting and simulation required for the PLC test are covered, high test efficiency can be obtained.

5. A simple language of simple symbol format allows easy and flexible designation of the type and address of PLC data to be tested, data processing method, screen display logic, data simulation logic, program logic, etc. .

6. By the method such as thorough modularization, separation of program part and data part, and adoption of simple language for data description, excellent high quality, versatility, maintainability, etc. as a test program are guaranteed. It

[Brief description of the drawings]

FIG. 1 is a block diagram showing a schematic configuration when a PLC test support system of the present invention is applied to a distributed control system.

FIG. 2 is a diagram showing a correspondence relationship between a test function and a program.

FIG. 3 is a diagram showing types of A and B test programs and their relations.

[Figure 4] A bit data display screen, B event bit trend display screen

[Figure 5] A analog data display screen, B analog trend display screen

[Figure 6] Diagram for executing the echo back function by the logging console

[Fig.7] Diagram for executing monitoring / search function by logging console

[Figure 8] Diagram of executing a simulation using the operation console

FIG. 9 is a configuration diagram showing an internal configuration of a PLC emulator.

FIG. 10 is a schematic diagram of a reaction system to which the PLC test support system of the present invention is applied.

FIG. 11 is a schematic diagram of a physical distribution control system to which the PLC test support system of the present invention is applied.

FIG. 12 is a schematic diagram of a batch control system to which the PLC test support system of the present invention is applied.

FIG. 13 is a block diagram showing a schematic configuration when a conventional PLC test support system is applied to a distributed control system.

[Explanation of symbols]

1 Operation Console (O / C) 2 Logging Console (L / C) 3 PLC Emulator 4 Printer 5 PLC (Programmable Logic Controller) 6 Communication Network (LAN)

Claims (5)

[Claims] 1. A PLC test support system for a personal computer, a workstation, a programmable logic controller, a communication interface, etc., which is connected on a communication network and constitutes a distributed system, and which is intended for PLC testing. The operation console including various test program parts to be displayed and means for displaying and recording the test results upon request, and various monitoring data values mounted on the PLC are constantly scanned at high speed and specified by request. A logging console for organizing and storing data according to the specified test items and methods, and a PLC emulator for simulating data transmission / reception and data storage functions with the target PC group instead of PLC on the communication network. Characterized in that PLC test support system. 2. The logging console has a simulated data output area, and the target PLC has a data buffer area for transferring the simulated data, and echoes back an input signal to the PLC in a simulated manner. The PLC test support system according to claim 1, wherein: 3. The logging console has a PLC monitoring program for monitoring the target data area of the PLC, a recording table for writing change information of the target data, and the operation console has a sequence display program for the target data. 3. The PLC test support system according to claim 1, wherein the change information can be retrieved. 4. The operation console is P
Program and P for LC data simulation
It has a data file for rewriting LC data, and PL
The C data simulating method according to claim 1,
The PLC test support system according to any one of 3 to 3. 5. The PLC emulator according to claim 1, wherein the PLC emulator has a program for emulation instead of a PLC, a pointer table and a pseudo PLC data area for PLC emulation.
LC test support system.