JPS63293611A - Simulation test method - Google Patents

Abstract

PURPOSE:To improve the simulation test efficiency by using plural digital controllers and CRT devices containing input devices together with the on-line and off-line circuits. CONSTITUTION:A control system comprises the CRT devices 1 containing input devices, the digital controllers 2, the on-line/off-line data ways 3A-3B, and the changeover switches 4A-4G. Four controllers 2 are provided to control the processes for each part. While a software simulation system is applied to one of those four controller 2 that is used for a halt or spare process for simulation. These devices 1 and controllers 2 are connected with switching to the ways 3A-3B by the changeover switches 4A-4G. Thus the input and the output of the controller 2 to be tested are confirmed by the device 1 so that a simulation test is carried out in a safe, economical and effective way.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a test method in a digital control system including sequence control.

[Conventional technology]

When configuring a digital control system, the focus is usually only on equipment costs at the time of construction, and little consideration is usually given to factory tests at the manufacturer before shipment and on-site tests after shipment. In particular, little consideration is given to on-site tests for expansions and modifications.

[The problem that the invention aims to solve]

As a result, a lot of time and effort are usually spent on factory tests and on-site tests at the time of delivery, and it is extremely difficult to carry out factory and on-site tests at the time of expansion and modification after construction.

In other words, a) Both sequence control and process control target actual input/output (process input/output);
When conducting factory tests, a large number of external wiring must be connected to simulate the controlled object. Furthermore, in on-site testing, switching between a test using a simulated device and a test targeting an actual facility requires changing the connection of a large number of outside lines, which requires a great deal of effort and time.

(g) During on-site testing, testing the control device after the equipment has even partially started operating involves a great risk of causing malfunctions on the process side.
As a result, sufficient testing cannot be performed and efficiency is poor.

C) CRTs have become the mainstream man-machine ink face for operation in recent digital control systems, but some operations are still performed using push buttons.

It is done with a lamp. Such tests require the production of a mock operation desk and external connections, which precludes economical testing.

There is a problem.

Therefore, an object of the present invention is to provide a method for safely, economically, and efficiently performing factory and field tests of digital control systems including sequence control not only during construction but also during expansion and modification.

[Means for solving problems]

While multiple control devices and CRT devices with input devices can be selectively connected to the online dataway or offline dataway, during testing, one CRT device, the control device not used for online use, and the test When the target control device under test is connected to the offline dataway, the control device connected to the dataway is equipped with a function to simulate the equipment driven by the control device under test. A test system used as a simulator is configured, and when the control device under test receives a test command from a CRT device, it performs a predetermined sequence operation based on this test command, and then sends a production command as a result of the operation to the simulator. After receiving a response signal given as a result of the simulation from the simulation device, the simulation test is performed by transmitting it to the CRT device and displaying it.

[Effect]

A plurality of digital control devices and CRT devices with input devices are provided, and two data ways are provided, one for online testing and the other for offline testing.

Then, a simulation test system is constructed using a digital control device for idle processes that are not in online operation or for backup, one CRT device, an offline dataway, and a control device under test.
At this time, the digital control device is equipped with predetermined software so as to function as a simulator of the plant (equipment) to be controlled, and is used as a plant simulator (simulator). As a result, the test command from the CRT device is given to the control device under test, so the device performs a predetermined sequence of operations, and the production command as the result of the operation is transmitted to the simulator file. Based on this, the simulator operates the equipment using software, and the response results are transmitted as output signals from the equipment to the control device under test via the data way. Because the inputs and outputs of the control device under test are verified by the CRT device, simulation tests are performed safely, economically, and efficiently.

〔Example〕

The figure is a control system configuration diagram for explaining the present invention in detail, and 1 (IA to IC) is a CRT device with an input device;
2 (2A to 2D) is a digital control device, 3A is an online data way, 3B is an offline data way, and 4A to 4G are changeover switches. For example, there are three CRT devices, and all three are normally used for operation, but one of them is used for testing during testing. Two dataways are prepared, one for operation (online) and the other for testing (offline). There are four control devices installed here, and each part of the process is controlled. One of the four control devices for idle processes or for backup
A software simulation system is installed to create a simulator. Further, the CRT and the control device are connected so as to be switchable between an online dataway and an offline dataway using a changeover switch.

Here, CRT devices IA, 1B and control devices 2A, 2
B is connected to the online dataway 3A and is in operation, and a control device 2D is added.

This section explains the case where a simulation test is performed after modification. At this time, the CRT device IC is normally used for operation, but during testing it is connected to the offline dataway 3B side by the changeover switch 4C. Control device 2C for idle process or backup and control device under test 2D
Similarly, it is connected to the offline data way 3B side using changeover switches 4F and 4G. Next, CRT device 1G,
A simulation test system is constructed by loading test software into the simulator 2C and loading actual process control software into the controlled device under test 2D. At this time, even if the input/output of the control device under test i2D is installed, consideration should be given to the software so that no signal is output. By doing so, the equipment connected to the control device under test 2D does not perform unnecessary operations, thereby ensuring safety.

In this state, by issuing a test command from the input device attached to the CRT device IC, a simulation test is performed as follows.

1) A test command is transmitted from the CRT device IC to the control device under test 2D via the data way 3B.

2) The control word WED to be tested executes a sequence operation in response to a test command from the CRT device IC (the resulting production command will be described below as a shutoff valve opening process).

3) The control device under test 2D transmits a signal to open the shutoff valve to the input file of the simulator 2C via the data way 3B.

4) The simulator 2C performs a simulation process of opening the shutoff valve,
Check the limit switch horizontal tJJ.

5) The simulator 2C transmits a confirmation signal for opening the shutoff valve by the simulated limit switch to the input file of the control device under test 2D via the data way 3B.

6) A signal for changing the display is transmitted from the control device under test 2D to the CRT device IC via the data way 3B.

One simulation operation is completed through this series of operations, but at this time, only the control device under test, the simulator, and the test CRT device are connected to the offline dataway, so even if the control device under test It is safe because even if the device malfunctions, only the target process can be operated. Furthermore, since all signals are processed via the data way and no actual process input/output devices are used, there is no need for a simulation device for this purpose and an external line cable to connect it.

〔Effect of the invention〕

According to this invention: a) It is possible to test independently of the equipment and control device in operation, and it is safe.

b) All that is required is a control device under test, a simulator, and a CRT device; operation buttons, lamps, or external signal sources for testing are not required.

C) There is no need to replace the process input/output interface with the equipment with test equipment for testing (it is more efficient).

Benefits such as:

[Brief explanation of drawings]

The figure is a control system configuration diagram for explaining the present invention in detail. Code explanation 1 (IA~IC)...CRT device with input device, 2
(2A-2D)...Digital control device, 3A...
Online data way, 3B... Offline data way, 4A to 4G... Changeover switch.

Claims (1)

[Claims] While each of a plurality of digital control devices (control devices) and CRT devices with input devices can be selectively connected to an online dataway or an offline dataway, only one CRT device is connected during testing. In addition to connecting a control device that is not used for online use and a control device under test to be tested to an offline dataway, the control device connected to the dataway is driven by the control device under test. When the control device under test receives a test command from a CRT device, it performs a predetermined sequence of operations based on the test command, and then displays the results of the operation. A simulation test method characterized in that a simulation test is performed by sending a production command to a simulation device, receiving a response signal given as a result of the simulation from the simulation device, and then transmitting this to a CRT device for display. .