KR101283026B1 - System for real time control of total control system and method thereof - Google Patents

Abstract

The present invention is to provide a real-time integrated processing and monitoring of the processing (Processing) by independently connecting the control panel composed of different heterogeneous and one or more and control PC (Personal Computer) as an integrated control system for each process.

The present invention comprises a multi-process including a DLL provided by the control panel manufacturing company, connecting each control panel corresponding to each process by the DDE method, and read the necessary input and output information, servo drive information, internal registers in the DLL Extracting the physical base address, which is an internal function for writing, Analyzing the execution image file format of the Windows system to calculate the location and size of the executable file and forcibly fixing it in shared memory to reside the executable file in shared memory Select the PLC of the control panel to be driven in the program, drive the PLC thread to be initially executed using the registered command function, create a waiting thread, and schedule to process a specific routine according to the interrupt signal generated from the kernel drive. After running each thread to process each corresponding routine statement. Setting a synchronization event to a non-signal state.

Control panel, PCL / CNC, DLL. Kernel drive, multiprocess

Description

Real time control device and method of integrated control system {SYSTEM FOR REAL TIME CONTROL OF TOTAL CONTROL SYSTEM AND METHOD THEREOF}

The present invention relates to an integrated control system, and more particularly, a real-time integrated processing and monitoring of the processing (Processing) by independently connecting a control panel composed of different heterogeneous types and one or more control panels and a personal computer (PC) for each process. It relates to a real-time control device and method of an integrated control system for providing a.

In general, a processing line for processing an engine or a transmission of an automobile is, as shown in FIG. 5, a processing machine 10 for processing a material, a loader 20 for inputting a material to be processed into the processing machine 10, It is composed of a control panel 30 for controlling the operation of the machine 10 and the loader 20 according to the set machining process, it is composed of FMS (Flexible Manufacturing System) that is connected to each other through a communication interface to execute a complex control.

Since the processing line composed of FMS is composed of different heterogeneous devices, in order to control the corresponding devices in the case of the control panel 30, the CNC / PCL controller 32 of SIEMENS and the CNC / PCL controller of FANUC ( 33) (34), MELSEC's PCL controller (35), which is a higher processor and is connected to the corresponding loader (20) via a field bus with a PC (31) that controls the overall operation of the workpiece. And control the operation of the processing machine 10.

In the case of the FMS configured as described above, the operation process set in the PC 31 should be modified so as to prevent the collisions and personal injury between the devices by performing simulation for each interlocking operation before actual operation.

As an example for simulation, the axis of the servomotor that operates the loader 20 according to the instructions of the CNC / PMC 33, 34 of FANUC is virtually set as a dummy axis, and the material is supplied from the PC 31. And send the machining instruction.

Accordingly, SIEMENS's CNC / PCL controller 32, FANUC's CNC / PCL controller 33, 34, and MELSEC's PCL controller 35 are loaded with loaders 20 according to material supply and machining instructions provided through the fieldbus. And control the operation of the processing machine 10.

At this time, the PC 31 processes the virtual graphics with respect to the movement of the loader 20 and analyzes whether the collision between the loader 20 and the processing machine 10 occurs or collides with a worker nearby. Identify the error of the operation program set in.

In particular, in field lines composed of FMS, many field buses are intertwined in each control period, so if there is a problem in one scan timing processing error, simultaneous signal measurement between heterogeneous types is impossible, so it is not possible to solve by tracking. There is a problem that is not easy.

FIG. 4 illustrates a PLC program simulation method that allows the I / O devices to be commissioned in a situation such as an actual program using only a PC in an automated factory.

It has a PC (1) equipped with a program simulator, a PLC (2) to be simulated and a program loader (3) for creating a PLC control program to take input variable values from the program loader (3) and delay device response. Check the time and if satisfied, execute the response logic, otherwise terminate the execution function.

When the response logic is executed stably, the result value is output as an output variable, the expression analyzer calculates the expression and outputs the result value as an image variable, and when the component execution is completed, transfers control to the execution process and executes it in the execution process. Run the following components according to the rules.

Therefore, even with a PC, the I / O devices can be virtually tested in a real system situation.

However, this method is composed of one or more heterogeneous, there is a problem that the manufacturer is not possible to simulate the different control panel (PLC / CNC).

In addition, when applying the same type of PLC to solve the problem of the field line, real-time processing of the program through the PC is somewhat possible, but there is a problem that the real-time monitoring of the program is impossible for the case of applying a plurality of heterogeneous PLC.

More specifically, in the case of implementing the integrated diagnostic function of the application target for one type of control panel (PLC) by constructing a program that can be diagnosed on a PC by the manufacturer-specific DLL file of the open control panel (PLC / CNC) Although the real time problem is somewhat reduced, real time processing can be a problem when analyzing the cause when integrated control or trouble occurs using various control panels (PLC / CNC).

For example, when an integrated control system as shown in FIG. 5 is implemented, heterogeneous control panels 32, 33, 34, and 35 mainly consisting of FANUC / MELSEC / SIEMENS are connected by a field bus, and the control panel is manufactured by each. Each company uses its own closed Real Time Operating System (RTOS), so real-time processing is not a problem.

However, when the operating system connects the PC 31 mounted with a window to the control panel (PLC), the processing time is determined by the priority of each process and task that prevents the progress of various purposes such as remote diagnosis / control and virtual simulation. In this case, real-time processing becomes a problem when implementing an integrated diagnosis system in a PC using a Windows operating system.

In other words, the operating system of the PC is a single process interrupt processing method, but real-time processing can be insufficient, but there is a problem that requires a short execution time of the process and is limited in the method of using the system resources, the implementation is not easy.

In particular, in the case of multiple processes, almost real-time implementation is impossible, which leads to the following problems.

When the disk swapping technique is applied to the virtual memory space but the contents are not in the physical memory, the contents are read from the disk and resident in the physical memory, and the unused portion of the current memory is stored on the disk again. I use it.

However, this technique has a problem that a speed delay occurs when a process to be executed currently exists on the disk.

In addition, only one service routine is assigned to one interrupt signal, and a corresponding process is executed by creating a corresponding process and thread so that a plurality of service routines must be executed. It is necessary to generate two processes, and the same number of hardware signals are required, resulting in a problem in that the process cannot be efficiently used, and a problem in that the efficiency of the system is lowered due to the occurrence of repetitive interrupts.

In addition, there is a problem in that communication with a general purpose PC, input / output of simulation data, and hold of a memory processing function are unnecessary for real-time functions.

The present invention has been invented to solve the above problems, the purpose of which is different from the manufacturer in the integrated control system, the heterogeneous control panel (PLC / CNC) consisting of one or more and the control PC independently connected by process To provide real-time integrated processing and monitoring of the processing.

Real-time control device of the integrated control system according to a feature of the present invention for realizing the above object,

A multi-process including a DLL provided by a control panel manufacturer, and each process includes an upper process connected to a corresponding control panel in a DDE manner; Shared memory for storing the input and output signal data obtained through communication with the hardware of the control panel to enable the other control panel to read and write; It includes a kernel drive that integrates and controls read / write processing of data stored in shared memory according to a real-time scheduler.

In addition, the real-time control method of the integrated integrated control system according to another feature of the present invention,

Configuring multiple processes including a DLL provided by a control panel manufacturing company, and connecting each control panel corresponding to each process in a DDE manner; Extracting a physical base address, which is an internal function for reading and writing the necessary input / output information, servo drive information, and internal registers from the DLL; Analyzing the executable image file format of the Windows system to calculate the location and size of the executable file and forcibly fixing the shared file to the shared memory so that the executable file resides in the shared memory; Selecting a PLC of a control panel to be initially driven, driving a PLC thread to be initially executed using a registered command function, and generating a waiting thread; The process includes setting a synchronization event to a non-signal state after processing a corresponding routine statement by driving a schedule thread for processing a specific routine according to an interrupt signal generated from a kernel drive.

By the above-described configuration, the present invention can be expected to provide an effect of providing stable integrated control and simulation real-time monitoring for a control panel consisting of a plurality of different manufacturers of different manufacturers.

DETAILED DESCRIPTION Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art may easily implement the present invention.

The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

In the drawings, parts irrelevant to the description are omitted in order to clearly describe the present invention, and like reference numerals designate like parts throughout the specification.

Also, when a part is referred to as "including " an element, it does not exclude other elements unless specifically stated otherwise.

1 is a view showing the configuration of a real-time control device of the integrated control system according to an embodiment of the present invention.

As shown, the kernel drive 100 and the upper process 200 and a plurality of heterogeneous control panel 300 is configured.

The upper process 200 configures the contents including the DLL provided by the control panel 300 manufacturing company such as PLC / CNC to be configured in a multi-threaded manner, and each of the input / output signal data obtained through communication with the hardware of the control panel 300. It contains a shared memory to transfer the value to another PLC / CNC.

The upper process 200 is implemented as a plurality of independent processes, each including a DLL provided by the control panel 300 manufacturing company such as PLC / CNC, each of these processes are independently connected to the corresponding control panel 300 .

The shared memory applies a format for sharing data so that each control panel 300 can read and write.

The upper process 200 and each control panel 300 including CNC / PLC are connected by a data dynamic exchange (DDE) method.

The kernel drive 100 is configured as a real-time scheduler to collectively control real-time read / write processing of parameters stored in the shared memory configured in the upper process 200.

In the configuration with the above connection, the operation of the upper process is executed as follows.

First, the upper process 200 independently configures multiple processes, including a DLL provided by each control panel 300 manufacturer for real-time processing, and each control panel 300 corresponding to each process is DDE. Connect in the manner (S101).

For example, among multiple independently configured processes, process 1 210 including the PLC_1 interface DLL is connected to the PLC 310 of Melsec, and process 2 220 including the PLC_2 interface DLL is a CNC / PLC (Fanuc). Processor 3 230, which includes a PLC_3 interface DLL, is coupled to Siemens' CNC / PLC 330.

As described above, when each of the multiple processes is connected to the corresponding control panel 300, the physical base address, which is an internal function for reading and writing the input / output information, the servo drive information, the internal register, etc. required by the DLL is extracted (S102). .

Thereafter, by analyzing the execution image file format of the window system, the location and size of the execution file are obtained, and the portions thereof are fixed so that the program area always resides in the memory (S103) (S104).

The method of residing the executable file in the memory is to read the image executable file for each PLC / CNC manufacturing company constituting the control panel 300, analyze the header file IMAGE_DOS_HEADER, and compare the IMAGE_NT_HEADER / IMAGE_OPTIONAL_HEADER structure with the Winnt.h header file. Then, the size of the entire program is obtained by adding the program execution code size and data size, and forcedly fixed with the virtual lock API function for use with the real-time kernel.

In addition, there are hundreds of interface input / output DLL functions for each PLC / CNC manufacturing company constituting the control panel 300, and select a PLC of the control panel 300 to be initially driven, and drive a PLC thread to be initially performed.

At this time, each instruction function is registered in advance in a case statement to create a waiting thread (S105).

Accordingly, in response to the interrupt signal generated from the kernel drive 100, a schedule thread for processing a specific routine is driven to process each corresponding routine statement, and then a synchronization event is set to a non-signal state (S106).

Accordingly, the present invention is capable of performing multiple processing by one interrupt, thereby efficiently using an interrupt signal and at the same time not affecting the routine processing of other processes and threads.

In addition, the operation of the kernel drive 100 providing real time integrated control will be described with reference to FIG. 3.

Registers an Interrupt Service Routine (ISR) in the Interrupt Description Table (IDT) for configuring the control panel 300 and selecting a plurality of heterogeneous PLC / CNC hardware interrupt numbers as a timer inside the PC. (S201).

The task processing time for real time monitoring and display is measured, and each task syntax function registers a function for reading / writing parameters stored in input / output and shared memory of a plurality of PLC / CNC processes / multithreads (S202).

Thereafter, the scheduler of the interrupt service routine, which is the execution of the process, is stored in the stack-type memory (S203), and generation of unnecessary hardware interrupts that interfere with real-time processing is prevented (S204).

Subsequently, the stack pointer and the task syntax of the current state are stored in each register of the base stack, and then the tasks of the scheduler processing target stored in the register are sequentially read in real time processing (S205). S206) The stack register is restored to just before the real-time processing is secured, and the stack register is restored (S207).

The embodiments of the present invention described above are not implemented only through the apparatus and the method, but may be implemented through a program for realizing a function corresponding to the configuration of the embodiments of the present invention or a recording medium on which the program is recorded.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, It belongs to the scope of right.

1 is a view showing the configuration of a real-time monitoring device of the integrated control system according to an embodiment of the present invention.

FIG. 2 is a diagram illustrating an execution flow of the multiple processes illustrated in FIG. 1.

FIG. 3 is a diagram illustrating a real-time processing flow of the kernel drive shown in FIG. 1.

4 is a diagram showing the configuration of a conventional PLC simulation apparatus.

5 is a view showing a schematic configuration of a general integrated control system.

<Explanation of symbols for the main parts of the drawings>

100: kernel drive 200: parent process

300: multiple control panel

Claims (4)

delete delete Configuring multiple processes including a DLL provided by a control panel manufacturing company, and connecting each control panel corresponding to each process in a DDE manner; Extracting a physical base address, which is an internal function for reading and writing the necessary input / output information, servo drive information, and internal registers from the DLL; Analyzing the executable image file format of the Windows system to calculate the location and size of the executable file and forcibly fixing the shared file to the shared memory so that the executable file resides in the shared memory; Selecting a PLC of a control panel to be initially driven, driving a PLC thread to be initially executed using a registered command function, and generating a waiting thread; Setting a synchronization event to a non-signal state after processing a corresponding routine statement by driving a schedule thread for processing a specific routine according to an interrupt signal generated from a kernel drive; / RTI &gt; The method of resident in the shared memory, Analyzing the header file IMAGE_DOS_HEADER by reading an image executable file of each manufacturing company constituting the control panel; Comparing the IMAGE_NT_HEADER / IMAGE_OPTIONAL_HEADER structure of the header file with a Winnt.h header file and calculating the size of the entire program by adding the program execution code size and the data size; Real-time control method of the integrated control system including forcibly fixing with a virtual fixed API function for use with the real-time kernel. The method of claim 3, Execution of a specific routine according to the interrupt signal to the kernel drive, Registering an interrupt service routine (ISR) in the interrupt definition table (IDT) for selecting a plurality of PLC / CNC hardware interrupt numbers constituting the control panel; Measuring a task processing time for real-time time monitoring and display and registering each task syntax function as a function for reading / writing of input / output and shared memory data of multiple processes; Storing a scheduler of the interrupt service routine in the shared memory and preventing generation of unnecessary hardware interrupts that interfere with real-time processing; Storing a current stack pointer and a task syntax in each register of the base stack and sequentially reading and performing a task of a scheduler processing target stored in the register; Real-time control method of the integrated control system comprising the step of restoring the stack register when the task is finished.

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