KR101376387B1 - Appartus and method for real-time diagnosis network 0f in redundant plc system - Google Patents

Abstract

The present invention provides a network inspection unit that examines the state of two redundant base base modules and a plurality of redundant extension base modules constituting a PLC system, and connection information of cables connecting the two redundant base base modules and the redundant extension base module; O / S storage unit for storing an O / S program, a program storage unit for storing a user program, a control unit performing an operation according to the user program, and controls the PLC system, input / output data of the PLC system and the An apparatus and method for real-time network diagnosis of a redundant PLC system including a data storage unit for storing an operation result according to a user program.

Description

APPARATUS AND METHOD FOR REAL-TIME DIAGNOSIS NETWORK 0F IN REDUNDANT PLC SYSTEM}

The present invention relates to a redundant programmable logic controller (PLC) system, and more particularly, to an apparatus and method for diagnosing a network of a redundant PLC system in real time.

The PLC is a programmable logical controller. Generally, a PLC acts like a computer, processes a signal transmitted by a device such as a machine into a program inside the PLC, and then outputs the processed signal to the device.

The PLC replaces the functions of a control device such as a relay, a timer, and a counter with a semiconductor device such as an integrated device and a transistor.

PLC includes basic sequence control function and numerical operation function, so that program control and logic of program stored in PLC internal memory can be executed.

PLC is widely used in various fields such as device control, device numerical setting, time control, real time monitoring, real time data collection, and safety device operation.

Since the PLC system using the PLC processes data such as power generation facilities and social infrastructure projects, when an error occurs in the PLC system, a large social cost is generated, so the stability of the PLC system is very important.

In order to prevent this, in general, the PLC system is configured by duplexing the module (Module) performing the same function.

Currently, when an error occurs in the redundant expansion driver or cable of the redundant PLC system, the redundant PLC system provides only information that an error has occurred, so that the user has a problem in which position of the redundant PLC system is found. .

The technical problem to be solved by the present invention is to display the network connection information of the redundant PLC system on the screen in real time, if a failure occurs in the expansion driver or cable during the operation or stop of the redundant PLC system, the user It is to provide a network real-time diagnostic device and method that can easily determine where the failure occurred in the location.

In addition, by displaying the network connection information of the redundant PLC system on a real-time screen, the network real-time diagnostic device that can know which module has been added or dropped in the redundant PLC system, and in which position the network cable is incorrectly connected or disconnected; To provide a way.

In order to solve the above technical problem, the network real-time diagnostic apparatus of the redundant PLC system of the present invention, the state of the two redundant basic base module and the plurality of redundant expansion base module constituting the PLC system and the two redundant basic base module And a network inspection unit that checks connection information of a cable connecting the redundant expansion base module, an O / S storage unit storing an O / S program, a program storage unit storing a user program, and performing operations according to the user program. And a controller configured to control the PLC system, and a data storage configured to store input / output data of the PLC system and a calculation result according to the user program.

The apparatus for real-time network diagnosis of a redundant PLC system according to the present invention may further include a network information unit configured to store information about a change of a network of the PLC system.

The network real-time diagnostic apparatus of the redundant PLC system of the present invention displays the configuration of the network of the redundant PLC system, and when an abnormality or a failure occurs in the two redundant basic base modules, the plurality of expanded base modules, and the cable. And a display unit for displaying the corresponding position on the configuration diagram.

In the present invention, a network real-time diagnosis method of a redundant PLC system includes: reading, by the PLC system, a contact state value of an input module and storing the contact state value in an input image area, executing the scan program by the PLC system, and identifying the PLC system. If the condition is satisfied, stopping the execution of the scan program and executing a task program; inspecting a network of the PLC system by the PLC system; storing the scan program and the task program execution result in an output image area by the PLC system; And outputting a contact state to the output module by the PLC system, and inspecting a network of the PLC system comprises: two redundant basic base modules and a plurality of redundant extension base modules constituting the PLC system. Status and phases with the two redundant base base modules To check the connection information for the cables connecting the plurality of redundant extension base unit can be characterized.

The network real-time diagnostic method of the redundant PLC system of the present invention may further comprise the step of the PLC system communicating with the peripheral device after the step of storing the result of the execution in the output image area.
The network real-time diagnostic method of the redundant PLC system of the present invention, if the two redundant basic base module, the plurality of expansion base module and the cable occurs after the step of storing the performance result in the output image area, The location may be displayed on a network configuration diagram of the redundant PLC system.

According to the present invention as described above, while the PLC is running or stopped, the location of an error or failure of the expansion driver or cable is displayed on the screen, so that the user can easily grasp where the failure occurs.

Since the present invention displays the network connection information of the PLC system in real time, there is an effect of knowing which module is added or dropped to the redundant PLC system, and at which position of the PLC system, the network cable is incorrectly connected or dropped.

1 is a configuration diagram of a conventional PLC system.
FIG. 2 is a configuration diagram of a controller system of the PLC system of FIG. 1.
3 is a flowchart illustrating an operation of the PLC system of FIG. 1.
4 is a configuration diagram of a redundant basic base module of a conventional redundant PLC system.
5 is a configuration diagram of a redundant expansion base module of a conventional redundant PLC system.
6 is a configuration diagram of a conventional redundant PLC system.
7 is an example of configuration of a PLC system according to the present invention.
8 is an exemplary view of a controller system configuration of a PLC system according to the present invention.
9 is an example of a flowchart illustrating the operation of a PLC system according to the present invention.
10 is an exemplary view of a display unit displaying a configuration of a redundant PLC system according to the present invention.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the invention is not intended to be limited to the particular embodiments, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

Terms including ordinals such as first, second, etc. may be used to describe various elements, but the elements are not limited by such terms. These terms are used only to distinguish one component from another.

When a component is said to be 'connected' or 'connected' to another component, it may be directly connected to or connected to that other component, but other components may be present in between. It should be understood that. On the other hand, when an element is referred to as being "directly connected" or "directly connected" to another element, it should be understood that there are no other elements in between.

The terminology used in this application is used only to describe a specific embodiment and is not intended to limit the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this application, the terms "comprises", "having", and the like are used to specify that a feature, a number, a step, an operation, an element, a component, or a combination thereof, But do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

Hereinafter, with reference to the accompanying drawings illustrating a problem of a conventional redundant PLC system, a preferred embodiment according to the present invention will be described in detail. Wherein like reference numerals refer to like elements throughout.

1 is a configuration diagram of a conventional PLC system.

Referring to FIG. 1, the PLC system 10 performs a calculation according to a power supply unit 11, a peripheral device unit 12 which creates a user program and monitors various calculation results according to the program and the state of the PLC system 10, and a program. It consists of a control system 20 for performing the operation, storing the calculation results and controlling various communication functions and the PLC system 10 and an input / output unit 13 for transmitting / receiving data with an external device connected to the PLC system 10. do.

FIG. 2 is a configuration diagram of the controller system 20 of the PLC system 10 of FIG. 1.

Referring to FIG. 2, the controller system 20 of the PLC system 10 assists the functions of the O / S storage unit 21 and the PLC system 10 that store an operating system (O / S) program. Alternatively, the peripheral circuit unit 22 including a data backup circuit and a reset circuit for stopping the operation of the controller 23 when the power supply of the PLC system 10 is turned off, and calculated according to a program. And a control unit 23 for controlling the PLC system 10, a program storage unit 24 for storing a user program, and a data storage unit 25 for storing input / output data and calculation results according to the program. .

3 is a flowchart showing the operation of the PLC system 10 of FIG.

Referring to FIG. 3, when the operation of the PLC system 10 starts (S1), the PLC system 10 reads the contact state value of the input module (S2) and performs an input image area refresh (S3).

Next, a scan program is performed (S4), and when a specific condition is satisfied, a task program is performed (S5).

When the scan program execution S4 is completed, the output image area refresh S6 is performed, and a contact state is output to the output module S7.

After one scan is finished, the PLC system 10 performs the input image area refresh (S3) again, and repeats the program (S8).

4 is a configuration diagram of a redundant basic base module of a conventional redundant PLC system.

Referring to FIG. 4, the conventional redundant basic base module may be classified into CPU-A and CPU-B.

As described above, since the conventional redundant basic base modules use the same CPU module, it is necessary to distinguish the redundant basic base modules. The user operates the CPU module A / B side switch (CPU classification switch) located in the redundant basic base module to designate the redundant basic base module as CPU-A or CPU-B to distinguish between identical redundant basic base modules. .

In addition, each redundant basic base module (CPU-A, CPU-B) includes two power modules, one CPU module and a plurality of slots. Each redundant basic base module includes two power modules, so the power module itself is redundant.

5 is a configuration diagram of a redundant expansion base module of a conventional redundant PLC system.

Referring to FIG. 5, the redundant expansion base module includes two power supplies, expansion drive A, expansion drive B, and a plurality of input and output slots.

6 is a configuration diagram of a conventional redundant PLC system.

Referring to FIG. 6, the conventional redundant PLC system 60 includes two redundant basic base modules 61 and 62 and a plurality of redundant expansion base modules 63, 64 and 65.

In the conventional redundant PLC system, the CPU modules of the redundant basic base modules 61 and 62 are connected to each other by using a synchronization cable. One of the redundant basic base modules 61 and 62 becomes a master in charge of the operation of the redundant PLC system 60, and the other has a standby in place of the master when the master fails. do.

If the master fails, standby takes over. In addition, when the failure of the existing master is restored, the existing master becomes a new standby, and during operation of the redundant PLC system 60, the user may program a tool and a key switch of the redundant PLC system 60. By operating, one of the redundant basic base modules 61 and 62 can be changed to the master.

As shown in FIG. 5, the redundant expansion base modules 63, 64, and 65 each include an expansion drive A and an expansion drive B, and thus duplicate the expansion drive itself.

The network of the redundant PLC system 60 can be comprised by a ring or a line.

When an error occurs in the redundant extension driver or cable of the conventional redundant PLC system, the conventional redundant PLC system only provides information that an error has occurred, and the user grasps where in the redundant PLC system the error occurred. There is a difficult problem. The present invention is intended to solve such a problem. Hereinafter, the present invention will be described with reference to the drawings.

7 is an exemplary view illustrating the configuration of a PLC system 70 according to the present invention.

Referring to FIG. 7, the PLC system 70 according to the present invention includes a power supply unit 71, a display unit 72 for visually displaying a network configuration diagram of the PLC system 70, a user program, and various operations according to the program. Peripheral unit 73 for monitoring the results and the status of the PLC system 70, the control system 80 and the PLC system for performing calculations according to the program, storing the calculation results, and control various communication functions and the PLC system 70 ( And an input / output unit 75 for transmitting / receiving data with an external device connected to the device 70).

8 is an exemplary view illustrating a configuration of the controller system 80 of the PLC system 70 according to the present invention.

Referring to FIG. 8, the controller system 80 of the PLC system 70 stores a network inspection unit 81 and an O / S program that inspects connection information of modules and cables constituting the PLC system 70 in real time. In order to assist or expand the functions of the O / S storage unit 82 and the PLC system 70, a reset for stopping the operation of the control unit 23 when the data backup circuit and the PLC system 10 are powered off. (Reset) Peripheral circuit unit 83 including a circuit, etc., a control unit 84 for performing operations according to a program and controlling the PLC system 70, a program storage unit 85 for storing a user program, input / output data And a data storage unit 86 storing operation results according to a program and a network information unit 87 storing network information of the PLC system 70.

9 is an example of a flowchart showing the operation of the PLC system 70 according to the present invention.

Referring to FIG. 9, when the PLC system 70 starts operation (S11), the PLC system 70 reads the contact state value of the input module (S12) and performs an input image area refresh (S13).

The input image area refresh S13 reads the contact state value of the input module of the PLC system 70 before performing the scan program and stores it in the input image area.

The program of the PLC system 70 can be roughly divided into two types: a scan program and a task program. The scan program is a program that is repeatedly executed every 1 scan, and the task program is a program that is executed when a specific condition is satisfied. Specific conditions include, for example, timers, interrupts, and conditions caused by internal contacts.

In the scan program execution S14, when the specific condition of the task program S15 is satisfied, the PLC system 70 stops performing the scan program S14 and performs the task program S15. When the PLC system 70 completes the task program execution (S15), the PLC system 70 returns to the interrupted portion of the previous scan program and performs the scan program (S14).

The scan program execution (S14) is completed and the network of the PLC system 70 is checked (S16). That is, the method of checking and checking the normal operation of the module installed in the PLC system 70, whether the module is missing, the connection change of the PLC system 70 network, and the like will be described in detail below.

The module information data of the redundant basic base module 61, 62 is composed of an XGR_BASIC_INFO structure and an XGR_NODE_INFO structure. The XGR_BASIC_INFO structure contains information such as the total number of modules, network type (ring, bus, base redundancy declaration, etc.), standby status, and the like. That is, the basic information of the PLC system 70 network is included.

XGR_NODE_INFO structure exists as the number of modules, type of module (master, standby, slave, etc.), station number of module (module unique ID), module position (connected with CPU-A or CPU-B in case of slave) Station number of the module connected to the 1st port or 2nd port of the master (if not connected, NULL is displayed instead of the station number), type of module (electrical, optical, mixed), module version (OS version information), cable It contains information such as the type, length, measurement date, and status. That is, the detailed information of the modules constituting the PLC system 70 network is included.

Step A. The XGR_BASIC_INFO structure collects XGR_NODE_INFO structure information that exists as many as the number of modules.

Step B. Based on the collected information, the information of the first module corresponding to the module station number connected to the first port of the master is collected.

Step C. On the basis of the information collected in the first module found in step B collects the information of the second module corresponding to the station number of the module connected to the first port of the first module.

Step D. Repeat steps B and C sequentially, collecting all the information of the modules connected to the first port of the master. The end condition of the repetition is when the collected station address information is the master station number or NULL.

Step E. In order to collect module information corresponding to the module station number connected to the second port of the master, steps B to D are sequentially repeated based on the second port of the master.

Step F. Also in the case of standby, steps B to F are performed in the same manner, and the repetition termination condition is when the collected station number information is a station number of a standby or NULL.

If there is no information of the module itself, it is determined that the module is missing. If the information of the module connected to the first port and the second port is different from the XGR_NODE_INFO structure information, it is determined that the cable is dropped.

After all the above steps, it is possible to collect all the network information of the PLC system 70 in real time.

Upon completion of the inspection (S16) of the network of the PLC system 70, the controller 80 of the PLC system 70 refreshes the output image area (S17) in order to check whether there is an error in the program execution result on the PLC system 70. ). The output image area refresh S17 stores the result of the execution of the scan program and the task program in the output image area instead of immediately outputting the result.

The controller 80 of the PLC system 70 outputs an error message if there is an error on the PLC system 70, and outputs data stored in the output image area to the output module if there is no error. That is, the contact state is output to the output module (S18).

The output image area refreshes (S17), and outputs the contact state to the output module (S18).

After the output image area refresh (S17), based on the network information of the collected PLC system 70, if there is a change in the network, in real time within a range that does not affect the time to perform the scan program (S14). Update changed network information.

When the network information is updated, the PLC system 70 communicates with the peripheral device (S18), and the display unit 72 of the PLC system 70 displays the updated network information of the PLC system 70 in real time.

 After one scan is finished, the PLC system 70 performs the input image area refresh (S13) again, and repeats the program (S20).

10 is an exemplary view of a display unit 72 displaying a configuration of a redundant PLC system according to the present invention.

Referring to FIG. 10, the display unit 72 according to the present invention is connected to a redundant basic base module 91 serving as a master, a redundant basic base module 92 serving as a standby, and respective redundant basic base modules 91 and 92. The redundant expansion base modules 93, 94, and 95 which are multiple bases are shown. According to the purpose of constructing the redundant PLC system, the number of redundant expansion base modules can be changed.

In addition, the display unit 72 according to the present invention also displays a cable connecting to the master and a cable connecting to the standby. For example, the cable of the redundant expansion base modules connected to the master may be represented by a solid line, the cable of the redundant expansion base modules connected to the standby may be indicated by a dotted line, and it is obvious to display the cable in various other ways.

The display unit 72 displays error positions and error detail information of the network of the redundant PLC system. For example, when a cable dropout or an extension driver dropout occurs, the dropped position is visually displayed.

While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims. Accordingly, the true scope of the present invention should be determined by the following claims.

70: PLC system 71: power supply
72: display unit 73: peripheral unit
75: input / output section 80: control system
80: control unit 81: network inspection unit
82: O / S storage unit 83: peripheral circuit
84: control unit 85: program storage unit
86: data storage unit 87: network information unit
91, 92: Redundant basic base module
93, 94, 95: redundant expansion base module

Claims (6)

A network inspecting unit for inspecting a state of two redundant base base modules and a plurality of redundant extension base modules constituting a PLC system and connection information of cables connecting the two redundant base base modules and the redundant extension base module;
An O / S storage unit for storing an O / S program;
A program storage unit for storing a user program;
A control unit which performs an operation according to the user program and controls the PLC system; And
Network real-time diagnostic apparatus of a redundant PLC system including a data storage for storing the input / output data of the PLC system and the calculation result according to the user program.
The method of claim 1,
Network real-time diagnostic apparatus of the redundant PLC system further comprises a network information unit for storing information about the change of the network of the PLC system.
The method of claim 1,
The configuration diagram of the network of the redundant PLC system is displayed, and if an error or a failure occurs in the two redundant basic base modules, the plurality of expansion base modules, and the cable, the corresponding position is displayed on the configuration diagram. Network real-time diagnostic device of the redundant PLC system further comprising a display.
Reading, by the PLC system, the contact state value of the input module and storing it in the input image area;
The PLC system executing a scan program;
Stopping the execution of the scan program and executing a task program when the PLC system satisfies a specific condition;
Checking, by the PLC system, a network of the PLC system;
Storing, by the PLC system, a result of performing a scan program and a task program in an output image area; And
The PLC system outputting a contact state to an output module,
The checking of the network of the PLC system may include connecting two redundant basic base modules and a plurality of redundant basic base modules and the plurality of redundant extended base modules constituting the PLC system. A network real-time diagnostic method of a redundant PLC system, characterized in that for checking the connection information of the cable.
5. The method of claim 4,
And the PLC system communicating with a peripheral device after the storing of the performance result in an output image area.
5. The method of claim 4,
If an abnormality or a failure occurs in the two redundant basic base modules, the plurality of extended base modules and the cable after the storing of the result in the output image area, the corresponding position is displayed on the network configuration diagram of the redundant PLC system. Network real-time diagnostic method of redundant PLC system to display on.

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