KR20080110216A - Simultaneous distributed control and independent control system - Google Patents

Abstract

A distributed control and an independent control system are provided to implement stable high-speed communications and control function and to implement stable communication faster than 100Mbps by replacing a Back Plane communications and control method. An Ethernet bus(310) adds a memory function for replacing existing back plane communications. A control board(#1~#N) includes a controller and an Ethernet module for Ethernet bus communications and control in each control board. The Ethernet module generated and assigns IP for dividing each control board adding the Ethernet module. A CPU control board(315) and an operating computer already stores a TCP protocol.

Description

Simultaneous Distributed Control and Independent Control System

1: is a general illustration of the structure of the DCS and PCS systems currently used.

2 is a schematic illustration of a simultaneous distributed control and independent control system using the Ethernet bus method in an increasingly large control system.

3 is an exemplary diagram of a more stable simultaneous distributed control and independent control system that drastically reduces communication and control steps without the concept of a master / slave control board.

4 is a schematic block diagram of respective control boards further including an Ethernet module 425 and a controller 405.

5 is a block diagram of a multifunction integrated control board 500 to clarify the advantages of the Ethernet Bus schemes 210 and 310.

FIG. 6A is a diagram illustrating a comparison between TCP / IP and an international standard OSI (Open System Interconnection) 7 Layer protocol and an implementation method of the present invention.

6B is a schematic illustration of a communication protocol domain implementation.

7 is a flowchart illustrating a communication and control sequence between an upper operating computer 305, a CPU control board 215, and lower control boards # 1 to # n, 220, and 315.

FIG. 8 is a diagram illustrating a result of each control board # 1 to #n, 220, and 315 performing a control command and transmitting a site input signal to a higher operating computer 305 or a CPU control board 215. Flowchart.

9 is a flow chart for the steps of creating and assigning an IP in the operating computer 305 or the CPU control board 215.

Large plant control equipment receives signals from as few as thousands of points to as many as tens of thousands of points, and also outputs control signals to these points to drive control objects (drive valves, motors, conveyors, relays ON / OFF, etc.) at the end site. Control.

As described above, a large-scale control facility called a DCS (Distribute Control System) or a PCS (Plant Control System) to receive a signal from thousands of points and output a control signal for driving a control object for thousands of points. Will be used.

The above DCS consists of a master CPU control board and a single slave control board (Analog Input / Output Board, Digital Input / Output Board, Communication Board, Power Supply Board, Special Input / Output) according to the usage environment. Board) is combined into one sub rack in the form of a master / slave, and the rack is mounted in one control cabinet by adding several sub racks below the master rack. In addition, the control cabinet is added to a number depending on the application field to perform a large plant control task.

The master / slave control concept above controls various types of slave control boards that perform the control object control and field signal input functions in the field where the master CPU control board is mounted in the same sub-rack directly through the back plane. It is made in the form of receiving a signal.

However, the backplane communication and control method of the large control system currently used (the processing speed of about 25 Mbps is used although it varies slightly depending on the CPU speed of the master CPU control board ). There are 10 master CPU control boards. The above slave control board is controlled through the back plane, and the control result and the site signal input data of the slave control board are transmitted to the same back plane, and the received data is determined and transmitted back to the upper operating computer. To perform.

When the master CPU control board processing speed and the communication speed due to the above reasons, a large amount of data is transmitted from each of the slave control board at the same time, or the slave control board is trying to transmit data to each other at the same time, or If the slave control board loses its function while occupying the communication bus for data transmission during data transmission, it causes unexpected system stoppage and malfunction.

The above problems are solved because all control signals and field input signals are communicated and controlled through the master CPU control board, and the speed of the control system, which is becoming larger and faster, is solved by the conventional back plane communication and control method. Because you can't. It is considered that as the automation progresses in the future, more problems as described above will occur.

1 is an exemplary diagram of a structure of a DCS generally used for better understanding.

105 shows a back plane in which a back plane and a control board are mounted in a pin type, and 110 shows a back plane in which a back plane and a control board are mounted in a slot type. The two types of back planes are generally used. 115 is an exemplary diagram of a control board that is commonly used, and 120 is a completed sub-rack in which a control board is mounted by adding a guide to the back plane. The plurality of sub-racks as described above are mounted in the control cabinet 125 according to the number of control targets, the control cabinet 125 also comprises a collection of as little as one to collect a DCS.

The control boards receive field signals from as many as eight points to as many as 64 points and also output control commands to the points.

In addition, the control boards mounted in the sub rack, such as the CPU control board of the sub rack performs communication and control through the back plane of the master / slave concept.

Master / slave is a CPU control board created in the sub rack acting as a master, and the rest of the control boards (Analog Input / Output Board, Digital Input / Output Board, Communication Board, Power Supply Board, Special Purpose) through the Back Plane. And I / O boards) and receive the phenomenon signals received from the respective control boards through the Back Plane, and transmit them to the upper operating computer. The remaining control boards act as slaves. In addition, the control system consisting of several sub racks is divided into a master sub rack and a slave sub rack, and the CPU control boards of all slave sub racks receive commands from the CPU control board of the master sub rack to provide time synchronization, control, and communication functions. Configured to perform.

In the back plane communication method of large control system (DCS, PCS), a multi-layer circuit board structure for signal transmission is required because a large amount of communication must be simultaneously performed for control signal transmission and field signal transmission between the master CPU control board and the slave control board. At the same time, dozens of units per second are configured to enable communication, but unexpected communication traffic and collisions cause system downtime, causing stability problems.

In addition, the large control system wastes a lot of time in the design considering the communication and control relationship between as few as hundreds of control boards and as many as thousands of control boards. In order to ensure the stability of communication between boards, after completion of the development and performance improvement period of 1 ~ 2 years, it is transferred to the buyer, which leads to a long development completion period (usually 5-7 years).

In addition, the VME (Versa Module Eurocard) bus method and the multi-bus method, which are most commonly used in the large control systems (DCS and PCS), also generally use the back plane communication method. Communication collision between CPU board and slave control board (Analog Input / Output board, Digital Input / Output board, communication board, Power supply board, special purpose I / O board) and communication between each control board occur so that it can be used for reliability and stabilization. There is a problem. The reason for the final delivery to the buyer after the commissioning period of 1 ~ 2 years after the establishment of the control equipment of the large plant is also as described above. This is because the case occurs.

Versa Module Eurocard ( VME ) bus, one of the most widely used backplanes , is a 32-bit bus and 64-bit bus specification developed by US motorola and Thomson CSF in France. It was proposed in 1981 as the Eurocard version of the VERSA bus, which was developed in 1979 as a system bus for small computers equipped with the system. Based on these modifications and extensions, in 1986 and 1987, the International Electrotechnical Commission (IEC) and the American Institute of Electrical and Electronics Engineers (IEEE) standardized to IEC 821 and IEEE 1014, respectively, to become international standards, resulting in more than 300 manufacturers worldwide. It produces a wide range of high-performance workstations that employ a bus as a standard bus, and is widely used in industrial, business, and military fields. Until now, it is used as the most stable and fast control and communication method in a large system, but as mentioned above, there is a problem in communication speed in the control system application which is gradually enlarged by using the back plane method.

Ethernet is a short-range packet-switched network developed by Xerox in the 1970s and is defined in the IEEE 802.3 standard. It is the technology currently used on the most popular LAN and transmits data at 10Mbps, 100Mbps, 1Gbps, and 10Gbps.

The Ethernet communication method uses CSMA / CD (Carries Sense Multiple Acccss / Collision Detection) method, which is a host (computer) to send a collision when a packet is transmitted from another host (computer) to a transmission medium. It's a high-speed, reliable communication network that gets noticed on the other side and tries to resend it for some time. The present invention further includes a buffering function in a separate memory in addition to the CSMA / CD function in order to implement more reliable communication stability, and relates to a method and system for preventing communication collision as well as duplication of transmission data and errors in advance. will be.

In addition, the present invention is meaningful as a method and system for extending the Ethernet method applied only to the field of information and communication (IT field) to factory automation, process automation in the general industrial field.

TCP / IP is a communication protocol for many hosts to form a single or multiple networks.

An application layer which is an application program phase used on the network host;

A transport layer including TCP, which guarantees the reliability of data transmission by generating the order and serial number (segment) sent to the transmitted packet data header of the communication and information to guarantee transmission;

IP (Internet Protocol) that generates several control fields according to the source address, destination address, outgoing data (control command, control command execution result, field input signal, etc.) and communication conditions for the actual packet data to be transmitted. Internet Layer including),

This layer is responsible for the actual transmission . It assigns the hardware address of the host (computer) on the network ( the unique number of the computer LAN (or Ethernet) card, usually 6 bytes from the LAN card manufacturer, usually called the Ethernet address or MAC address) . It consists of a physical layer that contains Ethernet that matches and matches each other with the IP.

In this LAN environment, the network is usually configured by using an Ethernet card in hardware. In Ethernet, a unique number is used for a 6-byte card by specifying an address. This assigned address, along with the IP address, allows the system to be found under the network. In other words, the packet data received from TCP / IP is made into an Ethernet packet and sent to the network.

An object of the present invention is a communication traffic between a master CPU control board and a slave control board or between each slave control board, which is a problem of the back plane communication and control method of the master / slave concept in a control system that is gradually being enlarged. And the simultaneous distributed control and independent control system of the Ethernet bus method for the development of a stable large-scale control system by preventing unexpected malfunctions and unexpected stops due to a collision and a collision.

In addition, an object of the present invention is to replace the backplane communication and control method to implement a stable high-speed communication and control function of a large control system Ethernet bus method that can implement a stable communication of 100Mbps or more communication and control bus between each control beam The present invention relates to a method and system development for using an Ethernet module in each of the control boards and utilizing TCP / IP independently in software.

In addition, an object of the present invention by using the Ethernet Bus method for the stable communication and control of 100Mbps or more to the master CPU control board to perform a stable communication and control function with the slave control card without being significantly affected by the CPU speed And a method and system for the same.

In addition, another object of the present invention is that each control board (Analog Input / Output board, Digital Input / Output board, communication board, power supply board, special purpose input / output board) is removed from the concept of master / slave control board More stable simultaneous distributed control and independence by performing field signal input and field control object control functions and dramatically reducing communication and control steps that independently transmit performance results and field input signals to the upper operating computer without going through the master CPU control board. A method and system for control system development.

In addition, an object of the present invention is that each control board (Analog Input / Output board, Digital Input / Output board, communication board, Power Supply board, special purpose input / output board) to perform the above simultaneous distributed control and independent control functions A method and system having an Ethernet communication function in each of the control boards.

In addition, an object of the present invention is to control the operation, operating environment, etc. of each slave control board through the back plane, and also receives the field signal obtained from the slave control board through the back plane to transmit to the upper operating computer The master CPU control board function, which plays a key role, is distributed to each slave control board (Analog Input / Output Board, Digital Input / Output Board, Communication Board, Power Supply Board, and Special Purpose Input / Output Board) . The present invention relates to a method and system for implementing the slave control board to perform a control and communication function independently of an upper host computer.

Furthermore, another object of the present invention is to implement an Ethernet communication function on the control board and a control function (CPU function), analog input / output function, digital input / It is a multifunctional integrated control board that integrates output function, communication function, power supply function, and special purpose input / output function.

1 is a general illustration of the configuration of the DCS, PCS system currently being used.

Reference numeral 105 shows a back plane in which a back plane and a control board are mounted in a pin type, and reference numeral 110 shows a back plane in which a back plane and a control board are mounted in a slot type. The two types of back planes are generally used. Reference numeral 115 is an illustration of the shape of a control board generally used, and (120) shows a sub rack of a completed form in which a control board is mounted by adding a guide to a back plane. The plurality of sub-racks as described above are mounted in the control cabinet 125 according to the number of control targets, the control cabinet 125 also comprises a collection of as little as one to collect a DCS.

2 is a communication between the master control board and the slave control board or each slave control board, which is a problem of the back plane communication and control method of the master / slave concept in a control system that is gradually being enlarged. This is a schematic illustration of simultaneous distributed control and independent control system using Ethernet bus method to solve traffic and collision problems.

The CPU control board 215 is provided with an IP (Internet Protocol, Unique Address) generation and assignment function for Ethernet communication, so that each control board (# 1 to #n, 220) performs mutual communication and control functions. Assign an IP address. The CPU control board 215 recognizes the control boards (# 1 ~ #n, 220) based on the unique IP assigned by them to perform communication and control. In addition, each of the control boards # 1 to #n, 220 includes an Ethernet module for external Ethernet communication as shown in FIG.

The CPU control board 215 transmits a control command to each of the control boards # 1 to #n and 220 through the Ethernet bus 210, and receives each control board to receive the control command. , 220 transmits the result of the control command and the field input signal to the CPU control board 215 through the Ethernet Bus 210. At this time, the Ethernet bus 210 stores only the transmission data exceeding the processing capacity of the CPU control board 215 in its own memory in consideration of communication traffic and the processing speed of the CPU control board 215, and then stores the CPU. A function of transmitting to the control board 215 is further provided to prevent a system stop due to CPU processing speed delay. In addition, the CPU control board 215 transmits control result data and field input signals of the respective control boards # 1 to #n, 220 to the upper operating computer 205 that oversees the entire control system by Ethernet. In addition, the control board (# 1 to #n, 220) is controlled by receiving a command from the operating computer 205.

3 is a control board (Analog Input / Output Board, Digital Input / Output Board, Communication Board, Power Supply Board, Special Purpose I / O Board, # 1 ～) that removes the concept of a Master / Slave Control Board. #n, 315) ) independently performs the field signal input and the field control object control function, and independently transmits the result and the field input signal to the upper operating computer 305 without passing through the CPU control board 215 and An illustration of a more stable simultaneous distributed control and independent control system that dramatically reduces the control phase.

Each control board (# 1 ～ # n, 315, Analog Input / Output Board, Digital Input / Output Board, Communication Board, Power Supply Board, Special Purpose I / O Board ) performs its own functions (Analog Input Board: Acquisition of analog signal on site with sampling rate and resolution commanded from the host computer, Analog Output board: 4 ~ 20mA control current or 0 ~ 10V control voltage output commanded from the host computer, Digital Input board: Digital contact signal on site Acquisition, Digital Output board: Direct contact with Ethernet module 425 and upper operating computer 305 for Ethernet Bus 310 communication as well as contact outputs such as field relays, communication boards, power supply boards, special purpose I / O boards) And a control unit (including an internal memory) 405 for communication and control. In this case, IP generation and allocation for distinguishing each of the control boards # 1 to #n and 315 performed by the CPU control board 215 in FIG. 2 are performed by the operating computer 305.

In addition, the control boards (# 1 ~ #n, 315) directly receives a control command from the upper operating computer 305, and until the separate modified control command is received from the operating computer (305) The control command is stored in the memory of the controller 405 to be performed independently.

The operating computer 305 is the respective control boards (# 1 to #n, 315) for distinguishing the control boards (# 1 to #n, 315) performed by the CPU control board 215 in FIG. Create and assign IP for IP address (In case of applying IP Address Class B method, it is possible to control and communicate with 65,000 control boards in theory .) That is, each control board (# 1 ~ # for Ethernet Bus (310) method). When the Ethernet module 425 function and the control function 405 are added to the n and 315, a large control system can be stably controlled by one operating computer 305.

FIG. 4 shows the control boards # 1 to # where the respective control boards # 1 to #n, 220 and 315 are used in the control system to use the Ethernet bus methods 210 and 310. FIG. The block diagrams of the respective control boards further include the Ethernet module 425 and the controller 405 for n, 220, and 315.

In the analog input board , the input unit 415 converts the analog input signal received at the field into a current signal of 4-20 mA (or 0-20 mA) or a 0-10 V (or 0-5 V) voltage signal to convert an AD (Analog To) signal. The AD converter 410, which is transmitted to a digital (hereinafter referred to as AD) converter 410 and receives an analog input signal of the field, has a sampling rate and resolution (resolution) previously set by the controller 405, and the input unit is selected to the selected input channel. The analog input signal transmitted from 415 is converted into a digital signal and then stored in the memory 420. The controller 405 transmits the field input signal (hereinafter, referred to as data) converted to digital in the memory 420 to the CPU control board 215 or the upper operating computer 305, and the data to be transmitted to the IP of the final destination. After generating a header including segment information for confirming whether or not to receive the data, the data is separated into predetermined packet units and transmitted to the Ethernet module 425 together with the header, and the Ethernet module 425 receiving the data is transmitted. ) Is transmitted to the CPU control board 215 or the upper operating computer 305 through the Ethernet bus (210, 310).

In the analog output board , the Ethernet module 425 receives a control command from the upper operating computer 305 or the CPU control board 215 through the Ethernet buses 210 and 310 and transmits the control command to the controller 405. The controller 405 analyzes the control command to determine whether to output the current or the voltage by controlling the current / voltage selector 435, and the control command value received from the Ethernet module 425 is DA ( The digital to analog (DA) converter 430 converts an actual field control object into an analog control value (current or voltage value) that can be controlled. The Ethernet module 425 has an IP address pre-assigned by the upper operating computer 305 or the CPU control board 215, and other control boards (# 1 to #N, 220, 315) through the IP address. It is distinguished from.

Signals for the normal operation of the site control object or the operating conditions such as alarms are usually transmitted in the form of digital signals (On / Off contact signals) . In the digital input board , the controller 405 receives the digital signal of the field control object from the input unit 450 and transmits it to the channel selector 455, and the channel selector 455 transmits a preset channel. Through the input digital signal to the Ethernet module 425. The controller 405 and the Ethernet module 425 can confirm whether the digital signal has been transmitted to the CPU control board 215 or the upper operating computer 305 and has received the IP of the destination to be transmitted and the data to be transmitted. After generating a header including information, the digital signal is separated into predetermined packet units and transmitted through the Ethernet buses 210 and 310 together with the header.

In the digital output board , the Ethernet module 425 receives a control command from the upper operating computer 305 or the CPU control board 215 via the Ethernet buses 210 and 310 to control the operating computer 305 or the CPU control board. The control command 405 is transmitted to the control unit 405 at the same time as the information about the completion of the control command reception is received. The control unit 405 analyzes the control command and the control command for which control object of the control object in the field by analyzing the control command to control the control object through the output unit 460 and the control result Transfer to the operating computer 305 or the CPU control board 215.

Although only the analog input / output boards and digital input / output boards, which are the core of the control system, have been described above, those with ordinary knowledge in this field are used for various special purposes applied to various control environments. It will be appreciated that the boards (counter boards, temperature input boards, etc.) are also configured in the same manner as above.

In addition, in the fields of information and communication, network and Internet, users of TCP / IP or Ethernet without knowing the configuration of TCP / IP or the address (or MAX) of Ethernet card (or LAN card) are not aware. This is because operating systems such as Windows and Linux are automatically controlled by the driver software for each Ethernet card for the convenience of non-experts.

However, the limitations of available memory in large industrial control systems (usually tens of Kbytes to tens of Mbytes are only a few thousandths or hundreds of typical OS capacities (hundreds of Mbytes to hundreds of Mbytes)). Unnecessary and reliability of many functions irrespective of control and communication are the top priority, so depending on the situation, the embedded OS (Industrial OS, Window CE, Embedded Linux, Vxwork with only necessary functions for the purpose of implementation) (The price is high-priced tens of thousands of won)) , but in general, the lower level of the Ethernet Bus (210, 310) does not use the above general OS, and most of the CPU (Central Process Unit) without the OS is used. All functions are implemented in a hardware way to minimize the amount of memory used by direct firmware programming of necessary functions.

The present invention is a drive software provided by the manufacturer according to the type of Ethernet card that the OS (Windows XP, Linux) which is generally used in the fields of information communication, network, and the Internet to secure the reliability of the industrial control system. Ethernet card (hardware) is not recognized and controlled automatically (generally using Windows or Linux OS is not possible due to memory capacity and also difficult to use in reliability) , each control board without using the OS ( The control unit 405 and the Ethernet module 425 are further provided in # 1 to #n, 220, and 315 so that the control unit 405 recognizes the Ethernet module 425 as a peripheral device, and is required for control and communication. / IP communication protocol and control functions for performing the functions of each control card (# 1 to #n, 220, 315) can be programmed directly to the controller in the form of firmware. It is characterized by. In other words, Ethernet can be used by selecting only the necessary parts without burdening the drive software.

In addition, according to the type and function of each control board (# 1 ~ #n, 220, 315) Firmware program including TCP / IP to be implemented in the control unit is different in the form and capacity of the Sourec Code, unexpected error When a general OS (Windows, Linux, embedded system) is used, it is dependent on the OS and the cause of the OS itself error is often unknown, but TCP / IP and control of functions required for the controller 405 as in the present invention. Firmaware program can directly understand all the functions and modify the functions. Therefore, immediate error can be taken and the capacity of the used program can be reduced by thousands to tens of thousands.

5 is to clarify the advantages of the Ethernet bus method (210, 310) applied to the simultaneous distributed control and independent control system to form a more stable large control system by eliminating communication traffic and collision as the purpose of the present invention; Is a block diagram of a multi-function integrated control board 500 for the purpose.

In Figure 5, one of the core of the present invention can be seen that the present invention is applied to a small, medium, large scale control system according to the implementation of the independent control and the implementation of the independent control function without extra effort.

2 is a conventional CPU control board 215 and the respective control boards (# 1 ~ #n, 220, Analog Input / Output board, Digital Input / Output board, communication board, power supply board, special Purpose I / O board ) This is a block diagram of communication and control method using Ethernet Bus 210 method, not back plane communication and control method. In the large control system configuration using the Ethernet Bus (210, 310) method, it prevents communication traffic or collision, and uses the stable communication protocol of TCP to secure higher speed communication and reliability than the existing back plane communication and control system. There is a problem in that the load concentrated on the CPU control board 215 cannot be solved, and distributed control is implemented because it does not deviate from the master / slave concept, but independent control in which each of the control boards independently performs control is completely implemented. I can't.

FIG. 5 of the present invention is inefficient in that control command execution results and field input signals of the respective control boards # 1 to #n and 220 are transmitted to the upper operating computer 205 via the CPU control board 215. the order to achieve the surface of each control board (# 1 ~ # n, 315 ) on the Ethernet module 425 comprises, as well as each of the control boards specific features (Analog Input board of (# 1 ~ # n, 315 ): the upper Acquisition of analog signal in the field by sampling rate and resolution commanded from the operating computer, Analog Output board: 4 ~ 20mA control current or 0 ~ 10V control voltage output commanded by the host computer, Digital Input board: Acquisition of digital contact signal on site , Digital output board: the relay of the field, such as the contact output, communication boards, Power Supply board, input and output boards of the special) integration, by further comprising a multi-function integration control board 500, add the control function the control board (# 1 Each of the 315 is required for control One will all function to implement such a small system to perform independently to a method and system for direct communication and control with higher operating computer 305. The

The controller # 1 505 controls the Ethernet module 540 to receive control commands from the upper operating computer 305 and control results or field input signals of the multi-function integrated control board 500 through the Ethernet module 540. Transfer to the operating computer 305. In addition, the contact signal of the field is input from the digital input module 520 and the digital output 525 and the analog output module 530 are controlled to output a control command to the control object in the field. Power for driving each module is supplied from the switching power module 545, and the analog port stored in the control unit # 2 (510) by controlling the dual port memory 515 to implement a physically perfect multi-function integrated control board 500. It receives the input signal and transmits it to the operating computer (305).

The analog input function requires a lot of control resources for signal characteristics and signal processing procedures. When the control unit # 1 505 controls the analog input module 535, the communication of the multi-function integrated control board 500 is slowed down as a whole, and functions of other modules (digital input / output, analog output, and Ethernet modules) are realized. Will be less efficient. In addition, when the Dual Port memory is full, if the memory management is not properly performed, there is a problem that the entire system is down (difficult to integrate the function).

Due to the above reason, the present invention has a control unit # 2 (510) further implemented to control exclusively for the analog input module 535, and the driving power is also configured to input the analog input module separately configured by the linear power module 550 The signal is constructed so that it is less affected by noise.

The control unit # 2 510 controls the analog input module 535 to receive the analog input signal of the field through the sampling rate, resolution, and input channel transmitted from the operating computer 305, and the dual port memory 515. To save to. The dual port memory 515 is a memory implemented to prevent memory conflicts that occur when two controllers share the same memory.

In addition, due to the difficulty in technical configuration such as the above-mentioned communication traffic and collision, the dual port memory only when the operating computer 305 takes data stored in the dual port memory 515 when necessary or when a specific condition occurs. In order to solve the existing inefficient method of uploading the data stored in the 515 to the upper operating computer 305 (high speed data communication is possible due to the Ethernet bus ), the field input acquired from the analog input module 535 in real time. And a function of transmitting a signal to the operating computer 305.

FIG. 6A is an exemplary diagram illustrating a comparison between TCP / IP, which is a communication protocol for implementing the Ethernet Bus (210, 310), and an international standard OSI (Open System Interconnection) 7 Layer protocol, and an implementation method of the present invention.

The TCP / IP protocol is often referred to as the application layer (605) on which the application programs (drive software, etc.) we use,

Transmission Layer (610, hereinafter referred to as Trans-mission Control Protocol, which guarantees reliable communication so that the other side can receive the information packet to the system to be arrived without error and without duplication. Performing a function of configuring the information packet including a serial number and information for confirming whether the information packet has been received ),

Network layer (615, IP (Internet Protocol) Layer ) that transmits datagram consisting of sender address, receive address, sender data, control field,

It consists of a data link and a physical layer (620, hereinafter referred to as Ethernet or MAC Layer, Physical Layer) which transmit packet information transferred from TCP / IP into a network packet again.

In addition, the Ethernet included in the data link and the physical layer performs a Carries Sense Multiple Access / Collision (CSMA / CD) function to avoid a collision when an information jacket is transmitted from another host to a host to which the information packet is to be sent. This function ensures stable host-to-host communication by sending back at certain time intervals.

As described above, the Ethernet bus method maintains the communication stability in TCP, and can be said to be a stable network communication method that prevents another communication collision in the last step, the data link and the physical layer Ethernet.

Open System Interconnection (OSI) is a communications protocol developed by the International Organization For Standardization (ISO) to provide a model of computer communication architecture and a standard framework for future protocols. Although the protocol is based on the OSI protocol, it does not comply with 100% accurate regulations depending on the application environment.

As shown in the diagram of FIG. 6A, TCP / IP, which is the most widely used communication protocol, is also based on the OSI, but does not follow 100% of the rules.

In brief, the Application 625, the Presentation 630, and the Session Layer 635 of the OSI perform the Application Layer (605) function of the TCP / IP, and the Session 635, Transport of the OSI. The layer 640 corresponds to the transport layer 610 of the TCP / IP, and the data link 650, the physical 655, and the network layer 645 are the data link and physical layer of the TCP / IP. It performs the function of (Physical Layer, 620). The Internet Layer 615 of the TCP / IP corresponds to the Network Layer 645 of the OSI. Hereinafter, referring to TCP / IP, referring to FIG. 6A, the data link and physical layer (Physica Layerl, 620) and the Internet layer (Internet Layer, 615) may be referred to as hardware areas 660. The area from the physical layer 620 to the transport layer 610 is divided into a hardware area 660 and a firmware area 660 that is intermediate between the software area and the software area. In addition, the software area 670 is divided from the firmware programmed to the Ethernet board to the application layer 605 except for the hardware of the Ethernet board. In describing the important role sharing based on the area division, the application layer (605) in the TCP / IP is an area for executing an application program desired by a user in a user space (680, user space) as the name (computer Drive software of peripheral devices such as graphics boards and Ethernet boards is added.) The remaining transport layer, Internet layer, data link and physical layer (Transport, Internet, Physical Layer, 610, 615, 620) are operating systems (OS). 675) is an area that is automatically controlled by the OS 675 according to the purpose of use even if the user is not conscious.

However, as described above, there is a problem in that the OS 675 and the drive software 680 cannot be used in the control system of the lower end of the Ethernet bus 210 or 310 in the general industrial field because of memory capacity and reliability issues.

FIG. 6B is a schematic diagram of an implementation of a communication protocol region for solving the above problem.

The difference from FIG. 6A is that the OS area 675 of FIG. 6A (which covers most areas of TCP / IP), which is one of the features of the present invention, is replaced by the new firmware area 685 and optimized communication independent of the OS 675. And the CPU control board 215, which is a lower level of the Ethernet bus 210, 310, and the respective control boards by implementing the control protocol directly as firmware and adding the functions of communication and control protocol generation and allocation to the user space area 690. (# 1 ~ # n, 220, 315) It is to control the realization of the function implementation, addition and modification in real time.

FIG. 7 illustrates communication and control sequences between the upper operating computer 305 and the CPU control board 215 and the lower control boards # 1 to #n, 220 and 315 on the Ethernet buses 210 and 310. FIG. Is a flowchart.

After selecting the control target control boards (# 1 to #n, 220, 315) from the operating computer 305 or the CPU control board 215 (705), and generates a control command (710). In order to implement a reliable communication, the generated control command is a serial number and information that can confirm whether it is transmitted to the other party in the TCP / IP layer (610, 615), sender address, address to receive, control command (the data to be sent) , Control Generate the packet data consisting of the field (715), the configured packet data is the MAC (620, Media Access Control Address) Address generation step (layer including Ethernet) physical MAC address to actually transmit the logical IP address (620, Ethernet Address) is converted (720) and transmitted to the network (725). The control boards # 1 to #n, 220, and 315 that have received the control command transmit 730 to the operating computer 305 or the CPU control board 215 that the control command has been received. 735 also prevents the operating computer 305 or the CPU control board 215 from retransmitting the same control command. In addition, the control boards # 1 to #n, 220, and 315 perform the control command (740), and then transmit a control command execution result and a site input signal to the operating computer 305 or the CPU control board 215. Transmit (745). If the control board (# 1 ~ #n, 220, 315) to receive the control command in the step 725 of transmitting the control command is receiving a previous command or another control card (# 1 ~ #n, 220 and 315 are in communication (755), the MAC address generation step (620, Ethernet Address) after a certain interval in order to prevent communication collisions to be retransmitted (725).

FIG. 8 shows the results of the control commands performed by the respective control boards # 1 to #n, 220, and 315 on the Ethernet buses 210 and 310, and displays the site input signals as the upper operating computer 305 or It is a flow chart for the step of transmitting to the CPU control board (215).

The operating computer 305 receives the data of the control result and the field input signal from the respective control boards # 1 to #n, 220, and 315 performing the control command through the Ethernet bus 210 and 310 (805). ) And the CPU control board 215 are MAC addresses (620) in the data packet header of the received control result and field input signal in the data link and physical layer 620, which is the lowest level of the Ethernet Bus 210, 310 structure. , Ethernet Address) and MAC addresses (620 or Ethernet addresses) of the Ethernet modules 425 and 540 of the operating computer 305 and the CPU control board 215 match. If it does not match, the data is ignored (810). If there is a match, the data reception completion is transmitted to each of the control boards (# 1 to #n, 220, 315) that transmitted the data (815). The data is transmitted to the Internet layer 615 (IP layer) (820). The header IP of the transmitted data packet is compared with the IPs of the operating computer 305 and the CPU control board 215 in the Internet layer 615, and if not matched, it is ignored (825). If matched (830), data is separated from the received data packet and transmitted to the transport layer (610, transport layer or TCP layer) (835). In the transport layer (610, transport layer or TCP layer) to determine the application layer (605, Application Layer) that the transmitted data is to be transmitted to the final application of the operating computer 305 and the CPU control board 215 The control command execution result and the field input signal are transmitted.

FIG. 9 is a flowchart of a step of generating and assigning an IP in the operating computer 305 or the CPU control board 215.

The operating computer 305 or the CPU control board 215 retrieves the quantity of each control board (# 1 to #n, 220, 315) used for the entire control system. (905) Used for the entire control system described above. When the quantity check for each of the control boards (# 1 to #n, 220, 315) is completed, the operating computer (305) or the CPU control board 215 is the identified control board (# 1 to #n, 220 and 315 are generated as many IPs and assigned to the respective control boards # 1 to #n, 220 and 315 through Ethernet buses 210 and 310. (910) The angles to be used in the entire control system When the IP allocation to the control boards # 1 to #n, 220, and 315 is completed (910), the operating computer 305 or the CPU control board 215 tests whether the IP is correctly generated and assigned. 915, for example, transmitting / receiving a ping command or preset check data for network confirmation) the operating computer 305 or the CPU control board 215 of the control system If IP generation and allocation for the control boards (# 1 to #n, 220, 315) are successful (920), the standby state is ready for control (930), and if the IP generation and allocation have failed In case (925), the total control board quantity is searched again (905), and the control board (# 1 to #n, 220, 315) which is not in communication with the operating computer (305) or the CPU control board (215) is searched again for IP Create, assign (910) and test (915).

According to the present invention, in the development of a large control system, communication traffic and communication collisions between control boards can be prevented in advance, thereby making it possible to construct a large control system with high speed and reliability.

In addition, the present invention can significantly reduce the time spent in the design considering the communication and control relationship between the control beams in the development of a large control system can reduce the overall control system development cost.

In addition, the present invention reduces the control system construction cost and high-speed reliable control system by applying the Ethernet communication method that is applied only in the field of information communication (IT field) to the communication and control fields of factory automation and process automation in the general industrial field Can be built.

In addition, the present invention has a feature that can be utilized in the field of information and communication such as production automation by performing independent control functions as well as distributed control.

In addition, the present invention builds standardization of the hardware by integrating the control boards, which are the core elements of the control system, into a multifunctional integrated control board, and adds not only distributed control but also independent control concept in the overall control system. Secure flexibility in constructing small, medium, and large control systems according to the number of use of the integrated control board (Small control system: use the operation computer in one multi-function integrated control board, medium control system: use the operation computer in multiple multi-function integrated control board) , Large control system: a multi-functional integrated control board can be used for dozens to millions of operating computers) , and it is convenient to build a small control system constructed as needed in medium or large size without any extra effort. And maintenance costs can also be significantly reduced.

Claims (10)

In a high speed communication and control system with high reliability and stability, a communication and control system using a TCP / IP communication method and an Ethernet method for realizing the physical implementation of the TCP / IP, Ethernet Bus with added memory function that replaces existing Back Plane communication and control method; And A control board further comprising an Ethernet module and a control unit in each control board for the Ethernet bus communication and control; And It further comprises a CPU control board and an operating computer for generating and assigning an IP to distinguish each of the control boards to which the Ethernet module has been added for the Ethernet bus communication and control, and pre-stored its own independent TCP protocol. Simultaneous distributed control and independent control system. According to claim 1, wherein the control board, An Ethernet module is provided on each control board for distributed control using an Ethernet bus, and a separate distributed control and independent control system is further provided with a control unit for independent control. The method of claim 1 wherein the TCP / IP communication protocol, High speed and reliable TCP / IP communication and control using the Ethernet Bus method between the CPU control board and the control board or between the control boards or between the control board (multifunctional integrated control board) and the upper operating computer without using an operating system ( OS ) . For the simultaneous distributed control and independent control system further comprises a storage medium for replacing the OS (675, Operating System) area of the TCP / IP layer with a firmware area for the According to claim 1, wherein the control unit and the operating computer of the control board, Further comprising a storage medium to communicate and control with the control board by coding a predetermined TCP / IP command during the control and communication program source coding operation in the application layer of the upper operating computer without a separate drive software Simultaneous distributed control and independent control system According to claim 1, wherein the firmware area of the TCP / IP, Simultaneous distributed control and independent control system, characterized in that the control unit 405, 505, 510 firmware of the control board previously stored in the upper operating computer further includes a function to directly modify in real time through the Ethernet bus Each control board (Analog Input / Output Board, Digital Input / Output Board, Communication Board, Power Supply Board, Special Purpose I / O Board) removes the concept of Master / Slave Control Board independently from the field signal input and field control object. Simultaneous distributed control and independent control system that performs the control function and transmits the result and field input signal to the upper operating computer independently through the Ethernet bus without going through the CPU control board. Ethernet Bus with added memory function that replaces existing Back Plane communication and control method; And Equipped with an Ethernet module on each control board for the Ethernet bus communication and control, and to remove the CPU control board to enhance the independent control function of each control board and control the control unit (405, 505, 501) of each control board A multi-functional integrated control board further comprising a function of each control board (Analog Input / Output, Digital Input / Output, communication, power supply, special purpose input / output function) to further clarify the independent control function; And An operating computer for generating and assigning an IP to distinguish the respective control boards to which an Ethernet module is added for the Ethernet bus communication and control ; And Simultaneous distributed control and independent control system, characterized in that further comprising a storage medium that pre-stores its own independent TCP protocol. The method of claim 6, Add Ethernet module to certain control boards and double the unique function of each control board ( Analog Input Board: Acquire local analog signal with Sampling Rate and Resolution commanded from the host computer, Analog Output Board: Command from the host computer a field such as a relay contact output, communication boards, Power Supply board, input and output boards of the special): a 4 ~ 20mA control current or 0 ~ 10V control voltage output, digital input board: obtaining a digital contact signal of a scene, digital output board Multi-function integrated control board, characterized in that the multi-functional integrated control board to integrate and add a control function to be a small system that performs all functions necessary for control independently and individually, and directly communicates and controls with the upper operating computer. In the simultaneous distributed control and independent control method using the Ethernet bus method that replaces the back plane communication and control method of the master / slave concept in the control system that is becoming larger and larger, The CPU control board or operating computer searching for the quantity of control boards to be used for the entire control system; And Performing IP generation and allocation to distinguish each of the control boards in the future according to the number of the control boards found; And Testing whether an IP assigned to each control board is normal after generating and assigning an IP to the control board to be used in the entire control system; And Recognizing and tying each control board as a network of the entire control system; simultaneous distributed control and independent control method comprising a The method and method of claim 8, wherein the CPU control board and the operating computer transmit control commands to each control board. Selecting a control target control board in the application layer and generating a control command; And Generating a TCP header file, generating an IP address, and converting a protocol to accurately transmit the control command to a corresponding control board; And Converting the control command into a final MAC (Ethernet Address); And Receiving a message about completion of receiving the transmitted control command of the control card receiving the control command after transmitting the control command; And And receiving a control command execution result and a field input signal transmitted by the control board receiving the control command. The method of claim 8, wherein the CPU control board and the operation computer receive the execution result and the field input signal after performing the control command of each control board, Comparing the MAC address and IP of the control command execution result and the field input signal data packet received by the CPU control board and the operating computer from each control board; and Transmitting the received data to a TCP layer when the result of performing the received control command and the MAX address and IP of the field input signal data packet match; and The application layer which determines the application layer to which the received data is to be transmitted in the TCP layer and transmits it to the application program of the corresponding application layer and transmits the control command is controlled by the application program. And finally delivering the result of performing the control command transmitted by the card and the field input signal.

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