WO2018179250A1 - プレイバックシミュレーション試験システム - Google Patents
プレイバックシミュレーション試験システム Download PDFInfo
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- WO2018179250A1 WO2018179250A1 PCT/JP2017/013318 JP2017013318W WO2018179250A1 WO 2018179250 A1 WO2018179250 A1 WO 2018179250A1 JP 2017013318 W JP2017013318 W JP 2017013318W WO 2018179250 A1 WO2018179250 A1 WO 2018179250A1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0256—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/23—Pc programming
- G05B2219/23445—Real time simulation
Definitions
- the present invention relates to a playback simulation test system.
- a parallel controller has been carried out in which a new controller is connected to the existing plant equipment in the field, and the plant equipment is operated in parallel by the control by the existing controller and the control by the new controller.
- the pararun test is a test in which a control signal output by the control function of the newly installed controller and a control signal output by the control function of the existing controller are compared and checked and adjusted.
- Patent Document 1 and Patent Document 2 are known as simulators for confirming the operation of the newly installed controller instead of the local pararun test.
- control system network data collected in time series from the inside of an existing controller is fetched as time series data, and this captured control system network data is passed through a shared memory to a virtual controller having software that simulates a new controller.
- a playback simulator apparatus is disclosed that performs simulation by executing software of a virtual controller.
- Patent Document 2 discloses an existing controller connected to an existing control network, a data collection device that collects signal data transmitted to the existing control network, and data that accumulates signal data collected by the data collection device. There is disclosed a playback simulator device comprising storage means and a data playback device that plays back and outputs signal data stored in the data storage means to a test control system network.
- the playback simulator device disclosed in Patent Document 1 reproduces all the functions of a new controller on a computer in a simulated manner by software, and checks the operation of the new controller in this simulated environment.
- the playback simulator apparatus disclosed in Patent Document 1 reproduces all the signals that simulate the functions of the newly installed controller, the operation state of the local plant equipment, and the control state of the equipment on the computer. There is a problem that the test has a large cost and duration. In addition, there is a possibility that the simulated environment produced by software and the actual environment of the local plant equipment may be different from each other, and there is a problem from the viewpoint of ensuring equivalence with the local parallax verification environment.
- the signal data transmitted to the existing control network is collected and stored, and the stored signal data is reproduced and output to the test control network.
- a simulation test environment equivalent to the local parallax verification environment can be easily constructed.
- the present invention has been made to solve the above-described problems, and accumulates signal data transmitted to each of a plurality of existing networks in a state in which the order is guaranteed and reproduces it on a test network.
- An object of the present invention is to provide a playback simulation test system that can output and realize a simulator test environment equivalent to a parallax verification environment in the field.
- the playback simulation test system according to the embodiment of the present invention is configured as follows.
- the playback simulation test system reproduces and outputs a data collecting device, a data accumulating device for accumulating signals collected by the data collecting device, and a signal accumulated in the data accumulating device connected to the test network to the test network.
- a data reproducing device reproduces and outputs a data collecting device, a data accumulating device for accumulating signals collected by the data collecting device, and a signal accumulated in the data accumulating device connected to the test network to the test network.
- the data collection device controls the first existing network to which the first existing controller that outputs a control signal for controlling the first component device of the existing plant facility is connected, and the second component device of the existing plant facility. To the second existing network to which the second existing controller that outputs the control signal is connected.
- the data collection device is connected to x (x ⁇ 2) or more existing networks.
- the data collection device includes a first receiving unit, a second receiving unit, a count-up unit, and a data synchronization processing unit.
- the data collection device When the data collection device is connected to x existing networks, the data collection device includes x reception units.
- the first receiving unit receives first signal data including a control signal transmitted to the first existing network.
- the second receiving unit receives second signal data including a control signal transmitted to the second existing network.
- the count-up unit counts up the unique collection number at regular time intervals.
- Each collection number is a unique sequential number within the data collection device.
- the passage of a certain time is measured by an internal clock of the data processing device.
- the data synchronization processing unit stores the collection number at the time of reception in the data storage device in association with the first signal data when the first reception unit receives the first signal data. Further, when the second receiver receives the second signal data, the data synchronization processor stores the collection number at the time of reception in association with the second signal data and stores it in the data storage device.
- the data reproduction device includes a count-up unit and a data reproduction output unit.
- the count-up unit counts up a unique reproduction number corresponding to the collection number at regular time intervals.
- the data reproduction / output unit sequentially acquires signal data associated with the reproduction number from the data storage device, and reproduces and outputs the signal data to the test network.
- the data processing apparatus since the data processing apparatus includes a plurality of receiving units, it can receive signal data from each of a plurality of existing networks.
- the data processing apparatus associates the collection number at the time of reception with the signal data. Therefore, regardless of the processing time after reception, the reception order of the signal data received from each of the plurality of existing networks (for example, the signal data received from the first existing network and the signal data received from the second existing network)
- the signal data can be stored in the data storage device in a state in which the reception order is guaranteed.
- FIG. 1 is a block diagram illustrating a configuration when data is collected in the playback simulation test system according to Embodiment 1 of the present invention.
- FIG. 2 is a block diagram illustrating a configuration when data is reproduced and compared in the playback simulation test system according to the first embodiment of the present invention.
- the playback simulation test system has a data collection device 30 connected to both the first existing network 10 and the second existing network 20, and reproduces and outputs the signal data collected by the data collection device 30 to the test network 40. To do.
- the first existing network 10 is a control network for exchanging signals necessary for operation control and the like between various devices constituting the plant facility in the existing plant facility.
- the first existing network 10 is configured by a LAN (Local Area Network) using, for example, TCP / IP.
- the first existing network 10 is connected to the component equipment of the existing plant equipment so as to be able to communicate with each other.
- the constituent devices are the existing high-order computer 11, the existing controller 12, the inverter 13, the sensor / actuator 14, and the field device 15.
- parameter setting values used for control by the existing controller 12 are set in advance for each process performed in the existing plant equipment. Then, the existing high-order computer 11 transmits parameter setting values used in the process to the existing controller 12 via the first existing network 10 at an appropriate time such as the start of each process. Moreover, the time schedule of the process implemented in the existing plant equipment is also preset in the existing high-order computer 11. The existing host computer 11 outputs a timing signal for synchronizing the operation timing of each plant component device to the first existing network 10 at the start / end of each process.
- the existing controller 12 (first existing controller) outputs a control signal for electrically controlling the operation of the first component device while maintaining an appropriate temporal relationship.
- the first component device is the inverter 13, the sensor / actuator 14, or the field device 15.
- the existing controller 12 includes, for example, a programmable logic controller (Programmable
- the existing controller 12 calculates a control signal to be output based on the parameter setting signal and timing signal output from the existing host computer 11 and the feedback signal output from the sensor / actuator 14 and the field device 15, A control signal is transmitted to a necessary device via the first existing network 10.
- the inverter 13 supplies, for example, variable voltage variable frequency power to an electric motor or the like that drives the plant equipment.
- the sensor / actuator 14 is a sensor that measures a physical quantity necessary for plant control or an actuator that drives plant equipment.
- the field device 15 is a collective term for the components of the plant equipment, almost the same as the sensor / actuator 14, and includes, for example, a pressure gauge, a flow meter, a valve, and the like.
- These plant component devices operate according to the control signal from the existing controller 12, and the measurement result by the sensor / actuator 14 and the field device 15 is output to the first existing network 10 as a feedback signal.
- the playback simulation test system includes a second existing network 20. Similar to the first existing network 10, the second existing network 20 is a control system network for exchanging signals necessary for operation control and the like between various devices constituting the plant facility in the existing plant facility. is there.
- the second existing network 20 is connected to the components of the existing plant equipment so as to be able to communicate with each other.
- the constituent devices are the existing host computer 21, the existing controller 22 (second existing controller), the inverter 23, the sensor / actuator 24, and the field device 25.
- the existing host computer 21, the existing controller 22, the inverter 23, the sensor / actuator 24, and the field device 25 are the existing host computer 11, the existing controller 12, and the inverter connected to the first existing network 10, respectively.
- the sensor / actuator 14 and the field device 15 have the same configuration, and a description thereof will be omitted. Note that a configuration in which predetermined components are further added may be used, or a configuration without some components may be used.
- the data collection device 30 is configured as follows.
- the data collection device 30 is communicably connected to both the first existing network 10 and the second existing network 20.
- the data collection device 30 collects various signal data transmitted on the first existing network 10 and various signal data transmitted on the second existing network 20.
- the data collection device 30 includes a first reception unit 31, a second reception unit 32, a count-up unit 33, a data synchronization processing unit 34, a collection device screen display unit 35, and a collection device data compression / decompression processing unit 36. Furthermore, the data collection device 30 is connected to a data accumulation device 37 (storage) that accumulates signals collected in the data collection device 30.
- the first reception unit 31 receives first signal data including a control signal transmitted to the first existing network 10.
- the second receiving unit 32 receives second signal data including a control signal transmitted to the second existing network 20.
- the count-up unit 33 counts up the unique collection number at regular time intervals.
- Each “collection number” is a unique consecutive number in the data collection device 30.
- the data collection device 30 includes an internal clock, and the passage of “certain time” is measured by the internal clock.
- the “certain time interval” is set according to the performance of the data collection device 30, but is preferably a short time interval (for example, less than several milliseconds).
- the data synchronization processor 34 associates the collection number at the time of reception with the first signal data and accumulates it in the data storage device 37. Further, when the second receiving unit 32 receives the second signal data, the data synchronization processing unit 34 stores the collection number at the time of reception in association with the second signal data and stores it in the data storage device 37.
- the collection device screen display unit 35 provides a GUI (Graphic User Interface) to the operator of the data collection device 30.
- GUI Graphic User Interface
- the operator of the data collection device 30 can confirm the progress of signal data accumulation in the data collection device 30 and the contents of the data by displaying on the collection device screen display unit 35.
- the data collection device 30 includes an input device (for example, a keyboard, a mouse, a touch panel, etc.) that receives input from the operator.
- the operator operates the input device to change the display content of the collection device screen display unit 35 or to confirm the display content of the playback device screen display unit 53 while accumulating signals in the data collection device 30.
- Data conditions can be set arbitrarily.
- the collection device data compression / decompression processor 36 is used to perform data compression processing on the stored signal data when storing the signal data in the data storage device 37 in order to effectively utilize the storage capacity of the data storage device 37. It is done. Conversely, when the signal data stored in the data storage device 37 is extracted, the collecting device data compression / decompression processing unit 36 performs a data decompression (data decompression) process to restore the original signal data. .
- FIG. 3 is a time-series diagram illustrating an example of data processing in the data collection device 30 according to Embodiment 1 of the present invention.
- a line 70 is a time axis of an internal clock provided in the data collection device 30.
- Line 71 represents a unique collection number whose number is counted up at regular time intervals.
- the line 77 represents the timing (timing 72 to 76) at which the data collection device 30 received the first signal data transmitted to the first existing network 10.
- the line 78 represents the timing (timing 79, 80) at which the data collection device 30 receives the second signal data transmitted to the second existing network 20.
- the data synchronization processing unit 34 associates the collection number (1) at the time of reception with the first signal data, and sends it to the data storage device 37. accumulate.
- the data synchronization processing unit 34 associates the collection number (3) at the time of reception with the second signal data, and the data storage device 37. To accumulate.
- the data synchronization processing unit 34 associates the collection number (6) at the time of reception with the first signal data, and sends it to the data storage device 37. accumulate.
- the data synchronization processing unit 34 repeats the same processing, thereby associating each signal data with a unique collection number and storing it in the data storage device 37. .
- the data collection device 30 can receive signal data from each of a plurality of existing networks, and associates the collection number at the time of reception with the signal data. Therefore, regardless of the processing time after reception, the reception order of the signal data received from each of the plurality of existing networks (for example, the signal data received from the first existing network and the signal data received from the second existing network)
- the signal data can be stored in the data storage device in a state in which the reception order), the time interval of the signal data, and the content of the signal data are guaranteed.
- each signal data collected from different networks can be synchronized and accurately reproduced on the test network 40 by the data reproducing device 50 described later.
- the data storage device 37 receives the signal data (parameter setting signal timing signal, control signal, and filter signal) collected by the data collection device 30, the order in which these signal data were received by the data collection device 30, and the time of the signal data. Accumulation is performed while accurately reflecting the interval and the contents of the signal data.
- the components of the data table of the data storage device 37 include at least a collection number, a signal type of signal data, and a signal value.
- the accumulation period and signal type of the signal data accumulated in the data accumulation device 37 can be arbitrarily set using the collection device screen display unit 35 as described above.
- the accumulation period can be automatically collected for each event (each process) in the target plant facility.
- the start and end of each event (each process) can be automatically determined by checking the contents of the timing signal transmitted to the existing network.
- a timing schedule for the collection period may be set in advance, or simply (for example, 2) when necessary and sufficient data can be obtained (if the storage capacity of the data storage device 37 is sufficient).
- the collection may be continued for about a week).
- the test network 40 is a control network newly established for testing for exchanging necessary signals between various devices constituting a test environment for the new controller 42 described later.
- the test network 40 is also configured by a LAN (Local Area Network) using, for example, TCP / IP.
- test network 40 is prepared separately from the first existing network 10 and the second existing network 20.
- the test network 40 is typically a control system network installed in the company or the like where the test is performed, but may be a control system network separate from the first existing network 10 and the second existing network 20. For example, it is not limited to an in-house LAN.
- the test network 40 is communicably connected to a data reproduction device 50 for reproducing the transmission state of the signal accumulated in the data accumulation device 37 by the data collection device 30 in the test environment (test network 40).
- the data reproduction device 50 includes a count-up unit 51, a data reproduction output unit 52, a reproduction device screen display unit 53, and a reproduction device data decompression processing unit 54. Further, the data reproduction device 50 is connected to the data storage device 37.
- the count-up unit 51 counts up the reproduction number corresponding to the collection number used in the data collection device 30 in FIG. 1 at regular time intervals.
- Each “reproduction number” is a unique consecutive number in the data reproduction apparatus 50.
- the data reproducing device 50 includes an internal clock, and the passage of “certain time” is measured by the internal clock.
- the “certain time interval” is the same as the value set by the count-up unit 33 of the data collection device 30.
- the data reproduction output unit 52 sequentially acquires signal data (first signal data, second signal data) associated with the reproduction number from the data storage device 37, and reproduces and outputs the signal data to the test network 40. Specifically, the data reproduction output unit 52 searches the data storage device 37 using the reproduction number (i) as a key. When there is signal data (first signal data and / or second signal data) associated with the reproduction number (i), the signal data is reproduced and output to the test network 40. Thereafter, the count-up unit 51 counts up the reproduction number (i) to make the reproduction number (i + 1). The data reproduction / output unit 52 repeats the same processing for the reproduction number (i + 1) and thereafter.
- each signal data collected from different networks can be synchronized and accurately reproduced on the test network 40.
- the playback device screen display unit 53 provides a GUI to the operator of the data playback device 50.
- the operator of the data reproducing device 50 can confirm the contents of the data stored in the data storage device 37 and the progress of the reproduction output of the signal data in the data reproducing device 50 by displaying on the reproducing device screen display unit 53.
- the data reproducing device 50 includes an input device that receives input from the operator. By operating this input device, the operator changes the display content of the playback device screen display unit 53 or confirms the display content of the playback device screen display unit 53 while checking the playback content of the data playback device 50. It is possible to arbitrarily set signal data conditions.
- the playback device data decompression processing unit 54 is used to perform data decompression (data decompression) processing and restore the original signal data when data stored in the data storage device 37 is extracted.
- the data storage device 37 is the one connected to the data collection device 30 in FIG.
- the data storage device 37 is detachably provided on the data collection device 30. After data collection, the data storage device 37 detached from the data collection device 30 is used by being detachably attached to the data reproduction device 50.
- the data playback output unit 52 of the data playback device 50 receives the signal data stored in the data storage device 37 (after being restored by the playback device data decompression processing unit 54 as necessary) the reception order, time interval, In addition, the values are output to the test network 40 in a state where the values are accurately maintained.
- the data reproducing device 50 reproduces the signal transmission state in the first existing network 10 and the second existing network 20 in the test network 40. In other words, when paying attention to the output signal, the data reproducing device 50 is connected to the connecting portion of the data reproducing device 50 with the first existing network component device group and the second existing network component device group. Behaves as if
- test network 40 is further communicably connected to a new upper computer 41 and a new controller 42.
- the new high-order computer 41 corresponds to the existing high-order computer 11 (21) in FIG. 1, and is used when adding or replacing the high-order computer with the update to the new controller 42 described later.
- the same host computer 11 (21) as the existing host computer 11 may be used as the new host computer 41.
- the new controller 42 corresponds to the existing controller 12 (22) in FIG. 1, and is a device constituting the plant equipment to be controlled (the inverter 13 (23) after the new controller 42 is newly installed or replaced in the existing plant). , A control signal is output to the sensor / actuator 14 (24) and the field device 15 (25)), and the operation of these devices is electrically controlled while maintaining an appropriate mutual relationship in time. Is.
- the new controller 42 is, for example, a PLC like the existing controller 12 (22).
- the new controller 42 outputs based on the parameter setting signal and timing signal output from the new upper computer 41 and the signal data (parameter setting signal, timing signal and feedback signal) reproduced and output from the data reproducing device 50.
- the power control signal is calculated, and the calculated control signal is output to the test network 40.
- the test network 40 is communicably connected to a data comparison / collation device 60 for comparing and collating the control signal output from the new controller 42 with the signal reproduced / output from the data reproduction device 50.
- the data comparison / collation device 60 includes a comparison / collation device signal processing unit 61, a comparison / collation device screen display unit 62, a comparison / collation device data compression / decompression processing unit 63, a data comparison / collation processing unit 64, and a data storage unit 65.
- the comparison / verification device signal processing unit 61 performs reception processing of the signal transmitted to the test network 40.
- the comparison / collation device screen display unit 62 provides a GUI to the operator of the data comparison / collation device 60.
- the operator of the data comparison / collation device 60 can confirm the comparison / collation result of the signal data by displaying the comparison / collation device screen display unit 62.
- the data comparison / collation device 60 includes an input device that receives input from the operator. By operating this input device, the operator changes the display content of the comparison / collation device screen display unit 62 or confirms the display content of the comparison / collation device screen display unit 62 while using the data comparison / collation device 60. It is possible to arbitrarily set conditions for signal data to be compared and verified.
- the comparison collation device data compression / decompression processing unit 63 receives the data received by the comparison collation device signal processing unit 61 and the comparison collation result data in the data comparison collation processing unit 64 to be described later when storing the data in the data storage unit 65. This is for performing compression processing. Conversely, when data is extracted from the data storage unit 65, data decompression (data decompression) processing is performed to restore the original data.
- the data comparison / matching processing unit 64 is a control signal (reproduction local control signal) output from the data reproduction device 50.
- the control signal (new control signal) output from the new controller 42 is compared and collated. In this comparison and collation, other signal data (parameter setting signal, timing signal and feedback signal) may be referred to as necessary.
- the comparison / collation result by the data comparison / collation processing unit 64 is displayed on the comparison / collation device screen display unit 62 in, for example, a graph format or a comparison table format. Further, the data comparison / collation processing unit 64 may have a function of outputting (exporting) the comparison / collation result and the received signal data to the outside in, for example, a CSV format.
- the data collection device 30 and the data reproduction device 50 may be provided with the data external output function in the CSV format or the like.
- the target period and the target data type can be arbitrarily set in the same manner as the collection target in the data collection device 30 and the reproduction target in the data reproduction device 50.
- the data storage unit 65 is for storing the signal received by the comparison / collation device signal processing unit 61 and the comparison / collation result data in the data comparison / collation processing unit 64.
- the new control signal output from the new controller in the simulation test environment is compared with the local control signal in the existing plant environment, and the new control output from the new controller 42 is obtained. It can be confirmed whether there is any abnormality such as a signal loss.
- the signal data transmitted to each of a plurality of existing networks is accumulated in a state in which the order is guaranteed, and this is stored in the test network 40. Can be reproduced and output, and a simulator test environment equivalent to the local parallax verification environment can be realized. Therefore, the operation check and adjustment of the new controller 42 can be performed accurately in the replacement and update work of the controller in the existing plant equipment.
- the host computer (the existing host computer 11 (21), the new host computer 41) is installed above the controller.
- the host computer May not be installed.
- the data collection device 30 collects signal data from the two existing control networks, the first existing network 10 and the second existing network 20.
- the number of existing control system networks may be three or more.
- the data collection device 30 includes x reception units, and when each reception unit receives signal data, the collection number at the time of reception is associated with the signal data. Then, the data may be stored in the data storage device 37.
- system of the first embodiment described above may be configured without the collection device data compression / decompression processing unit 36, the playback device data decompression processing unit 54, and the comparison verification device data compression / decompression processing unit 63.
- FIG. 4 is a conceptual diagram illustrating a hardware configuration example of a processing circuit included in the data collection device 30, the data reproduction device 50, and the data comparison / collation device 60 described above.
- Each unit in these devices represents a part of the function, and each function is realized by a processing circuit.
- the processing circuit includes at least one processor 91 and at least one memory 92.
- the processing circuit comprises at least one dedicated hardware 93.
- each function is realized by software, firmware, or a combination of software and firmware. At least one of software and firmware is described as a program. At least one of software and firmware is stored in the memory 92.
- the processor 91 implements each function by reading and executing the program stored in the memory 92.
- the processing circuit When the processing circuit includes dedicated hardware 93, the processing circuit is, for example, a single circuit, a composite circuit, a programmed processor, or a combination thereof. Each function is realized by a processing circuit.
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Abstract
Description
<データの収集>
図1は、本発明の実施の形態1に係るプレイバックシミュレーション試験システムにおいてデータを収集する際の構成を説明するブロック図である。図2は、本発明の実施の形態1に係るプレイバックシミュレーション試験システムにおいてデータを再生及び比較照合する際の構成を説明するブロック図である。プレイバックシミュレーション試験システムは、第1既設ネットワーク10および第2既設ネットワーク20の両方に接続されたデータ収集装置30を有し、データ収集装置30に収集された信号データを試験用ネットワーク40へ再生出力する。
図1を参照しながら、プレイバックシミュレーション試験システムにおいてデータを収集する際の構成を説明する。第1既設ネットワーク10は、既設のプラント設備において当該プラント設備を構成する各種の機器の間で、動作制御等に必要な信号をやり取りするための制御系ネットワークである。第1既設ネットワーク10は、例えばTCP/IP等を利用したLAN(Local Area Network)から構成されている。
プレイバックシミュレーション試験システムは、第2既設ネットワーク20を備える。第2既設ネットワーク20は、第1既設ネットワーク10と同様に、既設のプラント設備において当該プラント設備を構成する各種の機器の間で、動作制御等に必要な信号をやり取りするための制御系ネットワークである。
上述のような構成において、第1既設ネットワーク10と第2既設ネットワーク20とは、異なるネットワークであり、異なるネットワーク間では時刻の同期は難しい。そのため、第1既設ネットワーク10に伝送されている信号データと、第2既設ネットワーク20に伝送されている信号データとを収集して、試験用ネットワーク40上で正確に再現するためには、異なるネットワーク間で収集する信号データの順番を保証する必要がある。そのため、データ収集装置30は次のように構成されている。
図1に戻り説明を続ける。データ蓄積装置37は、データ収集装置30に収集された信号データ(パラメータ設定信号タイミング信号、制御信号及びフィルター信号)を、これらの信号データがデータ収集装置30に受信された順序、信号データの時間間隔、並びに信号データの内容を正確に反映した状態で蓄積する。
(試験用ネットワーク)
次に、図2を参照しながら、プレイバックシミュレーション試験システムにおいて、収集したデータを再生する際の構成を説明する。試験用ネットワーク40は、後述する新設コントローラ42のための試験環境を構成する各種の機器の間で、必要な信号をやり取りするための、試験用に新設された制御系ネットワークである。試験用ネットワーク40も、第1既設ネットワーク10および第2既設ネットワーク20と同様に、例えばTCP/IP等を利用したLAN(Local Area Network)から構成されている。
データ再生装置50は、カウントアップ部51、データ再生出力部52、再生装置画面表示部53及び再生装置データ解凍処理部54を備える。さらに、データ再生装置50は、データ蓄積装置37に接続している。
続いて、図2を参照しながら、プレイバックシミュレーション試験システムにおけるデータの比較照合について説明する。試験用ネットワーク40は、データ再生装置50に加え、さらに、新設上位計算機41及び新設コントローラ42と通信可能に接続している。
ところで、上述した実施の形態1のシステムにおいては、データ収集装置30は、第1既設ネットワーク10と第2既設ネットワーク20の2つの既設制御系ネットワークから信号データを収集することとしている。しかし、既設制御系ネットワークの数は3つ以上であってもよい。例えば、x個の既設制御系ネットワークが接続される場合、データ収集装置30は、x個の受信部を備え、各受信部が信号データを受信した時に、受信時の収集番号を信号データに関連付けてデータ蓄積装置37に蓄積すればよい。
図4は、上述したデータ収集装置30、データ再生装置50、およびデータ比較照合装置60が有する処理回路のハードウェア構成例を示す概念図である。これらの装置内の各部は機能の一部を示し、各機能は処理回路により実現される。一態様として、処理回路は、少なくとも1つのプロセッサ91と少なくとも1つのメモリ92とを備える。他の態様として、処理回路は、少なくとも1つの専用のハードウェア93を備える。
11、21 既設上位計算機
12、22 既設コントローラ
13、23 インバータ
14、24 センサ/アクチュエータ
15、25 フィールド機器
20 第2既設ネットワーク
30 データ収集装置
31 第1受信部
32 第2受信部
33 カウントアップ部
34 データ同期処理部
35 収集装置画面表示部
36 収集装置データ圧縮解凍処理部
37 データ蓄積装置
40 試験用ネットワーク
41 新設上位計算機
42 新設コントローラ
50 データ再生装置
51 カウントアップ部
52 データ再生出力部
53 再生装置画面表示部
54 再生装置データ解凍処理部
60 データ比較照合装置
61 比較照合装置信号処理部
62 比較照合装置画面表示部
63 比較照合装置データ圧縮解凍処理部
64 データ比較照合処理部
65 データ記憶部
91 プロセッサ
92 メモリ
93 ハードウェア
Claims (2)
- 既設プラント設備の第1構成機器を制御するための制御信号を出力する第1既設コントローラが接続された第1既設ネットワーク、および、前記既設プラント設備の第2構成機器を制御するための制御信号を出力する第2既設コントローラが接続された第2既設ネットワークの両方に接続されたデータ収集装置と、
前記データ収集装置により収集された信号を蓄積するデータ蓄積装置と、
試験用ネットワークに接続され、前記データ蓄積装置に蓄積された信号を前記試験用ネットワークへ再生出力するデータ再生装置と、を備え、
前記データ収集装置は、
前記第1既設ネットワークへ伝送される制御信号を含む第1信号データを受信する第1受信部と、
前記第2既設ネットワークへ伝送される制御信号を含む第2信号データを受信する第2受信部と、
固有の収集番号を一定時間間隔でカウントアップするカウントアップ部と、
前記第1受信部が前記第1信号データを受信した時に当該受信時における前記収集番号を前記第1信号データに関連付けて前記データ蓄積装置に蓄積し、前記第2受信部が前記第2信号データを受信した時に当該受信時における前記収集番号を前記第2信号データに関連付けて前記データ蓄積装置に蓄積するデータ同期処理部と、
を備えることを特徴とするプレイバックシミュレーション試験システム。 - 前記データ再生装置は、
前記収集番号に相当する固有の再生番号を一定時間間隔でカウントアップするカウントアップ部と、
前記データ蓄積装置から前記再生番号に関連付いた信号データを順次取得し、前記試験用ネットワークへ再生出力するデータ再生出力部と、
を備えることを特徴とする請求項1記載のプレイバックシミュレーション試験システム。
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CN201780089329.1A CN110476132B (zh) | 2017-03-30 | 2017-03-30 | 重现模拟试验系统 |
BR112019016301A BR112019016301A2 (pt) | 2017-03-30 | 2017-03-30 | sistema de teste de simulação de reprodução |
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