WO2015133175A1 - 制御システム、制御装置および制御方法 - Google Patents
制御システム、制御装置および制御方法 Download PDFInfo
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- WO2015133175A1 WO2015133175A1 PCT/JP2015/050921 JP2015050921W WO2015133175A1 WO 2015133175 A1 WO2015133175 A1 WO 2015133175A1 JP 2015050921 W JP2015050921 W JP 2015050921W WO 2015133175 A1 WO2015133175 A1 WO 2015133175A1
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/42—Loop networks
- H04L12/423—Loop networks with centralised control, e.g. polling
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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
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L12/40006—Architecture of a communication node
- H04L12/40019—Details regarding a bus master
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L12/403—Bus networks with centralised control, e.g. polling
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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
- G05B2219/10—Plc systems
- G05B2219/12—Plc mp multi processor system
- G05B2219/1215—Master slave system
Definitions
- the present invention relates to a control system, a control device, and a control method used for controlling operations of machines and equipment.
- PLC programmable controller
- Patent Document 1 discloses a programmable controller system in which at least one CPU module and a plurality of I / O modules are connected to a ring bus. .
- a control system for controlling a controlled object includes a master device including a calculation unit and a communication processing unit, and one or more slave devices connected to the master device via a network.
- the communication processing unit is configured to manage cyclic transmission of data strings including data handled by the master device and one or more slave devices on the network.
- the computing unit is configured to repeatedly execute the output process and the input process at a predetermined execution cycle, and to repeat the program execution process during a non-execution period of the output process and the input process.
- the input process includes a process of updating input data according to information from the control target collected by one or more slave devices.
- the output process includes a process of generating output data including the execution result of the program execution process.
- the communication processing unit starts cyclic transmission of the first data string including the output data to one or more slave devices in conjunction with execution of the output processing in the calculation unit, and inputs the input in the calculation unit
- a cyclic transmission of the second data string for acquiring information collected from the control target by one or more slave devices starts a predetermined period before the execution of the process. It is configured.
- the communication processing unit transmits the second data string without depending on arrival of the first data string at the master device.
- the first data string and the second data string have the same data structure.
- each of the first data string and the second data string includes a command for acquiring information from one or more slave devices and output data.
- the output data included in the second data string is invalidated.
- each of the one or more slave devices is configured to discard the output data included in the second data string.
- the master device determines the timing of sending the second data string based on the offset value stored in advance with reference to the timing of starting the execution of the input process.
- the master device determines the offset value based on the initial configuration result of the network.
- a control device for controlling a control target includes a calculation unit and a communication processing unit coupled to the calculation unit.
- the control device is connected to one or more slave devices via a network.
- the communication processing unit is configured to manage cyclic transmission on the network of a data string including data handled by the own device and one or more slave devices.
- the computing unit is configured to repeatedly execute the output process and the input process at a predetermined execution cycle, and to repeat the program execution process during a non-execution period of the output process and the input process.
- the input process includes a process of updating input data according to information from the control target collected by one or more slave devices, and the output process includes a process of generating output data including the execution result of the program execution process. Including.
- the communication processing unit starts cyclic transmission of the first data string including the output data to one or more slave devices in conjunction with execution of the output processing in the calculation unit, and inputs the input in the calculation unit
- a cyclic transmission of the second data string for acquiring information collected from the control target by one or more slave devices starts a predetermined period before the execution of the process. It is configured.
- the control device is connected to one or more slave devices via a network, and the control device and one or more control devices are connected. It is configured to manage the cyclic transmission of data strings including data handled by the slave devices on the network.
- the control method includes a step of repeatedly executing the output process and the input process at a predetermined execution cycle and repeating the program execution process during a non-execution period of the output process and the input process.
- the input process includes a process of updating input data according to information from the control target collected by one or more slave devices, and the output process includes a process of generating output data including the execution result of the program execution process. Including.
- the control method further includes a step of starting cyclic transmission of the first data string including the output data to one or more slave devices in conjunction with execution of the output process, and starting execution of the input process.
- the control system can repeatedly execute a program necessary for controlling a control target in a shorter cycle.
- control system a system centered on a PLC will be exemplified.
- PLC the PLC
- various industrial computers can be mainly used.
- a new processing device an Arimetic device
- such a new processing device can also be employed.
- FIG. 1 is a schematic diagram showing an overall configuration of a PLC system 1 according to the present embodiment.
- a PLC system 1 is a control system for controlling an object to be controlled, and includes a main processing device 2 and one or more remote devices 40_1, 40_2, 40_3,..., 40_N (hereinafter, “ Remote device 40 ").
- the main processing device 2 and the remote device 40 are control devices that constitute at least a part of the PLC system 1, and are connected via the field network 4.
- Communication via the field network 4 is controlled mainly by the main processing device 2.
- the main processing device 2 sends out data that is sequentially transmitted over the field network 4 in accordance with a predetermined timing or rule.
- data sequentially transmitted on the field network 4 is also referred to as “communication frame”.
- the main processing device 2 is referred to as a “master device”, and each of the remote devices 40_1, 40_2, 40_3,..., 40_N is also referred to as a “slave device”.
- the main processing device 2 executes a program (including a user program and a system program as will be described later) necessary for controlling the control target, thereby allowing input signals (hereinafter referred to as “external signals”) from external switches and sensors.
- “Field information” or "IN data” is collected, processing for performing a control operation based on the collected field information, and a command value calculated by the control operation (hereinafter also referred to as "OUT data"). Realizes processing to external relays and actuators.
- the main processing device 2 includes a CPU unit 10, one or more IO units 20, and a power supply unit 30 as its device configuration.
- the CPU unit 10 and the IO unit 20 are connected to each other via an internal bus (not shown) so that data communication is possible.
- the power supply unit 30 supplies power of an appropriate voltage to the CPU unit 10 and the IO unit 20.
- the CPU unit 10 includes a calculation unit that executes a program necessary for controlling a control target, and a communication controller 110 that corresponds to a communication processing unit for controlling communication with the remote device 40 via the field network 4. Including.
- the remote device 40 receives field information from an external switch or sensor, and transmits the received field information number (IN data) to the main processing device 2 via the field network 4. At the same time, the remote device 40 outputs the command value (OUT data) received from the main processing device 2 via the field network 4 to an external relay or actuator. Alternatively, the remote device 40 may operate by itself according to a command value (OUT data) received via the field network 4. For example, as the remote device 40, a simple IO unit having no arithmetic function, an IO unit having an arithmetic function, a device including an actuator such as a motion controller, and the like are assumed.
- the communication controller 110 of the CPU unit 10 is also referred to as a data string (in this embodiment, “communication frame”) including data handled by the main processing device 2 (master device) and one or more remote devices 40 (slave devices). )
- a data string in this embodiment, “communication frame”
- FIG. 1 schematically shows a so-called ring network, but it may be a daisy chain connection network as will be described later. That is, the network according to the present embodiment may adopt any configuration as long as it can transmit data strings (communication frames) cyclically.
- the communication processing according to the present embodiment can be applied to a total frame type network.
- FIG. 2 is a schematic diagram showing a device configuration of the CPU unit 10 included in the PLC system 1 according to the present embodiment.
- CPU unit 10 includes a processor 100 as a calculation unit, a main memory 102, a nonvolatile memory 104, and an internal bus controller 106 in addition to a communication controller 110 as a communication processing unit. . These components are configured to be capable of data communication with each other via the internal bus 108.
- the processor 100 executes a program related to control.
- the processor 100 reads out a necessary program from the nonvolatile memory 104 or the like and develops it in the main memory 102 for execution.
- the control program typically includes a user program and a system program.
- the internal bus controller 106 is connected to the IO unit 20 via the internal bus 109 and mediates exchange of data (IN data and OUT data) between the processor 100 and the IO unit 20.
- the communication controller 110 is connected to the remote device 40 via the field network 4 and mediates exchange of data (IN data and OUT data) between the CPU unit 10 and the remote device 40. More specifically, the communication controller 110 includes a shared memory 112, a transmission buffer 120, a transmission circuit 122, a reception buffer 130, and a reception circuit 132.
- the transmission buffer 120 and the transmission circuit 122 realize processing related to frame transmission from the communication controller 110 to the external device
- the reception buffer 130 and the reception circuit 132 realize processing related to frame transmission from the external device to the communication controller 110.
- the communication controller 110 includes a shared memory 112, and the processor 100 directly accesses the shared memory 112 to write OUT data and acquire IN data. That is, the OUT data written in the shared memory 112 is transferred to the transmission buffer 120 and sent from the transmission buffer 120 to the external device.
- the IN data acquired from the external device is received by the reception buffer 130 and then transferred to the shared memory 112.
- the communication controller 110 may implement part or all of it using software. Alternatively, a part or the whole may be realized by using a hardware circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field-Programmable Gate Array).
- ASIC Application Specific Integrated Circuit
- FPGA Field-Programmable Gate Array
- FIG. 3 is a schematic diagram illustrating an example of a device configuration of the remote device 40 included in the PLC system 1 according to the present embodiment.
- FIG. 3 shows a configuration example having an arithmetic function and an IO function.
- remote device 40 includes an arithmetic processing unit 400, an input circuit 402, an output circuit 404, and a communication controller 410.
- the arithmetic processing unit 400 executes a predetermined process based on the data transmitted via the field network 4 and transmits the data obtained as a result of the process via the field network 4.
- the input circuit 402 outputs information (digit value) indicating the signal value (IN data) input from the field side to the arithmetic processing unit 400.
- the output circuit outputs a signal corresponding to the OUT data given from the arithmetic processing unit 400 to the field side.
- the communication controller 410 is connected to the CPU unit 10 via the field network 4 and mediates exchange of data (IN data and OUT data) between the remote device 40 and the CPU unit 10. More specifically, the communication controller 410 includes a shared memory 412, a reception buffer 420, a reception circuit 422, a transmission buffer 430, and a transmission circuit 432. Since these components have the same functions as the above-described shared memory 112, transmission buffer 120, transmission circuit 122, reception buffer 130, and reception circuit 132 (all of which are shown in FIG. 2), detailed description thereof will be repeated. Absent. However, the processing when the communication controller 410 that is a part of the slave device receives the communication frame and the processing when the communication frame is transmitted are the communication controller 110 of the CPU unit 10 that is a part of the master device. It is different from the processing in.
- the remote device 40 (the arithmetic processing unit 400, the input circuit 402, the output circuit 404, and the communication controller 410) may realize all or a part of its functions using software, but may include hardware such as an ASIC or FPGA. It is preferable to implement part or all of the circuit.
- the communication method in the field network 4 a method capable of data transmission with a predetermined communication cycle (that is, capable of real-time communication) is preferable.
- various industrial Ethernet registered trademark
- the industrial Ethernet include, for example, EtherCAT (registered trademark), PROFINET IRT, MECHATROLINK (registered trademark) -III, Powerlink, SERCOS (registered trademark) -III, and CIP Motion.
- EtherCAT registered trademark
- PROFINET IRT PROFINET IRT
- MECHATROLINK registered trademark
- MECHATROLINK registered trademark
- Powerlink SERCOS (registered trademark) -III
- CIP Motion CIP Motion
- FIG. 4 is a diagram for explaining a communication frame transmitted on the field network 4 according to the present embodiment.
- communication frame 50 is transmitted cyclically on field network 4. That is, the communication frame 50 transmitted from the main processing device 2 that is a master device is sequentially transferred to the remote devices 40_1, 40_2, and 40_3 that are slave devices.
- the communication frame 50 transferred to all the remote devices 40 returns to the main processing device 2. That is, the communication frame 50 is cyclically transmitted through the main processing device 2 and the remote devices 40_1, 40_2, 40_3,.
- the communication frame 50 includes a header 51, data areas 52, 53, and 54 assigned to each slave device, and a footer 55.
- the header 51 stores the destination of the communication frame and various attribute information.
- OUT data and IN data for the corresponding slave device are stored.
- the footer 55 stores information such as an end code and a parity bit.
- the master device generates and transmits the communication frame 50 by writing the OUT data given to each slave device to the data area assigned to the target slave device.
- each slave device receives the communication frame 50 from the host side, it extracts the OUT data addressed to itself from the data area allocated to itself from the received communication frame 50 and collects it at its own station.
- the existing IN data is written in the data area assigned to the own station, the communication frame 50 is regenerated, and is transmitted to the lower side.
- the OUT data and the IN data are sequentially updated by cyclically transferring the communication frame 50.
- the communication frame 50 storing the OUT data (command value) addressed to all slave devices is transmitted from the master device, and the OUT data (command value) is transmitted from each slave device.
- IN data feedback value
- FIG. 5 is a diagram for explaining an outline of processing included in the PLC system 1 according to the present embodiment.
- FIG. 5A is a diagram for explaining the repeated execution of a program in the CPU unit according to the related art
- FIG. 5B is a diagram for explaining the repeated execution of the program in the CPU unit 10 according to the present embodiment. It is a figure for doing.
- a program related to control is periodically and repeatedly executed.
- this program execution cycle is also referred to as a “PLC system cycle”.
- the programs to be executed include a system program 60 and a user program 70.
- the system program 60 is for executing processing essential for proper operation of the PLC system 1, and typically includes an output process 62, a communication process 64, and an input process 66.
- the output process 62 includes a process (also referred to as “framing process” or the like) that generates the communication frame 50 by aggregating OUT data calculated by executing the user program 70 or the like.
- the communication process 64 includes a process of sending the generated communication frame 50 to the slave device, and a process of collecting IN data from the communication frame 50 returned after going through all the slave devices.
- the input process 66 includes a process of updating internal data (or internal variables) based on IN data collected from the returned communication frame 50.
- the user program 70 is a program arbitrarily created by the user of the PLC system 1 according to the purpose and application, and may be subdivided into one or a plurality according to the control content, the controlled object, the control application, and the like.
- the user program 70 may include sequence control logic, motion control logic, PID control logic, and the like.
- an execution cycle or execution priority may be set for a user program subdivided into a plurality.
- the execution cycle set for the user program may be longer than the PLC system cycle (usually an integer multiple of the PLC system cycle), and in this case, the program is a plurality of cycles of the PLC system cycle. Will be executed over a period of time.
- the user program 70 includes an A process 72, a B process 74, and a C process 76.
- the processor 100 that is a calculation unit repeatedly executes the output process 62 and the input process 66 in a predetermined execution cycle (PLC system cycle), and does not execute the output process 62 and the input process 66.
- the program execution process (execution process of the user program 70) is repeated during the period.
- the input process 66 includes a process of updating the input data according to information (field information or IN data) from the control target collected by one or more slave devices (remote devices 40).
- the output process 62 includes a process of generating output data (communication frame or OUT data) including an execution result of the program execution process (execution process of the user program 70).
- the system program 60 is always executed once every PLC system cycle. As shown in FIG. 5A, in the communication process 64 of the system program 60, if the communication frame 50 is transmitted from the master device and the communication frame 50 does not return to the master device through all the slave devices, the master device The update of OUT data and IN data between the device and the slave device cannot be completed.
- each slave device receives the command value (OUT data) from the communication frame 50 and places the feedback value (IN data) on the communication frame 50.
- the master device waits until the communication frame 50 returns.
- the time required for the communication frame 50 transmitted from the master device to return to the master device (hereinafter also referred to as “communication frame cycle D”) depends on the number of slave devices connected to the field network 4. And get longer.
- the PLC system cycle T2 corresponds to the sum of the time required for executing the system program 60 (x1 + x2 + x3) and the time required for executing the user program 70 (x4 + x5 + x6).
- the user program 70 includes a process that requires high-speed execution (repeated execution with a shorter cycle) such as motion control logic (continuous control logic of position (angle) of a multi-axis robot or the like). May be included. Therefore, there is a desire to shorten the PLC system cycle T2 as much as possible.
- the time required for executing the communication process 64 of the system program 60 is relatively long. This is because the process waits until the transmitted communication frame 50 returns.
- the inventors of the present application pay attention to such a waiting state in communication processing, and reduce the PLC system cycle T2 by reducing the waiting time as small or zero as possible. I came up with the means. This new solution will be described with reference to FIG.
- the CPU unit 10 has a communication frame 50A mainly for collecting IN data within one PLC system cycle, and the same as FIG. A communication frame 50 is transmitted.
- the time required for the communication process can be substantially ignored. That is, if the communication frame 50A for collecting IN data is returned to the master device before the execution of the input process 66 that requires IN data collected from each slave device, the input process 66 is immediately executed. it can.
- the time required for the communication process can be substantially zero, and the executed system program 65 substantially includes only the output process 62 and the input process 66. It will be. That is, the communication frame 50A for collecting IN data (feedback value) is transmitted before the communication frame 50 in the related technique shown in FIG. 5A is transmitted from the master device. As a result, the communication frame 50 generated by the output process 62 can be sent immediately without waiting for the execution start of the input process 66.
- the communication controller 110 performs OUT data (output data or output data) with respect to one or more remote devices 40 (slave devices) in conjunction with execution of the output processing 62 in the processor 100 (arithmetic unit).
- the cyclic transmission of the communication frame 50 (first data string) including the command value is started.
- the communication controller 110 controls one or more remote devices 40 (slave devices) only a predetermined period before the start of execution of the input processing 66 in the processor 100 (calculation unit). Cyclic transmission of the communication frame 50A (second data string) for acquiring information (field information or IN data) collected from the target is started.
- the transmission start timing of the communication frame 50A is such that the transmitted communication frame 50A collects IN data from all the slave devices, and returns to the master device before starting the input processing 66 in the corresponding PLC system cycle. Any timing can be used as long as the timing is good. However, since it is necessary not to affect the transmission of the communication frame 50, the timing at which the communication frame 50A returns to the master device after the transmission is set to be just before the start of the input processing 66. preferable.
- the communication frame 50 may be transmitted from the master device after the communication frame 50A transmitted from the master device is transmitted and before the master device returns.
- the communication frame 50A may be sent from the master device before returning to the master device. That is, as long as the transmission period of the communication frame 50 and the communication frame 50A do not overlap, the transmission start timing of both can be arbitrarily set.
- the other communication frame can be transmitted without going through the field network 4 and depending on arrival at the master device.
- the arrival timing at the master device after one communication frame is completed and the transmission timing of the other communication frame can be determined independently of each other.
- Such processing can substantially reduce the waiting time in the master device to zero.
- the length of the PLC system cycle can be shortened by the time required for the communication process 64.
- the communication frame 50A is sent from the master device until it returns to the master device after going through all the slave devices. If the time, that is, the communication frame round cycle D2 is known, the transmission timing of the communication frame 50A can be determined. That is, the communication frame 50 ⁇ / b> A may be transmitted at a timing before the start timing of the input process 66 by a time corresponding to the communication frame round cycle D ⁇ b> 2.
- the transmission timing of the communication frame 50A is determined according to the length of the communication frame round cycle D2. That is, the communication frame round cycle D2 corresponds to an offset value for determining the transmission timing of the communication frame 50A.
- the communication frame round cycle D2 is typically measured in an initialization process executed when the field network 4 is configured by a master device and one or more slave devices. That is, in order to establish a network between the master device and one or more slave devices, necessary information is exchanged between the devices as an initialization process, and in this exchange of information, the communication frame cycle period D2 is also measured. Is done. The actually measured length of the communication frame round cycle D2 is held in the CPU unit 10, and the transmission timing of the communication frame 50A is determined each time using this value. That is, the length of the communication frame round cycle D2 is included in the initial network configuration result.
- the main processing device 2 (master device) sends the communication frame 50A (second data string) based on the offset value stored in advance, with the timing of starting the execution of the input processing 66 as a reference. To decide. Typically, the main processing device 2 (master device) determines an offset value based on the initial network configuration result.
- the communication frame round cycle may be calculated predictively using simulation or the like. Good. More specifically, based on the number of slave devices connected to the field network 4 and the type of each slave device (the processing capability and data processing amount of each slave device can be estimated), the communication frame 50A is transmitted to the field network. It is possible to estimate the time required to complete 4 rounds. Since the communication frame round cycle D can be estimated in advance without actually measuring, the design of the program can be facilitated.
- the communication frame cycle D2 is used as an offset value for determining the transmission timing of the communication frame 50A. That is, the main processing device 2 (master device) determines the timing for sending the communication frame 50A (second data string) based on the pre-stored offset value with reference to the execution start timing of the input processing 66. To do. As described above, this offset value (communication frame round cycle D2) may be determined by simulation.
- the timing for sending the communication frame 50A may be determined as an absolute value of the time (count number) counted by the common timer (counter), or the execution of the input process 66 It may be determined as a relative value based on the start timing.
- FIG. 6 is a diagram illustrating an example of a data structure of a communication frame used in the PLC system 1 according to the present embodiment.
- a data structure of the communication frame 50A is shortened compared to the data structure of the communication frame 50.
- An example of adoption will be shown. More specifically, in the normal communication frame 50, a data area for OUT data and IN data allocated to each slave device is provided between the header and the footer.
- the header stores an instruction (IN data refresh instruction) for instructing each slave device to write the field information input to the local station to the assigned IN data data area.
- Each slave device writes the latest feedback value in the data area of the IN data allocated to the local station in accordance with the IN data refresh command in the header.
- each slave device reads out the OUT data (command value) from the data area of the OUT data assigned to its own station, and executes the processing.
- the data area for OUT data is deleted, and only the data area for IN data exists. Since the IN data refresh command is stored in the header for each slave device, each slave device is updated in the data area of the IN data allocated to its own station according to the IN data refresh command in the header. Write feedback value. Thus, IN data collection using the communication frame 50A can be realized. In addition, since there is no data area for OUT data, the frame length (data amount) of the communication frame 50A can be reduced. That is, the communication frame cycle of the communication frame 50A can be shortened, and the time margin for the communication frame 50 can be increased.
- the communication frame 50A shown in FIG. 6B shows an example having the same data structure as the communication frame 50. That is, in the example shown in FIG. 6B, the communication frame 50 (first data string) and the communication frame 50A (second data string) have the same data structure.
- an invalid value is set as the OUT data of the communication frame 50A.
- “null value” is stored in each data area of the OUT data of the communication frame 50A. Even if each slave device receives the communication frame 50A, the valid OUT Data cannot be read. That is, the OUT data (output data) included in the communication frame 50A (second data string) is invalidated.
- each data area of OUT data may be invalidated by storing a value that is not possible as OUT data (for example, a negative value) instead of “null value”.
- the communication frame 50 and the communication frame 50A have the same data structure, both include an IN data refresh command. That is, the communication frame 50 (first data string) and the communication frame 50A (second data string) both have a command (IN data refresh instruction) and OUT data (output data) for acquiring information from the slave device. )including.
- FIG. 6C also shows an example in which the communication frame 50A has the same data structure as the communication frame 50. That is, in the example shown in FIG. 6B, the communication frame 50 (first data string) and the communication frame 50A (second data string) have the same data structure.
- the command value (OUT data) calculated by the latest execution of the program necessary for controlling the control target is stored.
- the header stores a declaration (OUT data invalidation declaration) indicating that the instruction value stored in the data area of OUT data is invalid for each slave device.
- each slave device executes processing for discarding the received command value (OUT data). That is, each of the slave devices is configured to discard the output data included in the communication frame 50A (second data string).
- the OUT data (output data) included in the communication frame 50A (second data string) is substantially invalidated by using the OUT data invalidation declaration.
- any value stored in the data area of OUT data is invalidated by the OUT data invalidation declaration, a random value may be stored in the data area. However, in terms of mounting, it is preferable to use the OUT data calculated by the most recent program execution.
- the communication frame 50A having a data structure different from that of the normal communication frame 50 is used.
- the same communication frame as the most recently transmitted communication frame 50 may be used as the communication frame 50A. That is, the communication frame 50 transmitted in the previous PLC system cycle may be retransmitted in the current PLC system cycle. Since all the communication frames include the latest set of OUT data in common, each slave device does not behave abnormally.
- the mounting configuration for realizing the communication processing according to the present embodiment can be further simplified.
- the data structure between the communication frame 50A and the communication frame 50 is not necessarily the same. Furthermore, it is not necessary to make the data lengths of IN data and OUT data stored in each communication frame the same. In order to shorten the time required to transfer the communication frame, the minimum necessary data length may be dynamically selected. Alternatively, it is possible to preliminarily estimate the optimum data length of the IN data and OUT data from the statistical information of the communication frame on the network and determine the communication frame so that the estimated data length is obtained. Good.
- FIG. 7 is a diagram illustrating an implementation example of the CPU unit 10 according to the present embodiment.
- the communication controller 110 includes an FPGA on which a control engine is installed, analog / digital conversion, memory, and the like.
- the ASIC on which the signal processing circuit is mounted is included.
- a communication frame 50A is generated and transmitted when an FPGA on which a control engine is mounted generates an internal signal. By using such an FPGA, it is not necessary to perform timing management by the processor 100, and higher speed control is possible.
- FIG. 7B shows an implementation example in which a dedicated processor 160 connected to the communication controller 110 is provided.
- the dedicated processor 160 manages the timing and gives an internal command for sending the communication frame 50 ⁇ / b> A to the communication controller 110 independently of the processor 100.
- FIG. 8 is a schematic diagram showing an overall configuration of a PLC system 1A according to a modification of the present embodiment.
- a PLC system 1A includes a main processing device 2 (master device) and one or more remote devices 40 (slave devices), which are connected via a daisy chain type field network.
- master device main processing device 2
- slave devices remote devices 40
- communication frames are sequentially transferred from the master device to each slave device (down frame), returned at the end, and then sequentially transmitted from each slave device to the master device (up frame).
- the CPU unit 10 has a communication controller 110A adapted to the daisy chain format. Since other configurations and processes are the same as those described above, detailed description will not be repeated.
- a process for the master device to collect field information from one or more slave devices via the network is preceded. And executed. Therefore, input processing executed after the completion of collection of field information is not waited. In other words, there is no waiting time between the process of transmitting OUT data (command value) to each slave device and the process of collecting IN data from each slave device, so a program necessary for controlling the control target
- the cycle (PLC system cycle) for executing can be shortened. That is, it is possible to provide an environment for executing the user program at a higher speed. As a result, the motion control logic and the like can be executed at higher speed, so that the control accuracy can be increased.
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Abstract
Description
好ましくは、第1のデータ列および第2のデータ列は、いずれも、1つ以上のスレーブ装置から情報を取得するためのコマンドおよび出力データを含む。
あるいは、さらに好ましくは、1つ以上のスレーブ装置の各々は、第2のデータ列に含まれる出力データを破棄するように構成されている。
まず、制御システムの一形態である、本実施の形態に係るPLCシステム1の全体構成について説明する。図1は、本実施の形態に係るPLCシステム1の全体構成を示す模式図である。
次に、本実施の形態に係るPLCシステム1に含まれるCPUユニット10の装置構成について説明する。図2は、本実施の形態に係るPLCシステム1に含まれるCPUユニット10の装置構成を示す模式図である。
次に、本実施の形態に係るPLCシステム1に含まれるリモート装置40の装置構成について説明する。図3は、本実施の形態に係るPLCシステム1に含まれるリモート装置40の装置構成の一例を示す模式図である。
次に、フィールドネットワーク4における通信処理について説明する。
次に、本実施の形態に係るPLCシステム1における処理の概要について説明する。図5は、本実施の形態に係るPLCシステム1に含まれる処理の概要を説明するための図である。図5(a)は、関連技術に係るCPUユニットにおけるプログラムの繰り返し実行を説明するための図であり、図5(b)は、本実施の形態に係るCPUユニット10におけるプログラムの繰り返し実行を説明するための図である。
次に、通信フレーム50Aの送出タイミングを決定するいくつかの方法について例示する。
図5(b)に示すように、通信フレーム50Aがマスター装置から送出されて、すべてのスレーブ装置を一巡した後にマスター装置へ戻ってくるまでの時間、すなわち通信フレーム一巡周期D2が既知であれば、通信フレーム50Aの送出タイミングを決定できる。すなわち、入力処理66の開始タイミングから通信フレーム一巡周期D2の時間分だけ前のタイミングで、通信フレーム50Aを送出すればよい。
上述したように、通信フレーム一巡周期を実測により決定する方法に代えて、シミュレーションなどを用いて、通信フレーム一巡周期を予測的に算出してもよい。より具体的には、フィールドネットワーク4に接続されているスレーブ装置の数および各スレーブ装置の種類(各スレーブ装置における処理能力およびデータ処理量を推定できる)などに基づいて、通信フレーム50Aがフィールドネットワーク4を一巡するのに要する時間を見積もることができる。実測しなくとも、通信フレーム一巡周期Dを予め推定できるので、プログラムの設計をより容易化できる。
次に、通信フレーム50および50A、ならびにスレーブ装置での処理について説明する。上述したように、基本的には、通信フレーム50Aは、INデータの収集ができれば十分である。そのため、通信フレーム50Aのデータ構造としては、INデータの収集に特化した構造を採用してもよいし、通信フレーム50と同様の構造を採用してもよい。
図6(a)には、通信フレーム50Aのデータ構造として、通信フレーム50のデータ構造に比較して短縮化された構造を採用する例を示す。より具体的には、通常の通信フレーム50では、ヘッダおよびフッタの間に、各スレーブ装置に割り当てられたOUTデータおよびINデータ用のデータエリアがそれぞれ設けられている。そして、ヘッダには、各スレーブ装置に対して、自局に入力されているフィールド情報を割り当てられたINデータのデータエリアに書き込むことを指示する命令(INデータリフレッシュ命令)が格納されている。各スレーブ装置は、ヘッダにあるINデータリフレッシュ命令に従って、自局に割り当てられたINデータのデータエリアに最新のフィードバック値を書き込む。同時に、各スレーブ装置は、自局に割り当てられたOUTデータのデータエリアからOUTデータ(指令値)を読み出して処理を実行する。
次に、図6(b)に示す通信フレーム50Aは、通信フレーム50と同一のデータ構造を有する例を示す。つまり、図6(b)に示す例では、通信フレーム50(第1のデータ列)および通信フレーム50A(第2のデータ列)は、同一のデータ構造を有している。
図6(c)にも、通信フレーム50Aが通信フレーム50と同一のデータ構造を有する例を示す。つまり、図6(b)に示す例では、通信フレーム50(第1のデータ列)および通信フレーム50A(第2のデータ列)は、同一のデータ構造を有している。
図6(a)~図6(c)には、通常の通信フレーム50とは異なるデータ構造を有する通信フレーム50Aを用いる例について示したが、通信フレーム50Aとして、直近に送出された通信フレーム50と全く同じ通信フレームを用いてもよい。つまり、1つ前のPLCシステム周期において送出した通信フレーム50を、現PLCシステム周期において再送出するようにしてもよい。いずれの通信フレームにも、最新であるOUTデータの組が共通に含まれるので、各スレーブ装置としては、異常な挙動になることはない。
なお、通信フレーム50Aと通信フレーム50との間のデータ構造を必ずしも同一にする必要はない。さらに、各通信フレームに格納されるINデータとOUTデータとのデータ長さについても同一にする必要はない。通信フレームの転送に要する時間を短縮するために、必要最小限のデータ長さを動的に選択するようにしてもよい。あるいは、ネットワーク上の通信フレームの統計情報などから、INデータおよびOUTデータのデータ長さの最適値を予め推測し、その推測したデータ長さになるように、通信フレームを決定しておいてもよい。
次に、上述のような通信フレームの送出に係るいくつかの実装例について例示する。
(1)通信コントローラ110の内部で通信フレームの送出をトリガーする実装例
図7(a)に示す実装例において、通信コントローラ110は、制御エンジンが実装されたFPGA、およびアナログ/デジタル変換やメモリなどの信号処理回路が実装されたASICを含む。この実装例においては、制御エンジンが実装されたFPGAが内部的な信号を発することで、通信フレーム50Aが生成されて送出される。このようなFPGAを用いることで、プロセッサ100でタイミングの管理などを行なう必要がなく、かつより高速な制御が可能になる。
図7(a)に示す実装例において、制御対象を制御するために必要なプログラム(ユーザプログラムやシステムプログラムなど)を実行するプロセッサ100において、タイミングを管理するスレッドを実行させて、そのスレッドから通信フレーム50Aをトリガーしてもよい。この場合には、通信フレーム50Aの生成および送出に係る内部コマンドが、プロセッサ100から通信コントローラ110へ与えられる。
図7(b)に示す実装例において、制御対象を制御するために必要なプログラム(ユーザプログラムやシステムプログラムなど)を実行するプロセッサ100_1に加えて、タイミングを管理するスレッドを実行する、別のプロセッサ100_2が実装されている。プロセッサ100_2が通信フレーム50Aをトリガーする。
図7(b)には、通信コントローラ110と接続された専用プロセッサ160が設けられている実装例を示す。この実装例においては、専用プロセッサ160がタイミングを管理し、プロセッサ100とは独立して、通信コントローラ110に対して、通信フレーム50Aを送出するための内部コマンドを与える。
上述の実施の形態においては、いわゆるリング形式のネットワークを例示したが、デイジーチェーン形式のネットワークにも適用できる。このようなデイジーチェーン形式のネットワークについて、図8を参照して例示する。
本実施の形態によれば、マスター装置と1つ以上のスレーブ装置とがネットワーク接続された構成において、マスター装置が1つ以上のスレーブ装置からネットワークを介してフィールド情報を収集するための処理が先行して実行される。そのため、フィールド情報の収集の完了後に実行される入力処理が待たされることがない。つまり、OUTデータ(指令値)を各スレーブ装置へ送信する処理と、各スレーブ装置からINデータを収集する処理との間に、待ち時間が発生しないので、制御対象を制御するために必要なプログラム(ユーザプログラムおよびシステムプログラムを含む)を実行する周期(PLCシステム周期)を短くできる。つまり、ユーザプログラムをより高速に実行するための環境を提供することができる。これによって、モーション制御ロジックなどをより高速に実行できるので、制御精度を高めることができる。
Claims (10)
- 制御対象を制御するための制御システムであって、
演算部および通信処理部を含むマスター装置と、
前記マスター装置とネットワークを介して接続された1つ以上のスレーブ装置とを備え、
前記通信処理部は、前記マスター装置および前記1つ以上のスレーブ装置が扱うデータを含むデータ列の前記ネットワーク上での巡回的な伝送を管理するように構成されており、
前記演算部は、出力処理および入力処理を予め定められた実行周期で繰り返し実行するとともに、前記出力処理および前記入力処理の非実行期間にプログラム実行処理を繰り返すように構成されており、前記入力処理は、前記1つ以上のスレーブ装置で収集された前記制御対象からの情報に応じて入力データを更新する処理を含み、前記出力処理は、前記プログラム実行処理の実行結果を含む出力データを生成する処理を含み、
前記通信処理部は、
前記演算部での前記出力処理の実行と連動して、前記1つ以上のスレーブ装置に対して前記出力データを含む第1のデータ列の巡回的な伝送を開始し、
前記演算部での前記入力処理の実行開始から予め定められた期間だけ前に、前記1つ以上のスレーブ装置が前記制御対象から収集している情報を取得するための第2のデータ列の巡回的な伝送を開始する、ように構成されている、制御システム。 - 前記通信処理部は、前記第1のデータ列の送出後、当該第1のデータ列の前記マスター装置への到着に依存することなく、前記第2のデータ列を送出する、請求項1に記載の制御システム。
- 前記第1のデータ列および前記第2のデータ列は、同一のデータ構造を有する、請求項1または2に記載の制御システム。
- 前記第1のデータ列および前記第2のデータ列は、いずれも、前記1つ以上のスレーブ装置から情報を取得するためのコマンドおよび前記出力データを含む、請求項1~3のいずれか1項に記載の制御システム。
- 前記第2のデータ列に含まれる前記出力データは、無効化されている、請求項4に記載の制御システム。
- 前記1つ以上のスレーブ装置の各々は、前記第2のデータ列に含まれる前記出力データを破棄するように構成されている、請求項4に記載の制御システム。
- 前記マスター装置は、予め格納されたオフセット値に基づいて、前記入力処理の実行開始のタイミングを基準として、前記第2のデータ列を送出するタイミングを決定する、請求項1~5のいずれか1項に記載の制御システム。
- 前記マスター装置は、前記ネットワークの初期構成結果に基づいて、前記オフセット値を決定する、請求項7に記載の制御システム。
- 制御対象を制御するための制御装置であって、
演算部と、
前記演算部に結合された通信処理部とを含み、
前記制御装置は、ネットワークを介して1つ以上のスレーブ装置と接続されており、
前記通信処理部は、自装置および前記1つ以上のスレーブ装置が扱うデータを含むデータ列の前記ネットワーク上での巡回的な伝送を管理するように構成されており、
前記演算部は、出力処理および入力処理を予め定められた実行周期で繰り返し実行するとともに、前記出力処理および前記入力処理の非実行期間にプログラム実行処理を繰り返すように構成されており、前記入力処理は、前記1つ以上のスレーブ装置で収集された前記制御対象からの情報に応じて入力データを更新する処理を含み、前記出力処理は、前記プログラム実行処理の実行結果を含む出力データを生成する処理を含み、
前記通信処理部は、
前記演算部での前記出力処理の実行と連動して、前記1つ以上のスレーブ装置に対して前記出力データを含む第1のデータ列の巡回的な伝送を開始し、
前記演算部での前記入力処理の実行開始から予め定められた期間だけ前に、前記1つ以上のスレーブ装置が前記制御対象から収集している情報を取得するための第2のデータ列の巡回的な伝送を開始する、ように構成されている、制御装置。 - 制御対象を制御するための制御装置における制御方法であって、
前記制御装置は、ネットワークを介して1つ以上のスレーブ装置と接続されており、当該制御装置および前記1つ以上のスレーブ装置が扱うデータを含むデータ列の前記ネットワーク上での巡回的な伝送を管理するように構成されており、前記制御方法は、
出力処理および入力処理を予め定められた実行周期で繰り返し実行するとともに、前記出力処理および前記入力処理の非実行期間にプログラム実行処理を繰り返すステップを含み、前記入力処理は、前記1つ以上のスレーブ装置で収集された前記制御対象からの情報に応じて入力データを更新する処理を含み、前記出力処理は、前記プログラム実行処理の実行結果を含む出力データを生成する処理を含み、
前記出力処理の実行と連動して、前記1つ以上のスレーブ装置に対して前記出力データを含む第1のデータ列の巡回的な伝送を開始するステップと、
前記入力処理の実行開始から予め定められた期間だけ前に、前記1つ以上のスレーブ装置が前記制御対象から収集している情報を取得するための第2のデータ列の巡回的な伝送を開始するステップとを含む、制御方法。
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JP6187674B2 (ja) | 2017-08-30 |
US10277417B2 (en) | 2019-04-30 |
US20170099158A1 (en) | 2017-04-06 |
EP3116166A1 (en) | 2017-01-11 |
EP3116166A4 (en) | 2017-08-30 |
CN106063197A (zh) | 2016-10-26 |
JPWO2015133175A1 (ja) | 2017-04-06 |
CN106063197B (zh) | 2019-04-09 |
EP3116166B1 (en) | 2018-09-05 |
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