Control device, control method, and control program

Abstract

To appropriately determine occurrence of a soft error.SOLUTION: The control device 10 collects data from each field device 20 constituting the plant via each input / output module, detects an input / output module in which an abnormality has occurred among the input / output modules based on the collected data, and determines the presence or absence of occurrence of a soft error in the control device 10 based on the number of input / output modules in which the occurrence of the abnormality has been detected.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a control device, a control method, and a control program. [Background technology]

[0002] A soft error is a phenomenon in which, for some reason (mainly cosmic rays or radiation causing electron excitation of internal atoms in the circuits of a semiconductor chip), the positive and negative polarities of the semiconductors that control storage and operation bits are reversed, destroying internal information.Unlike physical destruction or deterioration of the device, soft errors can be restored to their original state by rewriting the data. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2020-149467 Summary of the Invention [Problem to be solved by the invention]

[0004] However, it is difficult to accurately determine whether a soft error has occurred. For example, if a soft error occurs inside the control CPU (Central Processing Unit) module, multiple input / output modules (IOMs) defined in the system may simultaneously transition to a failed state (stopped functioning) even though the IOMs are functioning normally.

[0005] The present invention has been made in view of the above, and an object of the present invention is to appropriately determine the occurrence of a soft error. [Means for solving the problem]

[0006] A control device according to one embodiment of the present invention includes a first control unit that executes processing to collect data from each device constituting a system via each input / output module, detect an input / output module among the input / output modules in which an abnormality has occurred based on the collected data, and determine whether or not a soft error has occurred in the system based on the number of input / output modules in which the abnormality has been detected.

[0007] A control method according to one embodiment of the present invention includes a computer that collects data from each device constituting a system via each input / output module, detects an input / output module among the input / output modules in which an abnormality has occurred based on the collected data, and determines whether or not a soft error has occurred in the system based on the number of input / output modules in which the abnormality has been detected.

[0008] A control program according to one embodiment of the present invention causes a computer to execute a process of collecting data from each device constituting a system via each input / output module, detecting an input / output module among the input / output modules in which an abnormality has occurred based on the collected data, and determining whether or not a soft error has occurred in the system based on the number of input / output modules in which the abnormality has been detected. [Effects of the Invention]

[0009] According to the present invention, it is possible to appropriately determine whether a soft error has occurred. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 10 is a diagram illustrating an example of the configuration of an FCS. [Figure 2] 1 is a diagram illustrating a configuration example and a processing example of an abnormality diagnosis system according to an embodiment; [Figure 3] 1 is a block diagram showing an example of the configuration of each device of an abnormality diagnosis system according to an embodiment; [Figure 4]FIG. 4 is a diagram illustrating an example of a detection result storage unit of the control device according to the embodiment. [Figure 5] FIG. 4 is a diagram illustrating an example of a determination result storage unit of the control device according to the embodiment. [Figure 6] 3 is a flowchart showing an example of a flow of the abnormality diagnosis system according to the embodiment. [Figure 7] FIG. 2 is a diagram illustrating an example of a hardware configuration according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] A control device, a control method, and a control program according to an embodiment of the present invention will be described in detail below with reference to the drawings. Note that the present invention is not limited to the embodiment described below.

[0012] The configuration and processing of the abnormality diagnosis system 100 according to the embodiment, the configuration and processing of each device of the abnormality diagnosis system 100, the flow of each process of the abnormality diagnosis system 100, and the effects of the embodiment will be described below.

[0013] 1. Configuration and Processing of Abnormality Diagnosis System 100 The configuration and processing of an abnormality diagnosis system 100 according to an embodiment will be described using Figures 1 and 2. Below, an example of the configuration of an FCS (Field Control Station) will be described, followed by an example of the configuration of the entire abnormality diagnosis system 100, an example of the processing of the abnormality diagnosis system 100, and the effects of the abnormality diagnosis system 100. Note that in the embodiment, a control device 10 that controls a plant will be described as an example, but this does not limit the application target or field of use.

[0014] (1-1.FCS configuration example) An example of the configuration of an FCS will be described with reference to Fig. 1. Fig. 1 is a diagram showing an example of the configuration of an FCS. The FCS is a plant control system, and is composed of, for example, an FCU (Field Control Unit), an ESB (Extended Serial Backboard) bus node, and an optical ESB bus node. In the example of Fig. 1, the FCU corresponding to the control device 10 is composed of a plurality of power supply modules "PSU (Power Supply Unit)", a plurality of processor modules "CP461", a plurality of optical ESB bus repeater master modules "ANT401", a plurality of ESB bus coupler modules "EC402", and a plurality of input / output modules M "IOM". In addition, the ESB bus node that manages the field device 20 is connected to the FCU etc. via an ESB bus, and is composed of a plurality of power supply modules "PSU", a plurality of ESB bus slave interface modules "SB401", and a plurality of input / output modules M "IOM". In addition, the optical ESB bus node that manages the field device 20 is connected to the FCU etc. via an optical ESB bus, and is composed of multiple power supply modules "PSU", multiple optical ESB bus repeater slave modules "ATN502", and multiple input / output modules M "IOM".

[0015] The above-described FCS is an example of a plant control system to which the control device 10 of the abnormality diagnosis system 100 according to the embodiment is applied, but the configuration example of the plant control system is not particularly limited.

[0016] (1-2. Example of the overall configuration of the abnormality diagnosis system 100) Using FIG. 2, a configuration example of the entire abnormality diagnosis system 100 will be described. FIG. 2 is a diagram showing a configuration example and a processing example of the abnormality diagnosis system 100 according to the embodiment. The abnormality diagnosis system 100 includes a controller 10 and a plurality of field devices 20. Here, the controller 10 and the field devices 20 are communicably connected by wire or wirelessly via a predetermined communication network and an input / output module M (not shown). Note that various communication networks such as the Internet and dedicated lines can be adopted as the predetermined communication network.

[0017] (1-2-1. Controller 10) The controller 10 is a device used by an operator O who manages a plant and is a device that diagnoses abnormalities occurring in the plant. For example, the controller 10 is installed in an operator room or the like that monitors the plant. Note that the abnormality diagnosis system 100 shown in FIG. 1 may include a plurality of controllers 10. Also, in the example of FIG. 1, the case where the controller 10 is realized by an FCU is shown, but it may be realized by a desktop PC (Personal Computer), a notebook PC, a smartphone, a server device, a cloud system, or the like.

[0018] (1-2-2. Field Devices 20) The field devices 20 (20-1, 20-2, 20-3, ···) are devices installed in a plant and acquire various data. For example, the field devices 20 are measuring devices such as pressure gauges, flow meters, and vibration meters, and are installed at the plant site.

[0019] (1-2-3. Input / Output Module M) The input / output module M (M-1, M-2, M-3, ···) enables the transmission and reception of various data between the controller 10 and the field devices 20. For example, the input / output module M may be connected between the controller 10 and the field devices 20 as an independent device, may be built in the controller 10, or may be built in the field devices 20.

[0020] (1-3. Processing Example of Abnormality Diagnosis System 100) An example of processing of the abnormality diagnosis system 100 will be described below. The following describes data collection processing (step S1), abnormality detection processing (step S2), abnormality determination processing (step S3), and countermeasure execution processing (step S4). Note that the processing of steps S1 to S4 below can be executed in a different order. Also, some of the processing of steps S1 to S4 below may be omitted.

[0021] (1-3-1. Data collection process) First, the control device 10 collects various data from the field devices 20 via the input / output module M (step S1). For example, the control device 10 collects measurement data acquired by the field device 20-1 from the field device 20-1 via the input / output module M-1. The control device 10 also collects measurement data acquired by the field device 20-2 from the field device 20-2 via the input / output module M-2. The control device 10 also collects measurement data acquired by the field device 20-3 from the field device 20-3 via the input / output module M-3.

[0022] (1-3-2. Abnormality detection processing) Second, the control device 10 detects an abnormality that has occurred in the input / output module M (step S2). For example, the control device 10 diagnoses the collected measurement data and detects an abnormality that has occurred in the input / output module M, such as a data SUM abnormality, a configuration SUM abnormality, a data update abnormality, or an input / output module state abnormality.

[0023] Here, a data SUM abnormality refers to an abnormality in the sum (SUM value) of data transmitted and received between the control device 10 and the input / output module M. A configuration SUM abnormality refers to an abnormality in the sum (SUM value) of various settings (configurations). A data update abnormality refers to the stop of update processing such as counting up. An input / output module status abnormality refers to an abnormality related to the state, such as the state (status) of the input / output module M becoming "0", which indicates an abnormal state.

[0024] At this time, the control device 10 counts the number of input / output modules M in which an abnormality has occurred and stores the type of abnormality that has occurred. Furthermore, the control device 10 does not include in the count abnormalities due to physical factors such as the removal of an input / output module M, or abnormalities due to field factors, etc., other than soft errors, because multiple input / output modules M may transition to a failed state at the same time. The control device 10 then repeats the above process for all input / output modules M.

[0025] (1-3-3. Abnormality determination processing) Third, the control device 10 determines whether or not a soft error has occurred (step S3). For example, if an abnormality is detected in two or more input / output modules M, the control device 10 determines that a soft error has occurred in the control device 10. On the other hand, if an abnormality is detected in one input / output module M, the control device 10 determines that a soft error has not occurred in the control device 10 and that an abnormality has occurred in the input / output module M. Note that the control device 10 may determine that a soft error has occurred in the control device 10 if an abnormality is detected in two or more input / output modules M, which is a predetermined number or more. For example, the control device 10 may determine that a soft error has occurred in the control device 10 if an abnormality is detected in three or more input / output modules M. In other words, the number of input / output modules M used to determine a soft error is not particularly limited as long as it is two or more.

[0026] (1-3-4. Countermeasure execution process) Fourth, the control device 10 takes measures to deal with the abnormality that has occurred (step S4). For example, when the control device 10 determines that a soft error has occurred in the control device 10, the control right of each process is switched by changing the processes executed by the first control unit 13-1, which is the control CPU, to be executed by the second control unit 13-2, which is the standby CPU. On the other hand, when the control device 10 determines that an abnormality has occurred in the input / output module M, the control device 10 transitions the input / output module M in which the abnormality has been detected to a failed state.

[0027] (1-4. Effects of the Abnormality Diagnosis System 100) Below, an overview and problems of the abnormality diagnosis system 100P according to the reference technology will be explained, and then the effects of the abnormality diagnosis system 100 will be explained.

[0028] (1-4-1. Overview of the Abnormality Diagnostic System 100P) An overview of an abnormality diagnosis system 100P according to the reference technology will be described. In the abnormality diagnosis system 100P, a control device 10P according to the reference technology has a dual configuration of a control CPU and a standby CPU, and is connected to multiple input / output modules M. Furthermore, the control CPU and the standby CPU each have system software and an input / output coprocessor. The control device 10P uses the system software and the input / output coprocessor to diagnose the input / output modules M as follows.

[0029] First, the input / output coprocessor of the control CPU collects input data from input / output module M-1 and outputs the input data to the system software of the control CPU. Second, the system software of the control CPU performs diagnosis to confirm the validity of the input data collected from input / output module M-1. Third, if the input data is abnormal (e.g., data SUM abnormality, configuration SUM abnormality, data update abnormality, input / output module status abnormality), the system software of the control CPU transitions input / output module M-1 to a failed state. Then, the input / output coprocessor and system software of the control CPU perform diagnosis on all input / output modules M, such as input / output module M-2, input / output module M-3, ...

[0030] Furthermore, if a soft error occurs and the program of the input / output coprocessor of the control CPU is destroyed, the control device 10P can also take over the control right of the CPU. At this time, the control device 10P monitors whether the program of the input / output coprocessor is executed in the correct order, and if it is not executed in the correct order, it changes the CPU from the control CPU to the standby CPU, allowing control to continue with the normal CPU.

[0031] (1-4-2. Problems with the 100P Abnormality Diagnostic System) The following describes the problems with the fault diagnosis system 100P according to the reference technology. When a soft error occurs in the fault diagnosis system 100P, the soft error causes the input coprocessor and the hardware inside the control CPU to stop operating normally. In this case, even if the input / output module M is normal, multiple input / output modules M constituting the control system may transition to a failed state at the same time, and all input / output modules M may transition to a failed state at the same time. In other words, in the fault diagnosis system 100P, the occurrence of a soft error may cause multiple input / output modules M to transition to a failed state, which may affect plant operation. Furthermore, in the fault diagnosis system 100P, although replacing hardware components is possible as a countermeasure against soft errors, software-related countermeasures are preferable from a cost perspective.

[0032] (1-4-3. Overview of the Abnormality Diagnosis System 100) An overview of an abnormality diagnosis system 100 according to an embodiment will be described below. In the abnormality diagnosis system 100, system software executes diagnosis on input data, and when simultaneous abnormalities are detected in multiple input / output modules M, it is determined that a soft error has occurred in the CPU, and instead of transitioning the input / output modules M to a failed state, the control right of the CPU is switched over and control is continued by a new, normal control-side CPU.

[0033] Specifically, the abnormality diagnosis system 100 executes the following processes. First, when the control device 10 detects an abnormality (data SUM abnormality, configuration SUM abnormality, data update stop, input / output module status abnormality) during input data diagnosis that is thought to be caused by a soft error, it does not immediately transition the input / output modules M to a failed state. Instead, it counts the number of input / output modules M in which an abnormality occurred and stores the type of abnormality detected. At this time, the control device 10 does not include abnormalities due to physical factors, abnormalities due to field factors, etc. in the count. Second, the above process is repeated for all input / output modules M. Third, after completing the input data diagnosis of all input / output modules M, the control device 10 checks the number of input / output modules M in which an abnormality occurred. If two or more input / output modules M have occurred, the control right of the CPU is switched over without transitioning the input / output modules M to a failed state, and control is continued by a normal new control-side CPU. On the other hand, if the number of input / output modules M in which an abnormality occurred is one, the control device 10 transitions the input / output module M to a failed state.

[0034] (1-4-4. Effects of the abnormality diagnosis system 100) The effects of the abnormality diagnosis system 100 according to the embodiment will now be described. First, the abnormality diagnosis system 100 can grasp the status of all input / output modules M, and by using system software that ultimately diagnoses input data to determine soft errors, it is possible to prevent multiple input / output modules M from simultaneously transitioning to a failed state, regardless of the type of abnormal operation caused by a soft error. Second, the abnormality diagnosis system 100 can prevent the erroneous transfer of CPU control rights when an input / output module M is truly abnormal, rather than when a CPU soft error has occurred.

[0035] As described above, the abnormality diagnosis system 100 can appropriately determine the occurrence of a soft error.

[0036] 2. Configuration and Processing of Each Device in the Abnormality Diagnosis System 100 The configuration and processing of each device included in the abnormality diagnosis system 100 shown in Fig. 2 will be described using Fig. 3. Fig. 3 is a block diagram showing an example configuration of each device of the abnormality diagnosis system 100 according to the embodiment. Below, an example configuration of the entire abnormality diagnosis system 100 according to the embodiment, an example configuration and processing of the control device 10, an example configuration and processing of the field device 20, and an example configuration and processing of the input / output module M will be described.

[0037] (2-1. Example of the overall configuration of the abnormality diagnosis system 100) An example of the overall configuration of the abnormality diagnosis system 100 will be described. The abnormality diagnosis system 100 includes a control device 10, field devices 20 (20-1, 20-2, 20-3, . . .), and input / output modules M (M-1, M-2, M-3, . . .). The control device 10 and the field devices 20 are communicatively connected via a communication network N, such as the Internet or a dedicated line, and the input / output modules M. The field device 20-1 is connected to the input / output module M-1, the field device 20-2 is connected to the input / output module M-2, and the field device 20-3 is connected to the input / output module M-3. In the example of FIG. 3, the input / output module M is installed as an independent device outside the control device 10 and the field devices 20, but it may be installed inside the control device 10 or the field device 20.

[0038] (2-2. Configuration Example and Processing Example of Control Device 10) An example of the configuration and processing of the control device 10 will be described. The control device 10 is composed of a communication unit 11, a storage unit 12, a first control unit 13-1, and a second control unit 13-2. The control units 13 (first control unit 13-1, second control unit 13-2) are configured to be doubly redundant, but may be configured to be triple or more redundant. The control device 10 may also have an input unit (e.g., keyboard, mouse) that accepts various operations from the administrator of the abnormality diagnosis system 100, and a display unit (e.g., liquid crystal display) that displays various information.

[0039] (2-2-1. Communications Department 11) The communication unit 11 controls data communication with other devices. For example, the communication unit 11 executes data communication with each communication device via a router or the like. The communication unit 11 can also execute data communication with a terminal (not shown).

[0040] (2-2-2. Storage section 12) The storage unit 12 stores various pieces of information referenced by the control unit 13 when it operates and various pieces of information acquired when the control unit 13 operates. The storage unit 12 has a detection result storage unit 12a and a determination result storage unit 12b. Here, the storage unit 12 can be realized by, for example, a semiconductor memory element such as a random access memory (RAM) or a flash memory, or a storage device such as a hard disk or an optical disk. Note that, in the example of FIG. 3, the storage unit 12 is installed inside the control device 10, but it may also be installed outside the control device 10, or multiple storage units may be installed.

[0041] (2-2-2-1. Detection result storage unit 12a) The detection result storage unit 12a stores the detection results. For example, the detection result storage unit 12a stores the detection results output by a detection unit 13b-1 of the first control unit 13-1, which will be described later. Here, an example of data stored in the detection result storage unit 12a will be described with reference to FIG. 4. FIG. 4 is a diagram showing an example of the detection result storage unit 12a of the control device 10 according to the embodiment. In the example of FIG. 4, the detection result storage unit 12a has items such as "monitoring target," "input / output module," and "detection result."

[0042] "Monitoring target" indicates identification information for identifying the monitoring target or controlled target of the control device 10, such as the identification number or identification symbol of the control system that controls the plant. "Input / output module" indicates identification information for identifying the input / output module M connected to the devices that make up the system, such as the identification number or identification symbol of the input / output module M, or the identification number or identification symbol of the field device 20 connected to the input / output module M. "Detection result" indicates the type of abnormality that has occurred in the input / output module M, such as a data SUM abnormality, a configuration SUM abnormality, a data update abnormality, or an input / output module status abnormality.

[0043] 4 shows an example in which the following data is stored in the detection result storage unit 12a for the monitoring target identified by "control system #1": {Input / output module: "Input / output module #1", detection result: "Data SUM abnormal"}, {Input / output module: "Input / output module #2", detection result: "-"}, {Input / output module: "Input / output module #3", detection result: "Data update stopped"}. In FIG. 4, "-" indicates that no abnormality has been detected.

[0044] (2-2-2-2. Judgment result storage unit 12b) The judgment result storage unit 12b stores the judgment result. For example, the judgment result storage unit 12b stores the judgment result output by the judgment unit 13c-1 of the first control unit 13-1, which will be described later. Here, an example of data stored in the judgment result storage unit 12b will be described with reference to FIG. 5. FIG. 5 is a diagram showing an example of the judgment result storage unit 12b of the control device 10 according to the embodiment. In the example of FIG. 5, the judgment result storage unit 12b has items such as "monitoring target," "judgment date and time," and "judgment result."

[0045] "Monitoring target" indicates identification information for identifying the monitoring target or controlled target of the control device 10, such as the identification number or identification symbol of the control system that controls the plant. "Determination date and time" indicates the date and time when the determination result was output, and is expressed, for example, as year, month, day, hour, minute, and second. "Determination result" indicates the determination result of an abnormality that occurred in the control system, such as "soft error occurrence" indicating the occurrence of a soft error, or "IOM abnormality" indicating a failure or deterioration of the input / output module M.

[0046] That is, FIG. 5 shows an example in which the following data is stored in the judgment result storage unit 12b for the monitoring target identified by "control system #1", such as {judgment date and time: "judgment date and time #1", judgment result: "soft error occurred"}, {judgment date and time: "judgment date and time #2", judgment result: "IOM abnormality"}, {judgment date and time: "judgment date and time #3", judgment result: "soft error occurred"}, etc.

[0047] (2-2-3. First control unit 13-1) The first control unit 13-1 controls the entire control device 10. The first control unit 13-1 is the unit of the duplicated control unit 13 that currently executes each process, and is composed of a collection unit 13a-1, a detection unit 13b-1, a determination unit 13c-1, and an execution unit 13d-1. Here, the first control unit 13-1 can be realized, for example, by an electronic circuit such as a CPU or an MPU (Micro Processing Unit), or an integrated circuit such as an ASIC (Application Specific Integrated Circuit) or an FPGA (Field Programmable Gate Array). Furthermore, the first control unit 13-1 can be realized, for example, by system software for executing each process and an input / output module coprocessor.

[0048] (2-2-3-1. Collection section 13a-1) The collection unit 13a collects various types of information. The collection unit 13a may store the collected various types of information in the storage unit 12. The data collection process will be described below.

[0049] (Data collection and processing) The collection unit 13a executes a data collection process. For example, the collection unit 13a collects data from each device constituting a system via each input / output module M. In this case, the system is, for example, a plant. Furthermore, the devices are, for example, field devices 20 constituting the plant. That is, the collection unit 13a collects measurement data from, for example, each field device 20 constituting the plant via each input / output module M.

[0050] To explain a specific example of data collection processing, the collection unit 13a collects "measurement data #1" as measurement data acquired by the field device 20-1 via "input / output module #1," which is the input / output module M-1. The collection unit 13a also collects "measurement data #2" as measurement data acquired by the field device 20-2 via "input / output module #2," which is the input / output module M-2. The collection unit 13a also collects "measurement data #3" as measurement data acquired by the field device 20-3 via "input / output module #3," which is the input / output module M-3.

[0051] (2-2-3-2. Detector 13b-1) The detection unit 13b-1 outputs the detection result. The detection unit 13b-1 may store the output detection result in the storage unit 12. The abnormality detection process will be described below.

[0052] (Abnormality detection processing) The detection unit 13b-1 executes an abnormality detection process. For example, the detection unit 13b-1 detects an input / output module M in which an abnormality has occurred among the input / output modules M based on the collected data. At this time, the detection unit 13b-1 detects a data SUM abnormality as the abnormality that has occurred in the input / output module M. The detection unit 13b-1 also detects a configuration SUM abnormality as the abnormality that has occurred in the input / output module M. The detection unit 13b-1 also detects a data update stop as the abnormality that has occurred in the input / output module M. The detection unit 13b-1 also detects a status abnormality in the input / output module M as the abnormality that has occurred in the input / output module M.

[0053] Here, a data SUM abnormality refers to an abnormality in the sum (SUM value) of data transmitted and received between the control device 10 and the field device 20. A configuration SUM abnormality refers to an abnormality in the sum (SUM value) of various settings (configurations). A data update abnormality refers to the stop of update processing such as counting up. An input / output module status abnormality refers to an abnormality related to the state, such as the state (status) of the input / output module M becoming "0", which indicates an abnormal state.

[0054] To explain a specific example of the abnormality detection process, first, the detection unit 13b-1 acquires "measured data #1," "measured data #2," and "measured data #3" as data output by the collection unit 13a-1. Second, the detection unit 13b-1 detects "data SUM abnormality" as an abnormality that has occurred in "input / output module #1," which is input / output module M-1, from "measured data #1," and detects "data update stop" as an abnormality that has occurred in "input / output module #3," which is input / output module M-3, from "measured data #3." The detection unit 13b-1 also executes the abnormality detection process for all input / output modules M. Third, the detection unit 13b-1 stores the detection results, such as {input / output module: "input / output module #1," detection result: "data SUM abnormality"}, {input / output module: "input / output module #3," detection result: "data update stop"}, ..., in the detection result storage unit 12a.

[0055] (2-2-3-3. Judgment section 13c-1) The determination unit 13c-1 outputs the determination result. The determination unit 13c-1 may store the output determination result in the storage unit 12. The abnormality determination process will be described below.

[0056] (Abnormality determination processing) The determination unit 13c-1 executes an abnormality determination process. For example, the determination unit 13c-1 determines whether a soft error has occurred in the control device 10 based on the number of input / output modules M in which an abnormality has been detected. At this time, if the number of input / output modules M in which an abnormality has been detected is two or more, the determination unit 13c-1 determines that a soft error has occurred in the control device 10. On the other hand, if the number of input / output modules M in which an abnormality has been detected is one, the determination unit 13c-1 determines that an abnormality has occurred in the input / output module M in which the abnormality has been detected.

[0057] Taking "soft error occurrence" as a specific example of the abnormality determination process, first, the determination unit 13c-1 references {input / output module: "input / output module #1", detection result: "data SUM abnormal"}, {input / output module: "input / output module #2", detection result: "-"}, {input / output module: "input / output module #3", detection result: "data update stopped"}, ... as the detection results stored in the detection result storage unit 12a. Second, the determination unit 13c-1 determines that "a soft error has occurred" because the number of input / output modules M in which an abnormality has been detected is two. Third, the determination unit 13c-1 outputs {determination date and time: "determination date and time #1", determination result: "soft error has occurred"} as the determination result and stores it in the determination result storage unit 12b.

[0058] Further, regarding "IOM abnormality" as a specific example of the abnormality determination process, first, the determination unit 13c-1 refers to {Input / output module: "Input / output module #1", detection result: "Data SUM abnormality"}, {Input / output module: "Input / output module #2", detection result: "-"}, {Input / output module: "Input / output module #3", detection result: "-"}, ... as the detection results stored in the detection result storage unit 12a. Second, the determination unit 13c-1 determines that an "IOM abnormality" has occurred because the number of input / output modules M in which an abnormality has been detected is one. Third, the determination unit 13c-1 outputs {Determination date and time: "Determination date and time #2", determination result: "IOM abnormality"} as the determination result and stores it in the determination result storage unit 12b.

[0059] (2-2-3-4. Executive Section 13d-1) The execution unit 13d-1 executes various processes. The execution unit 13d-1 may store the output execution results in the storage unit 12. The countermeasure execution process will be described below.

[0060] (Countermeasure execution process) The execution unit 13d-1 executes a countermeasure execution process. For example, the execution unit 13d-1 executes a countermeasure for the abnormality that has occurred according to the determination result. At this time, the execution unit 13d-1 changes each process executed by the first control unit 13-1 so that it is executed by the second control unit 13-2. Meanwhile, the execution unit 13d-1 transitions the input / output module M in which the occurrence of the abnormality has been detected to a failed state.

[0061] Taking "soft error occurrence" as a specific example of the countermeasure execution process, first, the execution unit 13d-1 refers to {determination date and time: "determination date and time #1", determination result: "soft error occurrence"} as the determination result stored in the determination result storage unit 12b. Second, the execution unit 13d-1 switches the control right from the first control unit 13-1 currently executing each process to the second control unit 13-2 on standby, and changes the control unit 13 so that each process is executed by the second control unit 13-2.

[0062] Further, regarding "IOM abnormality" as a specific example of the countermeasure execution process, first, the execution unit 13d-1 refers to {determination date and time: "determination date and time #2", determination result: "IOM abnormality"} as the determination result stored in the determination result storage unit 12b. Second, the determination unit 13c-1 identifies the input / output module M in which the occurrence of the abnormality was detected as "input / output module #1", which is input / output module M-1, and transitions "input / output module #1" to a failed state.

[0063] (2-2-4. Second control unit 13-2) The second control unit 13-2 controls the entire control device 10. The second control unit 13-2 is the standby unit of the duplicated control unit 13 and is composed of a collection unit 13a-2, a detection unit 13b-2, a determination unit 13c-2, and an execution unit 13d-2. The second control unit 13-2 can execute each process executed by the first control unit 13-1. Here, the second control unit 13-2 can be realized, for example, by an electronic circuit such as a CPU or MPU, or an integrated circuit such as an ASIC or FPGA. The second control unit 13-2 can also be realized, for example, by system software for executing each process and an input / output module coprocessor. Note that the processes of the second control unit 13-2 after the execution unit 13d-1 of the first control unit 13-1 takes over control from the first control unit 13-1 are the same as those of the first control unit 13-1, so a description thereof will be omitted.

[0064] (2-3. Example of configuration and processing of field device 20) A description will be given of a configuration example and a processing example of the field device 20. The field device 20 is a device that constitutes a system. For example, the field device 20 is a device that constitutes a plant, and is a measuring instrument such as a pressure gauge, a flow meter, or a vibrometer.

[0065] The field device 20 acquires data in the system. For example, the field device 20 acquires measurement data such as pressure, flow rate, and vibration in the plant. The field device 20 also transmits the acquired measurement data to the control device 10 via the input / output module M.

[0066] The field device 20 receives a control signal in the system. For example, the field device 20 receives a control signal transmitted by the control device 10 via the input / output module M.

[0067] (2-4. Configuration example and processing example of input / output module M) An example of the configuration and processing of the input / output module M will be described. The input / output module M relays data transmission and reception between the control device 10 and devices that constitute the system. For example, the input / output module M relays data transmission and reception between the control device 10 and field devices 20 that constitute the plant. In this case, the input / output module M relays data transmission and reception in data formats such as AI (Analog Input), AO (Analog Output), DI (Digital Input), and DO (Digital Output).

[0068] 3. Flow of each process in the abnormality diagnosis system 100 The processing flow of the abnormality diagnosis system 100 according to the embodiment will be described with reference to Fig. 6. Fig. 6 is a flowchart showing an example of the processing flow of the abnormality diagnosis system 100 according to the embodiment. Note that the processing of the following steps S101 to S107 can also be executed in a different order. Furthermore, some of the processing of the following steps S101 to S107 may be omitted.

[0069] (3-1. Data collection and processing) First, the abnormality diagnosis system 100 executes a data collection process (step S101). For example, the control device 10 collects measurement data from the field devices 20 (20-1, 20-2, 20-3, . . .) via the input / output modules M (M-1, M-2, M-3, . . .).

[0070] (3-2. Abnormality detection processing) Second, the abnormality diagnosis system 100 executes an abnormality detection process (step S102). For example, the control device 10 diagnoses the collected measurement data and detects an abnormality that has occurred in the input / output modules M (M-1, M-2, M-3, . . .), such as a data SUM abnormality, a configuration SUM abnormality, a data update abnormality, or an input / output module state abnormality.

[0071] (3-3. Abnormality Judgment Processing) Third, the abnormality diagnosis system 100 executes an abnormality determination process. For example, if an abnormality is detected in two or more input / output modules M (step S103: Yes), the control device 10 determines that a soft error has occurred in the control device 10 (step S104), and proceeds to the process of step S105. On the other hand, if an abnormality is detected in one input / output module M (step S103: No), the control device 10 determines that a soft error has not occurred in the control device 10, and that an abnormality has occurred in the input / output module M (step S106), and proceeds to the process of step S107.

[0072] (3-4. Countermeasure execution process) Fourth, the abnormality diagnosis system 100 executes a countermeasure execution process. For example, when the control device 10 determines that a soft error has occurred in the control device 10, it switches the control rights of each process executed by the first control unit 13-1, which is the control CPU, to be executed by the second control unit 13-2, which is the standby CPU (step S105), and ends the process. On the other hand, when the control device 10 determines that an abnormality has occurred in the input / output module M, it transitions the input / output module M in which the abnormality has been detected to a failed state (step S107), and ends the process.

[0073] 4. Effects of the embodiment Finally, the effects of the embodiment will be described below: Effects 1 to 9 corresponding to the processing according to the embodiment will be described below.

[0074] (4-1. Effect 1) First, in the processing according to the embodiment described above, the control device 10 collects data from each device constituting the system via each input / output module M, detects which of the input / output modules M has an abnormality based on the collected data, determines whether a soft error has occurred in the control device 10 based on the number of input / output modules M in which an abnormality has been detected, and takes measures to address the abnormality that has occurred depending on the determination result. Therefore, this processing makes it possible to appropriately determine whether a soft error has occurred.

[0075] (4-2. Effect 2) Second, in the process according to the embodiment described above, the control device 10 takes measures to deal with the abnormality that has occurred depending on the determination result. Therefore, in this process, it is possible to appropriately determine the occurrence of a soft error and take appropriate measures to deal with the abnormality in the input / output module M.

[0076] (4-3. Effect 3) Third, in the process according to the embodiment described above, if the number of input / output modules M in which an abnormality has been detected is two or more, the control device 10 determines that a soft error has occurred in the control device 10 and changes the processes executed by the first control unit 13-1 so that the processes executed by the first control unit 13-1 are executed by the second control unit 13-2, which is capable of executing the processes executed by the first control unit 13-1. Therefore, in this process, if a soft error occurs, appropriate measures can be taken to address the abnormality in the input / output module M by changing the control right of the CPU.

[0077] (4-4. Effect 4) Fourth, in the processing according to the embodiment described above, if the number of input / output modules M in which an abnormality has been detected is one, the control device 10 determines that an abnormality has occurred in the input / output module M in which the abnormality has been detected, and transitions the input / output module M in which the abnormality has been detected to a failed state. Therefore, in this processing, if no soft error has occurred, it is possible to take appropriate measures to address the abnormality in the input / output module M by transitioning only the input / output module M in which the abnormality has occurred to a failed state.

[0078] (4-5. Effect 5) Fifth, in the processing according to the above-described embodiment, the control device 10 detects a data SUM abnormality as an abnormality that has occurred in the input / output module M. Therefore, in this processing, it is possible to appropriately determine the occurrence of a soft error and to implement appropriate measures against the data SUM abnormality in the input / output module M.

[0079] (4-6. Effect 6) Sixth, in the processing according to the embodiment described above, the control device 10 detects a Config SUM abnormality as an abnormality that has occurred in the input / output module M. Therefore, in this processing, it is possible to appropriately determine the occurrence of a soft error and to implement appropriate measures to deal with the Config SUM abnormality in the input / output module M.

[0080] (4-7. Effect 7) Seventh, in the processing according to the above-described embodiment, the control device 10 detects a data update stop as an abnormality occurring in the input / output module M. Therefore, in this processing, it is possible to appropriately determine the occurrence of a soft error and take appropriate measures against the data update stop in the input / output module M.

[0081] (4-8. Effect 8) Eighth, in the processing according to the above-described embodiment, the control device 10 detects a state abnormality in the input / output module M as an abnormality that has occurred in the input / output module M. Therefore, in this processing, it is possible to appropriately determine the occurrence of a soft error and to implement appropriate measures to address the state abnormality in the input / output module M.

[0082] (4-9. Effect 9) Ninth, in the processing according to the above-described embodiment, the system is a plant, and the devices are the field devices 20 that constitute the plant. Therefore, in this processing, it is possible to appropriately determine the occurrence of a soft error in a plant that is constituted by the field devices 20, and to take appropriate measures against the abnormality in the input / output module M.

[0083] [5. System] The information including the processing procedures, control procedures, specific names, various data and parameters shown in the above documents and drawings can be changed arbitrarily unless otherwise specified.

[0084] Furthermore, the components of each device shown in the figure are functional concepts and do not necessarily have to be physically configured as shown. In other words, the specific form of distribution and integration of each device is not limited to that shown. In other words, all or part of them can be functionally or physically distributed and integrated in any unit depending on various loads, usage conditions, etc.

[0085] Furthermore, all or any part of the processing functions performed by each device may be realized by a CPU and a program analyzed and executed by the CPU, or may be realized as hardware using wired logic.

[0086] [6. Hardware] An example of the hardware configuration of the control device 10 will be described. Note that other devices may also have a similar hardware configuration. FIG. 7 is a diagram showing an example of the hardware configuration according to the embodiment. As shown in FIG. 7, the control device 10 includes a communication device 10a, an HDD (Hard Disk Drive) 10b, a memory 10c, and a processor 10d. The components shown in FIG. 7 are connected to each other via a bus or the like.

[0087] The communication device 10a is a network interface card or the like, and communicates with other servers. The HDD 10b stores programs and databases that operate the functions shown in FIG.

[0088] The processor 10d reads out from the HDD 10b or the like a program that executes the same processes as the respective processing units shown in Fig. 3 and loads the program into the memory 10c, thereby operating a process that executes each function described in Fig. 3 or the like. For example, this process executes the same functions as the respective processing units of the control device 10. Specifically, the processor 10d reads out from the HDD 10b or the like a program that has the same functions as the collection unit 13a (13a-1, 13a-2), the detection unit 13b (13b-1, 13b-2), the determination unit 13c (13c-1, 13c-2), the execution unit 13d (13d-1, 13d-2), and the like. The processor 10d then executes a process that executes the same processing as the collection unit 13a (13a-1, 13a-2), the detection unit 13b (13b-1, 13b-2), the determination unit 13c (13c-1, 13c-2), the execution unit 13d (13d-1, 13d-2), etc.

[0089] In this way, the control device 10 operates as a device that executes various processing methods by reading and executing a program. The control device 10 can also realize functions similar to those of the above-described embodiment by reading the program from a recording medium using a media reader and executing the read program. Note that the program in these other embodiments is not limited to being executed by the control device 10. For example, the present invention can also be applied in the same way to cases where another computer or server executes the program, or where these execute the program in cooperation with each other.

[0090] This program can be distributed via a network such as the Internet. In addition, this program can be recorded on a computer-readable recording medium such as a hard disk, a flexible disk (FD), a CD-ROM, a magneto-optical disk (MO), or a digital versatile disk (DVD), and can be executed by being read from the recording medium by a computer.

[0091] [7. Other] Some examples of combinations of the disclosed technical features are set out below.

[0092] (1) A control device having a first control unit that executes processing to collect data from each device constituting a system via each input / output module, detect an input / output module among the input / output modules in which an abnormality has occurred based on the collected data, and determine whether or not a soft error has occurred in the device itself based on the number of input / output modules in which the abnormality has been detected.

[0093] (2) The control device according to (1), wherein the first control unit executes measures to deal with the abnormality that has occurred depending on the determination result.

[0094] (3) The control device according to (2), further comprising a second control unit capable of executing each process executed by the first control unit, wherein the first control unit determines that the soft error has occurred in the first control unit of the device when the number of input / output modules in which the abnormality has been detected is two or more, and changes each process executed by the first control unit to be executed by the second control unit.

[0095] (4) The control device described in (2) or (3), wherein, when the number of the input / output modules in which the abnormality is detected is one, the first control unit determines that the abnormality has occurred in the input / output module in which the abnormality is detected, and transitions the input / output module in which the abnormality is detected to a failed state.

[0096] (5) The control device according to any one of (1) to (4), wherein the first control unit detects a data SUM abnormality as the abnormality occurring in the input / output module.

[0097] (6) The control device according to any one of (1) to (5), wherein the first control unit detects a Config SUM abnormality as the abnormality occurring in the input / output module.

[0098] (7) The control device according to any one of (1) to (6), wherein the first control unit detects a data update stop as the abnormality occurring in the input / output module.

[0099] (8) The control device according to any one of (1) to (7), wherein the first control unit detects a state abnormality of the input / output module as the abnormality occurring in the input / output module.

[0100] (9) The control device according to any one of (1) to (8), wherein the system is a plant, and the device is a field instrument that constitutes the plant.

[0101] (10) A control method in which a computer executes a process in which it collects data from each device constituting a system via each input / output module, detects an input / output module among the input / output modules in which an abnormality has occurred based on the collected data, and determines whether or not a soft error has occurred in the device itself based on the number of input / output modules in which the abnormality has been detected.

[0102] (11) A control program that causes a computer to execute a process of collecting data from each device constituting a system via each input / output module, detecting an input / output module among the input / output modules in which an abnormality has occurred based on the collected data, and determining whether or not a soft error has occurred in the device itself based on the number of input / output modules in which the abnormality has been detected. [Explanation of symbols]

[0103] 10 Control device 10a Communication equipment 10b HDD 10c memory 10d processor 11 Communications Department 12 Storage section 12a Detection result storage unit 12b Judgment result storage unit 13 Control Unit 13-1 First Control Section 13-2 Second control section 13a, 13a-1, 13a-2 Collection section 13b, 13b-1, 13b-2 Detector 13c, 13c-1, 13c-2 Judgment section 13d, 13d-1, 13d-2 Executive Department 20 Field Devices 100 Abnormality diagnosis system M Input / Output Module N communication network O Operator

Claims

1. Data is collected from each device that makes up the system via each input / output module, Based on the collected data, an input / output module in which an abnormality has occurred is detected from among the input / output modules; determining whether a soft error has occurred in the device itself based on the number of the input / output modules in which the occurrence of the abnormality has been detected; A control device including a first control unit that executes processing.

2. The first control unit taking measures to deal with the abnormality that has occurred according to the determination result; The control device according to claim 1 .

3. The control device Further, a second control unit is provided that can execute each process executed by the first control unit, The first control unit If the number of the input / output modules in which the occurrence of the abnormality is detected is two or more, it is determined that the soft error has occurred in the first control unit of the own device, The processes executed by the first control unit are changed to be executed by the second control unit. The control device according to claim 2 .

4. The first control unit If the number of the input / output modules in which the occurrence of the abnormality has been detected is one, it is determined that the abnormality has occurred in the input / output module in which the occurrence of the abnormality has been detected; transitioning the input / output module in which the occurrence of the abnormality has been detected to a failed state; The control device according to claim 2 .

5. The first control unit detecting a data sum abnormality as the abnormality occurring in the input / output module; The control device according to claim 1 .

6. The first control unit Detecting a ConfigSUM abnormality as the abnormality occurring in the input / output module. The control device according to claim 1 .

7. The first control unit detecting a data update stop as the abnormality occurring in the input / output module; The control device according to claim 1 .

8. The first control unit detecting a state abnormality of the input / output module as the abnormality occurring in the input / output module; The control device according to claim 1 .

9. the system is a plant, and the device is a field device that constitutes the plant; The control device according to any one of claims 1 to 8.

10. The computer Data is collected from each device that makes up the system via each input / output module, Based on the collected data, an input / output module in which an abnormality has occurred is detected from among the input / output modules; determining whether a soft error has occurred in the device itself based on the number of the input / output modules in which the occurrence of the abnormality has been detected; A control method for performing a process.

11. On the computer, Data is collected from each device that makes up the system via each input / output module, Based on the collected data, an input / output module in which an abnormality has occurred is detected from among the input / output modules; determining whether a soft error has occurred in the device itself based on the number of the input / output modules in which the occurrence of the abnormality has been detected; A control program that executes processing.

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