Control Information Management System

Abstract

To provide a control information management system capable of storing past control information over a long term while suppressing oppression of a storage capacity of an information management device which stores, as backup data, control information stored in a programmable controller.SOLUTION: A control information management system 100 includes: a programmable controller 3; and an information management device 2 having first storage means 21 and second storage means 22 which store control information 324 stored in the programmable controller 3 as backup data. The first storage means 21 repeatedly communicates with the programmable controller 3, and if the control information 324 is updated, stores the control information 324 as backup data. The second storage means 22 communicates with the programmable controller 3 at a previously set time point, and if the control information 324 is updated, stores the control information 324 as backup data.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a control information management system that manages control information stored in a programmable controller for controlling a machine facility that is a control target. [Background technology]

[0002] Conventionally, a programmable controller for controlling machinery such as a machine tool stores control information including an operation program that specifies the operation of the machinery, and controls the machinery based on this control information. The control information is edited or updated by a peripheral device and written to the programmable controller, as described in Patent Document 1, for example. The peripheral device may store the control information before the update as backup data. The control information stored as backup data is written to the programmable controller to restore the control information, for example, when the operation of the machinery according to the updated control information is not satisfactory.

[0003] In recent years, a single management terminal has been used to manage the operation of a factory production line by communicating with multiple programmable controllers, as described in Patent Document 2. One possible function of such a management terminal is to store backup data of the control information of each programmable controller in case of a failure of the programmable controller, for example. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2014-127055 A [Patent Document 2] JP 2019-106158 A Summary of the Invention [Problem to be solved by the invention]

[0005] For example, when starting up or repairing a production line in a factory, the control information of the programmable controller is frequently updated. In such a case, if the control information is cumulatively stored in the peripheral device or management terminal every time it is updated, the storage capacity will be strained. Therefore, it is necessary to limit the amount of control information stored as backup data to, for example, the past few pieces of control information, and to erase the old control information one by one. For this reason, when it is desired to return the control information of the programmable controller to the state of the previous day, for example, the control information may have already been erased.

[0006] The present invention has been made in consideration of the above-mentioned circumstances, and its object is to provide a control information management system that is capable of storing control information over a long period of time while preventing the storage capacity of an information management device that stores control information stored in a programmable controller as backup data from being compressed. [Means for solving the problem]

[0007] In order to achieve the above object, the present invention provides a control information management system including a programmable controller that stores control information including an operation program that specifies the operation of a machine equipment to be controlled and controls the machine equipment based on the control information, and an information management device that stores the control information stored in the programmable controller as backup data, The information management device includes a first storage means for storing the control information read from the programmable controller in a first backup data storage section, and a second storage means for storing the control information read from the programmable controller in a second backup data storage section, and the first storage means performs a first determination by communication with the programmable controller to determine whether the control information stored in the programmable controller is newer than that stored in the first backup data storage section. At every specified timethe second storage means communicates with the programmable controller at a preset time and performs a second determination to determine whether the control information stored in the programmable controller at that time is newer than that stored in the second backup data storage means, and if the result of the second determination is positive, stores the control information stored in the programmable controller in the second backup data storage means; and the first storage means repeatedly performs the first determination at time intervals shorter than the time interval at which the second storage means performs the second determination; The second storage means stores past control information for n days (n is a plural number) from the day when the control information was updated. Provide a control information management system. Effect of the Invention

[0008] According to the control information management system of the present invention, it is possible to store control information for a long period of time while preventing the storage capacity of the information management device that stores the control information stored in the programmable controller as backup data from being compressed. [Brief description of the drawings]

[0009] [Figure 1] 1 is a schematic configuration diagram showing a control information management system according to an embodiment of the present invention. [Diagram 2] 2 is a block diagram showing an example of a functional configuration of a CPU module of an information management device and a programmable controller. FIG. [Diagram 3] 11 is a flowchart showing a specific example of a process executed by a first storage means. [Figure 4] 13 is a flowchart showing a specific example of a process executed by a second storage means. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] [Embodiment Mode] An embodiment of the present invention will be described with reference to Figures 1 to 4. Note that the embodiment described below is shown as a preferred specific example for carrying out the present invention, and while there are some parts that specifically exemplify various technical matters that are technically preferable, the technical scope of the present invention is not limited to this specific embodiment.

[0011] 1 is a schematic diagram showing a control information management system according to an embodiment of the present invention. This control information management system 1 is configured by connecting an information management device 2 and multiple programmable controllers 3 via a communication network 10 so that they can communicate with each other, and is installed in a factory. Each of the multiple programmable controllers 3 controls machinery and equipment 4. The machinery and equipment 4 is, for example, various machine tools such as an assembly machine, a lathe, a grinding machine, or a machining center.

[0012] 1 shows one programmable controller 3 and components of a machine equipment 4 controlled by this programmable controller 3, and shows other programmable controllers 3 and machine equipment 4 in a simplified manner, but these programmable controllers 3 and machine equipment 4 are configured in roughly the same manner. Also, in FIG. 1, an operation program editing device 5 connected to one programmable controller 3 is shown.

[0013] The programmable controller 3 is configured to include a power supply module 30, a CPU module 31, an output module 32, an input module 33, a communication module 34, and a base 300 on which these modules are mounted. The CPU module 31 is a module that forms the core of the programmable controller 3, and the other modules (the output module 32, the input module 33, and the communication module 34) are optional modules that are combined with the CPU module 31 to configure the programmable controller 3 according to the functions required for controlling the mechanical equipment 4.

[0014] The power supply module 30 converts, for example, a commercial power supply voltage of AC 100V to DC 5V and supplies it to each of the modules 31 to 34 via the base 300. The base 300 also has a printed circuit board on which a data bus is formed, and data can be exchanged between the CPU module 31 and the other modules 32 to 34 via this data bus.

[0015] The CPU module 31 executes an operation program that specifies the operation of the controlled mechanical equipment 4. The operation program is a user program created by a user to operate the mechanical equipment 4, and a typical example is a sequence program written in the ladder diagram language specified in IEC 61131-3.

[0016] A user can edit (create and update) an operation program using, for example, an operation program editing device 5 shown in Fig. 1. The operation program editing device 5 is, for example, a portable computer (notebook computer) on which application software for creating an operation program is installed, and is connected to the CPU module 31 by a communication cable 51. The operation program edited by the operation program editing device 5 is transmitted to the CPU module 31 and stored in the CPU module 31. The configuration of the CPU module 31 will be described later.

[0017] The output module 32 has a plurality of output relays respectively connected to a plurality of output elements 41 of the mechanical equipment 4, and is capable of operating the output elements 41 by turning on / off these output relays. The input module 33 has a plurality of input relays respectively connected to a plurality of input elements 42 of the mechanical equipment 4, and is capable of detecting the operating state of the mechanical equipment 4 by turning on / off these input relays. The output elements 41 are, for example, actuators or indicator lamps. The input elements 42 are, for example, limit switches or photoelectric switches. In the operation program, the conditions for turning on / off the output relays are described by combinations of the on / off states of the input relays, etc.

[0018] The communication module 34 communicates with other devices connected via a communication cable 341. The communication partner of the communication module 34 is, for example, an operation panel used by a worker in a factory to manually operate the mechanical equipment 4. In addition, the communication partner of the communication module 34 may be another programmable controller or a servo amplifier.

[0019] The information management device 2 is a computer to which a display 201, a keyboard 202, and a pointing device 203 are connected. The information management device 2 is capable of monitoring the operating state and the like of each piece of machinery and equipment 4 through communication with a plurality of programmable controllers 3. In this embodiment, the information management device 2 has a control information backup function for storing the control information stored in each of the plurality of programmable controllers 3 connected to the communication network 10 as backup data.

[0020] The control information includes an operation program as well as various kinds of parameter information necessary for the operation of the CPU module 31. The programmable controller 3 controls the machinery 4 based on this control information. For example, when the CPU module 31 breaks down and is replaced with a new one, the control information stored as backup data can be transferred to the replaced CPU module 31, so that the replaced CPU module 31 can control the machinery 4 in the same way as the previous one.

[0021] In addition, in this embodiment, in consideration of the above problems, the information management device 2 reads out control information from the CPU module 31 in two different modes and stores it as backup data. Next, a specific example of the configuration of the information management device 2 and the CPU module 31 will be described. Note that the information management device 2 is capable of communicating with a plurality of programmable controllers 3, and stores the control information stored in each of the plurality of programmable controllers 3 as backup data, but here, a process for storing the control information stored in one programmable controller 3 as backup data will be described in detail.

[0022] 2 is a block diagram showing an example of a functional configuration of the information management device 2 and the CPU module 31. The CPU module 31 has an operation program execution unit 311 that executes an operation program, a communication unit 312 that communicates with the information management device 2, and a storage unit 313 made of a non-volatile memory such as a flash memory. The storage unit 313 stores control information 314 and a system program 315.

[0023] The system program 315 is a program executed by a CPU (Central Processing Unit) mounted on the CPU module 31. The functions of the operation program execution unit 311 and the communication unit 312 are realized by the CPU executing the system program 315. Note that some or all of the functions of the operation program execution unit 311 and the communication unit 312 may be realized by hardware such as an FPGA (Field Programmable Gate Array) or an ASIC (Application Specific Integrated Circuit).

[0024] The control information 314 includes an operating program 314a, module parameters 314b which are parameters such as the module type of other optional modules combined with the CPU module 31 (in the example shown in FIG. 1, the output module 32, the input module 33, and the communication module 34), link parameters 314c which are setting information for communication with the communication module 34, and update date and time information 314d which indicates the update date and time (date and hour / minute / second) of the operating program 314a.

[0025] For example, when the control information 314 is written for the first time to an unused CPU module 31 at the start of a production line, the date and time of writing is stored as update date and time information 314d in the storage unit 313. Thereafter, when the contents of the control information 314 are rewritten by, for example, the operation program editing device 5, the date and time of the rewriting is stored in the storage unit 313 as update date and time information 314d.

[0026] The information management device 2 has a storage unit 25 formed of a storage such as a hard disk, and a part of this storage unit 25 serves as a first backup data storage unit 251 and a second backup data storage unit 252.

[0027] The information management device 2 also has, as functional components for the control information backup function, a first storage means 21 for storing the control information read from the CPU module 31 of the programmable controller 3 in a first backup data storage unit 251, a second storage means 22 for storing the control information read from the CPU module 31 of the programmable controller 3 in a second backup data storage unit 252, and a writing means 23 for writing control information selected by a user from the multiple pieces of control information stored in the first backup data storage unit 251 and the second backup data storage unit 252 to the CPU module 31 of the programmable controller 3 from which the control information was read. The first storage means 21, the second storage means 22, and the writing means 23 are realized by the CPU of the information management device 2 executing an application program 253 stored in the storage unit 25.

[0028] The information management device 2 also has a clock circuit 24 capable of outputting information on the current time referenced by the second storage means 22. The clock circuit 24 is also called an RTC (Real Time Clock), and the operation program editing device 5 also has a similar clock circuit built therein.

[0029] The first storage means 21, through communication with the CPU module 31 of the programmable controller 3, repeatedly performs a first determination to determine whether the control information 314 stored in the CPU module 31 is newer than that stored in the first backup data storage unit 251, and if the result of this first determination is positive, stores the control information 314 stored in the CPU module 31 in the first backup data storage unit 251.

[0030] The second storage means 22 communicates with the CPU module 31 of the programmable controller 3 at a preset time and performs a second determination to determine whether the control information 314 stored in the CPU module 31 at that time is newer than that stored in the second backup data storage unit 252, and if the result of this second determination is positive, stores the control information 314 stored in the CPU module 31 in the second backup data storage unit 252.

[0031] The first storage means 21 repeatedly performs the first judgment at time intervals shorter than the time intervals at which the second storage means 22 performs the second judgment. That is, the first storage means 21 and the second storage means 22 have different timings for storing the control information 314 stored in the CPU module 31 of the programmable controller 3 as backup data, and the second storage means 22 stores the control information in the second backup data storage unit 252 for a longer period than the first storage means 21.

[0032] The first storage means 21 performs the first judgment, for example, at intervals of several minutes (10 minutes or less) so that the control information can be stored as backup data each time the operating program is updated, even when the operating program is frequently updated, for example, when a production line in a factory is started up or repaired. The second storage means 22 communicates with the programmable controller 3 at a set time during the day, for example, and performs the second judgment. It is desirable that the time at which the second judgment is performed is later than the daytime hours when editing of the operating program is likely to be performed (for example, after 10 p.m.). The information management device 2 is basically used with the power on at all times.

[0033] The first storage means 21 stores the control information when the result of the first determination is positive in the first backup data storage unit 251 for the past multiple times when the first determination was positive. In FIG. 2, the first backup data storage unit 251 stores the control information in the backup buffers BA1 to BA nIn order not to overload the storage capacity of the information management device 2, n is preferably 10 or less.

[0034] The previous backup buffer BA1 in the first backup data storage unit 251 stores control information from the most recent backup by the first storage means 21, the second backup buffer BA2 stores the next most recent control information after the previous backup buffer BA1, the third backup buffer BA3 stores the next most recent control information after that, and the nth previous backup buffer BA n The oldest control information is stored in sequence up to the current control information.

[0035] The second storage means 22 stores control information for a plurality of times when the result of the second judgment is positive, in the second backup data storage unit 252, for a plurality of past times when the second judgment was positive. In FIG. 2, the second backup data storage unit 252 stores backup buffers BB1 to BB2 from one day ago to n days ago. n In the figure, n is the same as the number of backup buffers in the first backup data storage unit 251, for example, but may be different from the number of backup buffers in the first backup data storage unit 251.

[0036] The backup buffer BB1 of one day ago in the second backup data storage unit 252 stores control information at the time of the most recent backup by the second storage means 22, and the backup buffer BB2 of the second day to the backup buffer BB of n days ago are stored in the second backup buffer BB1. n The control information of the older date is stored in the table.

[0037] Next, a specific example of the process executed by the first storage means 21 and the second storage means 22 will be described with reference to the flowcharts of FIGS.

[0038] 3 is a flowchart showing a specific example of the processing executed by the first storage means 21. After the start of execution or after the execution of a series of processing steps (steps S11 to S19) of the previous cycle, the first storage means 21 repeatedly executes the processing steps from step S11 onwards at predetermined time intervals (for example, every few minutes).

[0039] The first storage means 21 judges whether a predetermined time has elapsed in the process of step S10, and if the predetermined time has elapsed (S10: Yes), sends a transmission request D for the update date and time information 314d of the control information 314 to the CPU module 31 of the programmable controller 3. 11 (See FIG. 2) After that, the first storage means 21 judges whether the update date and time information 314d has been received as a response from the CPU module 31 (step S12), and if not (S12: N), judges whether the response waiting time has elapsed (step S13).

[0040] If the result of the determination in step S13 is that the waiting time has not elapsed (S13: No), the first storage means 21 executes the determination process in step S12 again. On the other hand, if there is no response from the CPU module 31 before the waiting time elapses (S13: Yes), for example because the power of the programmable controller 3 is not turned on, the first storage means 21 returns the process to step S10.

[0041] The first storage means 21 stores the response R 11 When the first storage means 21 receives (transmission of update date and time information 314d) (S12: Yes), it compares the contents with the update date and time information stored in the previous backup buffer BA1 to determine whether or not there is a mismatch, i.e., whether or not the control information 314 of the CPU module 31 has been updated (step S14). This determination process in step S14 corresponds to the first determination described above. If the result of this determination is that the control information 314 has not been updated (S14: No), the first storage means 21 returns the process to step S10.

[0042] When it is determined in step S14 that the control information 314 of the CPU module 31 has been updated (S14: Yes), the first storage unit 21 sends a control information transmission request D 12 (Step S15). After that, the first storage unit 21 stores the response R 12 If control information is received (S16: Yes), the first storage means 21 shifts the buffer of the first backup data storage unit 251 (step S18). If control information is not received in step S16 (S16: No), the first storage means 21 waits until the waiting time has elapsed (step S17), and if the waiting time has elapsed (S17: Yes), the process returns to step S10.

[0043] The buffer shift in step S18 is performed by shifting the backup buffer BA1 from the previous backup buffer BA n-1 The contents of the backup buffer BA2 two times back to the backup buffer BA n As a result, the nth previous backup buffer BA n The contents stored in the backup buffer BA n-1 The contents stored in the backup buffer BA1 are overwritten and erased. After that, the first storage means 21 writes the control information received from the CPU module 31 into the previous backup buffer BA1 (step S19), and the process returns to step S10.

[0044] 4 is a flow chart showing a specific example of the process executed by the second storage means 22. As shown in FIG. 2, the second storage means 22 transmits a transmission request D for the update date and time information 314d of the control information 314 to the CPU module 31. 21 and the response R from the CPU module 31 21 , and a transmission request D of the control information 314 to the CPU module 31 22 and the response R from the CPU module 31 22The control information is backed up to the second backup data storage unit 252 by the above-mentioned method, but the timing and frequency of the backup are different from those of the first storage unit 21.

[0045] That is, the second storage means 22 acquires information on the current time from the clock circuit 24 of the information management device 2 (step S201), and determines whether or not a preset designated time has arrived based on the acquired current time (step S202). This designated time is preset by the user using the keyboard 202 or pointing device 203 connected to the information management device 2. Note that multiple times within a 24-hour period may be set as the designated time.

[0046] If it is determined in step S202 that the designated time has arrived (S202: Yes), the second storage means 22 executes the processes of steps S21 to S29. The contents of the processes of steps S21 to S29 are similar to the contents of the processes of steps S11 to S19 of the first storage means 21 described with reference to FIG. 3, and therefore detailed description thereof will be omitted.

[0047] The process of step S24 executed by the second storage means 22 is a process for determining whether or not the control information 314 of the CPU module 31 has been updated, and corresponds to the second determination described above. 21 This second determination is made by comparing the contents of the update time information 314d of the CPU module 31 received in with the update time information stored in the backup buffer BB1 from one day before.

[0048] If the result of the judgment in step S23 or the judgment in step S27 is No, the buffer shift process in step S28 and the write process in step S29 are not performed, so that the control information of the previous day is not necessarily stored in the backup buffer BB1 of one day ago. That is, the second backup data storage unit 252 stores, as backup data, past control information for n days up to the day when the control information 314 of the CPU module 31 was updated.

[0049] The control information stored in the first backup data storage unit 251 and the second backup data storage unit 252 is written by the writing means 23 to the CPU module 31 of the programmable controller 3 when necessary. The writing means 23 accepts a selection of which control information is to be written to the target CPU module 31 from among the multiple pieces of control information stored in the first backup data storage unit 251 and the second backup data storage unit 252, and writes the selected control information to the CPU module 31. The user performs a selection operation on the information management device 2 using the keyboard 202 or the pointing device 203.

[0050] It is necessary to write the control information stored in the first backup data storage unit 251 or the second backup data storage unit 252 to the CPU module 31 of the programmable controller 3, for example, when the CPU module 31 breaks down and needs to be replaced, or when some problem occurs in the operation of the mechanical equipment 4 after the operating program has been updated and it is desired to restore the operating program.

[0051] According to the embodiment of the present invention described above, since the information management device 2 has the second storage means 22 in addition to the first storage means 21, it is possible to store past control information over a long period of time as backup data while suppressing the pressure on the storage capacity of the information management device 2. In other words, if all control information updated over the past several days were stored as backup data, it would be necessary to store a large amount of control information when starting up or repairing a production line, and there is a risk that the storage capacity of the information management device 2 would be pressured. However, by performing backup processing using the first and second storage means 21 and 22, which have different timings and frequencies for executing backup processing of the control information, in combination, it is possible to store past control information over a long period of time while suppressing the required storage capacity.

[0052] (Additional Note) The present invention has been described above based on the embodiments, but the invention according to the claims is not limited to these embodiments. It should be noted that not all of the combinations of features described in the embodiments are essential to the means for solving the problems of the invention. The present invention can be modified as appropriate by omitting some components or adding or replacing components without departing from the spirit of the invention. [Explanation of symbols]

[0053] 1...Control information management system 2...Information management device 21: First storage means 22: Second storage means 23... Writing means 251... First backup data storage unit 252: Second backup data storage unit 3: Programmable controller 31...CPU module 314...Control information 314a...Operation program 4...Machinery equipment

Claims

1. A control information management system including: a programmable controller that stores control information including an operation program that specifies an operation of a machine equipment to be controlled, and controls the machine equipment based on the control information; and an information management device that stores the control information stored in the programmable controller as backup data, the information management device comprises a first storage means for storing the control information read from the programmable controller in a first backup data storage unit, and a second storage means for storing the control information read from the programmable controller in a second backup data storage unit; the first storage means, by communication with the programmable controller, repeatedly performs a first determination at predetermined time intervals to determine whether the control information stored in the programmable controller is newer than that stored in the first backup data storage unit, and when a result of the first determination is positive, stores the control information stored in the programmable controller in the first backup data storage unit; the second storage means communicates with the programmable controller at a preset time, performs a second determination to determine whether the control information stored in the programmable controller at that time is newer than the control information stored in the second backup data storage unit, and if the result of the second determination is positive, stores the control information stored in the programmable controller in the second backup data storage unit; the first storage means repeatedly performs the first determination at a time interval shorter than a time interval at which the second storage means performs the second determination; The second storage means stores past control information for n days (n is a plural number) from the day when the control information was updated. Control information management system.

2. the first storage means stores the control information when the result of the first determination is positive in the first backup data storage unit for a plurality of past times when the first determination is positive; the second storage means stores the control information when the result of the second determination is positive in the second backup data storage unit for a plurality of past times when the second determination was positive; The control information management system according to claim 1 .

3. the information management device is capable of communicating with a plurality of the programmable controllers and stores the control information stored in each of the plurality of the programmable controllers as backup data; The control information management system according to claim 1 or 2.

4. the information management device further includes a writing unit that receives a selection of which of the plurality of pieces of control information stored in the first backup data storage unit and the second backup data storage unit is to be written to the programmable controller, and writes the selected control information to the programmable controller. The control information management system according to any one of claims 1 to 3.

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