Engineering tool

Abstract

Provided is an engineering tool that enables prior elimination of factors causing an abnormal shut-down of a controller. An engineering tool according to an embodiment is capable of monitoring the state of a controller that monitors and controls a plant. The engineering tool according to the embodiment comprises: a log acquisition unit that acquires, from the controller, mounted module information indicating a first module mounted to the controller; a controller information acquisition unit that can acquire controller information including a second module mountable to the controller and corresponding maintenance information; and an information generation unit that can generate alarm information indicating the mounted module information and the maintenance information corresponding to the first module in association with each other, on the basis of the mounted module information and the controller information.

Description

Engineering tool

[0001] An embodiment of the present invention relates to an engineering tool.

[0002] A controller is known that executes a control program (hereinafter referred to as a POU (Program Organization Unit)) related to the control of a controlled device based on input information input from sensors of a plant or the like, and outputs output information including the execution result of the POU to the controlled device. The controller can store an event log that is a history of changes in the operating state of the controlled device (for example, power on or off, transition of the operating mode), an error log that is a history of monitoring and diagnosis of the controlled device (for example, self-diagnosis, occurrence status of abnormalities in connected devices connected to the control device), etc. as system data in an internal memory.

[0003] On the other hand, an engineering tool is known as a functional element that performs engineering of a controller connected via a control network and monitors and diagnoses the operating state of the controller. The engineering tool has a function of displaying the version information, failure state, and operating mode state of the controller to provide to the user.

[0004] When a failure of a module in a certain operating state is confirmed by the engineering tool, in order to recover this, it is necessary to conduct an investigation and countermeasure of the failure state, module replacement, etc. During this investigation, countermeasure, and module replacement, the controller may be in an operation stop state. The operation stop of the controller will affect various aspects such as the operation of the plant using the controller and module replacement.

[0005] JP-A-2008-211313 JP-A-2022-071950 JP-A-2003-316428

[0006] Thus, conventional engineering tools required the controller to be shut down if a module failure or other issue was detected. The engineering tool of this embodiment was developed to solve this problem and aims to provide an engineering tool that enables the prior elimination of factors that would cause the controller to shut down abnormally.

[0007] The engineering tool of the embodiment is an engineering tool capable of monitoring the status of a controller that monitors and controls a plant. The engineering tool of the embodiment comprises: a log acquisition unit that acquires implementation module information indicating a first module implemented in the controller from the controller; a controller information acquisition unit that can acquire controller information including a second module that can be implemented in the controller and corresponding maintenance information; and an information generation unit that can generate alarm information indicating the association between the implementation module information and the maintenance information corresponding to the first module, based on the implementation module information and the controller information.

[0008] This is a block diagram showing the configuration of the engineering tool according to the first to fourth embodiments. This is a diagram showing an example of the system configuration managed by the engineering tool according to the first to fourth embodiments. This is a diagram showing an example of alarm information output by the engineering tool according to the first to fourth embodiments. This is a flowchart showing an example of the operation of the engineering tool according to the first embodiment. This is a diagram showing an example of controller information that can be acquired by the engineering tool according to the first embodiment. This is a diagram showing an example of fault information that can be acquired by the engineering tool according to the first embodiment. This is a diagram showing an example of alarm information that can be output by the engineering tool according to the first embodiment. This is a flowchart showing an example of the operation of the engineering tool according to the second embodiment. This is a diagram showing an example of controller information that can be acquired by the engineering tool according to the second embodiment. This is a diagram showing an example of change history information that can be acquired by the engineering tool according to the second embodiment. This is a diagram showing an example of alarm information that can be output by the engineering tool according to the second embodiment. This is a flowchart showing an example of the operation of the engineering tool according to the third embodiment. This is a diagram showing an example of controller information that can be acquired by the engineering tool according to the third embodiment. This is a diagram showing an example of alarm information that can be output by the engineering tool according to the third embodiment. This is a flowchart showing an example of the operation of the engineering tool according to the fourth embodiment. This is a diagram showing an example of controller information that can be acquired by the engineering tool according to the fourth embodiment. This figure shows an example of combination conditions that can be acquired by the engineering tool according to the fourth embodiment. This figure shows an example of alarm information that can be output by the engineering tool according to the fourth embodiment. This figure shows an example of combination conditions that can be output by the engineering tool according to the fourth embodiment.

[0009] The engineering tool in this embodiment is configured to provide the user with the latest information on the controller, including failure information and the latest release information for the modules that make up the controller. By comparing this information with the user's controller configuration, it becomes possible to improve proactive failure prevention measures, system expansion, and maintenance and inspection of the controller.

[0010] (Configuration of the First to Fourth Embodiments) The configurations of the engineering tools and controllers of the embodiments will be described with reference to Figures 1 to 3. Figure 1 is a block diagram showing the configuration of the engineering tools according to the first to fourth embodiments. Figure 2 is a diagram showing an example of the system configuration managed by the engineering tools according to the first to fourth embodiments. Figure 3 is a diagram showing an example of alarm information output by the engineering tools according to the first to fourth embodiments. The functional configurations of the engineering tools of the first to fourth embodiments are generally the same. Therefore, common functional elements are indicated with common reference numerals, and redundant explanations are omitted.

[0011] As shown in Figure 1, the engineering tool 1 of the embodiment is connected to the controller 100 via a monitoring and control network NW1. The controller 100 is a functional element to which a controlled device is connected and which can output system data of the controlled device to the engineering tool 1. The system data includes, for example, the system log, system configuration, system information, and alarm information of the controlled device. Here, the system log includes, for example, the event log and error log of the controlled device. The system information includes, for example, module version information. The alarm information includes, for example, information such as module abnormalities. In the example shown in Figure 1, the controller 100 has a CPU module 110 and I / O modules 121 to 128 under it that are connected to each other. The controller 100 can be realized by a computer device equipped with, for example, a CPU (Central Processing Unit) (not shown), memory as main memory, a hard disk drive (HDD) or solid-state drive (SSD) as auxiliary storage, input / output interfaces and network interfaces.

[0012] The CPU module 110 is a functional element that realizes the overall calculation processing and control of the controller 100. The CPU module 110 is configured to communicate with the engineering tool 1 via the monitoring and control network NW1. In the example shown in Figure 1, the CPU module 110 implemented in the controller 100 has the module name "CPU-01" and its version is "Rev.A / Ver.2".

[0013] I / O modules 121, 122, 124, 127, and 128 are interface elements connected to controlled devices (not shown). I / O modules 121, 122, 124, 127, and 128 are configured to acquire information from the connected controlled devices and to transmit the execution results and output information of the POU to the controlled devices. In the example shown in Figure 1, I / O module 121 implemented in the controller 100 has the module name "I / O-01" and its version is "Rev.A". I / O module 122 implemented in the controller 100 has the module name "I / O-01" and its version is "Rev.B". Similarly, the I / O modules 124, 127, and 128 implemented in the controller 100 are named "I / O-03", "I / O-01", and "I / O-04", respectively, and their versions are "Rev.B", "Rev.B", and "Rev.A".

[0014] The monitoring and control network NW1 is a network that connects the engineering tool 1 and the controller 100. The monitoring and control network NW1 is configured as a closed network confined to monitoring and control units such as plants and control centers, and can be implemented using network standards such as Ethernet. Alternatively, the monitoring and control network NW1 may be built as a closed environment using VPN (Virtual Private Network) technology on an open network such as the internet.

[0015] The CPU module 110 generates system logs, alarm information, etc., based on the information acquired by the I / O modules 121, 122, 124, 127, and 128, and stores them in memory (not shown). At this time, the CPU module 110 may transmit these as system data to the engineering tool 1. The CPU module 110 is also configured to execute the POU sent from the engineering tool 1 and transmit the execution results, etc., to the controlled device via the I / O modules 121, 122, 124, 127, and 128.

[0016] Engineering tool 1 is a functional element that performs engineering of controller 100 and monitors and diagnoses its operating status. Engineering tool 1 can be realized, for example, by executing a computer program on a computer device equipped with a CPU (Central Processing Unit) (not shown), memory as main memory, a hard disk drive (HDD) or solid-state drive (SSD) as auxiliary storage, input / output interfaces, and network interfaces. As shown in Figure 1, engineering tool 1 has an external communication unit 10, an input unit 20, a display unit 30, an internal communication unit 40, a storage unit 50, and an arithmetic unit 60.

[0017] The external communication unit 10 is an interface that can communicate with the outside world via a network NW2, which is different from the monitoring and control network NW1. The input unit 20 is an input interface such as a human-machine interface, exemplified by a keyboard, mouse, touch panel, and terminal interface. The display unit 30 is a device or interface that can present information to the user, exemplified by a display device, display panel, and speaker device. The internal communication unit 40 is an interface that can communicate with the controller 100 via the monitoring and control network NW1.

[0018] The memory unit 50 is a storage medium capable of storing system data and other information acquired from the controller 100. In addition to functioning as an auxiliary storage device for storing programs and data, the memory unit 50 may also function as the main memory for the arithmetic unit 60. The memory unit 50 can be implemented, for example, by a hard disk drive or a semiconductor drive device. The arithmetic unit 60 is a functional element that enables the engineering tool 1 to function. The arithmetic unit 60 includes an information acquisition unit 62 capable of acquiring information from the outside and an information generation unit 64 capable of generating information and performing calculations.

[0019] The information acquisition unit 62 is a functional element capable of acquiring system data such as system logs, alarm information, and system configuration from the controller 100, for example. The information acquisition unit 62 may acquire system information including version information for the CPU module 110 and I / O modules 121, 122, 124, 127, and 128 as system data. In other words, the information acquisition unit 62 functions as a log acquisition unit that works in cooperation with the internal communication unit 40 to acquire implementation module information from the controller 100 indicating the modules implemented in the controller 100. Furthermore, the information acquisition unit 62 can acquire controller information and the like from the outside via the network NW2.

[0020] The information generation unit 64 generates display information to be displayed on the display unit 30 based on information acquired by the information acquisition unit 62, for example. Figure 2 is an example of display information 30a generated by the information generation unit 64, which includes system configuration information registered in the engineering tool 1 by the input unit 20, etc. In the example shown in Figure 2, the display information 30a includes the system configuration related to the modules implemented by the controller 100. For example, it is shown that the controller 100 has CPU-01 as the CPU module 110, and that I / O-01, I / O-01, I / O-03, I / O-01, and I / O-04 are connected to nodes 1, 2, 4, 7, and 8 as I / O modules 121, 122, 124, 127, and 128.

[0021] System configuration information is information about the system configuration registered in engineering tool 1. The system configuration information is downloaded from engineering tool 1 to controller 100, and controller 100 accesses the registered nodes based on the system configuration information. Controller 100 can determine whether there is a match, a mismatch, or an abnormality by comparing the registered module and the implemented module related to the registered node. The determination result is sent from controller 100 to engineering tool 1 as alarm information included in the system data.

[0022] Figure 3 shows an example of display information 30b, which includes alarm information generated by the information generation unit 64 based on the system data of the controller 100. In the example shown in Figure 3, the alarm information in the display information 30b is listed in association with the modules registered in the engineering tool 1, the versions of the hardware and software implemented in each module, the failure state, and the operating mode. For example, the module "CPU-01" registered as part of the system configuration is shown to have an implemented hardware version of "Rev.A", a software version of "Ver.2", a failure state of "Normal", and an operating mode of "ERR" (error occurred). Similarly, the module "I / O-01" of node 7 registered as part of the system configuration is shown to have an implemented hardware version of "Rev.B", a failure state of "Failure", and an operating mode of "ERR". In other words, it can be seen that the module "I / O-01" of node 7 has failed and is in an error state, while the module "CPU-01" itself is functioning normally, but its operating mode is in an error state. In this way, the alarm information can provide information to determine the state of the module implemented in the controller 100.

[0023] The engineering tool 1 of this embodiment is configured to be connectable to an external server 200 via a network NW2. The external server 200 is a data server capable of storing and providing information. The network NW2 is a network line such as the Internet. In the example shown in Figure 1, the external server 200 has a server unit 210 and a database 220. The server unit 210 is a server engine capable of providing information in response to requests from the outside, such as a web server. The database 220 is a storage medium that stores the information provided by the server unit 210. The external server 200 provides information in response to requests from, for example, the external communication unit 10 of the engineering tool 1.

[0024] The external server 200 may be operated, for example, by a business entity responsible for the manufacturing and maintenance of the controller 100. In this case, the database 220 of the external server 200 can store information on the types and latest versions of modules that can be implemented in the controller 100, the failure rate for each module, the replacement cycle, the failure causes, and the status of countermeasures for those failures. That is, the external server 200 can provide information on the failure rate and latest version of modules implemented in the controller 100, the replacement cycle of configurable modules, the failure causes, and the status of countermeasures for those failures. At this time, the information acquisition unit 62 of the engineering tool 1 functions as a controller information acquisition unit that can acquire controller information, including modules that can be implemented in the controller 100 and corresponding maintenance information, in cooperation with the external communication unit 10.

[0025] The engineering tools of the first to fourth embodiments are configured to acquire controller information and fault information from the Web. They can then generate display information that allows comparison between the information acquired from the controller and the information acquired from the Web, and provide this information to the user.

[0026] (Operation of the First Embodiment) Next, the operation of the engineering tool of the first embodiment will be described with reference to Figures 1 to 8. Figure 4 is a flowchart showing an example of the operation of the engineering tool according to the first embodiment. Figure 5 is a diagram showing an example of controller information that can be acquired by the engineering tool according to the first embodiment. Figure 6 is a diagram showing an example of fault information that can be acquired by the engineering tool according to the first embodiment. Figure 7 is a diagram showing an example of alarm information that can be output by the engineering tool according to the first embodiment. Figure 8 is a diagram showing an example of operational fault information that can be output by the engineering tool according to the first embodiment.

[0027] In the first embodiment, the database 220 of the external server 200 records, as controller information, the types and latest versions of modules (second modules) that can be implemented in the controller 100, the failure rate for each module or its replacement parts, the replacement cycle, the cause of failure, and the status of countermeasures (maintenance information). Meanwhile, the information acquisition unit 62 acquires system logs such as event logs and error logs of modules (first modules) implemented in the controller 100, as well as system data such as system configuration (implemented module information), through the functions of the engineering tool 1, and stores them in the storage unit 50.

[0028] The input unit 20 receives information input from the user of the engineering tool 1 (S100). For example, the keyboard acting as the input unit 20 receives the access URL of the external server 200 entered by the user.

[0029] The information acquisition unit 62 sends an information acquisition request to the external server 200 based on the information received by the input unit 20. The server unit 210 acquires controller information from the database 220 in response to the information acquisition request and returns it to the engineering tool 1. The information acquisition unit 62 passes the received controller information to the information generation unit 64, and the information generation unit 64 generates display information based on the received controller information. The display unit 30 displays the display information and presents it to the user (S110).

[0030] Figure 5 shows an example of the display information displayed by the display unit 30. The display information 30c includes controller information, which includes module information and component replacement information, and a download button 30d. In the example shown in Figure 5, the failure rate of the I / O module I / O-01 is shown to be selected.

[0031] In the example shown in Figure 5, the module information includes the module name of the module that the controller 100 can install, the latest version of the module, and the failure rate of the module. Similarly, the parts replacement information includes the module name of the module that the controller 100 can install, and the replacement cycle of the module or its replacement parts. In other words, the controller information illustrated in Figure 5 includes maintenance information such as the latest version and failure rate for each module that can be installed in the controller 100, and the replacement cycle for each module or its replacement parts.

[0032] When display information 30c is displayed on the display unit 30, if an arbitrary failure rate is clicked using the mouse, which is the input unit 20, the information generation unit 64 generates display information indicating the failure status of the module corresponding to the clicked failure rate based on the received controller information and displays it on the display unit 30. Figure 6 is an example of display information 30e that is displayed when a failure rate is clicked. The display information 30e includes the failure status, including the failure cause and the status of countermeasures. Such failure status information was included in the controller information obtained from the external server 200.

[0033] The input unit 20 waits for the user to click the download button 30d of the displayed information 30c (S120).

[0034] The information acquisition unit 62 sends a request to the external server 200 to download controller information in response to a click of the download button 30d received by the input unit 20. The server unit 210 retrieves the controller information from the database 220 in response to the download request and sends it to the engineering tool 1. The information acquisition unit 62 stores the received controller information in the storage unit 50 (S130).

[0035] The information generation unit 64 generates alarm information based on controller information received from the external server 200 and system data received from the controller 100 (S140). The alarm information generated here associates the version, failure status, and operating mode of the module implemented in the controller 100 with the latest version, failure rate, and replacement time of these modules. Based on the controller information obtained from the external server 200 and the system data obtained from the controller 100, the information generation unit 64 extracts the module name of the registered module, the version of the implemented module, the failure status, operating mode, latest version, failure rate, and replacement time to generate the alarm information. The display unit 30 displays display information including the generated alarm information (S150).

[0036] Figure 7 shows an example of alarm information 31b generated in S140. In the alarm information 31b illustrated in Figure 7, the version of the installed module, the failure status of the installed module, and the operating mode obtained from the controller 100 are compared with the latest version corresponding to the installed module, the failure rate of each installed module, and the replacement timing obtained from the external server 200. In other words, by referring to the alarm information 31b, the user can obtain information to determine whether the module installed in the controller 100 under their management is the latest version, what the failure rate is as determined by the maintenance provider, and when the replacement timing should be.

[0037] Here, the input unit 20 waits for a click selection of an arbitrary failure rate for each module in the alarm information 31b (S160). In the example shown in Figure 7, the failure rate of I / O-01, which is the I / O module of node 7, is shown to have been selected.

[0038] The information generation unit 64 extracts the operating status and failure status of the selected module from the storage unit 50 as operating failure information in response to the click selection received by the input unit 20 (S170), and the display unit 30 displays the operating failure information (S180). The information generation unit 64 generates operating status information by extracting the start date of operation from the system data acquired from the controller 100 and calculating the operating period. Similarly, the information generation unit 64 generates failure status information by extracting the failure cause and countermeasure status of the selected module from the controller information acquired from the external server 200.

[0039] Figure 8 shows an example of operational failure information 31f when I / O-01, the I / O module of node 7, is selected. The operational failure information 31f illustrated in Figure 8 includes the operational status and the failure status. The operational status includes the start date and operational period of I / O-01, the I / O module of node 7 of the controller 100. The failure status includes the failure cause and countermeasures for I / O-01, which is also an I / O module. The operational status is generated based on information obtained from the controller 100, which is the controlled device, and the failure status is generated based on information obtained from the external server 200 regarding the I / O module, I / O-01.

[0040] Thus, according to the engineering tool of this embodiment, information regarding failures in modules implemented in the controller, which is the controlled device, is output from an external source in association with the information. As a result, users can easily predict and address failures in each module of the controller under their management. In other words, the failure rate allows for the prediction of failures occurring during the operating period of the module in question, enabling users to plan in advance for module replacement or the purchase of spare modules.

[0041] In particular, the engineering tool of this embodiment is configured to display failure factors and countermeasures for modules implemented in the controller, allowing users to proactively prevent controller module failures. For example, if "overcurrent due to lightning strike / review of grounding conditions" is displayed, users can eliminate failure factors in advance, such as by re-inspecting the grounding conditions when expanding equipment.

[0042] (Operation of the Second Embodiment) Next, referring to FIGS. 1, 9 to 13, the operation of the engineering tool of the second embodiment will be described. FIG. 9 is a flowchart showing an operation example of the engineering tool according to the second embodiment. FIG. 10 is a diagram showing an example of controller information that can be acquired by the engineering tool according to the second embodiment. FIG. 11 is a diagram showing an example of change history information that can be acquired by the engineering tool according to the second embodiment. FIG. 12 is a diagram showing an example of alarm information that can be output by the engineering tool according to the second embodiment. FIG. 13 is a diagram showing an example of change history information that can be output by the engineering tool according to the second embodiment. The engineering tool of the second embodiment has the same configuration as that of the first embodiment but different display information. In the following description, elements common to the first embodiment are denoted by common reference numerals, and redundant descriptions are omitted.

[0043] In the second embodiment, the database 220 of the external server 200 records, as controller information, the types and latest versions of modules (second modules) that can be implemented in the controller 100, the history and change contents of the versions, the failure rate for each module, the replacement cycle, the cause of failure, and the status of countermeasures (maintenance information).

[0044] The input unit 20 receives information input from the user of the engineering tool 1 (S100). The information acquisition unit 62 transmits an information acquisition request to the external server 200 based on the information received by the input unit 20. The server unit 210 acquires controller information from the database 220 in response to the information acquisition request and returns it to the engineering tool 1. The information acquisition unit 62 passes the received controller information to the information generation unit 64, and the information generation unit 64 generates display information based on the received controller information. The display unit 30 displays the display information and presents it to the user (S110).

[0045] Figure 10 shows an example of the display information displayed by the display unit 30. The display information 32c includes controller information, which includes module information and component replacement information, and a download button 30d. In the example shown in Figure 10, the latest version of module "CPU-01" is selected.

[0046] When display information 32c is displayed on the display unit 30, and the latest version is clicked using the mouse, which is the input unit 20, the information generation unit 64 generates display information showing the version change history of the module corresponding to the clicked latest version based on the received controller information, and displays it on the display unit 30. Figure 11 is an example of the display information 32g that is displayed when the latest version is clicked. The display information 32g lists the change date and content as the version change history for the selected module, CPU-01. Such a change history was included in the controller information obtained from the external server 200.

[0047] The input unit 20 waits for a user to click the download button 30d of the displayed information 30c (S120). The information acquisition unit 62 sends a request to the external server 200 to download controller information in response to the click of the download button 30d received by the input unit 20. The server unit 210 retrieves the controller information from the database 220 in response to the download request and sends it to the engineering tool 1. The information acquisition unit 62 stores the received control information in the storage unit 50 (S130).

[0048] The information generation unit 64 generates alarm information based on controller information received from the external server 200 and system data received from the controller 100 (S140). Based on the controller information obtained from the external server 200 and the system data obtained from the controller 100, the information generation unit 64 extracts the module name of the registered module, the version of the implemented module, the failure status, the operating mode, the latest version, the failure rate, and the replacement time to generate alarm information. The display unit 30 displays display information including the generated alarm information (S150).

[0049] Figure 12 shows an example of the alarm information 32b generated in S140. In the alarm information 32b illustrated in Figure 12, the version of the implemented module acquired from the controller 100, the failure state and operation mode of the implemented module, the latest version corresponding to the implemented module acquired from the external server 200, the failure rate and replacement time of each implemented module are compared. At this time, when the version of the implemented module is older than the latest version of the implemented module, the corresponding information is highlighted. That is, in the example shown in Figure 12, for CPU-01 of the CPU module 110, the version of the implemented software (S / W) is Ver.2, while its latest version is Ver.3, so the version display of the latest version is highlighted. The same applies to the hardware version of I / O-01 which is the I / O module 121. In the example shown in Figure 12, the state where the latest version in CPU-01 which is the CPU module 110 is selected is shown.

[0050] Here, the input unit 20 waits for a click selection of any latest version in each module of the alarm information 32b (S162).

[0051] The information generation unit 64 extracts, as change history information, the change history, change year and month, and change content of the version history of the selected module from the storage unit 5 according to the click selection received by the input unit 20 (S172), and the display unit 30 displays the change history information (S182). When the version of the implemented module is not the latest, the information generation unit 64 highlights the latest version display.

[0052] Figure 13 shows an example of the change history information 32h when the latest version of CPU-01 which is the CPU module 110 is selected. The change history information 32h illustrated in Figure 13 includes the version history, change year and month, and change content of the selected module. In the example shown in Figure 13, Ver.3 which is the latest version is highlighted.

[0053] Furthermore, in the example shown in Figure 13, the latest version "Ver.3" of the CPU module 110 includes "support for I / O-05," but the I / O module with model number "I / O-05" shown in the alarm information 32b in Figure 12 is not implemented in the controller 100. In other words, it can be determined that there is no need to update the software of the CPU module 110 to the latest version at this time. On the other hand, if an I / O module with model number "I / O-05" is to be introduced through system expansion of the controller 100, it can be determined that the software of the CPU module 110 needs to be updated to the latest version.

[0054] According to the engineering tool of this embodiment, controller information includes version history and changes, and when the implemented module version is older than the latest version, it is highlighted, making it easy to check the release status of the implemented module.

[0055] Furthermore, by configuring the system to allow referencing of version history and changes, it becomes easy to determine whether or not the modules implemented in the controller 100 need to be updated.

[0056] (Operation of the Third Embodiment) Next, the operation of the engineering tool of the third embodiment will be described with reference to Figures 1, 14 to 17. Figure 14 is a flowchart showing an example of the operation of the engineering tool according to the third embodiment. Figure 15 is a diagram showing an example of controller information that can be acquired by the engineering tool according to the third embodiment. Figure 16 is a diagram showing an example of alarm information that can be output by the engineering tool according to the third embodiment. Figure 17 is a diagram showing an example of replacement status that can be output by the engineering tool according to the third embodiment. The engineering tool of the third embodiment has the same configuration as the first embodiment, but the display information is different. In the following description, elements common to the first embodiment will be denoted by the same reference numerals, and redundant explanations will be omitted.

[0057] In the third embodiment, the database 220 of the external server 200 records controller information including the type and latest version of modules (second modules) that can be implemented in the controller 100, the failure rate for each module, the replacement cycle of replacement parts that make up the module, the cause of failure, and the status of countermeasures (maintenance information). In addition, the event log data obtainable from the controller 100 includes the most recent replacement date (implementation date) of the replacement parts that make up the implemented module.

[0058] The input unit 20 receives information input from the user of the engineering tool 1 (S100). The information acquisition unit 62 sends an information acquisition request to the external server 200 based on the information received by the input unit 20. The server unit 210 acquires controller information from the database 220 in response to the information acquisition request and returns it to the engineering tool 1. The information acquisition unit 62 passes the received controller information to the information generation unit 64, and the information generation unit 64 generates display information based on the received controller information. The display unit 30 displays the display information and presents it to the user (S110).

[0059] Figure 15 shows an example of the display information displayed by the display unit 30. The display information 33c includes controller information, which includes module information and component replacement information, and a download button 30d. In the example shown in Figure 15, the download button 30d is shown to be selected.

[0060] The input unit 20 waits for a user to click the download button 30d of the displayed information 33c (S120). The information acquisition unit 62 sends a request to the external server 200 to download controller information in response to the click of the download button 30d received by the input unit 20. The server unit 210 retrieves the controller information from the database 220 in response to the download request and sends it to the engineering tool 1. The information acquisition unit 62 stores the received control information in the storage unit 50 (S130).

[0061] The information generation unit 64 generates alarm information based on controller information received from the external server 200 and system data received from the controller 100 (S140). Based on the controller information obtained from the external server 200 and the system data obtained from the controller 100, the information generation unit 64 extracts the module name of the registered module, the version of the implemented module, the failure status, the operating mode, the latest version, the failure rate, and the replacement time to generate alarm information. The display unit 30 displays display information including the generated alarm information (S150). The replacement time included in the alarm information can be calculated, for example, based on the most recent replacement date of the replacement parts constituting the implemented module obtained from the controller 100 and the replacement cycle of the replacement parts constituting the module obtained from the external server 200.

[0062] Figure 16 shows an example of alarm information 33b generated in S140. In the alarm information 33b shown in Figure 16, the version of the installed module, the failure status of the installed module, and the operating mode obtained from the controller 100 are compared with the latest version corresponding to the installed module, the failure rate of each installed module, and the replacement time obtained from the external server 200. In this case, if the replacement time of an installed module is approaching or has passed, for example, if there are less than six months until the replacement time, the replacement time of the corresponding module is highlighted. That is, in the example shown in Figure 16, the battery replacement time for CPU-01 of the CPU module 110 has passed and is highlighted.

[0063] Here, the input unit 20 waits for a click selection of the replacement timing for each module in the alarm information 33b (S163).

[0064] The information generation unit 64 extracts information such as the replacement parts of the selected module, the most recent replacement date, the replacement cycle, and the replacement timing from the storage unit 50 as replacement timing information in response to the click selection received by the input unit 20 (S173), and the display unit 30 displays the replacement timing information (S183). The information generation unit 64 highlights the replacement timing of replacement parts that are nearing or have already passed their replacement time.

[0065] Figure 17 shows an example of replacement timing information 33i when a replacement timing is selected for the CPU module 110, which is CPU-01. The replacement timing information 33i shown in Figure 17 includes the replacement parts related to the selected module, the most recent replacement date, the replacement cycle of the replacement parts that make up the module, and the replacement timing. In the example shown in Figure 17, the battery replacement timing for the CPU module "CPU-01" is highlighted.

[0066] According to the engineering tool of this embodiment, controller information obtainable from the external server 200 includes the modules that can be implemented in the controller 100 and the replacement cycles of the replacement parts that make up those modules, and event log data obtainable from the controller 100 includes the timing of replacement of the replacement parts that make up the implemented modules. Therefore, it is possible to know when replacement parts of the relevant modules, such as batteries and fan filters, will need to be replaced. Generally, the replacement cycle of replacement parts differs depending on the module type and the replacement parts, and the replacement date also differs for each implemented module. Therefore, the replacement timing display makes it possible to plan in advance the preparation of replacement parts and the date of replacement.

[0067] (Operation of the Fourth Embodiment) Next, the operation of the engineering tool of the fourth embodiment will be described with reference to Figures 1, 18 to 22. Figure 18 is a flowchart showing an example of the operation of the engineering tool according to the fourth embodiment. Figure 19 is a diagram showing an example of controller information that can be acquired by the engineering tool according to the fourth embodiment. Figure 20 is a diagram showing an example of combination conditions that can be acquired by the engineering tool according to the fourth embodiment. Figure 21 is a diagram showing an example of alarm information that can be output by the engineering tool according to the fourth embodiment. Figure 22 is a diagram showing an example of combination conditions that can be output by the engineering tool according to the fourth embodiment. The engineering tool of the fourth embodiment has the same configuration as the first embodiment, but the display information is different. In the following description, elements common to the first embodiment are denoted by the same reference numerals, and redundant explanations are omitted.

[0068] In the fourth embodiment, the database 220 of the external server 200 records, as controller information, the types and latest versions of modules (second modules) that can be implemented in the controller 100, compatible version combinations, failure rates for each module, replacement cycles for replacement parts that make up the modules, failure causes, and the status of countermeasures (maintenance information). Among the controller information, the compatible version combinations indicate whether the corresponding relationship between the software version of the CPU module 110 and the version of the I / O module is supported. That is, if a combination of a specific version of the CPU module and a specific version of the I / O module is not supported and normal operation cannot be expected, then that combination is not recommended for use or is not usable.

[0069] The input unit 20 receives information input from the user of the engineering tool 1 (S100). The information acquisition unit 62 sends an information acquisition request to the external server 200 based on the information received by the input unit 20. The server unit 210 acquires controller information from the database 220 in response to the information acquisition request and returns it to the engineering tool 1. The information acquisition unit 62 passes the received controller information to the information generation unit 64, and the information generation unit 64 generates display information based on the received controller information. The display unit 30 displays the display information and presents it to the user (S110).

[0070] Figure 19 shows an example of the display information displayed by the display unit 30. The display information 34c includes controller information, which includes module information and component replacement information, and a download button 30d. In the example shown in Figure 19, the CPU module "CPU-01" is shown to have been selected.

[0071] When display information 34c is displayed on the display unit 30, if an arbitrary module name is clicked using the mouse, which is the input unit 20, the information generation unit 64 generates display information indicating the combination conditions of modules corresponding to the clicked module name based on the received controller information and displays it on the display unit 30.

[0072] Figure 20 shows an example of the display information 34j that appears when a module name is clicked. The display information 34j lists the version combination conditions for the selected module CPU-01. In the example shown in Figure 20, the CPU module CPU-01 has software versions from Ver.1 to Ver.3, but if the software version of the CPU module CPU-01 is Ver.1, the supported I / O modules are limited to I / O-01 to I / O-03, and I / O-04 to I / O-05 are not supported. In other words, if I / O-04 or I / O-05 are to be introduced as I / O modules to the controller 100, the version of the CPU module CPU-01 must be updated to Ver.2 or Ver.3. Such version combination conditions were included in the controller information obtained from the external server 200.

[0073] The input unit 20 waits for a user to click the download button 30d of the displayed information 30c (S120). The information acquisition unit 62 sends a request to the external server 200 to download controller information in response to the click of the download button 30d received by the input unit 20. The server unit 210 retrieves the controller information from the database 220 in response to the download request and sends it to the engineering tool 1. The information acquisition unit 62 stores the received control information in the storage unit 50 (S130).

[0074] The information generation unit 64 generates alarm information based on controller information received from the external server 200 and system data received from the controller 100 (S140). Based on the controller information obtained from the external server 200 and the system data obtained from the controller 100, the information generation unit 64 extracts the module name of the registered module, the version of the implemented module, the failure status, the operating mode, the latest version, the failure rate, and the replacement time to generate alarm information. The display unit 30 displays display information including the generated alarm information (S150).

[0075] Figure 21 shows an example of alarm information 34b generated in S140. In the alarm information 34b shown in Figure 21, the version of the installed module, the failure status of the installed module, and the operating mode obtained from the controller 100 are compared with the latest version corresponding to the installed module, the failure rate of each installed module, and the replacement timing obtained from the external server 200. In this case, if the versions of the installed modules do not conform to the version combination conditions, the relevant information is highlighted. In the example shown in Figure 21, I / O-05, the I / O module of node 8, is highlighted. That is, in the version combination conditions shown in Figure 20, the version of the installed software (S / W) for CPU-01 of CPU module 110 is Ver.2, while the software version of CPU-01 required by I / O module I / O-05 is Ver.3. Therefore, the relevant part of the alarm information 34b shown in Figure 21 is highlighted.

[0076] Here, the input unit 20 waits for a click selection of any version (highlighted version) in each module of the alarm information 34b (S164).

[0077] The information generation unit 64, in response to the click selection received by the input unit 20, applies the selected module's version to the version combination conditions and extracts it as combination condition information (S174), and the display unit 30 displays the combination condition information (S184). The information generation unit 64 highlights versions of the implemented modules that do not conform to the version combination conditions.

[0078] Figure 22 shows an example of combination condition information 33k when a highlighted I / O module (I / O-05) version is selected. In the combination condition information 33k illustrated in Figure 22, the implemented module version is applied to the version combination condition, and non-compliant versions are highlighted.

[0079] According to the engineering tool of this embodiment, the version combination conditions of the modules implemented in the controller are obtained from an external server 200, thereby preventing abnormal shutdowns of the controller due to version incompatibility between implemented modules and preventing errors when adding or replacing modules.

[0080] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents.

[0081] 1...Engineering tool, 10...External communication unit, 20...Input unit, 30...Display unit, 30a-30c, 30e, 32c, 32g, 33c, 34c, 34j...Display information, 30d...Download button, 31b, 32b, 33b, 34b...Alarm information, 31f...Operation failure information, 32h...Change history information, 33i...Replacement timing information, 33k...Combination condition information, 40...Internal communication unit, 50...Storage unit, 60...Calculation unit, 62...Information acquisition unit, 64...Information generation unit, 100...Controller, 110...CPU module, 121, 122, 124, 127, 128...I / O module, 200...External server, 210...Server unit, 220...Database, NW1...Monitoring and control network, NW2...Network

Claims

1. An engineering tool capable of monitoring the status of a controller that monitors and controls a plant, comprising: a log acquisition unit that acquires implementation module information indicating a first module implemented in the controller from the controller; a controller information acquisition unit that can acquire controller information including a second module that can be implemented in the controller and corresponding maintenance information; and an information generation unit that can generate alarm information indicating the association between the implementation module information and the maintenance information corresponding to the first module, based on the implementation module information and the controller information.

2. The engineering tool according to claim 1, characterized in that the implementation module information includes version information indicating the version of the first module, the maintenance information includes latest version information indicating the latest version of the first module, and the alarm information indicates the version information and the latest version information in association.

3. The engineering tool according to claim 1, wherein the maintenance information includes failure rate information indicating at least one of the failure rate and replacement timing of the first module, and the alarm information indicates the implementation module information and the failure rate information in association.

4. The engineering tool according to claim 1, characterized in that the maintenance information includes failure countermeasure information indicating the failure cause of the first module and countermeasure information thereof, and the alarm information indicates the implementation module information and the failure countermeasure information in association.

5. The engineering tool according to claim 1, characterized in that the mounting module information includes information indicating the most recent replacement time of the replacement parts constituting the first module, the maintenance information includes information indicating the replacement cycle of the replacement parts constituting the first module, and the alarm information indicates the relationship between the mounting module information and the replacement time of the replacement parts constituting the first module based on the mounting module information and the maintenance information.

6. The engineering tool according to claim 1, characterized in that the implementation module information includes version information indicating the version of the first module, the maintenance information includes version combination conditions indicating combinations of versions that can be combined with the second modules, and the alarm information indicates whether the combination of versions of the first modules in the controller is suitable or not based on the version information and the maintenance information.

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