JP4820898B2 - Plant monitoring control device and plant monitoring control program - Google Patents

Description

  The present invention relates to a plant monitoring control apparatus and a plant monitoring control program that support operations of a steel plant or the like.

  Conventionally, in a monitoring control system for a large plant or the like, process data (real-time data) for controlling an operating plant has been recorded and reproduced, and used for testing and investigation when a problem occurs.

  For example, in Patent Document 1, in a system in which the operation state of a plant is monitored by a CRT control device, the operation monitoring CRT screen displayed on the CRT control device is monitored when a factor such as a plant trip occurs. Process data status change is automatically detected, process data with status change is stored in a preset period and sample period, and the process data corresponding to the current time and the time is again requested by the operator There is disclosed a plant monitoring apparatus that can change an operation state that changes excessively in a time series in an arbitrary time period to reproduce an excessively changing operation state of the plant.

  Further, in Patent Document 2, a process switching event and an inter-process communication event on a measurement target computer are detected, these events are collected as time series information, and a running period and a non-running period for each process from the process switching event. In addition to creating process operation display data indicating inter-process communication events, inter-process communication data consisting of a pair of transmission process and transmission time and reception process and reception time of inter-process communication is created from the inter-process communication event. An analysis / display device configured to display a traveling period in time series is disclosed.

JP 2001-154731 A JP 2003-157185 A

However, the above prior art has the following problems.
(1) The input data of the supervisory control system includes a wide variety of transmission media (control LAN, Ethernet (registered trademark), serial bus), transmission protocols (control LAN dedicated protocol, TCP / IP, UDP, BSC, etc.) It is difficult to record and reproduce these data collectively, and it is difficult to accurately reproduce the input data in process units.
(2) In the supervisory control system, a plurality of processes are continuously operated in the server based on an external event generated by a lower-level controller or the like that controls plant equipment, and a function corresponding to the external event is realized. If multiple external events occur at the same time, the same process may run multiple times, so it is possible to confirm which external event corresponds to the history in the form of managing the context between processes by time It was difficult.

  In view of the above-described problems of the prior art, the present invention provides a plant monitoring control apparatus and a plant monitoring control program capable of grasping a relationship between an external event that has occurred and a process to be executed and performing an accurate reproduction test. With the goal.

Plant monitoring control system according to the present invention, are connected via a network to a device according to the lower-level controller and the control for controlling the plant equipment, a plant monitoring control unit for monitoring and control of the lower-level controller, it said An external event reception process definition section that predefines an external event reception process that is activated by the reception of an external event that has occurred in a lower controller or the device, and detects the occurrence of the external event defined in the external event reception process definition section while, the running external event reception process sequentially a predetermined process as the starting point based on the occurrence of the external event, and a control process execution unit which controls the lower-level controller, the sensed external event in the control process execution unit Identify Issues a vent number, the event ID, the process ID of the executed process, execution time, the boot source process ID, start destination process ID, inputted input data to the executed process, before and after the execution characterized by comprising a process execution history recording unit for the process execution history consisting of the output data resulting from the execution of the process the internal data and the process for recording in association with the event number, the in.

A plant monitoring control program according to the present invention is connected to a lower-level controller that controls plant equipment and a device related to the control via a network, respectively, and the lower-level controller or an external event definition step of predefining an external event reception process started by the reception of the external events that have occurred had contact to the device, as well as detecting the occurrence of a defined external events in the external event definition step, this the external event receiving process sequentially executes a predetermined process starting based on the occurrence of an external event, identification and control process execution step, the sensed external event in the control process execution step of controlling the lower-level controller With issues an event number to the event number, the process ID of the executed process, execution time, the boot source process ID, start destination process ID, inputted input data to the executed process, the execution characterized in that to execute a process execution history recording step of recording the process execution history consisting of the output data resulting from the execution of the process the internal data and the process associated with the event number before and after.

  ADVANTAGE OF THE INVENTION According to this invention, the plant monitoring control apparatus and plant monitoring control program which grasp | ascertained the relationship between the generated external event and the process performed, and can perform an exact reproduction test are provided.

The block diagram which shows the example of whole structure of the plant monitoring control apparatus which concerns on one Embodiment of this invention. The figure which shows the specific example of the memory content of the external event reception process definition part shown in FIG. The figure which shows the specific example of the memory content of the process execution log | history storage part shown in FIG. The figure which shows the hardware structural example of the computer applied to the plant monitoring control apparatus and operation terminal which are shown in FIG. The flowchart which shows the specific example of the process in the process execution history recording part shown in FIG. The figure which shows the example of issue of the event number and hierarchy number in the process execution history recording part shown in FIG. The figure explaining the process in the process execution history recording part shown in FIG. The flowchart which shows the specific example of the process in the process execution log | history reproduction | regeneration part shown in FIG. The figure explaining the process in the process execution log | history reproduction | regeneration part shown in FIG.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a block diagram showing an example of the overall configuration of a plant monitoring control apparatus 1 according to an embodiment of the present invention. As shown in the figure, the plant monitoring control device 1 is connected to the operation terminal 3 via an information system LAN 2 such as Ethernet (registered trademark), and is connected to a lower controller 5 via a control LAN 4. It is a device that monitors and controls the plant equipment 6 by transmitting information to the lower controller 5 that actually operates the plant equipment 6 (rolling mill, sensor, measuring instrument, servo valve, etc.).

  The operation terminal 3 is a terminal for displaying plant data in the plant monitoring control device 1 and correcting control information. Further, the operation terminal 3 reads a process execution history including inter-process interface information (input data and output data) from the plant monitoring control device 1, and the process execution grouped in the date order or for each external event in the plant monitoring control device 1. Display the history. Chart display is also possible based on the grouped list result. Furthermore, after the user refers to the display result of the process execution history and designates the number or process ID of the external event that the user wants to perform the reproduction test from the operation terminal 3, the operation terminal 3 sends the request to the plant monitoring control. It also has a function of transmitting to the device 1.

Unlike the information LAN 2, the control LAN 4 is a LAN capable of high-speed transmission corresponding to the plant equipment 6 that requires real-time performance in units of several milliseconds. For example, TC-net _TM, which is being standardized at the International Electrotechnical Commission (IEC), is adopted as the control LAN 4.

  As shown in FIG. 1, the plant monitoring control device 1 includes a control process execution unit 11, an external event reception process definition unit 12, a process execution history recording unit 13, a process execution history storage unit 14, and a process execution history reproduction unit. 15 includes a process execution history search unit 16, an input / output I / F unit 17, and a data transmission / reception unit 18.

  The control process execution unit 11 is a program that controls the lower controller 5 by detecting the occurrence of an external event in the operation terminal 3, the lower controller 5 and the like, and sequentially executing a predetermined process based on the detection of the external event. . In addition, it is not only the lower-level controller 5 and the operation terminal 3 that are handled as external events, but also other devices connected to the information system LAN 2 (a higher-level computer that is higher in the target plant monitoring device, a plant monitoring device of another plant, Events in measurement equipment) are also included.

  For example, in the case of a steel plant, specific examples of the external event include ON / OFF switching of a rolling mill (plant equipment 6) and reception of a specific signal. Further, as a specific example of the external event in the operation terminal 3, there is an input of control information (such as a plant operation stop command) from the operation screen. In addition, as a specific example of the process for controlling the steel plant, a configuration control process for performing a startup process, a shutdown process, a switching process to a standby system (not shown) connected to the information system LAN 2 and the control LAN 4, A tracking process for tracking the position of the material on the plant, a calculation process for calculating a set value for the plant equipment 6 using a mathematical model, a setting process for outputting the setting to the plant equipment 6, and collection of actual data of the plant equipment 6 Such as a collection process. In this embodiment, when a process is activated based on detection of an external event, detection information of the external event is notified to the process execution history recording unit 13 together with the ID of the activation process. Even when another process is started from a certain process, common external event detection information is notified.

  The external event reception process definition unit 12 is a process activated first by reception of an external event (hereinafter, “external event reception process”) as information for determining the type of process executed by the control process execution unit 11. It is a storage device that predefines the ID. FIG. 2 is a diagram showing a specific example of the contents stored in the external event reception process definition unit 12 shown in FIG.

  The process execution history recording unit 13 refers to the external event reception process defined in the external event reception process definition unit 12, issues an event number for identifying the external event detected by the control process execution unit 11, and A process execution history storage unit that is a storage device such as a hard disk in association with an event number and a process ID, which is associated with an event number and a process ID. 14 is a program to be recorded. The process operation at a certain timing is determined by the process internal data and input data at the time of the event occurrence, but it can be accurately reproduced by recording the process internal data and input data before processing in units of combinations of external events and processes. A test can be performed.

  FIG. 3 is a diagram showing a specific example of the contents stored in the process execution history storage unit 14 shown in FIG. Here, process execution time, event number, process ID, hierarchy number, start source process ID, start destination process ID, input data, process internal data (before processing), output data, and process internal data (after processing) are executed. It is listed as a history item. The process execution history is sorted by external event and hierarchy number, grouped for each external event, and displayed on the operation terminal 3 as a list or graphic.

  The process execution history reproducing unit 15 acquires, for each process ID, the process execution history recorded in the process execution history storage unit 14 by the process execution history recording unit 13 based on the event number or process ID externally input from the operation terminal 3. In addition, this is a program that outputs the acquired input data and internal process data before execution to the control process execution unit 11 in units of process IDs, and requests re-execution of a desired process.

  The process execution history search unit 16 is a program that acquires a process execution history from the process execution history storage unit 14 based on a search condition externally input from the operation terminal 3 and outputs the process execution history to the operation terminal 3.

  The input / output I / F unit 17 receives input information externally input from the operation terminal 3 and transmitted via the information system LAN 2, and receives a control process execution unit 11, a process execution history reproduction unit 15, and a process execution history search unit 16 is an interface (program) that outputs to 16 and outputs the processing results in each unit to the operation terminal 3.

  The data transmitter / receiver 18 is a communication program for transmitting / receiving data to / from the lower controller 5 via the control LAN 4. As a specific example of data received by the data transmitter / receiver 18, an external event occurrence in the lower controller 5 Information is output to the control process execution unit 11. Specific examples of data to be transmitted include control command information to the lower controller 5 output from the control process execution unit 11.

  FIG. 4 is a diagram illustrating a hardware configuration example of a computer applied to the plant monitoring control device 1 and the operation terminal 3 illustrated in FIG. 1. As shown in the figure, a computer applied to the plant monitoring control device 1 and the operation terminal 3 includes a CPU (Central Processing Unit) 71, a ROM (Read Only Memory) 72, a RAM (Random Access Memory) 73, and an input / output. It comprises an interface 74, a system bus 75, an input device 76, a display device 77, an auxiliary storage device 78, and a communication device 79. In addition, about the plant monitoring control apparatus 1 which concerns on this embodiment, in order to input and display data by the operation terminal 3, the input device 76 and the display apparatus 77 are omissible.

  The CPU 71 is a processing device that executes various arithmetic processes using programs, data, and the like stored in the ROM 72 and the RAM 73. The ROM 72 is a read-only storage device that stores basic programs and environment files for causing the computer to function. The RAM 73 is a storage device that stores a program executed by the CPU 71 and data necessary for executing each program, and can be read and written at high speed. The input / output interface 74 is a device and a program that mediate connection between various hardware and the system bus 75. The system bus 75 is an information transmission path shared by the CPU 71, ROM 72, RAM 73 and input / output interface 74.

  The input / output interface 74 is connected to hardware such as an input device 76, a display device 77, an auxiliary storage device 78, and a communication device 79. The input device 76 is a device that processes input from the user, and is, for example, a keyboard or a mouse. The display device 77 is a device that displays a calculation result, a creation screen, and the like to the user, and is a CRT, a liquid crystal display, a plasma display, or the like, for example. The auxiliary storage device 78 is a large-capacity storage device that stores programs and data, and is, for example, a hard disk device.

FIG. 5 is a flowchart showing a specific example of processing in the process execution history recording unit 13 shown in FIG.
In step S501, it is determined whether or not a process is activated. If it is determined that the process has been started, the process proceeds to S502. On the other hand, if it is determined that the process is not activated, the process waits until the process is activated.

  In S502, the external event reception process definition unit 12 is referred to based on the process ID of the activated process, and it is determined whether or not the process is an external event reception process. If it is determined that the activated process is an external event reception process, the process advances to step S503. On the other hand, if it is determined that the activated process is not an external event reception process, the process proceeds to S504.

In S503, 1 is added to the final event number to obtain the event number related to the activation process, and the hierarchy number is set to 1.
In S504, the same event number as the activation source process is set as the event number related to the activation process, and 1 is added to the hierarchy number of the activation source process to obtain the hierarchy number.

  FIG. 6 is a diagram showing an example of issuance of event numbers and hierarchy numbers in the process execution history recording unit 13 shown in FIG. When an external event occurs for a certain process, if the activated process is an external event receiving process (predefined), an event number is newly assigned. On the other hand, if the activation process is not an external event reception process, the event number set in the input data is inherited. Also, a value obtained by adding 1 is set as the hierarchy number. The event number and the hierarchy number are associated with input data when another process is started. Then, by repeating this recording process every time the process is activated, it is possible to acquire the hierarchy of the inter-process interface generated at a certain external timing. This recording process is suitable because it is not necessary to modify the control program itself by incorporating it into the event reception and transmission functions.

In S505, the input data and the process internal data before processing are acquired and recorded in the process execution history storage unit 14 as a process execution history together with the event number, the activation source process ID, and the hierarchy number.
In S506, it is determined whether or not the execution of the process is completed. If it is determined that the process has been executed, the process proceeds to S507. On the other hand, when it is determined that the execution of the process is not completed, the process waits until the process is completed.
In S507, the output data by the execution of the process and the internal data after the process are acquired, the record created in S505 is updated together with the activation destination process ID, and the process ends.

  FIG. 7 is a diagram for explaining processing in the process execution history recording unit 13 shown in FIG. Here, when the process B is started from the process A and the process C is started by executing the process B, the output data from the process A is used as the input data of the process B as the execution history of the process B. In addition, process internal data at the time of an external event generated by a call from the process A (before processing), process internal data after processing, and output data that is the execution result of the process B are collected in the process execution history recording unit 13, and the external It is shown that a predetermined process is performed with reference to the information of the external event reception process stored in the event reception process definition unit 12 and then stored in the process execution history storage unit 14.

FIG. 8 is a flowchart showing a specific example of processing in the process execution history reproducing unit 15 shown in FIG.
In S801, the presence / absence of a reproduction request from the operation terminal 3 is determined. If it is determined that there is a reproduction request, the process proceeds to S802. On the other hand, if it is determined that there is no reproduction request, the standby state is maintained until there is a request.

In S <b> 802, it is determined which of the event number and the process ID has been designated on the operation terminal 3. If it is determined that the event number is specified, the process advances to step S803. On the other hand, if it is determined that the process ID is specified, the process proceeds to S805.
In step S803, process IDs of all relevant processes including the external event reception process are acquired from the process execution history storage unit 14 using the designated event number as a key.

In step S804, each process execution history is acquired using the acquired process ID as a key.
In step S805, the process execution history is acquired from the process execution history storage unit 14 using the designated process ID as a key.

In S806, process internal data (before processing) in the process execution history is transmitted to the test target process and set as an initial value. In the present embodiment, when an event number is specified, process internal data (before processing) is set for all processes from the external event receiving process to the final process acquired in S803, and processing is continuously performed. By doing so, it is possible to test by event.
In step S807, the input data in the process execution history is transmitted, the execution of the test target process is requested, and the process ends.

  FIG. 9 is a diagram for explaining processing in the process execution history reproducing unit 15 shown in FIG. In accordance with the event number and process ID specified on the operation terminal 3, the process internal data before processing is acquired from the process execution history storage unit 14 and the process internal data is updated. Thereafter, the input data is transmitted, and the execution of the test target process is requested, and the result of this processing is stored again in the process execution history storage unit 14 by the process execution history recording unit 13 as shown in FIG. The results from the reproduction test can be evaluated.

Thus, according to the plant monitoring control device 1 according to the present embodiment, the following effects are produced.
(1) By recording not only the input data for the startup process but also the process internal data at the time of external event occurrence before and after the processing, the situation at the time of the trouble occurrence can be accurately grasped and the cause can be easily investigated.
(2) A reproduction test for each process can be performed accurately and easily with various transmission media and transmission protocols insulated. In addition, since the test using the local operation data can be easily performed without creating new test data, the cause of the trouble can be easily determined, and the test at the time of program modification can be easily performed.
(3) Since activation traces can be grouped for each external event, it is useful for combination tests in factories. In addition, it is possible to easily track which external event the problem has occurred.

  Note that the present invention is not limited to the above-described embodiment as it is, and can be embodied by modifying the constituent elements without departing from the scope of the invention in the implementation stage. In addition, various inventions can be formed by appropriately combining a plurality of components disclosed in the embodiment. For example, some components may be deleted from all the components shown in the embodiment.

DESCRIPTION OF SYMBOLS 1 ... Plant monitoring control apparatus 2 ... Information system LAN
3 ... Operation terminal 4 ... LAN for control
DESCRIPTION OF SYMBOLS 5 ... Lower level controller 6 ... Plant equipment 11 ... Control process execution part 12 ... External event reception process definition part 13 ... Process execution history recording part 14 ... Process execution history storage part 15 ... Process execution history reproduction part 16 ... Process execution history search part 17 ... Input / output I / F unit 18 ... Data transmission / reception unit 71 ... CPU
72 ... ROM
73 ... RAM
74: I / O interface 75 ... System bus 76 ... Input device 77 ... Display device 78 ... Auxiliary storage device 79 ... Communication device

Claims (5)

A plant monitoring control device that is connected to each of a lower-level controller that controls plant equipment and a device related to the control via a network and monitors and controls the lower-order controller,
An external event reception process definition unit that predefines an external event reception process that is activated by reception of an external event that has occurred in the lower controller or the device;
The occurrence of the external event defined by the external event reception process definition unit is detected, and a predetermined process is sequentially executed starting from the external event reception process based on the occurrence of the external event to control the lower controller. A control process execution unit ,
An event number identifying an external event detected by the control process execution unit is issued, and the event number, process ID of the executed process, execution time, start source process ID, start destination process ID, and the executed and process execution history recording unit for the process execution history consisting of the output data resulting from the execution of the process the internal data and the process for recording in association with the event number before and after the inputted input data, the execution for the process,
A plant supervisory control device comprising:   The process execution history recorded in the process execution history recording unit based on the externally input event number or the process ID is acquired for each process ID, and the acquired input data and the process before the execution are acquired. The plant monitoring control apparatus according to claim 1, further comprising a process execution history reproducing unit that outputs internal data to the control process execution unit in units of the process ID and requests re-execution of the process.   3. The process execution history recording unit records the process execution history by assigning a hierarchical number based on a starting order of the processes executed based on the external event. The plant monitoring control device described. A plant monitoring control device connected to each of a lower controller for controlling plant equipment and a device related to the control via a network and monitoring and controlling the lower controller,
An external event definition step of predefining an external event reception process started by the reception of the external events that have occurred had contact with the lower-level controller or the device,
A control process that detects the occurrence of an external event defined in the external event definition step, and sequentially executes a predetermined process starting from the external event reception process based on the occurrence of the external event to control the subordinate controller Execution steps ;
The event number identifying the external event detected in the control process execution step is issued, and the event number, the process ID of the executed process, the execution time, the start source process ID, the start destination process ID, and the executed and process execution history recording step of the process execution history consisting of the output data resulting from the execution of the process the internal data and the process for recording in association with the event number before and after the inputted input data, the execution for the process,
A plant monitoring control program characterized by causing   The process execution history recorded in the process execution history recording step based on the externally input event number or the process ID is acquired for each process ID, and the acquired input data and the process before the execution are acquired. 5. The plant monitoring control program according to claim 4, further comprising the step of outputting a process execution history reproduction step for outputting internal data in units of the process ID and requesting re-execution of the process.

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