JP2018005623A - Plant control apparatus testing system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To start a reproduction test in a state where the contents of an internal memory of an existing control apparatus is reflected in an internal memory of a test object control apparatus when executing the reproduction test to reproduce an external input signal of the existing control apparatus to the test object control apparatus.SOLUTION: An existing external input output signal collection part 12 collects existing external input signals input by an existing control apparatus 1 in each time of a collection period. An internal memory information save part 21 records information of the internal memory of the existing control apparatus 1 in a specific collection time during the collection period. An internal memory information conversion part 31 converts the internal memory information recorded by the internal memory information save part 21 into an update internal memory information corresponding to a format of an internal memory of a test object control apparatus 50. An update internal memory information load part loads the update internal memory information to the internal memory of the test object control apparatus 50. A reproduction test execution part 14 outputs in time-series order the existing external input signals collected after the collection time to the test object control apparatus 50 after the loading is completed.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a plant control device test system suitable for performing a test associated with replacement of a plant control device or program update or change.

  A large-scale plant such as a steel plant has a plurality of control devices for each process. Plant operation is realized by a plant control device (hereinafter simply referred to as a control device) controlling the control equipment of each process individually or as a whole. The control device is controlled by the control device in accordance with a sequence program. An operation amount signal from an operation input device operated by an operator and state feedback signals from various sensors attached to the control target plant are input to the control device, and control signals corresponding to these input signals are transmitted according to a sequence program. Output from the controller.

  The above-mentioned program is created according to the required specifications related to plant operation. When the control device is incorporated into an actual plant and operated, a program verified to operate according to the required specifications is used.

  However, even in existing plants, the control device may be replaced as necessary. In some cases, the program may be updated or changed. The work required in such a case is a test for confirming whether the control device after replacement or the control device after program update or change meets the required specifications. As one of the test methods, there is a test method using a plant simulator that can test the control device separately from the actual plant. However, in this test method, the accuracy of the test depends on the knowledge amount and experience value of the examiner.

  In another test method, first, an operation amount signal output from an operation input device of an existing actual plant and a state feedback signal output by controlling the control device of the actual plant by the existing control device, Recording is performed with a test device of a control device (hereinafter simply referred to as a test device). After that, connect the test equipment to the test environment disconnected from the actual plant, reproduce the recorded real plant signal from the test equipment, and input the control signal and the state feedback signal to the control device under test. Output. There is a test method for comparing the output of the existing control device recorded in the actual plant with the output of the control device under test by the control output comparison / determination device and the control output display device.

  The above test method is described in, for example, Japanese Patent Application Laid-Open No. 2012-14584 (Patent Document 1).

JP 2012-14584 A

  In the conventional test apparatus, only the external input / output signals (the above-described manipulated variable signal and state feedback signal) of the existing control apparatus are recorded from the actual plant. The test is performed without collecting the internal memory information of the existing control device of the actual plant.

  Information stored in the internal memory includes, for example, state values according to the position and speed of actuators and sensors, and cumulative values such as temperatures estimated from the operation history of the control device. The same output cannot be obtained even if the same input is given unless the control device and the device under test are set identically. In order to verify whether both can perform the same output, it is necessary to set the internal memory of the control device under test at the start of the test to the same setting as the internal memory of the existing control device.

  Conventionally, in order to set the internal memory of the control device under test to the same setting as the internal memory of the existing control device, the tester makes settings by trial and error. For this reason, a lot of time is required for setting, and in order to improve the efficiency of the test, the internal memory information (set value of the internal memory) of the controller under test at the start of the test is created from the internal memory information of the existing control device. There is a need to.

  The present invention has been made in order to solve the above-described problems. When an external control signal for recording an external input signal of an existing control device is recorded and played back to the control device under test, the existing control device is provided. An object of the present invention is to provide a plant control device test system that can start a regeneration test after reflecting the contents of the internal memory in the internal memory of the control device under test in a short time.

In order to achieve the above object, the present invention is a plant control device test system for reproducing the signals input and output by the existing control device of the actual plant system and verifying the operation of the control device under test.
At each time of the collection period, an existing external input / output signal collecting unit that collects an existing external input signal input by the existing control device and an existing external output signal output by the existing control device;
An internal memory information saving unit for recording information of an internal memory of the existing control device at a predetermined collection time during the collection period;
An internal memory information conversion unit that converts the internal memory information recorded by the internal memory information saving unit into updated internal memory information corresponding to the format of the internal memory of the device under test;
An updated internal memory information loading unit for loading the updated internal memory information into the internal memory of the control device under test;
A reproduction test execution unit that outputs the existing external input signals collected after the collection time to the device under test in chronological order after completion of the loading by the updated internal memory information loading unit. .

  Preferably, the internal memory information conversion unit includes a conversion table that defines a correspondence relationship between an address and a data value of the internal memory of the existing control device and an address and a data value of the internal memory of the control target device, Based on the conversion table, the internal memory information recorded by the internal memory information saving unit is automatically converted into updated internal memory information corresponding to the format of the internal memory of the device under test.

  Preferably, a comparison display processing unit that displays the existing external output signal collected after the collection time and the external output signal under test output by the control device under test in a time-sequentially arranged state for comparison. It is further provided with the feature.

  According to the present invention, when performing a reproduction test in which an external input signal of an existing control device is recorded and played back to the control device under test, the content of the internal memory of the existing control device is changed to the internal memory of the control device under test. The reproduction test can be started after reflecting in a short time.

BRIEF DESCRIPTION OF THE DRAWINGS It is the whole block diagram which showed the plant control apparatus test system which concerns on Embodiment 1 of this invention together with the actual plant system. It is a functional block diagram for demonstrating the function and operation | movement of a plant control apparatus test system. 3 is a diagram schematically showing a process of saving internal memory information of an existing control device 1, converting it into updated internal memory information by an internal memory information conversion unit, and loading it into an internal memory of a control device under test 50. FIG. It is the whole block diagram which showed the modification of the plant control apparatus test system which concerns on Embodiment 1 of this invention together with the actual plant system. 3 is a block diagram illustrating a hardware configuration example of processing circuits included in the test apparatus 10, the internal memory information management unit 30, and the comparison display unit 40, respectively. FIG.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, the same code | symbol is attached | subjected to the element which is common in each figure, and the overlapping description is abbreviate | omitted.

Embodiment 1 FIG.
FIG. 1 is an overall configuration diagram showing a plant control apparatus test system according to Embodiment 1 of the present invention together with an actual plant system.

<Real plant system>
The actual plant system includes a control device (not shown) of a control target plant, a plant control device (hereinafter simply referred to as an existing control device 1) for controlling the control device, and an operation input device (not shown) operated by an operator. Are connected to each other via the existing control network 2. The existing control device 1 is a tested control device, that is, a control device that has already been confirmed to meet the required specifications. Control of the control device by the existing control device 1 is performed according to a sequence program. The existing control device 1 inputs an operation amount signal from the operation input device and state feedback signals from various sensors attached to the control target plant. The existing control device 1 outputs these input signals and control signals corresponding to the internal memory information according to the sequence program.

<Plant control system test system>
Next, an outline of the plant control apparatus test system will be described with reference to FIG.
The plant control device test system includes a test device 10, an internal memory information collection device 20, an internal memory information management unit 30, and a comparison display unit 40. The test apparatus 10, the internal memory information management unit 30, and the comparison display unit 40 are connected to each other via the update control network 3. The internal memory information collecting device 20 is attached to the existing control device 1 and connected to the update control network 3 via the existing control network 2 and the gateway 4. The plant control device test system is connected to a plant control device to be tested (hereinafter simply referred to as a control device under test 50) via the update control network 3.

  The plant control apparatus test system records an input signal to the existing control apparatus 1 of the actual plant system, reproduces it as an input signal of the control apparatus under test 50, and performs a reproduction test for verifying the output signal of the control apparatus under test 50. It is a system for carrying out.

  The plant control device test system performs a regeneration test in a test environment separated from the actual plant system and a process for collecting data necessary for the regeneration test from the actual plant system in operation (hereinafter referred to as an actual plant process). The process is divided into two steps (hereinafter referred to as test steps).

  An outline of the actual plant process will be described. In the actual plant process, the existing external input signal (the operation amount signal and the state feedback signal described above) input to the existing control device 1 and the existing external output signal (the control signal described above) output from the existing control device 1 are It is output on the control network 2. The existing control network 2 and the update control network 3 to which the test apparatus 10 is connected are connected by a gateway 4 to interface signals. The test apparatus 10 accumulates the existing external input signal and the existing external output signal in the storage unit 100.

  In addition, when the existing external input signal and the existing external output signal are recorded from the actual plant system, the internal memory information collecting device 20 attached to the existing control device 1 is information on the internal memory of the existing control device 1 (internal memory). Information).

  The collected internal memory information of the existing control device 1 and its collection time are transmitted to the internal memory information management unit 30 via the existing control network 2, the gateway 4, and the update control network 3. The collected internal memory information of the existing control device 1 is converted into a format according to the internal memory of the control device under test 50 by the internal memory information management unit 30, and updated internal memory information (setting of the internal memory of the control device under test 50) Value) is stored in the storage unit 300.

  An outline of the test process will be described. In the test process, the controller under test 50 is connected to a test environment separated from the actual plant system, and a regeneration test is performed.

  Before starting the test, the updated internal memory information is output from the internal memory information management unit 30 to the control device under test 50 and set as an initial state of the internal memory of the control device under test 50. Thereafter, the test apparatus 10 starts a reproduction test. The test apparatus 10 outputs the existing external input signal and the existing external output signal stored in the storage unit 100 to the update control network 3. The existing external input signal and the existing external output signal are reproduced on the update control network 3, and the reproduced existing external input signal is input to the control device under test 50. The control device under test 50 outputs a control signal (external output signal under test) corresponding to the existing external input signal and the current state of the internal memory to the update control network 3 according to the internal program.

  The comparison display unit 40 takes in an existing external output signal and an external output signal to be tested output on the update control network 3 and displays them in a state in which they can be compared in a time-series order.

  Next, functions and operations of the plant control device test system will be described in more detail with reference to FIGS. FIG. 2 is a functional block diagram for explaining functions and operations of the plant control apparatus test system. FIG. 3 is a diagram schematically showing a process of saving the internal memory information of the existing control device 1, converting it into updated internal memory information by the internal memory information conversion unit, and loading it into the internal memory of the control device under test 50. .

  In FIG. 2, the test apparatus 10 includes a test data collection command unit 11, an existing external input / output signal collection unit 12, an initial setting command unit 13, and a reproduction test execution unit 14. The internal memory information collecting device 20 includes an internal memory information saving unit 21. The internal memory information management unit 30 includes an internal memory information conversion unit 31 and an updated internal memory information load unit 32. The comparison display unit 40 includes an external output signal collection unit 41 to be tested and a comparison display processing unit 42.

  The processing content of each part of FIG. 2 is demonstrated along the flow of the process in an actual plant process and a test process. First, processing in an actual plant process will be described.

  The test data collection command unit 11 outputs a data collection command for collecting data for regeneration test from the operating actual plant system in accordance with an operator operation on the test apparatus 10 or a task scheduled in advance. The data collection command is given a collection period.

  Next, the existing external input / output signal collecting unit 12 responds to the data collection command, and the existing external input signal input by the existing control device 1 and the existing external output signal output by the existing control device 1 at each time of the collection period. To collect. The test apparatus 10 associates the collected time with each collected signal and stores it in the storage unit 100 (FIG. 1).

  The internal memory information saving unit 21 is configured so that the existing control device 1 at a predetermined collection time during the above-described collection period in response to a data collection command from the test data collection command unit 11 or an operator's operation on the internal memory information collection device 20. The current state of the internal memory (internal memory information) is recorded. The internal memory information collection device 20 associates the collected internal memory information with the above-described predetermined collection time (hereinafter referred to as “memory information collection time”) and transmits it to the internal memory information management unit 30.

  The internal memory information conversion unit 31 converts the internal memory information recorded by the internal memory information saving unit 21 into updated internal memory information corresponding to the internal memory format of the control device under test 50. More specifically, as shown in FIG. 3, the internal memory information conversion unit 31 corresponds to the correspondence between the address and data value of the internal memory of the existing control device 1 and the address and data value of the internal memory of the control device under test 50. (Conversion rule) is provided, and the internal memory information recorded by the internal memory information saving unit 21 is automatically updated according to the format of the internal memory of the device under test 50 based on the conversion table. Convert to memory information. The updated internal memory information is stored in the storage unit 300 in association with the memory information collection time described above. The above is the range to be implemented in the actual plant process.

  Next, processing in a test process for executing a regeneration test on the control apparatus under test 50 in a test environment separated from the actual plant system will be described.

  First, the initial setting command unit 13 outputs an initial setting command for setting an initial value in the internal memory of the control apparatus under test 50.

  Next, the updated internal memory information loading unit 32 loads the updated internal memory information stored in the storage unit 300 into the internal memory of the control device under test 50 in response to the initial setting command. Thereby, the initial value of the internal memory of the control device under test 50 is set to be equivalent to the information of the internal memory of the existing control device 1 during the memory information collection time described above. After the loading is completed, the updated internal memory information loading unit 32 outputs a load completion notification to the initial setting command unit 13.

  The initial setting command unit 13 confirms the load completion notification and then instructs the execution of the regeneration test.

  The reproduction test execution unit 14 reproduces the existing external input signal and the existing external output signal stored in the storage unit 100 on the update control network 3. More specifically, the reproduction test execution unit 14 is associated with a time after the memory information collection time attached to the updated internal memory information among the existing external input signal and the existing external output signal stored in the storage unit 100. Play the signals in chronological order.

  The existing external input signal reproduced on the update control network 3 is input to the control device under test 50. The control device under test 50 outputs a control signal (external output signal under test) corresponding to the existing external input signal and the current state of the internal memory to the update control network 3 according to the internal program. Note that the current state of the internal memory of the control device under test 50 is updated as needed every time an operation is performed based on each existing external input signal input in chronological order after the initial setting. It is sufficient if the memory information is initialized.

  The tested external output signal collecting unit 41 collects the existing external output signal reproduced on the update control network 3 and the tested external output signal output to the update control network 3 by the tested device 50. Preferably, an existing external input signal is also collected.

  The comparison display processing unit 42 arranges the existing external output signal and the external output signal under test in time series order and displays them in a comparable state. Preferably, the existing external input signal, the existing external output signal, and the external output signal under test are displayed in a state that can be compared in a time-series order.

<Effect>
As described above, according to the plant control apparatus test system of the first embodiment described above, the internal memory information saving unit 21, the internal memory information conversion unit 31, the updated internal memory information load unit 32, and the reproduction test execution unit 14 are provided. Therefore, the reproduction test can be started after the contents of the internal memory of the existing control device are automatically reflected in the internal memory of the control device under test.

  Conventionally, when performing a regeneration test on the device under test 50 in a test environment separated from the actual plant system, the internal memory of the control device under test 50 generated as an initial operation is used as the internal memory of the existing control device 1. It is possible to shorten the time required for the adjustment work to make the same state by trial and error. As a result, more time can be devoted to the functional test, and the efficiency of the test work can be improved and the test quality can be improved.

<Modification>
As mentioned above, although embodiment of this invention was described, this invention is not limited to the above-mentioned embodiment. Various modifications can be made without departing from the spirit of the present invention. For example, modifications may be made as in the following examples.

  In the example illustrated in FIG. 1, the test apparatus 10, the internal memory information management unit 30, and the comparison display unit 40 are independent apparatuses. However, if the hardware specifications of the test apparatus 10 are sufficiently high, the test apparatus 10 includes the internal memory. Each function of one or both of the information management unit 30 and the comparison display unit 40 may be taken in.

  In the example shown in FIG. 1, the internal memory information management unit 30 is connected to the update control network 3, but as shown in FIG. 4, the internal memory information management unit 30a and the internal memory information collection device 20 are connected by a communication cable. Direct connection may be made to collect internal memory information. In this case, the collection process is executed by the operator operating the internal memory information collection device 20. The function of the internal memory information management unit 30 a is the same as that of the internal memory information management unit 30. The updated internal memory information is sent from the internal memory information management unit 30a to the control device under test 50 via a communication cable, a storage medium, or the like. The operator reproduces the existing external input signal from the test apparatus 10 after the loading is completed.

  In addition, since the internal clocks of the test apparatus 10, the internal memory information collection apparatus 20, and the internal memory information management unit 30 need to have the same time, it is desirable to have a function of synchronizing the time.

<Hardware configuration example>
FIG. 5 is a block diagram illustrating a hardware configuration example of processing circuits included in the test apparatus 10, the internal memory information management unit 30, and the comparison display unit 40. Each part shown in FIG. 2 shows a part of the functions of this system, and each function is realized by a processing circuit. For example, the processing circuit includes a CPU (Central Processing Unit) 101, a ROM (Read Only Memory) 102, a RAM (Random Access Memory) 103, an input / output interface 104, a system bus 105, an input device 106, a display device 107, a storage 108, and The computer includes a communication device 109.

  The CPU 101 is a processing device that executes various types of arithmetic processing using programs and data stored in the ROM 102 and the RAM 103. The ROM 102 is a read-only storage device that stores a basic program, an environment file, and the like for causing a computer to realize each function. A RAM 103 is a main storage device that stores a program executed by the CPU 101 and data necessary for the execution of each program, and can be read and written at high speed. The input / output interface 104 is a device that mediates connections between various hardware and the system bus 105. A system bus 105 is an information transmission path shared by the CPU 101, ROM 102, RAM 103, and input / output interface 104.

  The input / output interface 104 is connected to hardware such as an input device 106, a display device 107, a storage 108, and a communication device 109. The input device 106 is a device that processes input from a user. The display device 107 is a device that displays the state of the system. The storage 108 is a large-capacity auxiliary storage device that stores programs and data, and is, for example, a hard disk device or a nonvolatile semiconductor memory. The storage units 100 and 300 described above are realized by the storage 108. The communication device 109 is a device capable of data communication with an external device by wire or wireless.

DESCRIPTION OF SYMBOLS 1 Existing control apparatus 2 Existing control network 3 Update control network 4 Gateway 10 Test apparatus 11 Test data collection command part 12 Existing external input / output signal collection part 13 Initial setting command part 14 Reproduction test execution part 20 Internal memory information collection apparatus 21 Internal memory Information save unit 30, 30a Internal memory information management unit 31 Internal memory information conversion unit 32 Updated internal memory information load unit 40 Comparison display unit 41 External output signal collection unit under test 42 Comparison display processing unit 50 Control devices under test 100, 300 Storage Part 105 System bus

Claims (3)

A plant control device test system for reproducing the signals input / output by the existing control device of the actual plant system to verify the operation of the control device under test,
At each time of the collection period, an existing external input / output signal collecting unit that collects an existing external input signal input by the existing control device and an existing external output signal output by the existing control device;
An internal memory information saving unit for recording information of an internal memory of the existing control device at a predetermined collection time during the collection period;
An internal memory information conversion unit that converts the internal memory information recorded by the internal memory information saving unit into updated internal memory information corresponding to the format of the internal memory of the device under test;
An updated internal memory information loading unit for loading the updated internal memory information into the internal memory of the control device under test;
A reproduction test execution unit that outputs the existing external input signals collected after the collection time to the device under test in time series after loading by the updated internal memory information load unit;
A plant control apparatus test system comprising: The internal memory information conversion unit includes a conversion table that defines a correspondence relationship between the address and data value of the internal memory of the existing control device and the address and data value of the internal memory of the control device under test. Automatically converting the internal memory information recorded by the internal memory information saving unit into updated internal memory information according to the format of the internal memory of the control device under test,
The plant control device test system according to claim 1. A comparison display processing unit for displaying the existing external output signal collected after the collection time and the external output signal under test output from the control device under test in a time-sequentially arranged state for comparison.
The plant control device test system according to claim 1, further comprising:

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