This application claims priority to Japanese Patent Application No. 2012-267746 filed on Dec. 7, 2012, the disclosure of which, including the specification, drawings and abstract, is incorporated herein by reference in its entirety.
1. Field of the Invention
The invention relates to a system in which communication is performed between a programmable logic controller (PLC) and other devices, and when a communication line failure has occurred, the location of the failure can be identified.
2. Discussion of Background
A programmable logic controller (hereinafter referred to as “the PLC”) operates by communicating with other devices. Regarding a PLC, Japanese Patent Application Publication No. 6-324723 (JP 6-324723A) describes that in the case where one station is to receive data from another station, if the data is unable to be received for a predetermined period of time and a timer reaches a set time, it is determined that a communication failure has occurred. Japanese Patent Application Publication No. 2-235104 (JP 2-235104A) describes that the number of times retried calling operation has been performed is displayed to determine the number of retries that have been required for establishing data exchange communication.
However, if many communication devices are connected, it is difficult to identify a failed portion in communication lines.
The invention provides a programmable logic controller communication system that allows an operator to identify the location of a communication line failure when the communication line failure has occurred.
According to a feature of an example of the invention, there is provided a programmable logic controller communication system including: a programmable logic controller; a plurality of devices; three or more communication processing nodes that are provided respectively in the programmable logic controller and the devices to allow the programmable logic controller to communicate with each of the devices; and a plurality of communication lines that connect the communication processing nodes to each other so as to allow data communication, wherein the programmable logic controller detects an incommunicable state between two of the communication processing nodes, and wherein the programmable logic controller communication system further includes a display device, and in a case where there are a plurality of types of incommunicable states detected by the programmable logic controller, the display device displays a portion where communication lines that constitute the incommunicable states among the plurality of communication lines overlap with each other, as a line failure portion.
The foregoing and further objects, features and advantages of the invention will become apparent from the following description of example embodiments with reference to the accompanying drawings, wherein like numerals are used to represent like elements and wherein:
Hereinafter, embodiments of the invention will be described with reference to the accompanying drawings.
The configuration of an entire network system that includes a PLC communication system according to a first embodiment will be described with reference to
The network system includes, in addition to the PLC 20, an input device 10 that inputs parameters and network configuration diagrams to the PLC 20, and a display device 30 that displays information regarding the PLC 20. The network system further includes a communication processing node 41 (hereinafter referred to simply as “the node”) connected to the PLC 20. The node 41 is compliant with FL-net (controller level network based on Ethernet, standardized by Japan Electrical Manufacturers' Association), FL remote that is a form of the FL-net, and DeviceNet (registered trademark).
Referring to
The FL remote 200 includes a communication line 210, a plurality of nodes 240 communicably connected to the node 41 through the communication line 210, and other devices 250 each of which is connected to a corresponding one of the nodes 240. The DeviceNet 300 includes a communication line 310, a plurality of nodes 340 communicably connected to the node 41 through the communication line 310, and other devices 350 each of which is connected to a corresponding one of the nodes 340.
The other devices 150 communicably connected to the node 41 by the FL-net 100 include, for example, another PLC. The other devices 250 communicably connected to the node 41 by the FL remote 200 include, for example, I/O modules, such as an actuator and a sensor. The other devices 350 communicably connected to the node 41 by the DeviceNet 300 include, for example, another PLC and an I/O module. In each of the FL-net 100, the FL remote 200, and the DeviceNet 300, the number of other devices to be connected can be increased by using a hub or hubs.
The display device 30 displays an entire network configuration diagram, i.e., an entire communication line diagram. Further, the display device 30 displays a device failure, a line failure, and a line requiring caution, respectively, by different display methods, for example, by using different colors.
The PLC communication system according to the present embodiment will now be described with reference to
As shown in
In the FL-net 100, each of the nodes 41, 142, 143, and 144 transfers the transmission right, i.e., token, of data in a predetermined order. In
However, for example, if the node 144 is unable to receive the token at a timing at which the node 144 should receive the token from the node 143 for some reason, the node 144 reissues a token, i.e., performs a retry. More specifically, the node 144 issues a new token and transmits required data to another node and then sends the token to the specified succeeding node, namely, the node 41.
Referring to
Then, at time t2, the node 142 transmits the token to the succeeding node, namely, the node 143, without being affected by the power-off of the node 143. However, the node 143 is unable to receive the token. Hence, the node 143 is unable to transmit the token to the succeeding node, namely, the node 144.
Therefore, the node 144 is unable to receive the token at time t4. Thus, the node 144 reissues a token, i.e., performs a retry, and transmits the reissued token to the succeeding node, namely, the node 41. Subsequently, from time t5 to time t8, the same processing as that carried out from time t1 to time t4 is carried out. More specifically, the node 144 reissues a token again at time t8.
It is assumed that the power source of the node 143 is recovered after time t9. Then, at time t10, the node 143 receives the token transmitted from the preceding node, namely, the node 142. Therefore, at time t11, the node 143 transmits the token to the succeeding node, namely, the node 144. Thus, at time t12, the node 144 transmits the received token to the succeeding node, namely, the node 41, without reissuing a token.
The numbers of retries of the nodes 41, 142, 143, and 144 in the case where a token is transferred as shown in
A description will now be provided on the display contents of the display device 30 at time t9 and time t13 mentioned above. The display contents of the display device 30 at time t9 are as shown in
Further, at time t9, the number of retries of the node 144 is two. If the number of retries of any one of the nodes 41, 142, 143, and 144 reaches a set number of times (2 in this case), the PLC 20 recognizes that the communication lines connecting the node, whose number of retries has reached the set number of times, and its preceding node are in an incommunicable state. Accordingly, the display device 30 displays the communication lines 113, 114 and the hub 161, which are in the incommunicable state, as lines requiring caution, by using, for example, a yellow color (the dashed lines in
The display device 30 further displays the numbers of retries at the places of the nodes 41, 142, and 144 that are normal. In
Thus, at time t9, the display device 30 enables an operator to identify a node in which a device failure has occurred, and also to identify the location of the node in which the device failure has occurred, in the entire network configuration diagram. The display device 30 further enables the operator to recognize the lines that have caused the retries and to determine the degree of the failure, based on the numbers of retries.
The display contents of the display device 30 at time t13 are as shown in
Referring now to
The token is transferred as shown in
Again, due to the disconnection of the communication line 113, the node 144 is unable to receive the token transmitted from the node 143. Hence, the node 144 reissues a token and transmits the reissued token to the node 41 at time t4. Thereafter, the same processing as the processing carried out during the period of time t1 to t4 is carried out during the period of time t5 to t8, during the period of time t9 to t12, and during the period of time t13 to t16.
The numbers of retries of the nodes 41, 142, 143, and 144 in the case where a token is transferred as shown in
The display contents of the display device 30 at time t9 mentioned above are as shown in
The number of retries of the node 143 is equal to or larger than a set number (two) at time t9. Therefore, the PLC 20 recognizes that the communication lines 112, 113 and the hub 161, which connect the node 143 and its preceding node, namely, the node 142, are in the incommunicable state. In addition, the number of retries of the node 144 is equal to or larger than the set number. Therefore, the PLC 20 recognizes that the communication lines 113, 114 and the hub 161, which connect the node 144 and the preceding node, namely, the node 143, are in the incommunicable state.
In other words, at time t9, there is a plurality of types of incommunicable states as indicated by arrows A1 and A2 in
The display contents of the display device 30 in this case are as shown in
Further, the display device 30 displays the numbers of retries at the places of the nodes 41, 142, 143, and 144. As shown in
As described above, the display device 30 displays the portion in which the plurality of types of incommunicable states overlap with each other, as the line failure portion. It is apparent that
Further, if a plurality of incommunicable communication lines overlap with each other, an overlapping portion (the overlapping communication lines and the hub in the present embodiment) among many communication lines is highly likely to be abnormal. Thus, since the display device 30 displays the overlapping portion in a display manner different from a display manner in which other portions are displayed, the operator is able to identify the communication line failure portion. Especially by displaying the entire network configuration diagram and then displaying the line failure portion in the display manner different from the display manner in which the other portions are displayed, it is possible to identify the location of the line failure portion.
In the above configuration, even when no line failure and no device failure have occurred, the display device 30 displays lines requiring caution in some cases. In other words, the lines displayed as the lines requiring caution are communication lines constituting an incommunicable state. Even when a line failure has not occurred, by recognizing the communication lines that constitute the incommunicable state, it is possible to alert an operator working as a system administrator. This prevents occurrence of a line failure. Further, by displaying the numbers of retries, it is possible to predict a line failure, and thus, it is possible to further alert the operator.
In the foregoing embodiment, the description has been provided on the FL-net 100. The same virtually applies to the FL remote 200. More specifically, a PLC communication system that includes the FL remote 200 also enables an operator to recognize a line failure. As described above, since the FL remote is a form of the FL-net, each of the nodes constituting the FL remote 200 transfers a token in a predetermined order, as in the case of the FL-net. Further, in the foregoing embodiment, the entire network configuration diagram is displayed to allow a failed portion to be recognized in the entire displayed network configuration diagram. Alternatively, only the name or address of a failed portion may be displayed without displaying the entire network configuration diagram.
A description will now be provided on the display contents of the display device 30 in a network configuration shown in
In this case, the display device 30 displays the communication lines 112, 113, 114 and the hubs 161, 162 as line failure portions, by using a purple color (double lines in
Thus, the communication lines 112 and 113, in which disconnection has occurred, are displayed as the line failure portions. The portions displayed as the line failure portions include the communication line 114 and the hubs 161 and 162 in addition to the communication lines 112 and 113. However, the communication lines 112 and 113 in which disconnection has actually occurred can be detected early by checking the portions displayed as the line failure portions.
Further, by displaying the numbers of retries, it is possible to recognize the portions indicating a large number of retries. For example, in
A description will be provided on a case where the Transmission Control Protocol (TCP) is applied to a PLC communication system according to an embodiment. As shown in
Each of the nodes 41, 442 to 444 transmits data to another node according to the destination address to which the data is to be transmitted. If the data is unable to be transmitted, each of the nodes 41, 442 to 444 carries out retry processing for retransmitting the data.
In this example, in the case where the retry processing has been carried out a set number of times (two in this example), the PLC 20 recognizes that the communication line connecting a source node and a destination node is in the incommunicable state. More specifically, the PLC 20 recognizes that the transmission path from the node 41 to the node 443 is in the incommunicable state, that is, the communication lines 411, 413 and the hub 461 are in the incommunicable state, and defines the incommunicable state as a first incommunicable state. The PLC 20 recognizes that the transmission path from the node 442 to the node 443 in the incommunicable state, that is, the communication lines 412, 413 and the hub 461 are in the incommunicable state, and defines the incommunicable state as a second incommunicable state. The PLC 20 further recognizes that the transmission path from the node 444 to the node 443 is in the incommunicable state, that is, the communication lines 413, 414 and the hub 461 are in the incommunicable state, and defines the incommunicable state as a third incommunicable state.
The display contents of the display device 30 in this case are as shown in
Thus, also in the case where the TCP is applied, the communication line failure portion can be detected early. By displaying the lines requiring caution and the number of retries, it is possible to alert an operator. Although not shown, if there is a plurality of communication lines having line failures, a higher priority can be given to a communication line having a greater number of retries. This contributes to early recovery, as in the foregoing embodiment.
Referring now to
However, if the DeviceNet 300 has therein a daisy chain as shown in
It is assumed that the communication line 313 connecting the slave node 343 and the slave node 344 in
The display contents of the display device 30 in the foregoing case are as shown in
Thus, in the case of the daisy chain, the above-described display contents enable an operator to determine a failed portion in the communication lines. When the entire network configuration diagram is displayed and a line failure portion is displayed in the entire network configuration diagram, the operator can easily identify the location of the line failure portion.
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