Patent Publication Number: US-2016246273-A1

Title: Controller

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims the benefit of and priority to Japanese Patent Application No. 2015-032559, filed on Feb. 23, 2015, the entire contents of which are incorporated by reference herein. 
     TECHNICAL FIELD 
     The present invention relates to a controller used in a controlling system. 
     BACKGROUND ART 
     A controlling system is used to monitor and control, for example, ancillary facilities of buildings and to control plants. In addition, an instrument controlling device may be also used for this purpose (see PTL 1). The controlling system conducts controlling by exchanging signals with field devices such as process devices and various types of sensors installed in a field connected via a network such as a field bus. In addition, the instrument controlling device exchanges signals with field devices such as process devices and various types of sensors installed in the field, makes operation settings previously performed by connecting mobile terminals to the field devices in the field using parameter settings from a higher level, and displays the diagnostic results of the normal operation state of the field devices. 
     Since many field devices are to be controlled, the controlling system performs division into blocks, provides a controller in each of the blocks, and performs distributed control using the controllers. 
     For example, as illustrated in  FIG. 2 , controllers  202  provided for the individual blocks are connected to a controlling device  201 , an I/O module  203  is connected to each of the controllers  202 , and a plurality of field devices  204  are connected to each of the I/O modules  203 . A plurality of controllers  202  are connected to the controlling device  201  via a network  211  and the plurality of field devices  204  are connected to each of the I/O modules  203  via a signal line  212 . 
     Each of the I/O modules  203  is provided with I/O data points to which inputs from the field devices  204  such as sensors or opening outputs from the field devices  204  such as valve positioners are individually connected. 
     In the distributed control as described above, there are parameters to be set for each block. These parameters to be set in the controllers, called setting data, include parameters for controlling the controller and other parameters. The setting data are manually set in the controller. 
     For example, a system of FOUNDATION fieldbuses by Fieldbus Foundation uses function blocks, which include “resource blocks” configured by parameters concerning field devices, “transducer blocks” having parameters concerning sensors, operation terminals, and hardware included in field devices, “function blocks” for achieving input-output functions or calculation functions for PIDs, and so on. 
     When a controller is replaced in the case of a failure or maintenance such as periodical replacement or periodical inspection in such a controlling system, the setting data before the replacement needs to be recorded and then be set for a replacing controller. The first method for recording the setting data is to write it on paper. The second method is to save the setting data as electronic data using software such as a word processor or spreadsheet. The third method is to read the setting values using a controller setting device and save it as electronic data (see PTL 2). 
     CITATION LIST 
     Patent Literature 
     [PTL 1] JP-A-2012-014388 
     [PTl 2] JP-A-2006-134098 
     SUMMARY OF INVENTION 
     Problem to be Solved by the Invention 
     However, the above data setting methods requires means for temporarily storing setting data separately in the field in which the controller to be replaced is installed, and the time and effort for setting the setting data again after temporarily storing it, thereby workload of replacement work increases. 
     The invention addresses the above problems with an object of enabling the setting data to be set for the replacing controller while further reducing the load on replacement work. 
     Means for Solving the Problem 
     According to the invention, there is provided a controller performing control operation that outputs corresponding control data to a field device to be controlled, the controller including a setting data storing portion storing setting data for generating the control data, a control processing portion generating the control data based on the setting data stored in the setting data storing portion, an I/O controlling portion sending the control data generated by the control processing portion to the field device, a controller connection portion through which the controller is connected to another controller, a setting data sending portion outputting the setting data stored in the setting data storing portion to the other controller connected to the controller connection portion, and a setting data receiving portion receiving the setting data from the other controller connected to the controller connection portion and storing the setting data in the setting data storing portion. 
     Advantageous Effects of Invention 
     As described above, according to the invention, it is possible to obtain the beneficial effect of setting the setting data for the replacing controller while further reducing the load on replacement work. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a structural diagram illustrating a part of the structure of a controlling system using a controller  100  according to an embodiment of the invention. 
         FIG. 2  is a structural diagram illustrating the structure of a controlling system in which division into blocks is made to control each block. 
     
    
    
     MODE FOR CARRYING OUT THE INVENTION 
     An embodiment of the invention will be described with reference to the drawings.  FIG. 1  is a structural diagram illustrating a part of the structure of a controlling system including a controller  100  according to an embodiment of the invention. This system includes the controller  100 , a controlling device  121 , an I/O module  131 , and field devices  132 . 
     In the controlling device  121 , the controller  100  is connected to each of the blocks. In addition, the I/O module  131  is connected to the controller  100  and a plurality of field devices  132  are connected to the I/O module  131 . For example, the I/O module  131  is provided with I/O data ports (not illustrated) to which inputs from the field devices  132  such as sensors or opening outputs from the field devices  132  such as valve positioners are individually connected. Although a plurality of controllers are connected to the controlling device  121  via a network,  FIG. 1  illustrates the state in which the controller  100  is connected to the controlling device  121  and other controllers are not illustrated. 
     The controller  100  includes a setting data storing portion  101 , a control processing portion  102 , an I/O controlling portion  103 , a controller connection portion  104 , a setting data sending portion  105 , a setting data receiving portion  106 , a program storage portion  107 , a network controlling portion  108 , and an inputting portion  109 . 
     The setting data storing portion  101  stores setting data used to generate control data for controlling the field devices  132 . The control processing portion  102  generates control data based on the setting data stored in the setting data storing portion  101 . The I/O controlling portion  103  sends the control data generated by the control processing portion  102  to the field devices  132 . 
     The controller connection portion  104  connects the controller  100  to another controller. The setting data sending portion  105  outputs the setting data stored in the setting data storing portion  101  to the other controller connected to the controller connection portion  104 . The setting data receiving portion  106  receives the setting data from the other controller connected to the controller connection portion  104  and stores it in the setting data storing portion  101 . 
     The program storage portion  107  stores a program for operating the control processing portion  102 . The network controlling portion  108  establishes a network connection with the controlling device  121 . The inputting portion  109  receives instruction inputs concerning the operation of the setting data sending portion  105  and the operation of the setting data receiving portion  106 . 
     The replacement of the controller  100  that is built into the controlling system and connected to the controlling device  121  and the I/O module  131  with another controller (controller  100   a ) will be described below as an example. The controller  100   a  includes a setting data storing portion  101   a,  a control processing portion  102   a,  an I/O controlling portion  103   a,  a controller connection portion  104   a,  a setting data sending portion  105   a,  a setting data receiving portion  106   a,  a program storage portion  107   a,  a network controlling portion  108   a,  and an inputting portion  109   a.  This structure is similar to that of the controller  100 . 
     First, the controller connection portion  104  is connected to the controller connection portion  104   a  via a predetermined cable to make connection between the controller  100  and the controller  100   a.  The inputting portion  109  is operated in this state to put the setting data sending portion  105  in the operating state and then the inputting portion  109   a  is operated to put the setting data receiving portion  106   a  in the operating state. 
     In the controller  100 , the above operation causes the setting data sending portion  105  to output the setting data stored in the setting data storing portion  101  to the controller  100   a  connected to the controller connection portion  104 . On the other hand, in the controller  100   a,  the setting data receiving portion  106   a  receives the setting data from the controller  100  connected to the controller connection portion  104   a  and stores it in the setting data storing portion  101   a.    
     When the setting data stored in the setting data storing portion  101  is stored in the setting data storing portion  101   a  in this way, the controller  100  is stopped and the controller  100   a  is connected to the controlling device  121  and the I/O module  131  and built into the controlling system. Accordingly, in the controller  100   a  having started operating, the control processing portion  102   a  generates control data based on the setting data stored in the setting data storing portion  101   a  and the I/O controlling portion  103   a  sends the control data generated by the control processing portion  102   a  to the field devices  132 . The setting data stored in the setting data storing portion  101   a  is the data previously stored in the setting data storing portion  101  and the control by the controller  100   a  is similar to that performed by the controller  100 . 
     Here, the connection between the controller  100  (the controller connection portion  104 ) and the controller  100   a  (the controller connection portion  104   a ) only needs to be made by, for example, the USB (Universal Serial Bus). The connection via the USB enables power to be supplied to the controller  100   a.    
     If the controller connection portion  104  is connected to another controller when detecting establishment of a network by the network controlling portion  108  and a connection with the I/O module  131  by the I/O controlling portion  103 , the setting data sending portion  105  may operate. If the controller connection portion  104  is connected to another controller when not detecting establishment of a network by the network controlling portion  108  and a connection with the I/O module  131  by the I/O controlling portion  103 , the setting data receiving portion  106  may operate. 
     The connection between the controller  100  (the controller connection portion  104 ) and the controller  100   a  (controller connection portion  104   a ) may be performed via the PoE (Power over Ethernet (registered trademark)). This connection also supplies power to the controller  100   a.    
     In addition, the controller  100  (the controller  100   a ) may have a storing portion for storing model information, check the model of another controller to be connected based on the model information stored in the storing portion, and restrict the operation of the setting data sending portion  105  of own controller and the setting data receiving portion  106  of another controller when the model of another controller is different from its own. This prevents the setting data from being written when the model of the device is different, thereby preventing a replacement error. 
     In addition, both the controller  100  and the controller  100   a  may be connected to the controlling device  121  and the I/O module  131  so that the controller  100  stops operating automatically when the setting data sending portion  105  has output the setting data and the controller  100   a  starts operating when the setting data receiving portion  106   a  has stored the setting data in the setting data storing portion  101 . This eliminates the need to turn on the power again. 
     The following operation is also allowed. First, in the state in which the controlling system to which the controller  100  is connected is operating, the controller  100   a  is also connected to the controlling system. In this state, the controller  100  causes the setting data sending portion  105  to operate and enter a mode for writing setting data and the controller  100  sets its own address to an unused communication address in the network of the controlling system. 
     On the other hand, the controller  100   a  causes the setting data receiving portion  106   a  to operate and enter a mode for receiving setting data and the controller  100   a  sets its own address to an unused communication address in the network of the controlling system. In this state, data transfer is performed. Upon completion of data transfer, the controller  100  stops operating and the controller  100   a  sets its own address to the communication address used by the controller  100  before the data transfer and starts operating using the new setting data. After that, if the controller  100  is removed, the controlling system is put in the operable state. 
     As described above, since setting data can be transmitted and received between controllers in the invention, the setting data can be set in the replacing controller while further reducing the load on replacement work. 
     The invention is not limited to the above embodiment and it is appreciated that those skilled in the art may perform many modifications and combinations within the technical concept of the invention. 
     DESCRIPTION OF REFERENCE NUMERALS AND SIGNS 
       100 ,  100   a : controller,  101 ,  101   a : setting data storing portion,  102 ,  102   a : control processing portion,  103 ,  103   a : I/O controlling portion,  104 ,  104   a : controller connection portion,  105 ,  105   a : setting data sending portion,  106 ,  106   a : setting data receiving portion,  107 ,  107   a : program storage portion,  108 ,  108   a : network controlling portion,  109 ,  109   a : inputting portion,  121 : controlling device,  131 : I/O module,  132 : field device.