WO2008115096A1

WO2008115096A1 - Software hardware system for computer-aided testing and control

Info

Publication number: WO2008115096A1
Application number: PCT/RU2008/000149
Authority: WO
Inventors: Vladimir Saulovich Aizin
Original assignee: Otkrytoye Aktsionernoye Obschestvo 'moskovsky Zavod Teplovoy Avtomatiki'
Priority date: 2007-03-19
Filing date: 2008-03-18
Publication date: 2008-09-25
Also published as: RU2349949C2; RU2007109876A

Abstract

The invention can be used in systems for the computer-aided testing and control of a sophisticated production facility. The inventive software hardware system for the computer-aided testing and control of production processes comprises a common data bus and at least one controller comprising input/output and processing modules which are connected to the common data bus, using a single transport and logical protocol stack, in such a way as to form a single network of devices which can form queries to any of said devices and the responses to the requests addressed thereto. Said invention makes it possible to lift restrictions relating to the number of input/output and processing modules and to the connection of each processor and input/output module via the common data bus to the other devices of the system, thereby improving the reliability and easily scaling a control problem.

Description

COMPLEX OF SOFTWARE AND HARDWARE AUTOMATION

CONTROL AND MANAGEMENT

The invention relates to automation and computer technology and can be used in systems of automated control and management of a complex technological object, and / or a building, and / or a group of geographically separated objects using automatic control tools.

Automatically operating, containing many parts, large industrial facilities have many individual functions subject to mutual control and regulation, which are monitored, controlled and regulated by automated control systems. The complex of software and hardware for automation of the technological process of the enterprise contains integrated workstations and servers based on personal electronic computers, controllers and functional modules.

Known automatic control systems containing a common automated control system with automation devices, interconnected via at least one data line, and a local data transfer unit (processor module), which is connected via a communication element to the data bus (see patent RF Ns2096817, class G05B19 / 05, publ. 11/20/1997)

A disadvantage of such systems is the lack of autonomous operation of processor modules and control modules interconnected via one data line and through a local data transfer unit. The processor module with this connection processes all the signals received by the control module, which leads to high load of the processor module.

The closest analogue to the claimed solution can be recognized as a complex of software and hardware for automation of control and management of technological processes, including a common data bus (OShD) and at least one controller containing input / output modules for input and processing of signals from sensors and output signals control of actuators, and processor modules (PM), for controlling I / O modules and actuators by means of I / O modules, while I / O modules and processor modules are connected by a VME-bus system bus. (see RF patent N22279117, class G05B19 / 418, publ. 11/20/1997).

The disadvantages of the known software and hardware complex include a limited number of input / output modules and processor modules within a single controller, while the processor module of the controller is forced to process all the signals that are present at the inputs of its corresponding controller, and each controller can receive information from another controller only through its processor module. In addition, the complex devices are connected via different buses, which leads to an increase in the number of service devices and difficulties in accessing devices.

The task to which the invention is directed is the creation of a distributed and at the same time end-to-end monitoring and control system based on a single controller system bus.

The technical result that can be obtained by carrying out the invention is the ability to remove restrictions on the number of input / output modules and processor modules that perform their own task and fully or partially reserve the operation of other modules, as well as in the connection of each processor module and input / output module through a common data bus with devices related not only to this controller and providing access through a common data bus to each input / output module from devices that are not included the composition of this controller, without using the processor modules of this controller, which leads to an increase in the reliability of the entire system and makes it easy to scale the control task,

The specified technical result is achieved due to the fact that the complex of software and hardware automation control and process control, including a common data bus (OSD) and at least one controller containing input / output modules for input and processing of signals from sensors and output control signals actuators, and processor modules (PM), for controlling I / O modules and actuators by means of I / O modules, with IT, I / O modules and processor modules are connected to a common data bus using a single set of transport and logical protocols, with the possibility the formation of a single network of devices and the formation of requests to any of these devices and responses to requests addressed to them.

And also by the fact that it additionally contains control modules combining the functions of input / output modules and processor modules.

And also by the fact that it additionally contains smart sensors and smart actuators connected to a common data bus.

And also the fact that it additionally contains workstations and / or servers connected to a common data bus for visualizing, archiving and documenting data received from input / output modules, processor modules and control modules connected to a common data bus, signaling, operational and automatic process control, programming and maintenance of all devices included in the system and the functions it implements.

As well as the fact that it additionally contains operator panels connected to a common data bus.

And also the fact that it contains additional processor modules.

And also by the fact that the input / output modules and control modules are removed from the controller and are close to the control object.

And also by the fact that the input / output modules and / or processor modules and / or control modules are combined into common housings, or racks, or frames, or chassis, or cabinets, and / or protective shells providing their common power supply, a single system of terminals, heat sink and protection from the influence of the external environment.

As well as the fact that the common data bus is based on Ethernet, or Arspet, or Talkip-ripg.

And also the fact that the common data bus is made on the basis of various physical media of data transmission: coaxial cable, and / or twisted pair, and / or optical cable system and / or wireless radio-based implementation.

As well as the fact that the common data bus contains devices: amplifiers, and / or coordinators, and / or adapters from one physical implementation to another.

As well as the fact that the common data bus contains devices that implement its segmentation by restricting the transfer of most of the data within the selected segments, without interfering with the exchange of data between elements of different segments.

As well as the fact that the common data bus is redundant using various physical media and methods with unlimited multiplicity.

And also by the fact that a single set of transport and logical protocols includes the TCP / IP, and / or UPR / IP, and / or MODBUS, and / or BACpet.

The invention is illustrated by drawings, where figure 1 shows a diagram of a distributed controller; in FIG. 2 shows a diagram of a process plant control system.

An automated monitoring and control system based on a set of software and hardware automation tools generally consists of a common data bus 1 (OSD) and at least one controller 11 containing input / output modules 3 (USO) for input and processing signals from sensors and output signals, control of actuators, and processor modules 2 (PM) for controlling I / O modules 3 and actuators via I / O modules 3 (USO). The basis for the creation of the complex is the idea of “open distributed controller”. All elements of the complex are combined in one independent or in any way with unlimited multiplicity, using different physical media and methods of the redundant data bus 1. As a technology for implementing a common data bus, Ethert or Arkpet or Telkip-ripg can be used using different data rates and various physical media, such as coaxial cable, twisted pair, optical cable system, wireless implementation based on radio. It may also contain auxiliary devices: amplifiers, harmonizers, adapters from one physical implementation to another and any other devices that ensure the functioning of the data bus. The common data bus 1 may contain devices 10 that implement its segmentation by restricting the transfer of most of the data within the selected segments, without interfering with the exchange of data between elements of different segments.

Input / output modules 3 (USO) and processor modules 2 (PM) are connected to a common data bus 1 using a single set of transport and logical protocols, with the possibility of forming a single network of devices and generating requests to any of these devices and answering addressed to them: inquiries. A single set of transport and logical protocols can include TCP / IP, UDP / IP, MODBUS, BACpet. ^•

The software and hardware complex may include control modules 4, combining the functions of input / output modules 3 and processor modules 2, as well as workstations 8 connected to a common data bus 1 for visualization, archiving, and documentation of data received from input modules I / O 3, processor modules 2 and control modules 4 (connected to a common data bus 1), signaling, operational and automatic process control, programming and maintenance of all devices included in the system implemented its functions. The system can contain operator panels 7, also connected to a common data bus 1, as well as data servers 9 or additional processor modules 2. Separate input / output modules 3 and control modules 4 can be removed from the controller 11 and are close to the control object. I / O modules 3, processor modules 2 and control modules 4 included in the system are combined into common elements 12: cases, racks, frames, chassis, cabinets, protective shells providing their common power supply, a single system of terminals, heat sink and protection against influence the external environment. The system may also include smart sensors 5 and smart actuators 6 connected to a common data bus.

The process control in the proposed solution based on the proposed hardware-software complex is as follows. Signals from sensors are fed to the inputs of input / output modules 3 and / or control modules 4 and / or are directly accessible via a common data bus 1 using smart sensors 5. Next, the signals are converted by the listed devices and made available via a common data bus 1 to any devices connected to it . The processor modules 2 and / or control modules 4 process the values of the signals from the sensors, can keep local archives and ι based on the programs wired in them form the values of the control signals connected to the outputs of the input / output modules 3 and / or control modules 4 and / or commands for intelligent actuators 6 connected to a common data bus 1. Workstations ^; 8 and / or servers 9, can receive signal values and / or contents of local archives from processor modules 2 and / or control modules. 4 and directly to input / output modules 3 and / or smart sensors i 5 and / or smart actuators 6.

The ability to directly request servers 9 and workstations 8 for data from input / output modules 3, sensors and actuators removes some of the load from the processor modules 2 of the controllers 11, since they do not need to fulfill the relevant requests, process them, and then respond to requests from workstations , It also reduces the total amount of information transmitted, since the request for data is performed only once. On the other hand, the ability to access any devices connected to the common data bus 1 allows, without interfering with the working processes, using existing devices to expand the functions of the system by adding new devices. In addition, the absence of restrictions on the number of processor modules and free access to all system devices allows you to flexibly approach the tasks of increasing the reliability of the system. This can be achieved both due to the usual redundancy (duplication, tripling, etc.) of processor modules, and due to the separation of functions into several processor ones. modules and their partial functional redundancy, when part of the functions of one processor module can be performed by another. The listed features of a system with a common data bus increase the reliability of the entire system and make it easy to scale the control task.

The implementation of the inventive open distributed controller is illustrated by a non-exhaustive example of the operation of the control system (figure 2) of the technological installation.

The technological installation consists of three sections: a storage and preparation section for raw materials, a contacting section, for example a reactor, a finished product and storage section.

The control system ₍ includes two workstations for operators conducting the technological process (PC1 and PC2), and one engineering station that implements the tasks of programming and servicing the control system (RSZ).

Each technological section is controlled by a separate controller, consisting of at least two racks, with redundant processor modules (PM) and input / output modules (USO) installed in them, as well as a set of additional input / output modules brought closer to the technological equipment (USO) and combined modules (MU). Each rack provides the general power supply of the modules installed in it and their connection to a common data bus. The processor modules controlling each section interact with input, output and combined modules related to this section installed in the corresponding crates and removed to the technological equipment. However, for a number of tasks, they require data from the input / output modules of other sections. For this data, the processor modules access directly via a common data bus, bypassing the access to the processor modules that implement the control of the corresponding section.

In addition, the system contains two redundant processor modules that perform optimization tasks of the entire technological process. They are installed in a separate: crate. They apply for data to the USO, PM, and UM modules of each controller, calculate the optimal control parameters, and transfer corresponding tasks to the PM and UM of the controllers. AT In the same cradle, another processor module is installed, which can take control of any part of the process, in the event of a failure of the processor modules that implement this control normally.

Workstations interact with processor modules that control the process, requesting data from them processed and transmitting control commands and setting values to them. However, part of the data that is not directly involved in the management, but is required for presentation to the operator, workstations are requested directly from I / O modules or combined modules.

The common bus is divided into four segments:

1) A segment of devices serving the first technological section (the first controller with remote modules located on the object);

2) A segment of devices serving the second technological section (second controller with remote modules located on the object);

3) A segment of devices serving the third technological area (third. Controller with remote modules located at the facility);

4) The segment of the operational control loop devices (workstations of PC 1 and PC2 operators, ¹ RSZ engineering station, processor modules performing optimization and a backup processor module inserted in the PM rack)

All devices of each segment perceive all requests sent within this segment, and 'respond to requests addressed specifically to them. Moreover, for each device of any segment, all devices of the control system are available for inquiry.

Claims

CLAIM

1. A set of software and hardware automation tools for monitoring and control, including a common data bus and at least one controller containing input / output modules for input and processing signals from sensors and output signals for controlling actuators, and processor modules for control input / output modules and actuators by means of input / output modules, characterized in that the input / output modules and processor modules are connected to a common data bus using a single set of transport logical and logical protocols, with the possibility of forming a single network of devices and generating requests to any of these devices and responding to requests addressed to them.

2. The software and hardware complex according to claim 1, characterized in that it further comprises control modules connected to a common data bus, combining the functions of input / output modules and processor modules, and / or sensors and / or actuators connected to a common data bus.

3. The software and hardware complex according to claim 1 or claim 2, characterized in that it further comprises workstations and / or servers connected to a common data bus for visualizing, archiving and documenting data received from input / output modules, processor modules and control modules connected to a common data bus, signaling, operational and automatic process control, programming and maintenance of all the devices included in the system and its functions, and / or operator panels, connected to a common data bus, and / or processor modules.

4. The software and hardware complex according to claim 1 or claim 2, characterized in that the common data bus is based on Ethernet, or Arspet, or Talk-rig.

5. The complex of firmware according to claim 1 or claim 2, characterized in that the input / output modules and control modules are removed from the controller and are close to the control object.

6. The software and hardware complex according to claim 1 or claim 2, characterized in that the input / output modules and / or processor modules and / or control modules are combined into common housings, or racks, or frames, or chassis, or cabinets, and / or protective shells providing their general power supply, a single terminal system, heat sink and protection from the influence of the external environment.

7. The software and hardware complex according to claim 3, characterized in that the common data bus is based on Ethernet, or Arspet, or Talkgipip.

8. The software and hardware complex according to claim 4, characterized in that the common data bus is based on various physical data transmission media: coaxial cable, and / or twisted pair, and / or optical cable system, and / or wireless implementation on radio based.

9. The software and hardware complex according to claim 7, characterized in that the common data bus is based on various physical data transmission media: coaxial cable, and / or twisted pair, and / or optical cable system, and / or wireless implementation on radio based

10. The software and hardware complex of claim 8 or claim 9, characterized in that the common data bus contains devices that ensure its operation, such as, for example: amplifiers, and / or coordinators, and / or switches, and / or multipliers, and / or adapters from one physical implementation to another.

11. The complex of firmware on p. 8 or p. 9, characterized in that. the common data bus contains devices that implement its segmentation by restricting the transmission of most of the data within the selected segments, without interfering with the exchange of data between elements of different segments.

12. The software and hardware complex of claim 8 or claim 9, characterized in that the common data bus is redundant with unlimited multiplicity using various physical media and methods.

13. The software and hardware complex according to claim 1 or claim 2, characterized in that a single set of transport and logical protocols includes the TCP / IP, and / or UDP / IP, and / or MODBUS, and / or BACpet .

14. A set of software and hardware tools according to claim 3, characterized in that a single set of transport and logical protocols includes the TCP / IP, and / or UDP / IP, and / or MODBUS ₁ and / or BACpet.