A kind of redundancy control system and control method based on Ethernet
Technical field:
The invention belongs to industrial automatic control and on-the-spot control technology field, and in particular to a kind of based on the superfluous of Ethernet
Remaining control system and control method.
Background technology:
Some Process Control Systems, such as chemistry, oil, papermaking, metallurgy, some systems of nuclear power station industrial department,
Control device is asked to have high reliability, especially some complicated large-scale production systems, such as automobile assembling production line, as long as being
A place is gone wrong in system, will result in whole system stopping production, only by improving the reliable of control system hardware and software
Property meets that requirement of the above-mentioned industrial department to reliability is impossible, because programmable controller (Programmable
Logic Controller, abbreviation PLC) raising of the reliability of itself has certain limit, and the raising of reliability can make
Cost sharply increases.
Using general control technology, PLC system uses single CPU, and all control programs are stored in wherein.Once system occurs
Failure or program execution error, whole equipment occurs malfunction or stopped at once, causes consequence very serious.
Using single host computer system, once virus or failure, system can not also operate operation in computer.
Using triangular web, once going wrong, whole system stopping production, consequence caused by for enterprise will result in
Loss is quite serious, and security, the reliability of automaticity are the new technologies that all devices producer is all pursued.
The content of the invention:
A kind of the shortcomings that it is an object of the invention to overcome above-mentioned prior art, there is provided Redundant Control system based on Ethernet
System and control method, solve a series of problems caused by triangular web failure, and security, the reliability of automated system are high.
To achieve these goals, the present invention adopts the following technical scheme that:A kind of redundancy control system based on Ethernet,
Including Upper system, control system and execution system;
Upper system includes two industrial computers, configuration software is housed on every industrial computer, two industrial computers pass through standard network
Card composition LAN, upgrades in time, exchanges in time by realizing data between two industrial computers of LAN;One industrial computer occurs
Failure, do not interfere with other one and work on;
Control system includes two sets of PLC systems for being respectively arranged with software, and PLC system includes power supply module, redundancy CPU and is used for
The ethernet communication module of redundancy CPU communications, using optical fiber connection between the redundancy CPU in two sets PLC systems, realize that data are total to
Enjoy, when one piece of redundancy CPU breaks down, the redundant processing unit in fault redundance CPU automatically switches to other one piece of redundancy
CPU, in addition one piece of redundancy CPU start-up operation, every industrial computer pass through friendship by interchanger two sets of PLC systems of connection, industrial computer
Change planes with ethernet communication module communication, two sets of PLC systems are conducted interviews respectively, realize data sharing, exchange, it is any a set of
PLC system or industrial computer break down, and do not influence other set system and work on;
Execution system includes:Some I/O modules and some execution units, often cover PLC system and pass through Profibus-DP buses
It is connected respectively with some I/O modules, some I/O modules are connected with some execution units respectively.
Redundancy CPU in above-mentioned two sets of PLC systems one of is main redundancy CPU, and another piece is standby redundancy CPU, just
Under normal situation, standby redundancy CPU output is forbidden, when main redundancy cpu fault, puts into standby redundancy CPU at once.
In above-mentioned two industrial computers, one is engineer station, and another is operator station, and engineer station not only can be thereon
Operation, moreover it is possible to edit-modify picture;Operator station only allows to operate on it.
The CP1613 industry special network adapters of Siemens Company, the exchange are installed in the PCI slot in above-mentioned industrial computer
Machine is industrial switch, and the PLC system uses the 414H redundant systems of Siemens Company, and the ethernet communication module is west
The CP443-1IE ethernet communication modules of door subsidiary.
Above-mentioned execution unit includes:Water circulating pump, Aeration fan, magnetic valve, pneumatic operated valve, motor-driven valve, liquid level sensor, stream
Quantity sensor and pressure sensor.
Software in above-mentioned PLC system uses STEP7-V5.5 of the Siemens Company for S7-400 series of PLC system developments
Software.
The configuration software of above-mentioned industrial computer uses the WINCC7.0 of Siemens Company.
A kind of control method of the redundancy control system based on Ethernet, including:
(1) industrial computer downloads to control program in the redundancy CPU in every set PLC system;
(2) during system worked well, two sets of PLC system concurrent workings, two pieces of redundancy CPU run identical control program,
The execution unit being attached thereto is started by I/O modules, two pieces of redundancy CPU one of are main redundancy CPU, and another piece is standby
Redundancy CPU, under normal condition, standby redundancy CPU output is forbidden, main redundancy system control cpu work, standby redundancy
CPU input I/O mouths and input image register two industrial computer on line real-time monitorings, are adopted by main redundancy CPU synchronous refresh
Collection, operation, two industrial computer concurrent workings, data synchronization updating, any parameter, a data are modified, one in addition
Changed accordingly;
(3) it is automatic by the redundant processing unit in redundancy CPU when a set of PLC system failure during system jam
It is switched in the redundancy CPU in another set of PLC system, when main redundancy cpu fault fails, redundant processing unit is connected to main redundancy
After CPU fault message, control function is switched to standby redundancy CPU within 1~3 scan period, standby redundancy CPU's is defeated
Go out to open, standby redundancy system control cpu work, main redundancy CPU output is prohibited, will not when an industrial computer failure
The other industrial computer influenceed in LAN works on;
(4) after control system fault recovery, redundancy that the main redundancy CPU of fault recovery is sent signals in standby redundancy CPU
Processing unit, will control within 1~3 scan period after redundant processing unit receives the signal that main redundancy cpu fault recovers
Into main redundancy CPU, main redundancy system control cpu work, standby redundancy CPU output is prohibited function switch.
Above-mentioned 1~3 scan period is 5~15ms.
Relative to prior art, the present invention has advantages below:
1st, the redundancy control system being mainly made up of two sets of PLC systems and two industrial computers, adopt between two pieces of redundancy CPU
Connected with optical fiber, realize data sharing, when one piece of redundancy cpu fault, can automatically switched to separately by redundant processing unit
Outer one piece of redundancy CPU work, two industrial computers form LAN by standard network interface card, and two industrial computers pass through friendship using Ethernet
Change planes and two sets of PLC systems are conducted interviews respectively with ethernet communication module, realize data sharing, exchange, any a set of PLC systems
System or any industrial computer break down, and do not interfere with other one and work on, this redundancy control system solves
A series of problems caused by triangular web disorderly closedown, security, the reliability of automated system are high, while realize scene and hold
The remote real-time monitoring of row mechanism.
2nd, two sets of PLC system concurrent workings, two pieces of redundancy CPU run identical control program, are started by I/O modules and held
Row unit, two pieces of redundancy CPU one of are main redundancy CPU, and another piece is standby redundancy CPU, under normal circumstances, standby redundancy
CPU output is forbidden, main redundancy system control cpu work, and standby redundancy CPU input I/O mouths and input image are posted
Storage is synchronously refreshed by main redundancy CPU, two industrial computer on line real-time monitorings, collection, operations, two parallel works of industrial computer
Make, data synchronization updating, any parameter, a data are modified, also changed accordingly for one in addition, at redundancy
Reason unit carries out being switched fast between main redundancy CPU and standby redundancy CPU, using this redundancy control method, breaks down
Program switchover operation is rapid, does not interfere with whole system operation, can largely avoided equipment hang-up failure, meanwhile, behaviour
Make safe and reliable property to greatly enhance, huge income is brought for enterprise.
Brief description of the drawings
Fig. 1 is the structural representation of the present invention.
In figure:1st, industrial computer;2nd, PLC system;3rd, I/O modules;4th, execution unit;5th, Profibus-DP buses;6th, exchange
Machine.
Embodiment
The present invention will be further described in detail below in conjunction with the accompanying drawings.
As shown in figure 1, a kind of redundancy control system based on Ethernet, including Upper system, control system and perform system
System;
Upper system includes two industrial computers 1, configuration software is housed on every industrial computer 1, two industrial computers 1 pass through standard
Network interface card forms LAN, upgrades in time, exchanges in time by realizing data between two industrial computers 1 of LAN;One industrial computer 1
Break down, do not interfere with other one and work on;
Control system includes two sets of PLC systems 2 for being respectively arranged with software, and PLC system 2 includes power supply module, redundancy CPU and use
Connected between redundancy CPU in the ethernet communication module of redundancy CPU communications, two sets of PLC systems 2 using optical fiber, realize number
According to shared, when one piece of redundancy CPU breaks down, the redundant processing unit in fault redundance CPU automatically switch to other one piece it is superfluous
Remaining CPU, in addition one piece of redundancy CPU start-up operation, every industrial computer 1 pass through interchanger 6 and connect two sets of PLC systems 2, industrial computer 1
By interchanger 6 with ethernet communication module communication, two sets of PLC systems 2 are conducted interviews respectively, data sharing is realized, exchanges,
Any a set of PLC system 2 or industrial computer 1 break down, and do not influence other set system and work on;
Execution system includes:Some I/O modules 3 and some execution units 4, often cover PLC system 2 and pass through Profibus-DP
Bus 5 is connected with some I/O modules 3 respectively, and some I/O modules 3 are connected with some execution units 4 respectively.
Redundancy CPU in above-mentioned two sets of PLC systems 2 one of is main redundancy CPU, and another piece is standby redundancy CPU, just
Under normal situation, standby redundancy CPU output is forbidden, when main redundancy cpu fault, puts into standby redundancy CPU at once.
In above-mentioned two industrial computers 1, one is engineer station, and another is operator station, and engineer station not only can be at it
Upper operation, moreover it is possible to edit-modify picture;Operator station only allows to operate on it.
The CP1613 industry special network adapters of Siemens Company, the exchange are installed in the PCI slot in above-mentioned industrial computer 1
Machine is industrial switch, and the PLC system 2 uses the 414H redundant systems of Siemens Company, and the ethernet communication module is
The CP443-1IE ethernet communication modules of Siemens Company.
Above-mentioned execution unit 4 includes:Water circulating pump, Aeration fan, magnetic valve, pneumatic operated valve, motor-driven valve, liquid level sensor,
Flow sensor and pressure sensor.
Software in above-mentioned PLC system 2 uses the STEP7- that Siemens Company develops for S7-400 series of PLC system 2
V5.5 softwares.
The configuration software of above-mentioned industrial computer 1 uses the WINCC7.0 of Siemens Company.
A kind of control method of the redundancy control system based on Ethernet, including:
(1) industrial computer 1 downloads to control program in the redundancy CPU in every set PLC system 2;
(2) during system worked well, two sets of concurrent workings of PLC system 2, two pieces of redundancy CPU run identical control program,
The execution unit 4 being attached thereto is started by I/O modules 3, two pieces of redundancy CPU one of are main redundancy CPU, and another piece is standby
With redundancy CPU, under normal condition, standby redundancy CPU output is forbidden, main redundancy system control cpu work, standby superfluous
Remaining CPU input I/O mouths and input image register by main redundancy CPU synchronous refresh, two on line real-time monitorings of industrial computer 1,
Collection, operation, two concurrent workings of industrial computer 1, data synchronization updating, any parameter, a data are modified, one in addition
Also changed accordingly;
(3) during system jam, when a set of 2 failure of PLC system, by the redundant processing unit in redundancy CPU certainly
Dynamic to be switched in the redundancy CPU in another set of PLC system 2, when main redundancy cpu fault fails, redundant processing unit is connected to master
After redundancy CPU fault message, control function is switched to standby redundancy CPU, standby redundancy CPU within 1~3 scan period
Output open, standby redundancy system control cpu work, main redundancy CPU output is prohibited, when 1 failure of industrial computer,
The other industrial computer 1 not interfered with LAN works on;
(4) after control system fault recovery, redundancy that the main redundancy CPU of fault recovery is sent signals in standby redundancy CPU
Processing unit, will control within 1~3 scan period after redundant processing unit receives the signal that main redundancy cpu fault recovers
Into main redundancy CPU, main redundancy system control cpu work, standby redundancy CPU output is prohibited function switch.
Above-mentioned 1~3 scan period is 5~15ms.
Whole redundancy control system is control core with PLC system 2, and industrial computer (abbreviation industrial computer) is as upper
Machine, whole system is monitored, operated.
Using industrial computer 1 of the DELL work stations as Upper system, the legal complete versions of Windows XP are installed, using west gate
Subsidiary WINCC independent development HMI, industrial computer 1 are installed CP1613 network interface cards and are connected using ethernet communication mode with PLC system 2;
It is connected between two industrial computers 1 using common net card by LAN, realizes data interaction.
WINCC (i.e. WINDOWS CONTROL CENTER forms control centre), WINCC are that Siemens Company is automating
Using state-of-the-art technology and Microsoft in the industrial control software for occuping rank first of joint development, WINCC is in field
The monitoring system of the powerful all-round opening of One function, it can both be used for completing small-scale simple process monitoring application,
The application of complexity can be used for completing, WINCC can generate beautiful and easily man-machine dialogue interface under any circumstance, make
Operator can clearly manage and optimize production process.
Configuration software is equipped with two industrial computers 1, configuration software refers to the special-purpose software of data acquisition and process control,
Monitoring system is configuration picture (HMI), and the configuration picture of industrial computer 1 includes conventional monitoring function:As control interface, figure show
Show, realtime curve, warning message, equipment state, pond liquid level, parameter setting etc.;Also include the maintaining meter of equipment
Preventive maintenance prompting and maintaining record, the technological process of production setting and management, various Production databases with equipment are drawn,
To realize various Product Data Managements, data check, form and print output function.
Two concurrent workings of industrial computer 1, data synchronization updating, any parameter, a data are modified, one in addition
Changed accordingly;If there is a computer glitch in operation, do not interfere with other one and work on.
Edit configuration picture in advance in configuration software WINCC7.0, database, data are then established in industrial computer
Storehouse uses the private database dedicated for the CPU connections of 400H redundancies, all variables in configuration picture is defined, in PLC system 2
After establishing network connection in hardware configuration, all variables in configuration picture are downloaded into the redundancy CPU in PLC system 2.
" download " function is used to download to the hardware of industrial computer 1 and network configuration in the editing machine that industrial computer 1 configures, with
The application program of industrial computer 1 and network interface card enter normal working condition afterwards, and WINCC7.0 and PLC system 2 can be with normal communications.
By using the redundancy control system based on Ethernet, safe operation, reliability greatly enhance.
Using the redundancy control method based on Ethernet, during failure, program switchover operation is rapid, does not interfere with whole
The operation of system, equipment hang-up failure can be largely avoided, huge income is brought for enterprise.
Above content is to combine specific preferred embodiment further description made for the present invention, it is impossible to is assert
The embodiment of the present invention is only limitted to this, for general technical staff of the technical field of the invention, is not taking off
On the premise of from present inventive concept, some simple deduction or replace can also be made, should all be considered as belonging to the present invention by institute
Claims of submission determine scope of patent protection.