CN107943009A - A kind of industrial control system Fault Locating Method - Google Patents
A kind of industrial control system Fault Locating Method Download PDFInfo
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- CN107943009A CN107943009A CN201711392364.9A CN201711392364A CN107943009A CN 107943009 A CN107943009 A CN 107943009A CN 201711392364 A CN201711392364 A CN 201711392364A CN 107943009 A CN107943009 A CN 107943009A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24065—Real time diagnostics
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- General Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Automation & Control Theory (AREA)
- Debugging And Monitoring (AREA)
Abstract
The invention discloses a kind of industrial control system Fault Locating Method, it is characterised in that this method comprises the following steps：Step 1: data configuration data block, data record data block and data caching data block are set in industrial control system PLC；Step 2: when PLC system samples, collection is set into data and recorded in data record data block；Step 3: when PLC samplings stop, reading system date and time and recorded data configuration data block；Step 4: PCL data upload, the data of data configuration data block, data record data block are uploaded to data buffer storage data block；Step 5: PLC by SFB37 functional blocks by the data sending of data buffer storage data block to WINCC；Step 6: on host computer WINCC configuration, establish the connection with PLC, selection filing data link, records in variable, establish process control variable, the data sended on PLC are filed on WINCC.
Description
Technical field
The invention belongs to industrial control field technical field, and in particular to a kind of industrial control system Fault Locating Method.
Background technology
Modern Large group controls program, there is more safety interlock system.When there is interlocking jump car, failure is investigated
Means it is most using checking logout, chart etc..But many occasions, this is difficult to meet live actual demand.
Realize in process of the present invention, inventor has found that at least there are the following problems in the prior art：Some failures, logout is peace
After full interlocking as a result, immediate cause does not capture.In existing industrial control system, the real-time sampling cycle of PLC is generally set to 1
Second, the filing cycle of WINCC is generally set to 2-5 seconds, since the cycle is grown, it is difficult to capture abnormal data.If equipment fault category
Initial stage, in the accidental stage, it is more difficult to capture abnormal data.At this moment special tissue technical specialist group is generally required, it is repeatedly multi-party
Surface analysis, sometimes after multiple startup-shutdown, could finally investigate and be out of order a little.This is on the high ground of some start-up and shut-down costs
Side, is very passive, difficult certainly.In power industry, have using SOE systems, believed with each event of ms grades of resolution
The precedence of number state change, finds out head and is out of order.But a set of SOE systems of increase, software and hardware is costly, minimum million yuan
More than, used in metallurgy industry almost without producer.
The content of the invention
In order to solve above the deficiencies in the prior art, the present invention provides a kind of industrial control system Fault Locating Method,
By setting host computer to establish Fault Locating Method, solve the special tissue technical specialist group that generally requires, it is repeatedly many-sided
Analysis, sometimes after multiple startup-shutdown, could finally investigate and be out of order a little, have that cost is low, the quick beneficial effect of positioning.
In order to solve the above-mentioned technical problem, the present invention is achieved through the following technical solutions：A kind of industrial control system event
Hinder localization method, it is characterised in that this method comprises the following steps：Step 1: data are set to match somebody with somebody in industrial control system PLC
Put data block, data record data block and data caching data block；Step 2: when PLC system samples, collection is set into data record
Into data record data block；Step 3: when PLC samplings stop, reading system date and time and recorded data configuration data
Block；Step 4: PCL data upload, the data of data configuration data block, data record data block are uploaded to data buffer storage data
Block；Step 5: PLC by SFB37 functional blocks by the data sending of data buffer storage data block to WINCC；Step 6: in host computer
The configuration of upper WINCC, establishes the connection with PLC, selection filing data link, records in variable, establish process control change
Measure, the data sended on PLC are filed on WINCC.
The data record data block of this method is equipped with 20, and 50ms is sampled once, and 4s files once.The step 2 sampling
When, data sampling uses interrupt mode, and first read data bit puts pointer N, and the data order of selected measurement point is sampled, write-in
Specified data records data block, and lower 1 data write lower 1 data record data block, 20 crucial measuring point data record knots
Beam, records the latest position pointer N of data, and datacycle refreshes, and after writing completely, returns to the 1st data bit and re-writes.It is described
Two kinds of automatic trigger when the sampling of step 3 stops being triggered by hand push button and jumping car, it is to avoid jumping Chinese herbaceous peony to jump car automatic trigger
Critical data is lost, and is automatically stopped the write-in of new data；Configured on demand when triggering is data analysis manually.The step
Under three sampling stop modes, stop the refreshing of data, record stop timing, the data before retention fault generation.The data are delayed
Deposit data block is in the form of a data block by the data write-in data buffer storage data block of all channel datas record data block.
The variable name of process control variable is identical with No. AR_ID of the SFB37 functional blocks on PLC in the step 6.The step 3
After sampling stopping mode, the sampling operation mode of step 1 is again introduced into, data needed for fault diagnosis have been filed, so by old number
According to whole clearings, position indicator pointer N, date, time all reset.When the step 4 data upload, by data to be uploaded with
Defined form writes data buffer storage data block, calls " AR_SEND " functional block to send to WINCC by PLC and files.
Having the advantages that in above-mentioned technical proposal:Using the high-speed computation ability of computer, large storage capacity,
The historical record limitation of existing industrial control system is broken through, with the high-speed sampling time of 10ms, the intensive sampling of local data is realized, remembers
Record.Stop sampling during failure, exit record, reservation critical data is to be analyzed, plays the role of industrial control system black box.By
In greatly reducing the sampling time, 10MS grades are reached, have been greatly enhanced for the capturing ability of abnormal data.Due to key
Measuring point can be optional online, very convenient flexible when making emphasis investigation to faulty equipment.Original system is kept not to greatest extent
Become, have the characteristics that safe and practical.
Brief description of the drawings
The content expressed by this specification attached drawing and the mark in figure are briefly described below：
Fig. 1 is the sampling operation model process figure of the embodiment of the present invention.
Fig. 2 is the sampling stop mode flow chart of the embodiment of the present invention.
Fig. 3 is that the data of the embodiment of the present invention upload flow chart.
Fig. 4 be the present invention embodiment data transfer to data buffer storage data block flow chart.
Embodiment
Below against attached drawing, by the description of the embodiment, each component that the embodiment of the present invention is for example involved
Shape, construction, the mutual alignment and connection relation between each several part, the effect of each several part and operation principle, manufacturing process and
Operate with method etc., is described in further detail, to help those skilled in the art to inventive concept of the invention, technology
Scheme has more complete, accurate and deep understanding.
A kind of industrial control system Fault Locating Method, it is characterised in that this method comprises the following steps：Step 1:
Data configuration data block, data record data block and data caching data block are set in industrial control system PLC；Step 2: PLC
During systematic sampling, collection is set into data and recorded in data record data block；Step 3: when PLC samplings stop, system day is read
Phase and time recorded data configuration data block；Step 4: PCL data upload, by data configuration data block, data record data
The data of block are uploaded to data buffer storage data block；Step 5: PLC by SFB37 functional blocks by the data of data buffer storage data block
It is sent to WINCC；Step 6: on host computer WINCC configuration, establish the connection with PLC, selection filing data link,
Recorded in variable, establish process control variable, the data sended on PLC are filed on WINCC.
The data record data block of this method is equipped with 20, and 50ms is sampled once, and 4s files once.The step 2 sampling
When, data sampling uses interrupt mode, and first read data bit puts pointer N, and the data order of selected measurement point is sampled, write-in
Specified data records data block, and lower 1 data write lower 1 data record data block, 10 crucial measuring point data record knots
Beam, records the latest position pointer N of data, and datacycle refreshes, and after writing completely, returns to the 1st data bit and re-writes.It is described
Two kinds of automatic trigger when the sampling of step 3 stops being triggered by hand push button and jumping car, it is to avoid jumping Chinese herbaceous peony to jump car automatic trigger
Critical data is lost, and is automatically stopped the write-in of new data；Configured on demand when triggering is data analysis manually.The step
Under three sampling stop modes, stop the refreshing of data, record stop timing, the data before retention fault generation.The data are delayed
Deposit data block is in the form of a data block by the data write-in data buffer storage data block of all channel datas record data block.
The variable name of process control variable is identical with No. AR_ID of the SFB37 functional blocks on PLC in the step 6.The step 3
After sampling stopping mode, the sampling operation mode of step 1 is again introduced into, data needed for fault diagnosis have been filed, so by data
All reset, position indicator pointer N, date, time all reset.When the step 4 data upload, by data to be uploaded to advise
Fixed form write-in data buffer storage data block, calls " AR_SEND " functional block to send to WINCC and files by PLC.
After failure occurs, be parked in it is specific in the state of, constant, the new number of the crucial measuring point datas of retention fault first few minutes
According to no longer writing.Crucial measuring point can configuration, change online.Only data query when, host computer just reads the data of bottom PLC,
And carry out data filing.For quick sampling system, if the crucial measuring point 10ms of selection 10 is sampled 1 time, what is produced within 5 minutes adopts
Sample data have 300000.
By taking the most Siemens S7-400 series of PLC of industrial control system as an example.Since the maximum capacity of each DB data blocks is
64KB, is directly stored with the initial data (WORD types) after analog-converted.Need to establish 10 DB data recording numbers on PLC
According to block, 1 DB block defines 30000 (integral multiple of crucial measuring point quantity) WORD type data.
The working method of PLC is equipped with sampling operation mode, sampling stopping mode and data and uploads.Under sampling operation mode,
Data sampling uses interrupt mode, and first read data bit puts pointer N, and the data order of selected measurement point is sampled, and write-in refers to
Fixed data record data block, the lower 1 data record data block of lower 1 data write-in, 10 crucial measuring point data record ends,
Record the latest position pointer N of data.Datacycle refreshes, and after writing completely, returns to the 1st data bit and re-writes.Sampling stops
Two kinds of automatic trigger when only mode is triggered by hand push button and jumps car.It is that the critical data for avoiding jumping Chinese herbaceous peony is lost to jump car automatic trigger
Lose, be automatically stopped the write-in of new data；It is configured flexibly on demand when triggering is data analysis manually.Sampling stopping mode triggering
Afterwards, in addition to the write-in for stopping new data, date and time is recorded, in case checking.Data upload when, by data to be uploaded with
In certain form write-in data buffer storage data block, call " AR_SEND " functional block to send to WINCC by PLC and file.Sampling stops
Only after mode, sampling operation mode is again introduced into, it is believed that data have been filed needed for fault diagnosis, so legacy data is whole
Reset, position indicator pointer N, date, time all reset.WinCC shows filing procedure, and the technology of use is：In S7-400CPU
In, STEP7 uses SFB37 (AR_SEND) functional block, by process data collection into a corresponding data area, and transmits
Give functional block AR_SEND.When the event of definition occurs, AR_SEND functional blocks will be called and by one or more data
Block is transmitted in the filing data of WinCC.And standardization dynamic link libraries " nrms7pmc.dll " is called to explain these collections
The initial data arrived.
Embodiment 1：20 crucial measuring points, 50ms are sampled 1 time, and the filing example that 4S is produced, other are analogized.
1. on PLC, increase data record data block 20 newly, be respectively DB1001, DB1002 ..., DB1020, in being used for
Data record during disconnected record.Newly-increased data buffer storage data block DB900, by the data of all passages in the form of a data block
In writing data blocks.Predefined, the form identified with WINCC, the data buffering of WINCC is sent to as SFB37.
2. in OB35, if the break period is 0.05S, under sampling operation pattern, program timing writes data into passage note
Record in data block, program is as shown in Figure 1.
3. sampling under stop mode, stop the refreshing of data, record stop timing, the data before retention fault generation.Journey
Sequence is as shown in Figure 2.
4. data upload, collected in data to data caching data block DB900 by PLC, sent by SFB37 functional blocks
The data of dedicated tunnel are on WINCC.Program is as shown in Figure 3, Figure 4.
5. the configuration of WINCC on host computer, establishes the connection with S7,20 initial data variables are then established, are selected
Select filing data link.Recorded in variable, establish process control variable, variable name ensures the SFB37 functions with being defined on PLC
No. AR_ID of block is identical.In this way, the data sended on PLC can just file on WINCC.
6. on WINCC pictures, the data of quick history samples are inquired about and shown with online historical query control.
The present invention is exemplarily described above in conjunction with attached drawing, it is clear that the present invention implements and from aforesaid way
Limitation, as long as the improvement of the various unsubstantialities of inventive concept and technical scheme of the present invention progress is employed, or without changing
Other occasions are directly applied into by the design of the present invention and technical solution, within protection scope of the present invention.This hair
Bright protection domain should be determined by the scope of protection defined in the claims.
Claims (9)
1. a kind of industrial control system Fault Locating Method, it is characterised in that this method comprises the following steps：
Step 1: set data configuration data block, data record data block and data data cached in industrial control system PLC
Block；
Step 2: when PLC system samples, collection is set into data and recorded in data record data block；
Step 3: when PLC samplings stop, reading system date and time and recorded data configuration data block；
Step 4: PCL data upload, the data of data configuration data block, data record data block are uploaded to data buffer storage number
According to block；
Step 5: PLC by SFB37 functional blocks by the data sending of data buffer storage data block to WINCC；
Step 6: on host computer WINCC configuration, establish the connection with PLC, selection filing data link, remembers in variable
Under record, process control variable is established, the data sended on PLC are filed on WINCC.
2. industrial control system Fault Locating Method according to claim 1, it is characterised in that the data record of this method
Data block is equipped with 20, and 50ms is sampled once, and 4s files once.
3. industrial control system Fault Locating Method according to claim 1, it is characterised in that the step 2 sampling
When, data sampling uses interrupt mode, and first read data bit puts pointer N, and the data order of selected measurement point is sampled, write-in
Specified data records data block, and lower 1 data write lower 1 data record data block, 20 crucial measuring point data record knots
Beam, records the latest position pointer N of data, and datacycle refreshes, and after writing completely, returns to the 1st data bit and re-writes.
4. industrial control system Fault Locating Method according to claim 1, it is characterised in that the sampling of the step 3
Two kinds of automatic trigger when stopping being triggered by hand push button and jumping car, it is that the critical data for avoiding jumping Chinese herbaceous peony is lost to jump car automatic trigger
Lose, be automatically stopped the write-in of new data；Configured on demand when triggering is data analysis manually.
5. industrial control system Fault Locating Method according to claim 1, it is characterised in that the step 3 sampling stops
Only under pattern, stop the refreshing of data, record stop timing, the data before retention fault generation.
6. industrial control system Fault Locating Method according to claim 1, it is characterised in that the data buffer storage data
Block is in the form of a data block by the data write-in data buffer storage data block of all channel datas record data block.
7. industrial control system Fault Locating Method according to claim 1, it is characterised in that process in the step 6
Control the variable name of variable identical with No. AR_ID of the SFB37 functional blocks on PLC.
8. industrial control system Fault Locating Method according to claim 1, it is characterised in that the step 3 sampling stops
Only after mode, the sampling operation mode of step 1 is again introduced into, data needed for fault diagnosis have been filed, so legacy data is whole
Reset, position indicator pointer N, date, time all reset.
9. industrial control system Fault Locating Method according to claim 1, it is characterised in that in the step 4 data
During biography, data to be uploaded are write into data buffer storage data block with defined form, call " AR_SEND " functional block to send out by PLC
Send to WINCC and file.
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| CN201711392364.9A CN107943009A (en) | 2017-12-21 | 2017-12-21 | A kind of industrial control system Fault Locating Method |
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| CN201711392364.9A CN107943009A (en) | 2017-12-21 | 2017-12-21 | A kind of industrial control system Fault Locating Method |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111487919A (en) * | 2020-05-09 | 2020-08-04 | 柳州铁道职业技术学院 | P L C industrial automation control system and control method |
| CN112084758A (en) * | 2020-09-19 | 2020-12-15 | 浙江强盛压缩机制造有限公司 | Automatic extraction method of compressor quality inspection data |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111487919A (en) * | 2020-05-09 | 2020-08-04 | 柳州铁道职业技术学院 | P L C industrial automation control system and control method |
| CN112084758A (en) * | 2020-09-19 | 2020-12-15 | 浙江强盛压缩机制造有限公司 | Automatic extraction method of compressor quality inspection data |
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