CN109542030B - FPGA-based nuclear power station material loading and unloading machine state monitoring system and monitoring method thereof - Google Patents
FPGA-based nuclear power station material loading and unloading machine state monitoring system and monitoring method thereof Download PDFInfo
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- CN109542030B CN109542030B CN201811196521.3A CN201811196521A CN109542030B CN 109542030 B CN109542030 B CN 109542030B CN 201811196521 A CN201811196521 A CN 201811196521A CN 109542030 B CN109542030 B CN 109542030B
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Abstract
The invention belongs to the technical field of nuclear safety protection, and relates to a system and a method for monitoring the state of a material loading and unloading machine of a nuclear power station based on an FPGA. The monitoring system comprises a material handling machine sensor, a material handling machine main controller, an FPGA data acquisition module, an FPGA data processing module, an FPGA trigger control module, an FPGA data recording module and an FPGA data communication module. By using the monitoring system and the monitoring method thereof, when the state monitoring of the material loading and unloading machine of the nuclear power station is carried out, based on the defects of a PLC control system, a hardware control loop is flexibly deployed by using software through the FPGA-based technology, so that the parallel processing of data, the recording triggering, the logic judgment and the decision are realized; and simultaneously, complete data of the active behavior and the passive behavior of the equipment are synchronously recorded with time, so that important data are provided for tracing and analyzing fault reasons.
Description
Technical Field
The invention belongs to the technical field of nuclear safety protection, and relates to a system and a method for monitoring the state of a material loading and unloading machine of a nuclear power station based on an FPGA (field programmable gate array).
Background
The loading and unloading machine is a key device for completing reactor refueling during shutdown and refueling of a nuclear power plant, and carries out loading and unloading work on fuel assemblies between a reactor core and a fuel transfer system according to a specified path. From experience in use at home and abroad, a system based on a PLC (programmable controller) technology performs a cyclic scan mode to increase response time of a protection function.
The operation parameters of the material loading and unloading machine are numerous, the material changing operation is required to be completed preferentially after abnormality or failure occurs in the operation, and the root cause of the equipment failure cannot be found and analyzed in time without the data recording function. The state monitoring system of the material loading and unloading machine based on the FPGA technology realizes real-time monitoring of the state of equipment, instantly completes an interlocking protection function, and synchronously records complete running data of all active and passive behaviors from beginning to end with action time.
Disclosure of Invention
The invention mainly aims to provide a nuclear power station material loading and unloading machine state monitoring system based on an FPGA (field programmable gate array), so that when the state of the nuclear power station material loading and unloading machine is monitored, a hardware control loop is flexibly deployed by software through the FPGA-based technology based on the defects of a PLC (programmable logic controller) control system, and data parallel processing, trigger recording, logic judgment and decision making are realized.
In order to achieve the purpose, in a basic embodiment, the invention provides a nuclear power station material handling machine state monitoring system based on FPGA, which comprises a material handling machine sensor, a material handling machine main controller, an FPGA data acquisition module, an FPGA data processing module, an FPGA trigger control module, an FPGA data recording module and an FPGA data communication module,
the FPGA data acquisition module is used for acquiring signals of the material loading and unloading machine sensor, including a limit switch, an encoder and a load sensor;
the FPGA data processing module is used for processing the signals acquired by the FPGA data acquisition module and outputting the processed results to a hardware interlocking circuit of a control system of the material handling machine to realize interlocking protection or provide the results to a main controller of the material handling machine through internal data exchange;
the FPGA data communication module is used for receiving an instruction sent by the main controller of the material handling machine, receiving data output by the FPGA data recording module and transmitting the data to the main controller of the material handling machine;
the FPGA trigger control module is used for receiving the active behavior instruction transmitted by the FPGA data communication module and the passive behavior signal transmitted by the FPGA data processing module, and controlling the function of trigger recording through processing;
the FPGA data recording module is used for recording the signals acquired by the FPGA data acquisition module and recording related data of equipment while the active behavior and the passive behavior are triggered according to the output result of the FPGA trigger control module.
The second purpose of the present invention is to provide a method for monitoring the state of a nuclear power plant material handling machine by using the monitoring system, so as to implement data parallel processing, trigger recording, logic judgment and decision by flexibly deploying a hardware control loop by using software based on the technology of FPGA based on the deficiency of a PLC control system when monitoring the state of the nuclear power plant material handling machine. To achieve the purpose, in a basic embodiment, the invention provides a method for monitoring the state of a loader of a nuclear power plant by using the monitoring system, wherein the method comprises the following steps:
(1) the FPGA data acquisition module is used for acquiring signals of the material loading and unloading machine sensor including a limit switch, an encoder and a load sensor in parallel, and the signals are simultaneously provided for the FPGA data processing module and the FPGA data recording module according to requirements;
(2) the FPGA data processing module is used for processing the signals acquired by the FPGA data acquisition module, the processed normal results are output to a hardware interlocking circuit of a control system of the material handling machine to realize interlocking protection, and the triggered passive behavior is provided for a main controller of the material handling machine through internal data exchange of the FPGA communication module;
(3) the FPGA trigger control module receives an active action instruction of the main controller of the material loading and unloading machine and a passive action signal output by the FPGA data processing module, and outputs a trigger control signal to the FPGA data recording module after processing and classification;
(4) the FPGA data recording module receives a trigger control signal, selects corresponding data parameters according to signal types, records the data parameters with time marks synchronously with the time of behaviors, and provides the recorded data to the main controller of the material loading and unloading machine through the FPGA data communication module to realize data display and write-in file storage.
In a preferred embodiment, the invention provides a method for monitoring the state of a loader of a nuclear power plant by using the monitoring system, wherein in the step (1):
the FPGA data acquisition module acquires signals of the loading and unloading machine sensor and signals of a safety limit sensor and a hand wheel limit sensor by using an I/O module;
and parallelly acquiring all signals in an FPGA chip of the FPGA data acquisition module, and setting the sampling rate of the module.
In a preferred embodiment, the invention provides a method for monitoring the state of a loader of a nuclear power plant by using the monitoring system, wherein in the step (2):
when the FPGA data processing module processes the signals acquired by the FPGA data acquisition module, channel comparison is carried out after filtering and range check, if the comparison result is abnormal, the result is recorded and provided to a main controller of the material loading and unloading machine, and an interlocking signal is output at the same time; and if the comparison result is normal, entering the next cycle.
In a more preferred embodiment, the present invention provides a method for monitoring the state of a loader of a nuclear power plant by using the monitoring system, wherein in the step (2):
aiming at the switching value signal, in order to avoid EMC interference, the filtered digital signal participates in control;
utilizing a plurality of loop structures to process the safety limit of a plurality of operating mechanisms in parallel;
simultaneously transmitting the state of a switch signal to a main controller of the material loading and unloading machine;
and outputting an interlocking instruction after judging that the interlocking condition is met.
In a more preferred embodiment, the present invention provides a method for monitoring the state of a loader of a nuclear power plant by using the monitoring system, wherein in the step (2):
aiming at the load analog signal, in order to avoid EMC interference, the filtered digital signal participates in control, and whether the numerical range exceeds the normal range is checked;
processing a plurality of sensor channels in parallel using a plurality of loop structures;
and transmitting data to the main controller of the material loading and unloading machine through the FIFO queue after the correct load value is obtained, comparing the data with a design threshold value, and outputting an interlocking instruction after judging that the interlocking condition is met.
In a preferred embodiment, the invention provides a method for monitoring the state of a loader of a nuclear power plant by using the monitoring system, wherein in the step (3), the active behavior command comprises a motion command and a bypass operation sent by an operator.
In a preferred embodiment, the invention provides a method for monitoring the state of the loading and unloading machine of the nuclear power plant by using the monitoring system, wherein in the step (3), the passive action signal comprises a safety limit action, a load protection action and an encoder fault action.
The system and the method have the advantages that when the state monitoring of the nuclear power station material loading and unloading machine based on the FPGA is carried out, the hardware control loop is flexibly deployed by software through the FPGA-based technology based on the defects of a PLC control system, so that data parallel processing, trigger recording, logic judgment and decision making are realized; and simultaneously, complete data of the active behavior and the passive behavior of the equipment are synchronously recorded with time, so that important data are provided for tracing and analyzing fault reasons. The monitoring system and the main controller are integrated under the same control platform, and measures are taken immediately when dangerous working conditions occur, so that a reliable interlocking protection function is provided.
The invention is based on the FPGA control technology, realizes the customization of a complex pure hardware control circuit through software, achieves high reliability, high certainty and high real-time performance, and can realize real parallel operation. The invention integrates the equipment state monitoring and the equipment main controller under a control platform, and can make correct judgment in time and send out an interlocking instruction by acquiring and detecting various sensor signals, and meanwhile, the monitoring system can operate independently of the equipment main controller.
Aiming at the defect that the existing nuclear power station loading and unloading machine at home and abroad lacks an efficient equipment monitoring system which operates independently, the invention introduces the technology based on the FPGA chip, realizes the parallel real-time processing of all signals, and simultaneously records complete data, including providing the data to a main control to display a load curve so as to position the physical position of an abnormal signal. The monitoring system of the invention operates independently, judges the state of the equipment and outputs correct response action, thereby avoiding equipment or personal injury. In addition, the invention provides a safe and effective control function, ensures that necessary measures are taken in time when danger occurs, and has better reliability and safety compared with the prior control system.
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Fig. 1 is a flowchart illustrating a monitoring method of the monitoring system for the state of a nuclear power plant material handling machine based on an FPGA according to an exemplary embodiment of the present invention.
Detailed Description
The following further describes embodiments of the present invention with reference to the accompanying drawings.
The system comprises a loading and unloading machine sensor, a loading and unloading machine main controller, an FPGA data acquisition module, an FPGA data processing module, an FPGA trigger control module, an FPGA data recording module and an FPGA data communication module.
The FPGA data acquisition module is used for acquiring signals of a loading and unloading machine sensor, including a limit switch, an encoder and a load sensor;
the FPGA data processing module is used for processing the signals acquired by the FPGA data acquisition module and outputting the processed results to a hardware interlocking circuit of a control system of the material handling machine to realize interlocking protection or provide the results to a main controller of the material handling machine through internal data exchange;
the FPGA data communication module is used for receiving an instruction sent by the main controller of the material handling machine, receiving data output by the FPGA data recording module and transmitting the data to the main controller of the material handling machine;
the FPGA trigger control module is used for receiving the active behavior instruction transmitted by the FPGA data communication module and the passive behavior signal transmitted by the FPGA data processing module, and controlling the function of trigger recording through processing;
the FPGA data recording module is used for recording the signals acquired by the FPGA data acquisition module and recording related data of equipment while the active behavior and the passive behavior are triggered according to the output result of the FPGA trigger control module.
The flow of the exemplary method for monitoring the state of the nuclear power plant loader/unloader by the monitoring system of the present invention is shown in fig. 1, and includes the following steps:
(1) the I/O module of the FPGA data acquisition module is used for acquiring signals of a material loading and unloading machine sensor, including a limit sensor, an encoder and a load sensor. And parallelly acquiring all signals in an FPGA chip of the FPGA data acquisition module, and setting the sampling rate of the module.
(2) The signals acquired by the FPGA data acquisition module are processed by the FPGA data processing module, processed normal results are output to a hardware interlocking circuit of a control system of the material handling machine to realize interlocking protection, and abnormal results are provided to a main controller of the material handling machine through internal data exchange. When the FPGA data processing module processes the signals acquired by the FPGA data acquisition module, channel comparison is carried out after filtering and range check, if the comparison result is abnormal, the result is recorded and provided for the main controller of the material loading and unloading machine, and an interlocking signal is output at the same time.
In addition, in this step:
aiming at the switching value signal, in order to avoid EMC interference, the filtered digital signal participates in control; utilizing a plurality of loop structures to process the safety limit of a plurality of operating mechanisms in parallel; simultaneously transmitting the state of a switch signal to a main controller of the material loading and unloading machine; and outputting an interlocking instruction after judging that the interlocking condition is met.
Aiming at the load analog signal, in order to avoid EMC interference, the filtered digital signal participates in control, and whether the numerical range exceeds the normal range is checked; processing a plurality of sensor channels in parallel using a plurality of loop structures; and transmitting data to a main controller of the loading and unloading machine through an FIFO (first-in first-out queue) after the correct load value is obtained, comparing the data with a design threshold value, and outputting an interlocking instruction after judging that the interlocking condition is met.
(3) The FPGA trigger control module is responsible for triggering all active and passive behaviors and controls the FPGA data recording module to record related operation data. And the data recording and the action time are synchronously carried out, the data added with the time identification are written into a binary format file through an FPGA data communication module, the file is stored in the main controller of the material handling machine, and all the data are displayed in a chart mode.
In the practical application process of the above exemplary monitoring system and monitoring method of the present invention, a control platform based on the FPGA technology and a matched input module and output module may be adopted, for example, the control platform adopts an NI CompactRIO platform, and the programming software adopts NI LabVIEW software.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is intended to include such modifications and variations. The above-described embodiments are merely illustrative of the present invention, and the present invention may be embodied in other specific forms or other specific forms without departing from the spirit or essential characteristics thereof. The described embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. The scope of the invention should be indicated by the appended claims, and any changes that are equivalent to the intent and scope of the claims should be construed to be included therein.
Claims (5)
1. The utility model provides a nuclear power station loading and unloading machine state monitoring system based on FPGA which characterized in that: the monitoring system comprises a material handling machine sensor, a material handling machine main controller, an FPGA data acquisition module, an FPGA data processing module, an FPGA trigger control module, an FPGA data recording module and an FPGA data communication module,
the FPGA data acquisition module is used for acquiring signals of the material loading and unloading machine sensor, including a limit switch, an encoder and a load sensor;
the FPGA data processing module is used for processing the signals acquired by the FPGA data acquisition module and outputting the processed results to a hardware interlocking circuit of a control system of the material handling machine to realize interlocking protection or provide the results to a main controller of the material handling machine through internal data exchange;
the FPGA data communication module is used for receiving an instruction sent by the main controller of the material handling machine, receiving data output by the FPGA data recording module and transmitting the data to the main controller of the material handling machine;
the FPGA trigger control module is used for receiving the active behavior instruction transmitted by the FPGA data communication module and the passive behavior signal transmitted by the FPGA data processing module, and controlling the function of trigger recording through processing;
the FPGA data recording module is used for recording the signals acquired by the FPGA data acquisition module and recording related data of equipment while the active behavior and the passive behavior are triggered according to the output result of the FPGA trigger control module.
2. A method for monitoring the condition of a handler of a nuclear power plant using the monitoring system of claim 1, the method comprising the steps of:
(1) the FPGA data acquisition module is used for acquiring signals of the material loading and unloading machine sensor including a limit switch, an encoder and a load sensor in parallel, and the signals are simultaneously provided for the FPGA data processing module and the FPGA data recording module according to requirements;
(2) the FPGA data processing module is used for processing the signals acquired by the FPGA data acquisition module, the processed normal results are output to a hardware interlocking circuit of a control system of the material handling machine to realize interlocking protection, and the triggered passive behavior is provided for a main controller of the material handling machine through internal data exchange of the FPGA communication module;
when the FPGA data processing module processes the signals acquired by the FPGA data acquisition module, channel comparison is carried out after filtering and range check, if the comparison result is abnormal, the result is recorded and provided to a main controller of a material loading and unloading machine, and an interlocking signal is output at the same time; if the comparison result is normal, entering the next cycle;
aiming at the switching value signal, in order to avoid EMC interference, the filtered digital signal participates in control;
utilizing a plurality of loop structures to process the safety limit of a plurality of operating mechanisms in parallel;
simultaneously transmitting the state of a switch signal to a main controller of the material loading and unloading machine;
outputting an interlocking instruction after judging that the interlocking condition is met;
aiming at the load analog signal, in order to avoid EMC interference, the filtered digital signal participates in control, and whether the numerical range exceeds the normal range is checked;
processing a plurality of sensor channels in parallel using a plurality of loop structures;
transmitting data to a main controller of the material loading and unloading machine through an FIFO queue after a correct load numerical value is obtained, simultaneously comparing the data with a design threshold value, and outputting an interlocking instruction after judging that an interlocking condition is met;
(3) the FPGA trigger control module receives an active action instruction of the main controller of the material loading and unloading machine and a passive action signal output by the FPGA data processing module, and outputs a trigger control signal to the FPGA data recording module after processing and classification;
(4) the FPGA data recording module receives a trigger control signal, selects corresponding data parameters according to signal types, records the data parameters with time marks synchronously with the time of behaviors, and provides the recorded data to the main controller of the material loading and unloading machine through the FPGA data communication module to realize data display and write-in file storage.
3. The method of claim 2, wherein in step (1):
the FPGA data acquisition module acquires signals of the loading and unloading machine sensor and signals of a safety limit sensor and a hand wheel limit sensor by using an I/O module;
and parallelly acquiring all signals in an FPGA chip of the FPGA data acquisition module, and setting the sampling rate of the module.
4. The method of claim 2, wherein: in the step (3), the active behavior instruction comprises a movement instruction and a bypass operation sent by an operator.
5. The method of claim 2, wherein: in the step (3), the passive behavior signal comprises a safety limit action, a load protection action and an encoder fault action.
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CN111665752B (en) * | 2020-05-27 | 2022-09-27 | 中国核电工程有限公司 | FPGA-based loading and unloading machine motion control system and method |
CN112859725B (en) * | 2021-01-04 | 2022-06-24 | 中国核电工程有限公司 | Monitoring system for status characteristic signals of plant equipment |
CN113407474B (en) * | 2021-08-19 | 2021-11-23 | 美核电气(济南)股份有限公司 | Multi-channel nuclear power equipment contact scanning device and working method thereof |
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