CN110162020B - Industrial control equipment fault diagnosis method and system - Google Patents
Industrial control equipment fault diagnosis method and system Download PDFInfo
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- CN110162020B CN110162020B CN201910490576.3A CN201910490576A CN110162020B CN 110162020 B CN110162020 B CN 110162020B CN 201910490576 A CN201910490576 A CN 201910490576A CN 110162020 B CN110162020 B CN 110162020B
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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
- G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
- G05B23/0262—Confirmation of fault detection, e.g. extra checks to confirm that a failure has indeed occurred
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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
Abstract
The invention relates to a fault diagnosis method and a system for industrial control equipment, wherein the diagnosis method comprises the following steps: connecting the transmission link with the fault to a diagnosis link and starting diagnosis; sending a diagnostic request to cause the first node module to generate diagnostic data; the diagnostic data is transmitted to a third node module over the diagnostic link; judging the node module which has a fault according to the condition that the third node module receives the data; one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the failed transmission link originally functions to transmit the data of the first node module to the third node module via the second node module. The method can reduce the fault diagnosis range, quickly judge the node module with the fault and improve the diagnosis efficiency; in addition, the method does not need maintenance personnel to go to the site to check one by one, and the diagnosed fault information can be sent to the remote terminal, so that the time and labor cost are saved.
Description
Technical Field
The invention relates to the technical field of industrial control, in particular to a fault diagnosis method and system for industrial control equipment.
Background
Industrial control devices are used in more and more industries, and specific functions are realized by industrial control devices with different functions in the industrial field. For example, a water conservancy system with a remote monitoring function at least comprises: the flow meter, the data conversion processing module and the server are arranged in the water supply pipeline, under normal conditions, the flow meter collects flow information in the pipeline, the flow information data are transmitted to the data conversion processing module according to an agreed data transmission protocol, then the data conversion processing module carries out data processing, and finally the data containing the flow information are transmitted to the server.
In the industrial control system, data transmission is performed between two adjacent node modules through a specific transmission protocol. In the prior art, when an industrial control system has a fault, maintenance personnel need to be informed to go to the site to check node modules one by one to estimate the fault reason.
Disclosure of Invention
In view of this, the present invention provides a method and a system for diagnosing faults of industrial control equipment to overcome the defects of the prior art.
In order to achieve the purpose, the invention adopts the following technical scheme: a fault diagnosis method for industrial control equipment comprises the following steps:
connecting the transmission link with the fault to a diagnosis link and starting diagnosis; one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the originally normal function of a failed transmission link is: transmitting the data of the first node module to the third node module through the second node module;
sending a diagnostic request to cause the first node module to generate diagnostic data;
the diagnostic data is transmitted to the third node module over the diagnostic link;
and judging the node module which has a fault according to the condition that the third node module receives the data.
Optionally, the diagnostic data generated by the first node module includes:
and preset diagnosis data corresponding to the diagnosis request, or real-time data of the first node module in a working condition state.
Optionally, the determining, according to the condition that the third node module receives the data, the node module that has failed includes: within a preset time period after the diagnostic request is sent,
if the third node module does not receive the data, judging that the first node module has a fault;
and if the third node module receives the data, analyzing the data received by the third node module to determine the failed node module.
Optionally, analyzing the data received by the third node module to determine the failed node module includes:
judging whether the frame head, the frame tail, the check code and the total byte number of each received frame data are all correct, and if so, judging that the second node module has a fault;
and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module has a fault.
Optionally, the diagnostic method further comprises:
displaying the judged fault information; and/or the presence of a gas in the gas,
and sending the fault information to a remote terminal.
Optionally, the diagnosis link is an RS-485 communication link; the first node module at least comprises a terminal data acquisition module, the second node module at least comprises a PLC module with a data processing function, and the third node module is a server.
The invention also provides a fault diagnosis system for the industrial control equipment, which comprises the following components:
the fault diagnosis starting unit is used for connecting the transmission link with the fault to the diagnosis link and starting diagnosis; one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the originally normal function of a failed transmission link is: transmitting the data of the first node module to the third node module through the second node module;
a request transmitting unit for transmitting a diagnosis request to cause the first node module to generate diagnosis data;
a diagnostic link for transmitting the diagnostic data to a third node module;
and the fault judging unit is used for judging the node module which has a fault according to the condition that the third node module receives the data.
Optionally, the fault determining unit determines the node module with the fault according to the condition that the third node module receives the data, and specifically includes: within a preset time period after the diagnostic request is sent,
if the third node module does not receive the data, judging that the first node module has a fault;
and if the third node module receives the data, analyzing the data received by the third node module to determine the failed node module.
Optionally, analyzing the data received by the third node module to determine the failed node module includes:
judging whether the frame head, the frame tail, the check code and the total byte number of each received frame data are all correct, and if so, judging that the second node module has a fault;
and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module has a fault.
Optionally, the diagnostic system further comprises:
the display unit is used for displaying the judged fault information; and/or the presence of a gas in the gas,
and the fault information sending unit is used for sending the fault information to a remote terminal.
By adopting the technical scheme, the industrial control equipment fault diagnosis method comprises the following steps: connecting the transmission link with the fault to a diagnosis link and starting diagnosis; sending a diagnostic request to cause the first node module to generate diagnostic data; the diagnostic data is transmitted to the third node module over the diagnostic link; and judging the node module which has a fault according to the condition that the third node module receives the data. The diagnosis method can greatly reduce the fault diagnosis range, is favorable for quickly judging the node module with the fault, and improves the diagnosis efficiency; in addition, the fault diagnosis method does not need maintenance personnel to go to the site to check one by one, and diagnosed fault information can be sent to the remote terminal, so that time and labor cost are saved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic flow chart provided by a first embodiment of a fault diagnosis method for industrial control equipment according to the present invention;
FIG. 2 is a schematic flow chart of a fault diagnosis method for industrial control equipment according to a second embodiment of the present invention;
fig. 3 is a schematic structural diagram of a first embodiment of the fault diagnosis system for industrial control equipment according to the present invention.
In the figure: 1. a failure diagnosis starting unit; 2. a request transmitting unit; 3. diagnosing the link; 4. a failure determination unit; 5. a display unit; 6. a failure information transmitting unit; 7. a remote terminal; 8. a first node module; 9. a second node module; 10. and a third node module.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be described in detail below. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the examples given herein without any inventive step, are within the scope of the present invention.
Fig. 1 is a schematic flow chart provided by a first embodiment of the fault diagnosis method for industrial control equipment according to the present invention.
As shown in fig. 1, the fault diagnosis method according to the present embodiment includes:
s11: connecting the transmission link with the fault to a diagnosis link and starting diagnosis;
one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the originally normal function of a failed transmission link is: transmitting the data of the first node module to the third node module through the second node module;
s12: sending a diagnostic request to cause the first node module to generate diagnostic data;
further, the diagnostic data generated by the first node module includes:
and preset diagnosis data corresponding to the diagnosis request, or real-time data of the first node module in a working condition state.
S13: the diagnostic data is transmitted to the third node module over the diagnostic link;
s14: and judging the node module which has a fault according to the condition that the third node module receives the data.
Further, the diagnosis link is an RS-485 communication link; the first node module at least comprises a terminal data acquisition module, the second node module at least comprises a PLC module with a data processing function, and the third node module is a server.
In practical use, as a simplest use scenario, for example, an industrial control system includes: the flow meter, the PLC module and the server are arranged in the water supply pipeline, under the normal condition, the flow meter collects flow information in the pipeline, flow information data are transmitted to the PLC module according to an agreed data transmission protocol, data processing is carried out by the PLC module, and finally data containing the flow information are transmitted to the server. If the system has a fault, when the system is diagnosed, the transmission link with the fault can be connected to the diagnostic link, namely, the output end of the flow meter is connected with one end of the diagnostic link, and the receiving end of the server is connected with the other end of the diagnostic link, so that a path is established for fault diagnosis.
After the diagnosis operation is started, a diagnosis request is sent, the flow meter generates diagnosis data, the diagnosis data can be a flow value collected by the current flow meter, or preset diagnosis data (such as preset fixed diagnosis data) corresponding to the diagnosis request, if the flow meter is normal in function, the diagnosis data generated by the flow meter can be transmitted to a server through a diagnosis link in a preset time period after the diagnosis request is sent, and then the data received by the server is analyzed to determine a node module with a fault; and if the server does not receive the diagnosis data within a preset time period after the diagnosis request is sent, indicating that the flow meter has a fault.
The method can quickly judge the node module with the fault, and improves the diagnosis efficiency; according to the method, maintenance personnel do not need to go to the site to check one by one, and the diagnosed fault information can be sent to the remote terminal, so that the time and labor cost are saved.
Fig. 2 is a schematic flow chart provided by a second embodiment of the industrial control equipment fault diagnosis method of the present invention.
As shown in fig. 2, the fault diagnosis method according to the present embodiment includes:
s21: connecting the transmission link with the fault to a diagnosis link and starting diagnosis;
one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the originally normal function of a failed transmission link is: transmitting the data of the first node module to the third node module through the second node module;
s22: sending a diagnostic request to cause the first node module to generate diagnostic data;
s23: the diagnostic data is transmitted to the third node module over the diagnostic link;
s24: judging whether the third node module receives data within a preset time period after the diagnosis request is sent;
s25: if the third node module does not receive the data, judging that the first node module has a fault;
s26: if the third node module receives the data, judging whether the frame head, the frame tail, the check code and the total byte number of each received frame data are all correct;
s27: if all the nodes are correct, judging that the second node module has a fault;
s28: and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module has a fault.
S29: and displaying the judged fault information and sending the fault information to a remote terminal.
Further, the diagnosis link is an RS-485 communication link; the first node module at least comprises a terminal data acquisition module, the second node module at least comprises a PLC module with a data processing function, and the third node module is a server.
Further, the diagnosis link is an RS-485 communication link; the first node module at least comprises a terminal data acquisition module, the second node module at least comprises a PLC module with a data processing function, and the third node module is a server.
In practical use, the industrial control system mentioned in the first embodiment is also described, and if the system fails, when the system is diagnosed, the failed transmission link may be connected to the diagnostic link, that is, the output end of the flow meter is connected to one end of the diagnostic link, and the receiving end of the server is connected to the other end of the diagnostic link, so as to establish a path for fault diagnosis. After the diagnosis operation is started, a diagnosis request is sent, the flow meter generates diagnosis data, the diagnosis data can be a flow value collected by the current flow meter, and also can be preset diagnosis data corresponding to the diagnosis request, if the flow meter is normal in function, the diagnosis data generated by the flow meter can be transmitted to a server through a diagnosis link in a preset time period after the diagnosis request is sent, and then the data received by the server is analyzed: judging whether the number of a frame head, a frame tail, a check code and total bytes of each received frame data is correct or not according to a data transmission protocol, and if so, judging that the PLC module has a fault; if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the flow meter has a fault; if the server does not receive the diagnostic data within a preset time period after sending the diagnostic request, it is also said that the flow meter is malfunctioning.
It should be noted that, in actual use, the first node module may include not only a flow meter, but also other modules like a terminal data acquisition module, the second node module may also include other data processing and transfer modules besides the PLC module, and the third node module is not limited to the server. In this embodiment, the first node module, the second node module and the third node module are only intended to express the simplest transmission link composition structure, and the diagnosis method described in this embodiment is still applicable to transmission links including more node modules. When a transmission link including a plurality of node modules (for example, including n node modules) fails, the nodes 2 to n-1 may be regarded as a node module, which is equivalent to the second node module in the above example, the node 1 is regarded as the first node module, and the node n is regarded as the third node module, and which node module fails is determined according to the above determination process; when the second node module is judged to be in fault, the nodes from 2 to n-1 are regarded as a fault link to be diagnosed according to the method, namely: and the 2 nd node is taken as a first node module, the nodes from 3 rd to n-2 th are taken as a node module which is equivalent to a second node module, the n-1 th node is taken as a third node module, and the rest is repeated to carry out fault diagnosis.
The method can narrow the fault diagnosis range, quickly judge the node module with the fault and improve the diagnosis efficiency; in addition, the method does not need maintenance personnel to go to the site to check one by one, and the diagnosed fault information can be sent to the remote terminal, so that the time and labor cost are saved.
Fig. 3 is a schematic structural diagram provided by a second embodiment of the fault diagnosis system for industrial control equipment according to the present invention.
As shown in fig. 3, the fault diagnosis system according to the present embodiment includes:
a fault diagnosis starting unit 1 for connecting the transmission link with fault to the diagnosis link 3 and starting diagnosis; one end of the diagnosis link 3 is connected with the first node module 8, and the other end is connected with the third node module 10; the originally normal function of a failed transmission link is: transmitting the data of the first node module 8 to the third node module 10 through the second node module 9;
a request sending unit 2, configured to send a diagnostic request to enable the first node module 8 to generate diagnostic data;
a diagnostic link 3 for transmitting said diagnostic data to a third node module 10;
and a failure determination unit 4, configured to determine a node module that has failed according to a condition that the third node module 10 receives data.
Further, the determining unit 4 determines the node module having the fault according to the condition that the third node module 10 receives the data, and specifically includes: within a preset time period after the diagnostic request is sent,
if the third node module 10 does not receive data, it is determined that the first node module 8 fails;
if the third node module 10 receives data, the data received by the third node module 10 is analyzed to determine a failed node module.
Further, analyzing the data received by the third node module 10 to determine the failed node module includes:
judging whether the number of the frame head, the frame tail, the check code and the total bytes of each received frame data is correct, and if so, judging that the second node module 9 has a fault;
and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module 8 has a fault.
It should be noted that the diagnostic system further includes:
a display unit 5 for displaying the judged failure information; and/or the presence of a gas in the gas,
a failure information transmitting unit 6 for transmitting the failure information to a remote terminal 7.
The working principle of the diagnostic system of this embodiment is the same as that of the diagnostic method described above, and is not described herein again.
In actual use, the failure diagnosis starting unit 1 connects a failed transmission link to the diagnosis link 3 and starts diagnosis, the request sending unit 2 sends out a diagnosis request to enable the first node module 8 to generate diagnosis data, the diagnosis link 3 transmits the diagnosis data to the third node module 10, and the failure judging unit 4 judges the node module where the failure occurs according to the condition that the third node module 10 receives the data. The judged fault information is displayed through the display unit 5, and meanwhile, the fault information sending unit 6 can also send the fault information to the remote terminal 7 so as to realize that maintenance personnel can remotely check the fault information.
The fault diagnosis system can rapidly judge the node module with the fault, does not need to check the node module one by one on site by maintenance personnel, and is high in diagnosis efficiency and low in time and labor cost investment.
It is understood that the same or similar parts in the above embodiments may be mutually referred to, and the same or similar parts in other embodiments may be referred to for the content which is not described in detail in some embodiments.
It should be noted that the terms "first," "second," and the like in the description of the present invention are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Further, in the description of the present invention, the meaning of "a plurality" means at least two unless otherwise specified.
Any process or method descriptions in flow charts or otherwise described herein may be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps of the process, and alternate implementations are included within the scope of the preferred embodiment of the present invention in which functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present invention.
It should be understood that portions of the present invention may be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, the various steps or methods may be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, any one or combination of the following techniques, which are known in the art, may be used: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, an application specific integrated circuit having an appropriate combinational logic gate circuit, a Programmable Gate Array (PGA), a Field Programmable Gate Array (FPGA), or the like.
It will be understood by those skilled in the art that all or part of the steps carried by the method for implementing the above embodiments may be implemented by hardware related to instructions of a program, which may be stored in a computer readable storage medium, and when the program is executed, the program includes one or a combination of the steps of the method embodiments.
In addition, functional units in the embodiments of the present invention may be integrated into one processing module, or each unit may exist alone physically, or two or more units are integrated into one module. The integrated module can be realized in a hardware mode, and can also be realized in a software functional module mode. The integrated module, if implemented in the form of a software functional module and sold or used as a stand-alone product, may also be stored in a computer readable storage medium.
The storage medium mentioned above may be a read-only memory, a magnetic or optical disk, etc.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.
Claims (8)
1. A fault diagnosis method for industrial control equipment is characterized by comprising the following steps:
connecting the transmission link with the fault to a diagnosis link and starting diagnosis; one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the originally normal function of a failed transmission link is: transmitting the data of the first node module to the third node module through the second node module;
sending a diagnostic request to cause the first node module to generate diagnostic data;
the diagnostic data is transmitted to the third node module over the diagnostic link;
judging the node module which has a fault according to the condition that the third node module receives the data;
the method comprises the following steps: within a preset time period after the diagnostic request is sent,
if the third node module does not receive the data, judging that the first node module has a fault;
if the third node module receives data, judging whether the frame head, the frame tail, the check code and the total byte number of each received frame data are all correct, and if all correct, judging that the second node module has a fault;
and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module has a fault.
2. The fault diagnosis method according to claim 1, characterized in that the diagnostic data generated by the first node module comprises:
and preset diagnosis data corresponding to the diagnosis request, or real-time data of the first node module in a working condition state.
3. The fault diagnosis method according to any one of claims 1 to 2, characterized by further comprising:
displaying the judged fault information; and/or the presence of a gas in the gas,
and sending the fault information to a remote terminal.
4. The fault diagnosis method according to any one of claims 1 to 2, characterized in that the diagnosis link is an RS-485 communication link; the first node module at least comprises a terminal data acquisition module, the second node module at least comprises a PLC module with a data processing function, and the third node module is a server.
5. An industrial control equipment fault diagnosis system, characterized by comprising:
the fault diagnosis starting unit is used for connecting the transmission link with the fault to the diagnosis link and starting diagnosis; one end of the diagnosis link is connected with the first node module, and the other end of the diagnosis link is connected with the third node module; the originally normal function of a failed transmission link is: transmitting the data of the first node module to the third node module through the second node module;
a request transmitting unit for transmitting a diagnosis request to cause the first node module to generate diagnosis data;
a diagnostic link for transmitting the diagnostic data to a third node module;
the fault judging unit is used for judging the node module which has a fault according to the condition that the third node module receives the data;
the method comprises the following steps: within a preset time period after the diagnostic request is sent,
if the third node module does not receive the data, judging that the first node module has a fault;
if the third node module receives data, judging whether the frame head, the frame tail, the check code and the total byte number of each received frame data are all correct, and if all correct, judging that the second node module has a fault;
and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module has a fault.
6. The system according to claim 5, wherein the fault determining unit determines the node module having the fault according to the condition that the third node module receives the data, and specifically includes: within a preset time period after the diagnostic request is sent,
if the third node module does not receive the data, judging that the first node module has a fault;
and if the third node module receives the data, analyzing the data received by the third node module to determine the failed node module.
7. The fault diagnosis system according to claim 6, wherein analyzing the data received by the third node module to determine the failed node module comprises:
judging whether the frame head, the frame tail, the check code and the total byte number of each received frame data are all correct, and if so, judging that the second node module has a fault;
and if at least one error exists in the frame head, the frame tail, the check code and the total byte number, judging that the first node module has a fault.
8. The fault diagnosis system according to any one of claims 5 to 7, characterized by further comprising:
the display unit is used for displaying the judged fault information; and/or the presence of a gas in the gas,
and the fault information sending unit is used for sending the fault information to a remote terminal.
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