CN111294265A - DCS (distributed control system) double-path non-switching same-duplex modbus communication system and method - Google Patents
DCS (distributed control system) double-path non-switching same-duplex modbus communication system and method Download PDFInfo
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- CN111294265A CN111294265A CN202010241940.5A CN202010241940A CN111294265A CN 111294265 A CN111294265 A CN 111294265A CN 202010241940 A CN202010241940 A CN 202010241940A CN 111294265 A CN111294265 A CN 111294265A
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L12/40006—Architecture of a communication node
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L12/40169—Flexible bus arrangements
- H04L12/40176—Flexible bus arrangements involving redundancy
- H04L12/40182—Flexible bus arrangements involving redundancy by using a plurality of communication lines
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L5/00—Arrangements affording multiple use of the transmission path
- H04L5/14—Two-way operation using the same type of signal, i.e. duplex
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L2012/40208—Bus networks characterized by the use of a particular bus standard
- H04L2012/40228—Modbus
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Abstract
The invention belongs to the technical field of Distributed Control Systems (DCS), and particularly relates to a DCS double-path non-switching same-duplex modbus communication system and a method, which comprise a DCS system and a third-party system communication structure, wherein system hardware equipment comprises two DCS platform non-redundant communication clamping pieces, two PLC platform Ehternet/IP communication clamping pieces, two Ethernet switches and a PLC side table master-slave rack; the invention avoids the accidents of complete communication interruption caused by communication card faults, drive loss, exchanger faults and communication medium damage at the DCS side, and ensures the safe and stable operation of the factory production line. Meanwhile, due to the characteristics of high reliability and strong fault tolerance of the communication mode, the factory popularizes the communication mode of two-way non-switching and same-duplex communication to the communication between other third-party systems and the DCS, thereby greatly benefiting the economic benefit.
Description
Technical Field
The invention belongs to the technical field of Distributed Control Systems (DCS), and particularly relates to a DCS double-path non-switching same-duplex modbus communication system and method.
Background
At present, a DCS and a third-party control system in the industrial control field are mainly communicated in real time through a communication card supporting a modbus protocol, and the communication mode comprises a non-redundant single-path communication mode and a redundant two-path communication mode.
The non-redundant single-channel communication mode carries out single-link real-time communication with a third-party system communication card through the DCS non-redundant communication card, and the risks of complete communication interruption caused by card faults, drive loss and communication medium damage generally exist.
The redundant communication mode realizes redundant communication with a third-party system through the DCS redundant communication card, the redundant communication is not real-time redundant communication, and the standby communication card can be switched only when the main redundant communication fails, so that the possibility of switching failure exists; meanwhile, in the industrial control field, the condition that the whole drive of the redundant communication card is lost for many times to cause the simultaneous and complete interruption of the two-way communication is caused, so that great economic and property loss is caused.
Disclosure of Invention
The invention aims to provide a DCS double-path non-switching same-duplex modbus communication system and a method aiming at the defects, which realize that data is simultaneously received and sent through double channels, and can ensure the effectiveness of communication and data transmission establishment when a single or even multiple faults occur in a communication link.
The technical scheme of the invention is as follows:
a DCS double-path non-switching same-duplex modbus communication system is provided, wherein a communication structure of a DCS system and a third-party system is provided, and system hardware equipment comprises two DCS platform non-redundant communication clamping pieces, two PLC platform Ehternet/IP communication clamping pieces, two Ethernet switches and a PLC side table master-slave rack;
connecting a DCS side non-redundant communication card and a third-party system one-way communication card to the same Ethernet switch by using a TCP/IP network communication protocol through a network cable, and simultaneously configuring the other way of communication in a redundant manner, thereby realizing two-way one-to-one real-time communication on hardware;
a redundant PLC controller and a corresponding redundant conversion module are arranged at the side of a PLC controller of a third-party system, so that the main PLC controller can be switched to a standby controller when the main PLC controller fails;
two PLC platforms Ehternet/IP communication cards of a third-party system are connected through an Ethernet switch, and meanwhile, the two Ethernet switches are connected through a network cable for communication interconnection, so that the automatic exchange of IP addresses of a master PLC and a slave PLC can be realized when the master PLC performs master-slave conversion;
two non-redundant communication cards of the DCS are provided with the same target IP address, namely the address of the main PLC communication card of the third-party system, and the main PLC communication card can simultaneously receive and send communication data from two controllers at the DCS side through the Ethernet switch.
A PLC communication card piece is connected with a DCS non-redundant communication card piece one to one, constitutes double-path one to one communication mode altogether, and then sets up two way same-duplex data transmission channels, and two way channels carry out data receiving and sending simultaneously.
And the master-slave rack on the third-party system side is designed into a complete redundant structure, so that two paths of data are transmitted in real time in the third-party system.
In a third-party system, the IP addresses are automatically exchanged when the PLC controller performs master-slave switching through the redundancy module, and then the same target IP address is configured for the DCS communication card.
The DCS side non-redundant communication card only sets a unique target IP address.
A DCS double-path non-switching same-duplex modbus communication system method is characterized in that drive configuration file codes are respectively compiled for two DCS non-redundant communication cards, independent and different IP addresses are configured, and independent drive installation is carried out;
the corresponding redundant data type is that the same module has two-way input or output at the same time, so that the real-time same-duplex input/output of the two-way data is realized;
calculating the network identification of the communication network segment of a third-party system DCS according to the corresponding subnet mask bit number by taking the IP address of the third-party system side as a target, further designing the communication IP addresses of two non-redundant communication clamping pieces at the DCS side, and finally compiling a timely and accurate drive configuration file;
the corresponding redundant data type INR/BINR/BOUTR is used, and meanwhile, the effectiveness of receiving/sending double-path data of the redundant data module is opened, so that real-time same-duplex input/output of the double-path data is realized; and aiming at the type of the real integer/digital output data, the redundant data module is also used for realizing the double-path output of the data.
The two non-redundant communication card pieces are provided with mutually independent drives, so that when the communication drive of one of the non-redundant card pieces is lost, the other communication card piece can be kept in a normal working state without being influenced; meanwhile, the traditional repetitive data redundancy mode is replaced by using the redundant data type, namely one data module replaces two data modules, the data communication quantity between the two systems is reduced by 50%, and the communication reliability is improved laterally.
The invention has the beneficial effects that:
by utilizing the technical scheme of the invention, the accidents of complete communication interruption caused by communication card faults, drive loss, exchanger faults and communication medium damage at the DCS side are avoided, and the safe and stable operation of a factory production line is ensured. Meanwhile, due to the characteristics of high reliability and strong fault tolerance of the communication mode, the factory popularizes the communication mode of two-way non-switching and same-duplex communication to the communication between other third-party systems and the DCS, thereby greatly benefiting the economic benefit.
The invention innovatively provides a special redundancy working mode of the industrial communication system, the mode greatly improves the reliability of communication from a third-party system to the DCS, has great economic value, is obviously helpful for improving the safe and stable operation level of a large-scale factory, and the design and realization of the communication mode also provide a good reference blueprint for the reliability improvement of the system of the industrial Ethernet communication technology in the subsequent industrial control field.
Drawings
FIG. 1 is a schematic diagram of a communication structure between a DCS system and a third party system according to the present invention;
FIG. 2 is a schematic diagram of master-slave IP exchange of the PLC communication card of the present invention;
FIG. 3 is a schematic diagram of IIN/BIN/IOUT/BOUT redundancy communication implementation according to the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and specific embodiments.
As shown in figure 1, a DCS double-path non-switching same-duplex modbus communication system has a communication structure of a DCS system and a third-party system, and system hardware equipment comprises two DCS platform non-redundant communication clamping pieces, two PLC platform Ehternet/IP communication clamping pieces, two Ethernet switches and a PLC side table master-slave rack.
Connecting a DCS side non-redundant communication card and a third-party system one-way communication card to the same Ethernet switch by using a TCP/IP network communication protocol through a network cable, and simultaneously configuring the other way of communication in a redundant manner, thereby realizing two-way one-to-one real-time communication on hardware; a redundant PLC controller and a corresponding redundant conversion module are arranged at the side of a PLC controller of a third-party system, so that the main PLC controller can be switched to a standby controller when the main PLC controller fails; two PLC platforms Ehternet/IP communication cards of a third-party system are connected through an Ethernet switch, and meanwhile, the two Ethernet switches are connected through a network cable for communication interconnection, so that the automatic exchange of IP addresses of a master PLC and a slave PLC can be realized when the master PLC performs master-slave conversion; two non-redundant communication cards of the DCS are provided with the same target IP address, namely the address of the main PLC communication card of the third-party system, and the main PLC communication card can simultaneously receive and send communication data from two controllers at the DCS side through the Ethernet switch.
One PLC communication card is connected with one DCS non-redundant communication card in a one-to-one mode to form a two-way one-to-one communication mode, and then two same-duplex data transmission channels are set up and are used for receiving and sending data simultaneously;
the master-slave rack on the third-party system side is designed into a complete redundancy structure, so that two paths of data are transmitted in real time in a data signal in the third-party system, and when one path of data fails, the data transmission is not influenced;
in a third-party system, the IP addresses are automatically exchanged when the PLC controller performs master-slave switching through the redundancy module, and then two communication cards access the communication card of the master PLC at the same time by configuring the same target IP address for the DCS communication card;
with the communication of third party's system redundant communication fastener, DCS side non-redundant communication fastener only sets up only unique target IP address, main PLC promptly, need not to pay attention to standby PLC's IP address, abandons two main and standby communication fasteners and sets up the traditional design theory of two different target IPs.
The two-way one-to-one structure eliminates the risk of failure of the traditional redundant communication main-standby switching, avoids data loss caused by the main-standby switching, and simultaneously eliminates the hidden trouble of complete communication interruption caused by single fault phenomena such as communication card damage, communication medium damage and the like; because the same IP address is configured on the third-party system side, communication confusion is not easy to occur, and simultaneously, the design concept that two paths of data communication are still carried out in the third-party system in real time when one communication card on the DCS side fails is realized, and the communication reliability is improved.
DCS (distributed control system) double-path non-switching same-duplex modbus communication method
Respectively compiling drive configuration file codes for the two DCS non-redundant communication cards, configuring independent and different IP addresses, and carrying out independent drive installation, so that the communication drives of the two DCS non-redundant communication cards are completely independent and do not influence each other and work simultaneously;
the corresponding redundant data type, namely the same module has two-way input or output at the same time, realizes the real-time same-duplex input/output of two-way data, realizes the redundant selection of data through software, and completes the communication realization of the real integer/digital data type.
The two non-redundant communication card pieces are provided with mutually independent drives, so that when the communication drive of one of the non-redundant card pieces is lost, the other communication card piece can be kept in a normal working state without being influenced; meanwhile, the traditional repetitive data redundancy mode is replaced by using the redundant data type, namely one data module replaces two data modules, the data communication quantity between the two systems is reduced by 50%, and the communication reliability is improved laterally.
The IP address of the third-party system side is taken as a target, the network identification of the communication network segment of the third-party system DCS is calculated according to the corresponding subnet mask bit number, then the communication IP addresses of two non-redundant communication clamping pieces on the DCS side are designed, finally, a timely and accurate driving configuration file is compiled, and a communication mode that the same data is transmitted by two signal transmission channels simultaneously is realized from software;
the corresponding redundant data type INR/BINR/BOUTR is used, and meanwhile, the effectiveness of receiving/sending double-path data of the redundant data module is opened, so that real-time same-duplex input/output of the double-path data is realized; aiming at the data type of the real integer/digital output (IOUT/BOUT), the redundant data module is also used for realizing the double-path output of the data, and the communication of the data type of the real integer/digital input (IIN/BIN) is realized.
Claims (7)
1. A DCS double-path non-switching same-duplex modbus communication system is provided, wherein a communication structure of a DCS system and a third-party system is provided, and system hardware equipment comprises two DCS platform non-redundant communication clamping pieces, two PLC platform Ehternet/IP communication clamping pieces, two Ethernet switches and a PLC side table master-slave rack;
the method is characterized in that: connecting a DCS side non-redundant communication card and a third-party system one-way communication card to the same Ethernet switch by using a TCP/IP network communication protocol through a network cable, and simultaneously configuring the other way of communication in a redundant manner, thereby realizing two-way one-to-one real-time communication on hardware;
a redundant PLC controller and a corresponding redundant conversion module are arranged at the side of a PLC controller of a third-party system, so that the main PLC controller can be switched to a standby controller when the main PLC controller fails;
when two PLC platforms Ehternet/IP communication cards of a third-party system are connected through an Ethernet switch, the two Ethernet switches are connected through a network cable for communication interconnection, and automatic exchange of master-slave PLCIP addresses can be realized when the PLC performs master-slave conversion;
two non-redundant communication cards of the DCS are provided with the same target IP address, namely the address of the main PLC communication card of the third-party system, and the main PLC communication card can simultaneously receive and send communication data from two controllers at the DCS side through the Ethernet switch.
2. The DCS two-way switchless same-duplex modbus communication system of claim 1, wherein: a PLC communication card piece is connected with a DCS non-redundant communication card piece one to one, constitutes double-path one to one communication mode altogether, and then sets up two way same-duplex data transmission channels, and two way channels carry out data receiving and sending simultaneously.
3. The DCS two-way switchless same-duplex modbus communication system of claim 1, wherein: and the master-slave rack on the third-party system side is designed into a complete redundant structure, so that two paths of data are transmitted in real time in the third-party system.
4. The DCS two-way switchless same-duplex modbus communication system of claim 1, wherein: in a third-party system, the IP addresses are automatically exchanged when the PLC controller performs master-slave switching through the redundancy module, and then the same target IP address is configured for the DCS communication card.
5. The DCS two-way switchless same-duplex modbus communication system of claim 1, wherein: the DCS side non-redundant communication card only sets a unique target IP address.
6. A method of using the DCS two-way switchless same duplex modbus communication system of claim 1, characterized in that: respectively compiling drive configuration file codes for the two DCS non-redundant communication cards, configuring independent and different IP addresses, and carrying out independent drive installation;
the corresponding redundant data type is that the same module has two-way input or output at the same time, so that the real-time same-duplex input/output of the two-way data is realized;
calculating the network identification of the communication network segment of a third-party system DCS according to the corresponding subnet mask bit number by taking the IP address of the third-party system side as a target, further designing the communication IP addresses of two non-redundant communication clamping pieces at the DCS side, and finally compiling a timely and accurate drive configuration file;
the corresponding redundant data type INR/BINR/BOUTR is used, and meanwhile, the effectiveness of receiving/sending double-path data of the redundant data module is opened, so that real-time same-duplex input/output of the double-path data is realized; and aiming at the type of the real integer/digital output data, the redundant data module is also used for realizing the double-path output of the data.
7. The method of claim 6, wherein the method comprises the steps of: the two non-redundant communication card pieces are provided with mutually independent drives, so that when the communication drive of one of the non-redundant card pieces is lost, the other communication card piece can be kept in a normal working state without being influenced; meanwhile, the traditional repetitive data redundancy mode is replaced by using the redundant data type, namely one data module replaces two data modules, the data communication quantity between the two systems is reduced by 50%, and the communication reliability is improved laterally.
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Cited By (2)
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| CN115842609A (en) * | 2023-02-28 | 2023-03-24 | 浙江正泰中自控制工程有限公司 | Communication redundancy mechanism for SIS (Small information System) |
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