CN111897300A - OPC-UA (OLE for process control-user agent) -based software/hardware combined simulation system and self-adaptive cooperation method thereof - Google Patents
OPC-UA (OLE for process control-user agent) -based software/hardware combined simulation system and self-adaptive cooperation method thereof Download PDFInfo
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
- G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
- G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
- G05B13/042—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators in which a parameter or coefficient is automatically adjusted to optimise the performance
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B17/00—Systems involving the use of models or simulators of said systems
- G05B17/02—Systems involving the use of models or simulators of said systems electric
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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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
- G05B19/41855—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication by local area network [LAN], network structure
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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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM]
- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication
- G05B19/4186—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by the network communication by protocol, e.g. MAP, TOP
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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
- G05B2219/25—Pc structure of the system
- G05B2219/25232—DCS, distributed control system, decentralised control unit
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a software/hardware combined simulation system based on OPC-UA and an adaptive cooperation method thereof, relating to the technical field of system simulation. The system comprises an emulation unit, an emulation adapter, a communication module and a clock agent. The self-adaptive cooperation method of the system comprises the following steps: 1. creating a joint simulation environment and establishing a simulation model of each simulation unit; 2. configuring a joint simulation environment, establishing an information model, connecting each simulation adapter to a corresponding simulation unit, and setting the QoS (quality of service) requirements of each simulation unit; 3. determining a collaborative simulation step length according to the simulation step length of each simulation unit and a step length collaborative adaptive method; 4. running the joint simulation; 5. and (5) finishing the joint simulation and evaluating the result. The joint simulation scheme of the invention carries out cooperative control of all simulation units, optimizes the system structure, reduces the calculation complexity and can effectively process the scenes of complex actual industrial network structure and frequent information interaction.
Description
Technical Field
The invention relates to the technical field of system simulation, in particular to a software/hardware combined simulation system based on OPC-UA and an adaptive cooperation method thereof.
Background
The simulation system is a necessary means for verification test and optimized upgrade in the aspects of intelligent factory operation performance, efficiency, safety and the like. Because the intelligent factory scene covers various production process scenes and heterogeneous networks and contains a topological structure of a complex network, a simulation system under the scene not only needs to relate to software such as process simulation, logistics simulation, network simulation, energy simulation and the like, but also relates to a special hardware simulator such as a real-time hardware simulator, a physical test bed and the like. Therefore, the establishment of a precise and accurate simulation test needs to perform joint simulation on a soft/hard mixed multi-simulation system, so that the operation mechanism of the actual system can be simulated more comprehensively, and the design scheme of the system is evaluated.
Each Simulation Unit (SU) participating in the joint Simulation runs a part of the complete Simulation and needs to be time-synchronized with other Simulation units, thereby realizing the global Simulation of the complete coupled system. Ideally, each module or device of the plant provides its own simulation model, and system engineering methods are used to create, communicate, and maintain the simulation models, and finally integrate them into a complete system simulation model. However, the existing joint simulation standards are limited to specific industries or specific tools, and there is no unified standard for integration, such as Functional entity Interface (FMI) and High-Level Architecture (HLA).
When a plurality of simulation units are used for combined simulation, a plurality of simulation systems or equipment need to be managed in a unified and cooperative mode, and each simulator carries out simulation data interaction according to a set step length. However, due to the complexity of solving the operation modes (discrete, continuous and mixed) of each simulation system and the difference of the operation periods of the systems, the operation step sizes of the simulators have great difference. For example, the steps of communication and electrical are typically short, on the order of microseconds to milliseconds, and the steps of process and material flow are long, on the order of minutes or even hours. The difference of the synchronous step length can cause the efficiency of the collaborative simulation to be reduced, and the problem that the simulation system cannot be converged can be caused when the setting is unreasonable, so that a correct verification result cannot be obtained. Therefore, how to design the simulation step length of the joint simulation and ensure the safe and effective operation of the simulation system is a key technology to be solved for realizing the semi-physical simulation scheme of the complex system of the intelligent factory.
The patent of the domestic application number of 201610055323.X entitled "a power communication system joint simulation platform based on variable time window synchronization mode and synchronization method thereof" aims at that a simulation synchronization module designed for a power communication system switches a simulation synchronization time window according to simulation data of the power system to control two simulation tools, but the set time window is only switched at a set fixed wide and narrow time step, a proper time step cannot be set according to a plurality of simulation units of an intelligent factory complex system, and the simulation precision is limited. In the patent with the domestic application number of 201810498282.0 and the name of 'a multi-simulator collaborative simulation method, a simulation main control platform and a simulation system', a lagrange polynomial is adopted to interpolate a simulator with a simulation step length larger than a predicted collaborative step length, and the data is transmitted to other simulators to carry out collaborative simulation calculation, but the numerical prediction technology is only theoretical approximation and cannot accurately describe the real response of the simulator. The patent of the domestic application number 201810697108.9 entitled "method for realizing real-time synchronous control of multiple simulation devices" adopts a real-time communication network to connect a simulation computer and multiple simulation devices, the simulation computer collects feedback data of the corresponding simulation devices to complete simulation, but when the number of the devices participating in simulation is larger than a certain threshold value, a communication and interaction mechanism cannot ensure real-time and reliable transmission of a large amount of data, and meanwhile, the simulation computer cannot ensure real-time feedback of control instructions and control data. The patent with the domestic application number of 201610988418.7 entitled "automatic synchronous reliable communication method for simulation system" packages network communication codes into a class, and each class object includes a sending queue and a receiving queue, so that each simulation subsystem can realize reliable communication through the class object by transmitting effective data packets (data packets which are received once in sequence and only once), but when a certain subsystem or some subsystems in the simulation operation process are restarted due to faults, the communication relation in the last operation needs to be recovered, and the transmission reliability and safety when communication errors occur cannot be guaranteed.
In summary, the prior art solutions have the following disadvantages:
(1) most of the existing combined simulation systems aim at full software simulation or full hardware simulation, do not consider a complex coupling system with the existence of software and hardware at the same time, and are not suitable for a semi-physical system simulation scheme of an intelligent factory.
(2) Most of the existing joint simulation assumes that real-time reliable communication between simulation units can be realized, and the specific communication architecture and specification, communication and interaction mechanism are rarely involved to ensure effective interaction between the joint simulation units.
(3) The existing simulation schemes of multiple simulation systems adopt a client/server architecture based on an OPC-UA protocol, a coupling network is constructed by establishing point-to-point sessions to carry out data interaction, data processing is integrated in a master controller, and a simulation unit only receives instructions of the master controller and feeds back related data, so that the calculation load under the architecture is large, and when the number of simulation unit devices is too large, the reliability of data transmission cannot be guaranteed.
(4) In the prior art, switching is performed in a fixed time step length when the joint simulation step length of a plurality of simulation units is designed, interpolation prediction feedback data is adopted for the simulation units with the time step length longer than the collaborative simulation step length, and the fixed time step length and the interpolation prediction cannot guarantee the simulation accuracy of the complex coupling system.
Therefore, those skilled in the art are dedicated to developing a software/hardware joint simulation system based on OPC-UA and an adaptive cooperative method thereof, and a joint simulation scheme based on a subscription/release architecture of OPC-UA protocol is used to perform cooperative control of each simulation unit, so as to further optimize the system structure, reduce the computational complexity, and effectively process the scenes of complex actual industrial network structure and frequent information interaction.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, the technical problems to be solved by the present invention include:
(1) how to construct a software/hardware mixed simulation scheme in a complex coupling system of an intelligent factory;
(2) how to design a specific communication and interaction mechanism to ensure the reliability of data interaction of each simulation unit of the joint simulation;
(3) how to design a self-adaptive step length adjusting scheme aiming at a complex coupling system of an intelligent factory under the problem of inconsistent time step lengths of simulation units participating in joint simulation so that the joint simulation can be accurately and effectively carried out.
In order to achieve the above object, the present invention provides a software/hardware combined simulation system based on OPC-UA, which comprises a simulation unit, a simulation adapter, a communication module and a clock agent;
the simulation unit comprises software such as process simulation, logistics simulation, network simulation, energy simulation and the like, and a hardware simulator such as a special real-time hardware simulator, a physical test bed and the like;
the simulation adapter comprises an OPC-UA client and a simulation unit interface, adopts an OPC-UA protocol and is set as an interface for data interaction between the simulation unit and the middleware agent so as to complete the data interaction of joint simulation;
the communication module sets a transmission Protocol according to the transmission requirement of the simulation unit, and for the simulation unit with a low delay requirement, the communication module adopts a unified architecture Datagram Protocol (OPC UA Datagram Protocol, UADP); for the simulation unit which only needs non-real-time transmission stream, the communication module adopts any one of UADP or UDP protocol;
the clock agent controls the setting of the collaborative simulation step length of the joint simulation, after each simulation unit executes a simulation step length in the joint simulation, the clock agent sends a report message to the clock agent through the simulation adapter to report that the simulation step is completed, and when all the simulation units report that the current simulation step is completed, the clock agent sends a simulation step length confirmation message or a configuration adjustment message to each simulation unit to start the simulation step of the next simulation step length; and if the subsequent simulation step length needs to be adjusted, sending the configuration adjustment information, and if the subsequent simulation step length is kept unchanged, sending the simulation step length confirmation information.
Further, the clock agent is arranged to implement distributed interaction of the respective simulation units; and the working state and feedback data of each simulation unit are sent to the corresponding simulation adapter and the corresponding simulation unit through the corresponding simulation adapter and the communication module according to the subscription rule of the data among the simulators.
The invention also provides a self-adaptive cooperation method of the software/hardware combined simulation system based on OPC-UA, which comprises the following steps:
step 1: a user creates a joint simulation environment and establishes a simulation model of each simulation unit;
step 2: configuring the joint simulation environment, establishing an information model, connecting each simulation adapter to the corresponding simulation unit, setting the QoS (quality of service) requirement required by each simulation unit in the joint simulation environment, and establishing the basic joint simulation environment;
and step 3: determining the cooperative simulation step length of the joint simulation according to the simulation step length of each simulation unit and a step length cooperative adaptive method; the collaborative simulation step length can ensure the stable operation of the whole combined simulation system when an emergency (such as a fault) occurs in a certain simulation unit or some simulation units;
and 4, step 4: running the joint simulation;
and 5: and (5) after the joint simulation is finished, evaluating a simulation result.
Further, in the step 2, when the joint simulation environment is constructed, the simulation adapter of the simulation unit performs data interaction with the simulation unit by using an OPC-UA protocol.
Further, in the step 2, when the joint simulation environment is constructed, a publish/subscribe (Pub/Sub) mechanism based on an OPC-UA protocol is adopted to complete the distributed interaction of each simulation unit.
Further, in the step 3, the co-simulation step size is determined to be one of the following three cases:
the first condition is as follows: when each simulation unit normally operates, joint simulation is carried out based on time sequence division, and all simulation units need to complete self simulation calculation before the next time sequence step length; selecting the minimum common multiple of the minimum possible simulation time step length Ti (i is 1, …, N, N is the number of simulation units participating in the joint simulation) of all the simulation units which are close to the communication interaction period T by the joint simulation step length selection;
case two: when one or more simulation units are newly added, after the simulation of the current time step length is completed in the joint simulation, namely after the clock agent receives the information of all the simulation units reporting that the current simulation step is completed, the clock agent recalculates the cooperative simulation step length of the joint simulation; selecting the minimum common multiple of the joint simulation step length in the original normal operation and the minimum possible simulation time step length of the newly added simulation unit according to the joint simulation step length;
case three: when the emergency detection mechanism detects an emergency of one or some simulation units, the joint simulation is adaptively switched to an operation mode based on event triggering, all the emergency needs to be ensured to be sequentially executed according to a correct sequence, and the joint simulation is aperiodic. If the emergency event is preset in the Clock Agent (Clock Agent), the event trigger mode can be entered in advance of the previous time synchronization point, otherwise, each simulation unit returns to the previous simulation synchronization point. And determining the collaborative simulation step length of the joint simulation according to the triggering time points of all current emergency events and the least common multiple of the simulation time step lengths of the rest simulation units which normally operate.
Further, in step 3, each simulation unit performs simulation and data interaction according to its own simulation step size, and the collaborative simulation step size is only used as the minimum interval base step size.
Further, the step 4 comprises the following steps:
step 4.1: each simulation unit updates the own simulation output according to the simulation model established in the step 1 in each simulation time step;
step 4.2: each simulation unit sends the updated simulation configuration output to the simulation adapter;
step 4.3: each simulation adapter is used as a publisher to combine the output of the corresponding simulation unit into a data set for preparing data publishing; the nodes of the data set and the OPC-UA information model are connected and comprise a release data set and a data set domain;
step 4.4: the data sets issued by the simulation units are transmitted into a write group; the writing group is a producer of messages in data interaction, and a user can add a data set writing function by himself;
step 4.5: the communication module transmits data in a selected transmission layer by a corresponding transmission protocol according to the time delay requirement of the simulation unit;
step 4.6: after the corresponding simulation adapter serving as a subscriber receives message data of a subscribed topic, a subscription data set is obtained through a read-in group, and the data is sent to the corresponding simulation unit; the read-in group is a receiver of messages in data interaction, and a user can add a data set reading function;
step 4.7: the simulation unit completes the current simulation step, and sends a report message to the clock agent through the simulation adapter to report that the current simulation step is completed;
step 4.8: after confirming that all the simulation units complete the message report of the current time step, the clock agent sends a piece of simulation step length confirmation information or configuration adjustment information to all the current simulation units to inform the simulation units of going to the next long simulation step; if the subsequent simulation step length needs to be adjusted, sending the configuration adjustment information, and if the subsequent simulation step length is kept unchanged, sending the simulation step length confirmation information;
step 4.9: and returning to execute the step 4.1.
Further, in the step 4.3, the release data set is a container of release information, and is composed of released variables and meta information, and includes a set of variables, event filtering, application specific information, and meta data; the data set domain is the description of the release variables and contains the selected information model nodes and additional information such as release, sampling, error processing and the like.
Further, in the step 4.5, the data transmission includes the following two cases: for the data stream with low delay requirement, directly mapping to the layer 2 of the reference model by using UADP, and packaging the message in the Ethernet frame; directly mapping the UADP datagram to UDP aiming at the non-real-time data stream, and packaging the message in a UDP packet; the message needs to be transmitted after being safely encapsulated by a safety key server;
the security key server is constructed based on an OPC-UA protocol, manages the security keys of the publisher and the subscriber, and establishes connection with the publisher and the subscriber through an OPC-UA client-server form.
Compared with the prior art, the invention has the beneficial technical effects that:
(1) by adopting the joint simulation system, each simulation unit participating in joint simulation only runs one part of the complete simulation, and the global simulation of the complete coupling system is realized through data interaction with other simulation units, so that the problem caused by mixing of a plurality of software/hardware simulation systems of an intelligent factory is solved, and the operation mechanism of an actual system is simulated more comprehensively.
(2) The invention further optimizes the system structure, greatly reduces the calculation complexity, and obviously improves the reliability of the simulation system by distributed interaction among the simulation units, thereby effectively processing the scenes of complicated actual industrial network structure and frequent information interaction.
The conception, the specific structure and the technical effects of the present invention will be further described with reference to the accompanying drawings to fully understand the objects, the features and the effects of the present invention.
Drawings
FIG. 1 is a soft/hard hybrid joint simulation system architecture diagram according to a preferred embodiment of the present invention;
FIG. 2 is a flow chart of a cooperative adaptive control method in accordance with a preferred embodiment of the present invention;
FIG. 3 is a diagram illustrating QoS requirements for configuring a co-simulation environment in accordance with a preferred embodiment of the present invention;
FIG. 4 is a diagram illustrating publisher and subscriber data interaction in accordance with a preferred embodiment of the present invention;
FIG. 5 is a diagram illustrating a process of transmitting data issued by an emulation adapter by a communication module according to a preferred embodiment of the present invention.
The system comprises a communication module 1, an emulation adapter 2, an emulation unit 3, a clock agent 4, an OPC-UA client 21 and an emulation unit interface 22.
Detailed Description
The technical contents of the preferred embodiments of the present invention will be more clearly and easily understood by referring to the drawings attached to the specification. The present invention may be embodied in many different forms of embodiments and the scope of the invention is not limited to the embodiments set forth herein.
The invention aims to overcome the defects of the existing joint simulation scheme, provides a soft/hard hybrid joint simulation system aiming at an intelligent factory scene and a cooperative self-adaption method thereof, and can realize semi-physical complex system simulation of an intelligent factory.
As shown in fig. 1, a software/hardware joint Simulation system based on OPC-UA includes a communication module 1, several Simulation adapters 2 (SA), a Simulation Unit 3 (SU), and a Clock Agent 4(Clock Agent, CA). The emulation adapter 2 comprises an OPC-UA client 21 and an emulation unit interface 22.
When the joint simulation is operated, the clock agent 4 controls the simulation step length of the joint simulation to realize the distributed interaction of each simulation unit 3, the working state and the feedback data of each simulation unit 3 are sent to the corresponding simulation adapter 2 and the corresponding simulation unit 3 through the corresponding simulation adapter 2 and the communication module 1 according to the subscription rule of the data between the simulators, and the effective joint simulation is completed.
The communication module 1 sets a transmission protocol according to the transmission requirement of the simulation unit 3, and for the simulation unit 3 with a low delay requirement, a uniform architecture datagram protocol (OPC UA datagram protocol, UADP) can be adopted to directly map the datagram to the layer 2 of an OSI (Open System Interconnection, OSI) reference model, thereby ensuring the low cycle time requirement of the message; for the simulation unit that only needs a non-real-time transport stream, the former method may be adopted, and the UADP Datagram may also be mapped to a UDP packet of a User Datagram Protocol (UDP) for transmission.
The emulation adapter 2 adopts an emulation adapter based on OPC-UA, and comprises: an OPC-UA client 21 and an emulation unit interface 22. The OPC-UA client 21 is based on an OPC Unified Architecture (OPC-UA), which provides a consistent, complete address space and service model, enables communication across platforms, and has higher security and reliability. The seamless access of metadata can be realized by adopting the OPC-UA protocol to carry out the software/hardware mixed joint simulation in the intelligent factory scene, which is beneficial to improving the expansibility of a simulation system, thereby meeting the accurate simulation requirement of the production environment of flexible industrial manufacturing. The simulation unit interfaces 22 correspond to the simulation units 3 one by one, and perform data connection according to physical characteristics of the simulation units 3.
The simulation unit 3 comprises a software/hardware simulator in an intelligent factory scene, including software such as process simulation, logistics simulation, network simulation, energy simulation and the like, and a special hardware simulator such as a real-time hardware simulator, a physical test bed and the like.
The clock agent 4 controls the setting of the co-simulation step size of the co-simulation. During the joint simulation, after each simulation unit 3 executes a simulation step, a report message is sent to the clock agent 4 through the simulation adapter 2 to report that the simulation step is completed, and when all the simulation units 3 report that the current simulation step is completed, the clock agent 4 sends a piece of simulation step confirmation information or configuration adjustment information message to each simulation unit 3 to start the simulation step of the next simulation step. And if the subsequent simulation step length needs to be adjusted, sending configuration adjustment information, and if the subsequent simulation step length is kept unchanged, sending simulation step length confirmation information.
Fig. 2 is a flow chart of a cooperative adaptive method of a software/hardware joint simulation system based on OPC-UA, which includes the following steps:
step 1: a user creates a joint simulation environment and establishes a simulation model of each simulation unit (software and hardware mixed).
Step 2: and configuring a joint simulation environment and establishing an information model.
Step 2.1: the emulation adapters are connected to the respective emulation units.
Step 2.2: if the simulation adapter does not receive the connection request of the simulation unit within a reasonable time, the network connection is closed, and the simulation unit exits the joint simulation. The reasonable time depends on the type of application service and communication infrastructure, etc.
Step 2.3: and setting the Quality of Service (QoS) requirements of each simulation unit in the joint simulation environment, wherein the QoS requirements comprise the requirements of Bandwidth Guarantee (Bandwidth guaranteed) and Maximum delay (Maximum Latency). The bottom layer needs to read the corresponding QoS requirements and configure the corresponding parameters.
And step 3: and determining the collaborative simulation step length of the joint simulation according to the simulation step length of each simulation unit and the step length collaborative self-adaption method.
The step size cooperative self-adaptive method can adaptively adjust the cooperative simulation step size of the joint simulation system when one or more simulation units are newly added and the simulation step size needing to be more refined is caused by the occurrence of an emergency (such as a fault) in one or some simulation units, and comprises the following three conditions:
when each simulation unit normally operates, joint simulation is based on time sequence division, and all simulation units need to complete self simulation calculation before the next time sequence step length is carried out. Selecting the minimum common multiple of the minimum possible simulation time step length Ti (i is 1, …, N, N is the number of simulation units participating in the joint simulation) of all simulation units close to the communication interaction period T by the joint simulation collaborative simulation step length;
when one or more simulation units are newly added, after the simulation of the current time step length is completed in the joint simulation, the clock agent recalculates the cooperative simulation step length of the joint simulation after the clock agent receives the information of all the simulation units reporting that the current simulation step is completed. At the moment, the minimum common multiple of the joint simulation step length in the original normal operation and the minimum possible simulation time step length of the newly added simulation unit is selected as the joint simulation step length;
when the emergency detection mechanism detects that one or some simulation units have an emergency, the joint simulation is adaptively switched to an operation mode based on event triggering, all the emergency needs to be ensured to be sequentially executed according to a correct sequence, and the joint simulation is non-periodic at the moment. If the emergency event is preset in a Clock Agent (Clock Agent), the event trigger mode can be entered in advance of the previous time synchronization point, otherwise, each simulation unit returns to the previous simulation synchronization point. And determining the collaborative simulation step length of the joint simulation according to the minimum common multiple of the triggering time points of all the current emergency events and the simulation time step lengths of the rest simulation units which normally run.
And 4, step 4: and (5) running the joint simulation.
Step 4.1: and each simulation unit updates the own simulation output according to the simulation model obtained by the first step in each simulation time step.
Step 4.2: each simulation unit sends the updated simulation configuration output to the simulation adapter.
Step 4.3: each simulation adapter (publisher) outputs its corresponding simulation unit into a data set (Datasets) for preparation of data distribution. The data sets are connected with nodes (such as variables) of an information model of the OPC-UA, and comprise Published data sets (Published data sets) and data set Fields (data set Fields).
The published Data set is a container of published information, consisting of published variables and Meta-information, including a set of variables, event filtering, application specific information and Meta-Data (Meta Data).
The data set domain is the description of the release variable and contains the selected information model node and additional information such as release, sampling, error processing and the like.
Step 4.4: the data set issued by each emulation unit is passed into a write group (writegroup). The write group is the producer of the message in the data interaction, and the user may add a DatasetWrite function.
Step 4.5: and the communication module performs data transmission on the selected transmission layer by using the corresponding transmission protocol according to the time delay requirement of the simulation unit. The transmission process includes the following two cases: for the data stream with low delay requirement, directly mapping to the layer 2 of the reference model by using UADP, and packaging the message in the Ethernet frame; for non-real-time data streams, UADP datagrams are mapped directly to UDP, and messages are packed in UDP packets. The message needs to be transmitted after being securely sealed (Secure environment) by a Secure Key Server (Secure Key Server).
The safety key Server is a Server based on OPC-UA protocol, manages the safety keys of the publisher and the subscriber, and establishes connection with the publisher and the subscriber in a Client-Server form.
Step 4.6: after receiving the message data of the subscribed topic, the corresponding simulation adapter obtains the subscribed data set through the read-in group (ReaderGroup), and sends the data to the corresponding simulation unit (subscriber). The read-in group is the receiver of the message in the data interaction, and the user can add a DatasetRead function.
Step 4.7: the simulation unit completes the current simulation step, and sends a message to the clock agent through the simulation adapter to report that the current simulation step is completed.
Step 4.8: and after confirming that the message reports of the current time step of all the simulation units are completed, the clock agent sends a message to all the current simulation units to inform the current simulation units that the next long simulation step can be carried out. The message is confirmation information or configuration adjustment information of the simulation step length, if the subsequent simulation step length needs to be adjusted, the configuration adjustment information is sent, and if the subsequent simulation step length is kept unchanged, the confirmation information of the simulation step length is sent.
Step 4.9: go to step 4.1.
And 5: and (5) after the joint simulation is finished, evaluating a simulation result.
In the step 2, the schematic diagram of initializing and configuring the joint simulation environment and establishing the information model is shown in fig. 3.
In the above steps 4.3, 4.4 and 4.6, the schematic diagram of the publisher and subscriber data interaction process is shown in fig. 4.
In the above step 4.5, a schematic diagram of a process of the communication module transmitting the emulation adapter release data is shown in fig. 5.
The invention has the advantages that:
1. by adopting the joint simulation system, each simulation unit participating in joint simulation only runs one part of the complete simulation, and the global simulation of the complete coupling system is realized through data interaction with other simulation units, so that the problem caused by mixing of a plurality of software/hardware simulation systems of an intelligent factory is solved, and the operation mechanism of an actual system is simulated more comprehensively.
2. The invention further optimizes the system structure, greatly reduces the calculation complexity, and obviously improves the reliability of the simulation system by distributed interaction among the simulation units, thereby effectively processing the scenes of complicated actual industrial network structure and frequent information interaction.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concepts. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (10)
1. A software/hardware combined simulation system based on OPC-UA is characterized by comprising a simulation unit, a simulation adapter, a communication module and a clock agent;
the simulation unit comprises software such as process simulation, logistics simulation, network simulation, energy simulation and the like, and a hardware simulator such as a special real-time hardware simulator, a physical test bed and the like;
the simulation adapter comprises an OPC-UA client and a simulation unit interface, adopts an OPC-UA protocol and is set as an interface for data interaction between the simulation unit and the middleware agent so as to complete the data interaction of joint simulation;
the communication module sets a transmission Protocol according to the transmission requirement of the simulation unit, and for the simulation unit with a low delay requirement, the communication module adopts a unified architecture Datagram Protocol (OPC UA Datagram Protocol, UADP); for the simulation unit which only needs non-real-time transmission stream, the communication module adopts any one of UADP or UDP protocol;
the clock agent controls the setting of the collaborative simulation step length of the joint simulation, after each simulation unit executes a simulation step length in the joint simulation, the clock agent sends a report message to the clock agent through the simulation adapter to report that the simulation step is completed, and when all the simulation units report that the current simulation step is completed, the clock agent sends a simulation step length confirmation message or a configuration adjustment message to each simulation unit to start the simulation step of the next simulation step length; and if the subsequent simulation step length needs to be adjusted, sending the configuration adjustment information, and if the subsequent simulation step length is kept unchanged, sending the simulation step length confirmation information.
2. The OPC-UA based combined software/hardware emulation system of claim 1 wherein said clock agent is arranged to effect distributed interaction of respective ones of said emulation units; and the working state and feedback data of each simulation unit are sent to the corresponding simulation adapter and the corresponding simulation unit through the corresponding simulation adapter and the communication module according to the subscription rule of the data among the simulators.
3. An adaptive cooperation method of a software/hardware combined simulation system based on OPC-UA is characterized by comprising the following steps:
step 1: a user creates a joint simulation environment and establishes a simulation model of each simulation unit;
step 2: configuring the joint simulation environment, establishing an information model, connecting each simulation adapter to the corresponding simulation unit, setting the QoS (quality of service) requirement required by each simulation unit in the joint simulation environment, and establishing the basic joint simulation environment;
and step 3: determining the cooperative simulation step length of the joint simulation according to the simulation step length of each simulation unit and a step length cooperative adaptive method; the collaborative simulation step length can ensure the stable operation of the whole combined simulation system when an emergency (such as a fault) occurs in a certain simulation unit or some simulation units;
and 4, step 4: running the joint simulation;
and 5: and (5) after the joint simulation is finished, evaluating a simulation result.
4. The adaptive coordination method for OPC-UA based software/hardware co-simulation system according to claim 3, wherein in said step 2, when constructing said co-simulation environment, said simulation adapter of said simulation unit performs data interaction with said simulation unit using OPC-UA protocol.
5. The adaptive coordination method for OPC-UA based software/hardware co-simulation system according to claim 3, wherein in said step 2, when constructing said co-simulation environment, a publish/subscribe (Pub/Sub) mechanism based on OPC-UA protocol is used to complete distributed interaction of each simulation unit.
6. The adaptive collaborative method for OPC-UA based co-simulation systems according to claim 3, wherein in step 3, the collaborative simulation step size is determined to be one of the following three cases:
the first condition is as follows: when each simulation unit normally operates, joint simulation is carried out based on time sequence division, and all simulation units need to complete self simulation calculation before the next time sequence step length; selecting the minimum common multiple of the minimum possible simulation time step length Ti (i is 1, …, N, N is the number of simulation units participating in the joint simulation) of all the simulation units which are close to the communication interaction period T by the joint simulation step length selection;
case two: when one or more simulation units are newly added, after the simulation of the current time step length is completed in the joint simulation, namely after the clock agent receives the information of all the simulation units reporting that the current simulation step is completed, the clock agent recalculates the cooperative simulation step length of the joint simulation; selecting the minimum common multiple of the joint simulation step length in the original normal operation and the minimum possible simulation time step length of the newly added simulation unit according to the joint simulation step length;
case three: when the emergency detection mechanism detects an emergency of one or some simulation units, the joint simulation is adaptively switched to an operation mode based on event triggering, all the emergency needs to be ensured to be sequentially executed according to a correct sequence, and the joint simulation is aperiodic. If the emergency event is preset in the Clock Agent (Clock Agent), the event trigger mode can be entered in advance of the previous time synchronization point, otherwise, each simulation unit returns to the previous simulation synchronization point. And determining the collaborative simulation step length of the joint simulation according to the triggering time points of all current emergency events and the least common multiple of the simulation time step lengths of the rest simulation units which normally operate.
7. The adaptive coordination method for OPC-UA based software/hardware co-simulation system according to claim 3, wherein in said step 3, each of said simulation units performs simulation and data interaction according to its own simulation step size, said co-simulation step size being only used as a minimum interval base step size.
8. The adaptive collaborative method for OPC-UA based combined software/hardware emulation system according to claim 3, wherein the step 4 comprises the steps of:
step 4.1: each simulation unit updates the own simulation output according to the simulation model established in the step 1 in each simulation time step;
step 4.2: each simulation unit sends the updated simulation configuration output to the simulation adapter;
step 4.3: each simulation adapter is used as a publisher to combine the output of the corresponding simulation unit into a data set for preparing data publishing; the nodes of the data set and the OPC-UA information model are connected and comprise a release data set and a data set domain;
step 4.4: the data sets issued by the simulation units are transmitted into a write group; the writing group is a producer of messages in data interaction, and a user can add a data set writing function by himself;
step 4.5: the communication module transmits data in a selected transmission layer by a corresponding transmission protocol according to the time delay requirement of the simulation unit;
step 4.6: after the corresponding simulation adapter serving as a subscriber receives message data of a subscribed topic, a subscription data set is obtained through a read-in group, and the data is sent to the corresponding simulation unit; the read-in group is a receiver of messages in data interaction, and a user can add a data set reading function;
step 4.7: the simulation unit completes the current simulation step, and sends a report message to the clock agent through the simulation adapter to report that the current simulation step is completed;
step 4.8: after confirming that all the simulation units complete the message report of the current time step, the clock agent sends a piece of simulation step length confirmation information or configuration adjustment information to all the current simulation units to inform the simulation units of going to the next long simulation step; if the subsequent simulation step length needs to be adjusted, sending the configuration adjustment information, and if the subsequent simulation step length is kept unchanged, sending the simulation step length confirmation information;
step 4.9: and returning to execute the step 4.1.
9. The adaptive collaborative method for OPC-UA based co-simulation system of claim 8 wherein in step 4.3, the release data set is a container of release information, consisting of released variables and meta information, including a set of variables, event filtering, application specific information and meta data; the data set domain is the description of the release variables and contains the selected information model nodes and additional information such as release, sampling, error processing and the like.
10. The adaptive coordination method for OPC-UA based combined software/hardware emulation system according to claim 8, wherein in said step 4.5, said data transmission comprises the following two cases: for the data stream with low delay requirement, directly mapping to the layer 2 of the reference model by using UADP, and packaging the message in the Ethernet frame; directly mapping the UADP datagram to UDP aiming at the non-real-time data stream, and packaging the message in a UDP packet; the message needs to be transmitted after being safely encapsulated by a safety key server;
the security key server is constructed based on an OPC-UA protocol, manages the security keys of the publisher and the subscriber, and establishes connection with the publisher and the subscriber through an OPC-UA client-server form.
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