CN112526937A - Graphical logic interpreter, DCS control station and implementation method - Google Patents
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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] or 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] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
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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
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33273—DCS distributed, decentralised controlsystem, multiprocessor
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- 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]
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Abstract
The invention relates to the technical field of industrial process automation control, in particular to a graphical logic interpreter, a DCS control station and an implementation method, wherein the graphical logic interpreter comprises a kernel, a communication module, a setting module and a storage module; the DCS control station comprises a host machine, a standby machine, a main switch and a secondary switch, wherein the host machine and the standby machine are general industrial computers; the graphical logic interpreter is embedded into the open operating system, and a storage module of the interpreter stores a configuration program which can run on a kernel; the invention adopts a general industrial computer, so the calculation speed is greatly improved; meanwhile, an open operating system is adopted, so that a DCS control station can simultaneously and concurrently process more tasks, and the real-time performance is greatly improved; due to the adoption of the configuration software and the online modification technology of the autonomous core, an operator can intuitively use the software, and the programming difficulty is reduced.
Description
Technical Field
The invention relates to the technical field of industrial process automation control, in particular to a graphical logic interpreter, a DCS control station and an implementation method.
Background
The field of industrial process automation control is a relatively closed industry, a DCS (distributed control system) control station adopts a special control station (a special chip, a special network and a special system) at present, and each manufacturer carries out customized production, so that the problems of high cost, difficulty in continuous supply of spare parts and slow product updating iteration are brought.
The existing DCS special control station basically adopts a low-order CPU (Central processing Unit) in consideration of design specifications and heat dissipation problems, has poor calculation performance, is limited by the CPU, an operating system, a core technology and the like, controls the bandwidth of network communication within 10M and 100M, has poor visualization and usability of a programming configuration mode, and lacks comprehensive system diagnosis capability.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the graphical logic interpreter, the DCS control station and the implementation method are faster, more convenient and simpler to operate and capable of reducing cost better.
In order to solve the above technical problems, a first technical solution adopted by the present invention is:
a graphical logic interpreter comprising
A kernel; initializing, program interpreting and calculating, online modifying and processing, main and standby synchronous compression, redundancy switching judgment and system abnormity diagnosis;
the communication module is used for carrying out real-time communication;
the setting module is used for setting the attribute of the input and output block;
and the storage module stores the data.
In order to solve the above technical problem, the second technical solution adopted by the present invention is:
a DCS control station, which comprises a main machine, a standby machine, a main exchanger and a secondary exchanger,
the host is respectively in communication connection with the standby machine, the main switch and the auxiliary switch; the standby machine is in communication connection with the main switch and the auxiliary switch;
the main switch and the auxiliary switch are mutually redundant;
the host and the standby computer are general industrial computers;
and the graphical logic interpreter is embedded into an open operating system, and a storage module of the interpreter stores a configuration program which can run on a kernel.
In order to solve the above technical problems, the third technical solution adopted by the present invention is:
a method for implementing a DCS control station comprises the following steps:
initializing a system memory, creating a shared memory, loading programs and data of a power-off storage area, loading a dynamic link library algorithm of a function block, and initializing system time;
step two, according to the IO configuration of the control configuration, real-time communication is carried out with an IO block through an Ethernet, the numerical value of AI/DI is obtained, and the numerical value is stored in the memory space corresponding to IO;
step three, executing according to the sequence of tasks, programs and functional blocks according to the program configured by the user;
step four, broadcasting the network communication output of the station to the sharing area of the whole network, and simultaneously transporting the broadcast output areas of the other stations to the broadcast input sharing area of the station, thereby realizing data sharing among different control stations;
step five, the host synchronizes the result data of the intermediate calculation of the control program to the standby computer, and updates the calculation result of the standby computer in a covering manner;
and step six, carrying out real-time communication with the IO block through the Ethernet according to the IO configuration of the control configuration, refreshing and outputting the AO/DO value to the output module in real time, and returning to the step two.
The invention has the beneficial effects that: because a general industrial computer based on an Intel X86 framework is adopted, the computing speed is greatly improved compared with the computing capability of a CPU (central processing unit) of a traditional single chip microcomputer; meanwhile, a QNX multithreading technology is adopted, so that the DCS control station can simultaneously and concurrently process more tasks, and the real-time performance of the DCS control station is greatly improved; the operation is simpler, and due to the adoption of the configuration software and the online modification technology of the autonomous core, an operator can intuitively use the software to complete field debugging, so that the programming difficulty is greatly reduced.
Drawings
FIG. 1 is an architecture diagram of a graphical logic interpreter in accordance with an embodiment of the present invention;
FIG. 2 is an architecture diagram of a DCS control station according to an embodiment of the present invention;
FIG. 3 is a flowchart of a method for implementing a DCS control station according to an embodiment of the present invention;
Detailed Description
In order to explain technical contents, achieved objects, and effects of the present invention in detail, the following description is made with reference to the accompanying drawings in combination with the embodiments.
A graphical logic interpreter comprising
A kernel; initializing, program interpreting and calculating, online modifying and processing, main and standby synchronous compression, redundancy switching judgment and system abnormity diagnosis;
the communication module is used for carrying out real-time communication;
the setting module is used for setting the attribute of the input and output block;
and the storage module stores the data.
Further, a diagnosis module is also included.
From the above description, the diagnostic module can be responsible for monitoring the health state of the hardware device in real time, and once an abnormality occurs, an alarm can be given to inform a field of timely maintenance and treatment, so that the system abnormality is reduced.
Furthermore, the system also comprises a GPS clock synchronization module.
From the above description, it can be known that the synchronization of the GPS clock of the DCS control station can be facilitated by the clock synchronization module.
Further, the setting module comprises a module setting block and a hardware setting modification block.
As can be seen from the above description, the block setting block can be responsible for setting the attribute of the physical input/output module; the setting of the IP address can be completed by the hardware setting modification block.
Further, the communication module comprises a physical input/output block, a host standby state communication block, an inter-station shared data communication broadcast block, an external communication service end block, a point-to-point communication block and a ModbusTCP communication block.
As can be seen from the above description, the real-time communication with the physical input/output module of the entity is realized through the physical input/output block, the input/output data is refreshed, and the control of the field device is realized; the main machine and standby machine synchronous communication block and the inter-station shared data communication broadcast block are responsible for real-time communication tasks between the main machine (controller) and the standby machine (controller) to complete the judgment of real-time synchronization and main-standby switching; through the external communication service end block, the data interaction of a third party program and the DCS control station can be responsible; the point-to-point communication block can be responsible for executing point-to-point communication tasks among different DCS control stations; through the ModbusTCP communication block, the ModbusTCP communication module can be responsible for externally providing standard ModbusTCP protocol communication.
A DCS control station, which comprises a main machine, a standby machine, a main exchanger and a secondary exchanger,
the host is respectively in communication connection with the standby machine, the main switch and the auxiliary switch; the standby machine is in communication connection with the main switch and the auxiliary switch;
the main switch and the auxiliary switch are mutually redundant;
the host and the standby computer are general industrial computers;
and the graphical logic interpreter of any one of claims 1-5, which is embedded in an open operating system, and the storage module of which stores a configuration program that can run on the kernel.
From the above description, the main machine and the standby machine are general industrial computers, so that the problems of high cost, difficulty in continuous supply of standby parts and insufficient computing performance brought by the conventional special control station are solved; by adopting the latest CPU and integrated manufacturing technology, the iterative updating of the product is easier, and the calculation performance of the DCS control station is greatly improved; by the open operating system, the problems of non-opening, incompatibility, system resource shortage and single CPU operation caused by the traditional special control system are solved; the existing open type operating system has the characteristics of openness, real time and stability, and combines the micro-kernel, multi-task and multi-CPU (host/standby) core technology, so that a DCS control station is changed from the traditional single task into the multi-task and multi-CPU execution, the computing capability is greatly improved, the control station can effectively distribute the execution sequence according to the priority of the tasks, the task with the highest level can ensure the real-time performance of execution, such as the calculation and physical input and output of control logic, the two tasks directly influence the real-time performance and the safety of the control system, and the independent CPU resource and the highest execution sequence level can be distributed; through the communication connection among the host, the standby machine, the main exchanger and the auxiliary exchanger, triple communication redundancy is realized.
Further, the host and the standby computer are general industrial computers adopting an Intel X86 architecture.
Further, the main machine and the standby machine adopt a system diagnosis log in millisecond level.
From the above description, by adopting the millisecond-level system diagnosis log, the problem of system diagnosis capability deficiency caused by the limitation of the traditional DCS control station on computing resources and insufficient storage space is solved; the new generation DCS control station adopts a built-in comprehensive system diagnosis technology to realize the millisecond-level comprehensive diagnosis of software and hardware faults of the DCS control station by benefiting from the improvement of the CPU computing capacity and the realization of multiple concurrent tasks, and records the hardware abnormity and the software abnormity generated at each millisecond level in a high-speed memory of the DCS control station, so that the reason of the abnormity of the DCS control system can be rapidly found and analyzed, and the probability and the time of field shutdown of a factory are reduced.
A method for implementing a DCS control station comprises the following steps:
initializing a system memory, creating a shared memory, loading programs and data of a power-off storage area, loading a dynamic link library algorithm of a function block, and initializing system time;
step two, according to the IO configuration of the control configuration, real-time communication is carried out with an IO block through an Ethernet, the numerical value of AI/DI is obtained, and the numerical value is stored in the memory space corresponding to IO;
step three, executing according to the sequence of tasks, programs and functional blocks according to the program configured by the user;
step four, broadcasting the network communication output of the station to the sharing area of the whole network, and simultaneously transporting the broadcast output areas of the other stations to the broadcast input sharing area of the station, thereby realizing data sharing among different control stations;
step five, the host synchronizes the result data of the intermediate calculation of the control program to the standby computer, and updates the calculation result of the standby computer in a covering manner;
and step six, carrying out real-time communication with the IO block through the Ethernet according to the IO configuration of the control configuration, refreshing and outputting the AO/DO value to the output module in real time, and returning to the step two.
Has the advantages that: ensuring time synchronization through the first step, and realizing data sharing among different control stations through the fourth step; the calculation error at the time of switching is ensured to be minimized through the step five.
Further, the fifth step further includes:
and the host synchronizes the result data of the intermediate calculation of the control program to the standby computer every 100 milliseconds, and updates the calculation result of the standby computer in a covering manner.
Example one
A graphical logic interpreter comprising
A kernel; initializing, program interpreting and calculating, online modifying and processing, main and standby synchronous compression, redundancy switching judgment and system abnormity diagnosis;
the communication module is used for carrying out real-time communication;
the setting module is used for setting the attribute of the input and output block;
the storage module stores data;
the diagnosis module is used for monitoring the health state of the hardware equipment in real time;
and the GPS clock synchronization module is used for controlling the GPS clock of the DCS control station to carry out synchronization.
The setting module comprises a module setting block, an attribute setting and hardware setting modification block of the physical input/output module and a setting of the IP address.
The communication module comprises a physical input/output block, a host standby state communication block, an inter-station shared data communication broadcast block, an external communication service end block, a point-to-point communication block and a ModbusTCP communication block.
Wherein:
x1: a kernel;
x2: an IO communication driver client program;
x3: IPC hardware diagnostic routines;
x4: a master/standby state communication client/server program;
x5: the main and standby synchronous communication client/server program;
x6: sharing data communication/receiving program between stations;
x7: setting a program for the IO module;
x8: an external communication server program;
x9: a GPS clock synchronization program;
x10: a data storage program;
x11: IPC hardware setting modification program;
x13: an inter-station point-to-point dropping client program;
x14: a Modbus TCP/IP client communication program;
x15: and an OPC client communication program.
Example two
A DCS control station comprises a main machine, a standby machine, a main switch and a secondary switch, wherein the main machine and the standby machine are general industrial computers adopting an Intel X86 architecture.
The host is respectively in communication connection with the standby machine, the main switch and the auxiliary switch; the standby machine is in communication connection with the main switch and the auxiliary switch;
the main switch and the auxiliary switch are mutually redundant;
and the graphical logic interpreter is embedded into the QNX open operating system, and a storage module of the interpreter stores a configuration program which can run on a kernel.
The DCS control station also comprises an IO module which is in communication connection with the main switch and the auxiliary switch through IO communication adapters respectively;
the main machine and the standby machine adopt system diagnosis logs of millisecond level.
Wherein:
CPU _ A: a host (redundant controller of DCS control station);
CPU _ B: a standby machine (a redundant controller of a DCS control station);
HOSTA/HOSTB: gigabit industrial ethernet redundant communication interface of HMI (DCS operator station);
HOSTD: communication kilomega industrial Ethernet redundant communication interface between DCS control stations;
RIO _0/RIO _ 1: a kilomega industrial Ethernet redundant communication interface of an IO module of a DCS control station;
swtich _ 0: a master switch (control plane gigabit industrial ethernet switch);
swtich _ 1: a secondary switch (control plane gigabit industrial ethernet switch);
node: an IO frame;
MCU: an IO communication adapter;
CDXX: an IO module;
EXAMPLE III
An implementation method of the DCS control station according to the second embodiment includes:
initializing a system memory, creating a shared memory, loading programs and data of a power-off storage area, loading a dynamic link library algorithm of a function block, and initializing system time;
step two, according to the IO configuration of the control configuration, real-time communication is carried out with an IO block through an Ethernet, the numerical value of AI/DI is obtained, and the numerical value is stored in the memory space corresponding to IO;
step three, executing according to the sequence of tasks, programs and functional blocks according to the program configured by the user;
step four, broadcasting the network communication output of the station to the sharing area of the whole network, and simultaneously transporting the broadcast output areas of the other stations to the broadcast input sharing area of the station, thereby realizing data sharing among different control stations;
fifthly, synchronizing the result data of the intermediate calculation of the control program to the standby computer every 100 milliseconds by the host computer, and updating the calculation result of the standby computer in a covering manner;
and step six, carrying out real-time communication with the IO block through the Ethernet according to the IO configuration of the control configuration, refreshing and outputting the AO/DO value to the output module in real time, and returning to the step two.
Has the advantages that: ensuring time synchronization through the first step, and realizing data sharing among different control stations through the fourth step; the calculation error at the time of switching is ensured to be minimized through the step five.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all equivalent changes made by using the contents of the present specification and the drawings, or applied directly or indirectly to the related technical fields, are included in the scope of the present invention.
Claims (10)
1. A graphical logic interpreter, comprising
A kernel; initializing, program interpreting and calculating, online modifying and processing, main and standby synchronous compression, redundancy switching judgment and system abnormity diagnosis;
the communication module is used for carrying out real-time communication;
the setting module is used for setting the attribute of the input and output block;
and the storage module stores the data.
2. The graphical logic interpreter of claim 1, further comprising a diagnostic module.
3. The graphical logic interpreter of claim 1, further comprising a GPS clock synchronization module.
4. The graphical logic interpreter of claim 1, wherein the setup module comprises a module setup block and a hardware setup modification block.
5. The graphical logic interpreter of claim 1, wherein the communication modules comprise a physical input output block, a host standby state communication block, an inter-station shared data communication broadcast block, an external communication service end block, a point-to-point communication block, and a ModbusTCP communication block.
6. A DCS control station is characterized by comprising a main machine, a standby machine, a main exchanger and a secondary exchanger,
the host is respectively in communication connection with the standby machine, the main switch and the auxiliary switch; the standby machine is in communication connection with the main switch and the auxiliary switch;
the main switch and the auxiliary switch are mutually redundant;
the host and the standby computer are general industrial computers;
and the graphical logic interpreter of any one of claims 1-5, which is embedded in an open operating system, and the storage module of which stores a configuration program that can run on the kernel.
7. The DCS control station of claim 6, wherein the host computer and the standby computer are general purpose industrial computers using Intel X86 architecture.
8. The DCS control station of claim 6 wherein the primary and secondary machines employ millisecond system diagnostic logs.
9. A method of implementing a DCS control station as claimed in any one of claims 6 to 8, comprising:
initializing a system memory, creating a shared memory, loading programs and data of a power-off storage area, loading a dynamic link library algorithm of a function block, and initializing system time;
step two, according to the IO configuration of the control configuration, real-time communication is carried out with an IO block through an Ethernet, the numerical value of AI/DI is obtained, and the numerical value is stored in the memory space corresponding to IO;
step three, executing according to the sequence of tasks, programs and functional blocks according to the program configured by the user;
step four, broadcasting the network communication output of the station to the sharing area of the whole network, and simultaneously transporting the broadcast output areas of the other stations to the broadcast input sharing area of the station, thereby realizing data sharing among different control stations;
step five, the host synchronizes the result data of the intermediate calculation of the control program to the standby computer, and updates the calculation result of the standby computer in a covering manner;
and step six, carrying out real-time communication with the IO block through the Ethernet according to the IO configuration of the control configuration, refreshing and outputting the AO/DO value to the output module in real time, and returning to the step two.
10. The method of claim 9, wherein the step five further comprises:
and the host synchronizes the result data of the intermediate calculation of the control program to the standby computer every 100 milliseconds, and updates the calculation result of the standby computer in a covering manner.
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| CN102185911A (en) * | 2011-04-25 | 2011-09-14 | 杭州和利时自动化有限公司 | Peer-to-peer communication method and system for distributive control system |
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Application publication date: 20210319 |