CN113778010A - Stage control system and method based on heterogeneous redundancy - Google Patents
Stage control system and method based on heterogeneous redundancy Download PDFInfo
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- CN113778010A CN113778010A CN202111072539.4A CN202111072539A CN113778010A CN 113778010 A CN113778010 A CN 113778010A CN 202111072539 A CN202111072539 A CN 202111072539A CN 113778010 A CN113778010 A CN 113778010A
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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
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/052—Linking several PLC's
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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
- G05B2219/10—Plc systems
- G05B2219/14—Plc safety
- G05B2219/14014—Redundant processors and I-O
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Abstract
The invention provides a stage control system and method based on heterogeneous redundancy. The system comprises: the control system comprises a control console, a first controller connected with the control console, a second controller which is heterogeneous with the first controller, and a motor frequency converter connected with the first controller and the second controller; the console is used for sending a control instruction to the first controller or the second controller under manual control and receiving data sent back by the first controller or the second controller; the first controller and the second controller are used for controlling the motor frequency converter according to the received instruction; and when all the first controllers fail due to the same reason, the second controller controls the motor frequency converter. According to the invention, by arranging the second controller which is different from the first controller, when all the first controllers fail due to the same reason, the second controller is switched to work, so that the working reliability of the controllers can be obviously improved.
Description
Technical Field
The invention belongs to the technical field of stage control, and particularly relates to a stage control system and method based on heterogeneous redundancy.
Background
With the continuous development of the economic and mental culture construction in China, people have more and more requirements on various performances, and the complexity of the corresponding performances is continuously increased, so that a control system needs to be introduced to uniformly control a large-scale stage execution mechanism. However, the existing stage control architecture generally only meets the functional use requirements, and lacks deep optimization design in the aspects of robustness, reliability and the like of the whole system, and when a single point in the system fails during operation under the existing majority of stage control system architectures, the whole architecture may lose control capability, which finally causes performance failure and causes significant loss.
In order to prevent the problems, part of designers optimize and introduce a PLC hot standby redundancy system. This optimization only improves the reliability of the controller to a certain extent and the rest of the system does not improve. In addition, because the standby PLC and the main PLC in the prior art generally use devices of the same brand and model, the problem of simultaneous failure, i.e., common cause failure, of the main PLC and the standby PLC due to the same reason cannot be solved. Common cause failure refers to failure of two or more independent channels in a multi-channel system caused by one or more sources of failure. The failure causes are many, such as random hardware failure caused by external stress of temperature and humidity environment, dust, EMC and the like; or systematic failure caused by design or specification errors, etc.; or both of the above. The reason for the simultaneous failure of two or more independent channels is that the circuit structures and performance parameters of the channels are the same or similar.
Disclosure of Invention
In order to solve the above problems in the prior art, the present invention provides a stage control system and method based on heterogeneous redundancy.
In order to achieve the above object, the present invention adopts the following technical solutions.
In a first aspect, the present invention provides a stage control system based on heterogeneous redundancy, including: the control system comprises a control console, a first controller connected with the control console, a second controller which is heterogeneous with the first controller, and a motor frequency converter connected with the first controller and the second controller; the console is used for sending a control instruction to the first controller or the second controller under manual control and receiving data sent back by the first controller or the second controller; the first controller and the second controller are used for controlling the motor frequency converter according to the received instruction; the number of the first controllers is multiple, and when one working controller fails, the first controllers are automatically switched to other first controllers in a hot standby redundancy state; and when all the first controllers fail due to the same reason, the second controller controls the motor frequency converter.
Furthermore, the number of the control consoles is multiple, and workers can operate through any control console.
Furthermore, the console, the first controller and the second controller are in data communication through a dual-ring network, and one ring network is in communication through the other ring network when the other ring network fails.
Further, an output signal of the first controller is transmitted to the motor frequency converter through a PN bus; and the I/O signal output by the second controller is transmitted to the motor frequency converter through a hard wire.
Further, the first controller and the second controller are PLC controllers.
Furthermore, a manual control button is arranged on the motor frequency converter and used for carrying out local control by a worker through the manual control button after the console remote control fails.
In a second aspect, the present invention provides a method for controlling by using the system, including the following steps:
the control console sends a control instruction to the first controller under the control of a worker;
the first controller outputs a control signal to the motor frequency converter after receiving the control instruction, and controls the stage through the rotation of the motor;
when one first controller fails, the other first controller is automatically switched to work;
and when all the first controllers fail due to the same reason, switching to work of the second controller.
Furthermore, the number of the control consoles is multiple, and workers can operate through any control console.
Furthermore, the console, the first controller and the second controller are in data communication through a dual-ring network, and one ring network is in communication through the other ring network when the other ring network fails.
Further, the first controller and the second controller are PLC controllers.
Further, an output signal of the first controller is transmitted to the motor frequency converter through a PN bus; and the I/O signal output by the second controller is transmitted to the motor frequency converter through a hard wire.
Furthermore, a manual control button is arranged on a cabinet of the motor frequency converter and used for carrying out local control on a worker through the manual control button after the console remote control fails.
Compared with the prior art, the invention has the following beneficial effects.
The stage remote control system is provided with the console, the first controller connected with the console, the second controller which is different from the first controller, and the motor frequency converter connected with the first controller and the second controller, so that the stage remote control can be realized. According to the invention, by arranging a plurality of hot standby redundant first controllers, automatic redundant switching of the first controllers can be realized, and the working reliability of the controllers is improved; through the arrangement of the second controller which is different from the first controller, when all the first controllers fail due to the same reason, the second controller is switched to work, and the working reliability of the controllers is further obviously improved.
Drawings
Fig. 1 is a block diagram of a stage control system based on heterogeneous redundancy according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of a double loop network.
Fig. 3 is a flowchart of a method for performing control by using the system according to an embodiment of the present invention.
In fig. 1, 1-console, 2-first controller, 3-second controller, 4-motor frequency converter.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention clearer and more obvious, the present invention is further described below with reference to the accompanying drawings and the detailed description. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Fig. 1 is a block diagram of a stage control system based on heterogeneous redundancy according to an embodiment of the present invention, including: the control system comprises a control console 1, a first controller 2 connected with the control console 1, a second controller 3 which is different from the first controller 2, and a motor frequency converter 4 connected with the first controller 2 and the second controller 3; the console 1 is used for sending a control instruction to the first controller 2 or the second controller 3 under manual control and receiving data sent back by the first controller 2 or the second controller 3; the first controller 2 and the second controller 3 are used for controlling the motor frequency converter 4 according to the received instruction; the number of the first controllers 2 is multiple, and when one working controller fails, the first controllers 2 are automatically switched to other first controllers 2 in a hot standby redundancy state; when all the first controllers 2 fail due to the same reason, the motor frequency converter 4 is controlled by the second controller 3.
The embodiment provides a stage control system based on heterogeneous redundancy. The system can be divided into three layers of an operation layer, a control layer and a driving layer. The operation layer mainly comprises a console and provides an interface for issuing instructions to the system for workers; the control layer is mainly composed of a controller and is used for processing instruction information issued by the console and performing action decomposition, logic judgment and the like of each mechanism on the instruction; the driving layer receives the action command decomposed by the controller and drives the motor to execute specific action.
In this embodiment, the system mainly includes a console 1, a first controller 2, a second controller 3, and a motor frequency converter 4. The controllers belong to an operation layer, the first controller 2 and the second controller 3 belong to a control layer, and the motor frequency converter 4 belongs to a driving layer. The connection relationship of the parts is shown in fig. 1. Each of which is described below.
The console 1 is used for sending a control instruction to the first controller 2 or the second controller 3 under manual control and receiving data sent back by the first controller 2 or the second controller 3. The control console 1 is generally arranged in a control room far from the stage, and is operated by a worker to remotely control the stage. The console 1 is mainly composed of an operating keyboard, a mouse, a display and the like, and can be an industrial personal computer or a PC.
The first controller 2 is used for receiving a control instruction sent by the console 1 and controlling the motor frequency converter 4 according to the received instruction; and also sends data, such as the working state and fault information of the controlled device, to the console 1. The number of the first controllers 2 is multiple, one of the first controllers works, and the other controllers are in a hot standby redundancy state. When the first controller 2 in operation fails, the other first controllers 2 are automatically switched to, thereby improving the reliability of the controllers. The plurality of first controllers 2 are homogeneous controllers and adopt products of the same manufacturer and the same brand and model, so that the common cause failure problem cannot be solved.
The second controller 3 is mainly used for solving the common cause failure problem of the plurality of first controllers 2. The second controller 3 is a controller which is different from the first controller 2 in structure, controller products of different brands and models produced by different manufacturers from the first controller 2 are selected, the internal circuit structures of the second controller and the controller products are obviously different, and the second controller 3 can still work normally when all the first controllers 2 fail due to the same reason. For example, a PLC controller with the brand name Siemens S7-400 can be selected as the first controller 2, and a Zheda middle control G5 type PLC controller can be selected as the second controller 3. Due to the fact that the second controller 3 is different from the first controller 2, when all the first controllers 2 are detected to be failed, the second controller 3 is switched to, and the motor frequency converter 4 is controlled by the second controller 3 which is not failed.
And the motor frequency converter 4 is mainly used for driving a motor to provide driving force for stage control. The drive layer mainly consists of a motor frequency converter 4, a motor and an encoder, and in order to simplify fig. 1, only the motor frequency converter 4 connected with the controller is shown in fig. 1. In order to improve the working reliability of the driving layer, the motor frequency converter 4, the motor and the encoder adopt a 1:1 redundancy mode, namely the motor frequency converter 4, the motor and the encoder are controlled redundantly as a whole.
In the embodiment, by arranging a plurality of hot standby redundant first controllers 2, automatic redundant switching of the first controllers 2 can be realized, and the working reliability of the controllers is improved; by arranging the second controller 3 which is different from the first controller 2, when all the first controllers 2 fail due to the same reason, the second controller 3 is switched to work, and the working reliability of the controllers can be further improved.
As an alternative embodiment, the number of the control consoles 1 is multiple, and a worker can operate through any one of the control consoles 1.
This embodiment provides a technical solution for the redundancy of the console 1. In order to improve the reliability of the operation layer, in the present embodiment, a plurality of control consoles 1 are provided on the operation layer, and the operation can be performed through any one of the consoles without being divided into a master console and a slave console. Generally, after one console 1 is operated, the related data and the equipment operation information in the rest of the consoles 1 are updated accordingly. When a certain console 1 is out of order or operates abnormally, an operator can quickly perform related command transmission and data monitoring through the rest consoles 1.
As an optional embodiment, the console 1, the first controller 2, and the second controller 3 perform data communication through a dual ring network, and when one ring network fails, the other ring network performs data communication.
The embodiment provides a technical scheme of network redundancy. The console 1, the first controller 2 and the second controller 3 are all connected with a network through a switch, and data communication is achieved through the network. In this embodiment, the console 1, the first controller 2, and the second controller 3 perform data communication via a dual ring network, and when one ring network fails, the other ring network performs data communication. The ring network is a ring structure formed by the equipment through the network cable, and when one device in the structure and the network cable are damaged, the network communication of other equipment in the structure is not influenced. The double-ring network is formed by adding a ring network on the basis of a single ring network, so that higher redundancy is realized. A schematic diagram of a double loop network is shown in fig. 2.
As an alternative embodiment, the first controller 2 and the second controller 3 are PLC controllers.
The embodiment provides a technical scheme of the first controller 2 and the second controller 3. The Controller can be implemented by a plurality of schemes, a single chip microcomputer and a switch component can be used for building the Controller, and an industrial personal computer and a Programmable Logic Controller (PLC) can also be adopted. The first controller 2 and the second controller 3 of this embodiment all adopt the PLC controller, and the PLC controller is the industrial controller most commonly used, is suitable for field control, has the reliability height, interference killing feature strong, the interface is simple, small, the consumption is little, advantage such as price/performance ratio height.
As an alternative embodiment, the output signal of the first controller 2 is transmitted to the motor frequency converter 4 through a PN bus; the I/O signal output by the second controller 3 is transmitted to the motor frequency converter 4 through a hard wire.
This embodiment provides a technical solution of a way of outputting control signals by the first controller 2 and the second controller 3. In this embodiment, an output signal of the first controller 2 is transmitted to the motor frequency converter 4 through a PN bus, and the output signal is a digital signal; the output signal of the second controller 3 is transmitted to the motor frequency converter 4 through a hard wire, and the output signal is an I/O signal which can be directly controlled through switching value output. In the embodiment, the first controller 2 and the second controller 3 output different signal forms, which is also a heterogeneous expression of the two.
As an optional embodiment, a manual control button is arranged on the cabinet of the motor frequency converter 4, and is used for performing local control by a worker through the manual control button after the remote control of the console 1 fails.
The embodiment provides a technical scheme for realizing local control. The control console 1 is generally arranged in a control room far away from a stage, and the control console 1 controls the motor frequency converter 4 through network signal transmission, so that the control console belongs to remote control. In order to further improve the reliability of the stage control system, the manual control button is arranged on the cabinet of the motor frequency converter 4, and when the console 1 fails in remote control, a worker can perform local control through the manual control button.
Fig. 3 is a flowchart of a method for performing control by using the system according to an embodiment of the present invention, where the method includes the following steps:
102, the first controller 2 receives the control instruction and outputs a control signal to the motor frequency converter 4, and the stage is controlled through the rotation of the motor;
103, when one first controller 2 fails, automatically switching to another first controller 2 to work;
and step 104, switching to the second controller 3 to work when all the first controllers 2 fail due to the same reason.
Compared with the technical solution of the system embodiment shown in fig. 1, the method of this embodiment has similar implementation principle and technical effect, and is not described herein again. The same applies to the following embodiments, which are not further described.
As an alternative embodiment, the number of the control consoles 1 is multiple, and a worker can operate through any one of the control consoles 1.
As an optional embodiment, the console 1, the first controller 2, and the second controller 3 perform data communication through a dual ring network, and when one ring network fails, the other ring network performs data communication.
As an alternative embodiment, the first controller 2 and the second controller 3 are PLC controllers.
As an alternative embodiment, the output signal of the first controller 2 is transmitted to the motor frequency converter 4 through a PN bus; the I/O signal output by the second controller 3 is transmitted to the motor frequency converter 4 through a hard wire.
As an optional embodiment, a manual control button is arranged on the cabinet of the motor frequency converter 4, and is used for performing local control by a worker through the manual control button after the remote control of the console 1 fails.
The above description is only for the specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (10)
1. A stage control system based on heterogeneous redundancy, comprising: the control system comprises a control console, a first controller connected with the control console, a second controller which is heterogeneous with the first controller, and a motor frequency converter connected with the first controller and the second controller; the console is used for sending a control instruction to the first controller or the second controller under manual control and receiving data sent back by the first controller or the second controller; the first controller and the second controller are used for controlling the motor frequency converter according to the received instruction; the number of the first controllers is multiple, and when one working controller fails, the first controllers are automatically switched to other first controllers in a hot standby redundancy state; and when all the first controllers fail due to the same reason, the second controller controls the motor frequency converter.
2. A stage control system based on heterogeneous redundancy according to claim 1, wherein the number of the control consoles is multiple, and a worker can operate through any one of the control consoles.
3. A stage control system based on heterogeneous redundancy according to claim 1, wherein the console, the first controller and the second controller communicate data therebetween via a dual ring network, wherein one ring network communicates via the other ring network in case of failure.
4. A stage control system based on heterogeneous redundancy, according to claim 1, wherein the first and second controllers are PLC controllers.
5. A stage control system based on heterogeneous redundancy according to claim 4, wherein the output signal of the first controller is transmitted to a motor frequency converter through a PN bus; and the I/O signal output by the second controller is transmitted to the motor frequency converter through a hard wire.
6. A stage control system based on heterogeneous redundancy, according to claim 1, wherein the motor frequency converter is provided with a manual control button for local control by a worker through the manual control button when the console remote control fails.
7. A method of controlling using the system of claim 1, comprising the steps of:
the control console sends a control instruction to the first controller under the control of a worker;
the first controller outputs a control signal to the motor frequency converter after receiving the control instruction, and controls the stage through the rotation of the motor;
when one first controller fails, the other first controller is automatically switched to work;
and when all the first controllers fail due to the same reason, switching to work of the second controller.
8. The method of claim 7, wherein the number of consoles is multiple, and the operator can operate through any one of the consoles.
9. The method of claim 7, wherein the console, the first controller, and the second controller communicate data via a dual ring network, and wherein one ring network communicates via another ring network in the event of a failure.
10. The method as claimed in claim 7, wherein a manual control button is provided on the cabinet of the motor-frequency converter, and when the console remote control fails, a worker performs local control through the manual control button.
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| CN202111072539.4A CN113778010A (en) | 2021-09-14 | 2021-09-14 | Stage control system and method based on heterogeneous redundancy |
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| CN202111072539.4A CN113778010A (en) | 2021-09-14 | 2021-09-14 | Stage control system and method based on heterogeneous redundancy |
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101592941A (en) * | 2008-05-27 | 2009-12-02 | 总装备部工程设计研究总院 | Heterogeneous PLC multilevel redundancy control system |
| CN104495281A (en) * | 2014-11-26 | 2015-04-08 | 北方重工集团有限公司 | Control network redundancy system for long-distance conveyors |
| CN104597834A (en) * | 2015-01-30 | 2015-05-06 | 中国民航大学 | Multi lifting stage group control system |
| CN208399986U (en) * | 2018-08-15 | 2019-01-18 | 江苏领焰智能科技股份有限公司 | Multifunctional stage device controller and Multifunctional stage apparatus control system |
| CN213365279U (en) * | 2020-10-24 | 2021-06-04 | 广州马其纳工程技术有限公司 | Redundant stage mechanical control platform |
-
2021
- 2021-09-14 CN CN202111072539.4A patent/CN113778010A/en active Pending
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101592941A (en) * | 2008-05-27 | 2009-12-02 | 总装备部工程设计研究总院 | Heterogeneous PLC multilevel redundancy control system |
| CN104495281A (en) * | 2014-11-26 | 2015-04-08 | 北方重工集团有限公司 | Control network redundancy system for long-distance conveyors |
| CN104597834A (en) * | 2015-01-30 | 2015-05-06 | 中国民航大学 | Multi lifting stage group control system |
| CN208399986U (en) * | 2018-08-15 | 2019-01-18 | 江苏领焰智能科技股份有限公司 | Multifunctional stage device controller and Multifunctional stage apparatus control system |
| CN213365279U (en) * | 2020-10-24 | 2021-06-04 | 广州马其纳工程技术有限公司 | Redundant stage mechanical control platform |
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