CN113867126A - Method and system for testing synchronization performance of real-time control system with redundancy mechanism - Google Patents
Method and system for testing synchronization performance of real-time control system with redundancy mechanism Download PDFInfo
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- CN113867126A CN113867126A CN202111157204.2A CN202111157204A CN113867126A CN 113867126 A CN113867126 A CN 113867126A CN 202111157204 A CN202111157204 A CN 202111157204A CN 113867126 A CN113867126 A CN 113867126A
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Abstract
The invention discloses a system for testing the synchronous performance of a real-time control system with a redundancy mechanism, which comprises: the controller comprises a main control CPU and an auxiliary control CPU; the AO fastener is respectively connected with the main control CPU and the auxiliary control CPU, and the AO fastener is an analog quantity output fastener and is used for collecting and outputting the current output by the controller; the DO clamping piece is respectively connected with the main control CPU and the auxiliary control CPU, and is a digital output clamping piece and used for collecting and outputting the minimum voltage or the maximum voltage output by the controller; the data acquisition unit is used for receiving output signals of the AO card and the DO card; the monitoring software is used for downloading the configuration in the system and setting parameters; the method has higher acquisition time resolution, decouples the synchronization time and the switching time, verifies the influence of the synchronization performance on the output of the card, and combines the synchronization time and the synchronization correctness to judge the overall synchronization performance.
Description
Technical Field
The invention relates to a method and a system for testing the synchronization performance of a real-time control system with a redundancy mechanism, belonging to the technical field of controllers.
Background
The real-time control system is generally a real-time system for controlling a production process, and is required to collect field data in real time, process the collected data in time, and then automatically control corresponding execution mechanisms, so that certain parameter(s) (such as temperature, pressure, orientation and the like) can be changed according to a preset rule, thereby ensuring the quality of products and improving the yield.
Only one controller is communicated with the acquisition card piece through a bus, and then data are synchronously transmitted to the other controller; the data synchronization time between controllers is in millisecond level, the time resolution of historical data records is usually from hundreds of milliseconds to second level, and the synchronization time cannot be accurately judged according to the historical trend of the controller data.
The current testing method often couples the synchronous time and the switching time for testing, so that the difference of the redundant switching performance caused by the synchronous time or the switching time cannot be specifically analyzed when the redundant switching is carried out.
The method for respectively fetching data from a main controller and an auxiliary controller to carry out difference value calculation needs to involve that synchronous data of the main controller is transmitted to the auxiliary controller, and the data of the auxiliary controller is transmitted back to the main controller to carry out difference value calculation, has a plurality of process influence factors, and can not verify the influence of the synchronous difference on card output.
Meanwhile, it is not enough to acquire the controller synchronization time alone. The synchronization performance particularly needs to judge whether the current value of the digital quantity is accurately synchronized to the opposite side controller before switching so as to avoid the jump of the digital quantity output of the controller after switching.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, provides a method and a system for testing the synchronization performance of a real-time control system with a redundancy mechanism, has higher acquisition time resolution, decouples the synchronization time and the switching time, verifies the influence of the synchronization performance on the output of a card, and combines the synchronization time and the synchronization correctness to judge the overall synchronization performance.
In order to achieve the purpose, the invention is realized by adopting the following technical scheme:
in a first aspect, the present invention provides a system for testing synchronization performance of a real-time control system with a redundancy mechanism, including:
the controller comprises a main control CPU and an auxiliary control CPU, and the main control CPU is responsible for control strategy calculation and control output; the auxiliary control CPU takes over the main control CPU for control when the main control CPU is in fault, restarted or stopped, and switches to a standby state for redundant hot standby after the main control CPU is recovered;
the AO fastener is respectively connected with the main control CPU and the auxiliary control CPU, and the AO fastener is an analog quantity output fastener and is used for collecting and outputting the current output by the controller;
the DO clamping piece is respectively connected with the main control CPU and the auxiliary control CPU, and is a digital output clamping piece and used for collecting and outputting the minimum voltage or the maximum voltage output by the controller;
the data acquisition unit is used for receiving output signals of the AO card and the DO card;
and the monitoring software is used for downloading the configuration in the system and setting the parameters.
In a second aspect, the present invention provides a method for testing a synchronous performance testing system of a real-time control system with a redundancy mechanism according to the foregoing, including:
performing a synchronized time acquisition step, the synchronized time acquisition step comprising: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of the controller in the normal output process of the AO card, analyzing slope disturbance data acquired by a high-speed data acquisition unit during switching, and calculating the synchronization time of the controller;
repeatedly executing the synchronization time acquisition step to acquire a plurality of synchronization time data, and taking the average value of the synchronization time data as a synchronization performance reference value;
executing a synchronization correctness judging step, wherein the synchronization correctness judging step comprises the following steps: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of the controller in the normal output process of the DO card, analyzing square wave disturbance data of a high-speed data acquisition unit during switching, and judging the synchronous correctness of the controller according to the square wave disturbance data;
and repeating the step of judging the synchronization correctness, and judging that the synchronization correctness of the controller is good if the synchronization correctness is always good after multiple comparisons, or judging that the synchronization correctness is poor.
Further, carry out the redundancy switch to controller master control CPU and auxiliary control CPU in AO fastener normal output process, include: data are collected through a high-speed data collector, and a switching instruction is sent to a controller, so that a main control CPU (central processing unit) and an auxiliary control CPU of the controller perform redundancy switching; during switching, the ramp signal waveform is disturbed, and after the ramp signal waveform is recovered, the data acquisition of the high-speed data acquisition device is stopped.
Further, analyzing the slope disturbance data of the high-speed data acquisition unit during switching includes:
acquiring a first ramp value X2 after switching and a last ramp value X1 before switching, wherein the ramp signal is delta X of delta t increment of each execution cycle;
and calculating the synchronous time of the controller, wherein the synchronous time is (X2-X1)/delta X delta t.
Further, the redundancy switching is carried out on the main control CPU and the auxiliary control CPU of the controller in the normal output process of the DO card, and the redundancy switching method comprises the following steps: data are collected through a high-speed data collector, and a switching instruction is sent to a controller, so that a main control CPU (central processing unit) and an auxiliary control CPU of the controller perform redundancy switching; during switching, the waveform of the square wave signal is disturbed, and after the waveform of the square wave signal is recovered, the data acquisition of the high-speed data acquisition device is stopped.
Further, analyzing the square wave disturbance data of the high-speed data acquisition unit during switching comprises:
acquiring a first square wave value after switching and a last square wave value before switching;
and judging the synchronous correctness of the controller, wherein the synchronous correctness is poor when the two acquired square wave values are inconsistent, and the synchronous correctness is good when the two square wave values are consistent.
Further, the standby side of the controller heat engine and the monitoring software are both provided with switching buttons for switching control of the main control CPU and the auxiliary control CPU.
Further, the method further comprises: before data are collected through the high-speed data collector, the operation period of a slope, an AO card piece, a switching instruction and a DO card piece is set through monitoring software to be the minimum operation period delta t which can be achieved by the controller.
Further, the method further comprises: before data is collected through the high-speed data collector, the ramp signal is set to be increased by a fixed value delta x every operation period through monitoring software.
Further, the method further comprises: before data is collected through the high-speed data collector, the collection resolution of the high-speed data collector is set to be 0.1 ms.
Compared with the prior art, the invention has the following beneficial effects:
the invention provides a method for testing and judging the synchronization performance of a real-time control system with a redundancy mechanism, which comprises the steps of collecting 1-2 orders of magnitude higher than the requirement on the resolution, decoupling the synchronization time and the switching time, directly verifying the influence of the synchronization performance on the output of a card, and combining the synchronization time and the synchronization correctness to judge the overall synchronization performance. By configuring the types and the number of the clamping pieces, designing a ramp signal and a square wave signal, carrying out high-speed data acquisition, configuring sampling resolution, analyzing sampling data and the like, the acquired signals are more reasonable, the conclusion is more accurate and comprehensive, and the method is more suitable for judging the synchronization performance of the redundancy controller.
Drawings
Fig. 1 is a system schematic diagram of a system for testing synchronization performance of a real-time control system with a redundancy mechanism according to an embodiment of the present invention;
FIG. 2 is an enlarged view of AO output ramp data collected by the high-speed data collector under ideal conditions provided by the embodiment of the present invention;
fig. 3 is an enlarged view of a high-speed data collector collecting DO output square wave data under an ideal condition according to an embodiment of the present invention;
FIG. 4 is an enlarged view of the high-speed data collector provided by the embodiment of the present invention collecting AO output ramp data;
fig. 5 is an enlarged view of the high-speed data collector provided in the embodiment of the present invention for collecting DO output square wave data.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present invention is not limited thereby.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art through specific situations.
Example 1
This embodiment introduces a real-time control system synchronization performance test system with redundancy mechanism, which includes:
the controller comprises a main control CPU and an auxiliary control CPU, and the main control CPU is responsible for control strategy calculation and control output; the auxiliary control CPU takes over the main control CPU for control when the main control CPU is in fault, restarted or stopped, and switches to a standby state for redundant hot standby after the main control CPU is recovered;
the AO fastener is respectively connected with the main control CPU and the auxiliary control CPU, and the AO fastener is an analog quantity output fastener and is used for collecting and outputting the current output by the controller;
the DO clamping piece is respectively connected with the main control CPU and the auxiliary control CPU, and is a digital output clamping piece and used for collecting and outputting the minimum voltage or the maximum voltage output by the controller;
the data acquisition unit is used for receiving output signals of the AO card and the DO card;
and the monitoring software is used for downloading the configuration in the system and setting the parameters.
As shown in fig. 1, the system for testing synchronization performance of a real-time control system with a redundancy mechanism provided in this embodiment specifically includes: one of the redundant control processing units is used for controlling the calculation of the strategy and the control output for the main control CPU; the other is an auxiliary control CPU for standby by a heat engine; when the main control CPU is in fault, restarted or stopped, the auxiliary control CPU takes over to become the main control CPU immediately, and the original main control CPU becomes the auxiliary control CPU to carry out redundant hot standby after being recovered.
And the master control CPU and the auxiliary control CPU carry out state and data synchronization through a synchronous special line.
The upper monitoring software can realize the editing, downloading and monitoring of the configuration in the DPU.
AO is analog output card piece, and the output is the current value.
DO is the digital output fastener, and the output is the break-make value behind the relay, and the preceding output of relay is the voltage value, for reducing the error that relay reaction time caused, the voltage value of taking the preceding output of relay judges the output time of DO fastener.
The main control CPU and the auxiliary control CPU are respectively connected with the AO card and the DO card by communication buses.
The high-speed data acquisition unit is independent of equipment outside the control system and can acquire data of any signal source. The high-speed data acquisition unit receives output signals of AO and DO simultaneously, and can realize data acquisition with 0.1ms resolution.
The communication period of AO and DO and CPU-A and CPU-B through the bus can realize 1ms grade, can realize that the logic in the CPU emutexports the card fast.
Through monitoring software, the calculation periods of the AO module and the DO module are set to be the minimum operation period delta t which can be reached by the controller in the controller, and the ramp signal output by the AO module is a fixed value delta x accumulated in each calculation period.
Through monitoring software, a controller is provided with a DO channel to output square waves with the minimum operation period, and an AO channel to output logic operation slope variables.
The controller switching is realized by an upper monitoring switching button or a button on the controller, the slope variable value and the square wave variable value of the main controller are output in the last output period before the controller redundancy switching, and the slope variable value and the square wave variable value of the auxiliary controller are output in the first output period after the controller redundancy switching.
Ideally, the AO output data and the DO output data collected by the high-speed data collector are amplified as shown in fig. 2 and 3. X2 is X1, Y2 is Y1, where Δ T is the minimum operation period, Δ T is the switching time, X1 is the last ramp value before switching, X2 is the first ramp value after switching, Y1 is the last square wave value before switching, and Y2 is the first ramp value after switching. Because the sampling frequency of the high-speed data acquisition device is high, the displayed ramp signal is in a step shape.
When the synchronization time is long, the real-time value of the main controller is not transmitted to the auxiliary controller through the special synchronization line when the controllers are switched, and the output values in the main controller and the auxiliary controller are different. As shown in fig. 4 and 5.
According to fig. 4, after the switching is successful, the AO output value of the slave controller differs from the AO output value of the master controller by N minimum calculation periods Δ t, so that the synchronization time of the controller at the time of switching is N × Δ t. Wherein N ═ X2-X1)/Δ X.
The synchronization time is not a fixed value and slightly fluctuates according to the change of the operation state, so that the average value needs to be repeatedly obtained when the synchronization performance is tested.
According to fig. 5, when the DO output value of the auxiliary controller is compared with the DO output value of the main controller before the switching, the output of the DO before and after the switching jumps, which may cause abnormal output of the field device after the switching.
Similarly, since the synchronization time is not a fixed value, when performing this test, the controller with poor synchronization accuracy does not have a DO jump every time, and needs to repeatedly verify whether there is a DO output jump during switching.
Example 2
The test method provided by this embodiment according to embodiment 1 of the synchronous performance test system of the real-time control system with the redundancy mechanism includes:
performing a synchronized time acquisition step, the synchronized time acquisition step comprising: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of the controller in the normal output process of the AO card, analyzing slope disturbance data acquired by a high-speed data acquisition unit during switching, and calculating the synchronization time of the controller;
repeatedly executing the synchronization time acquisition step to acquire a plurality of synchronization time data, and taking the average value of the synchronization time data as a synchronization performance reference value;
executing a synchronization correctness judging step, wherein the synchronization correctness judging step comprises the following steps: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of the controller in the normal output process of the DO card, analyzing square wave disturbance data of a high-speed data acquisition unit during switching, and judging the synchronous correctness of the controller according to the square wave disturbance data;
and repeating the step of judging the synchronization correctness, and judging that the synchronization correctness of the controller is good if the synchronization correctness is always good after multiple comparisons, or judging that the synchronization correctness is poor.
The application process of the method for testing the synchronization performance of the real-time control system with the redundancy mechanism provided by the embodiment specifically relates to the following steps:
step 1: the controller is only provided with one AO clamping piece and one DO clamping piece and is used for accelerating the output speed of the controller to AO and DO, and the output speed can reach the level of 1 ms.
Step 2: and the AO outputs current and is connected to the high-speed data acquisition unit. The AO output is generally 4 to 20 mA.
And step 3: and the DO output voltage is connected to the high-speed data acquisition unit. The DO output is typically 0-24V.
And 4, step 4: through upper monitoring software, the operation period of a slope, an AO module, a square wave and a DO module is set in the controller as the minimum operation period which can be achieved by the controller. Such as: the current controller can reach 5-10 ms.
And 5: through upper monitoring software, the ramp signal is set in the controller to be increased by a fixed value every operation period. Such as: the ramp is increased by 1 per operation cycle.
Step 6: through upper monitoring software, the square wave signal is set to be turned over according to the minimum operation period in the controller, namely the pulse width is the minimum operation period, and the duty ratio is 50%.
Step 6: the acquisition resolution of the high-speed data acquisition device is set to be 0.1ms, the resolution is 1 to 2 orders of magnitude higher than the switching time, and the acquisition timeliness can be ensured.
And 7: and switching the DPU in the normal output process of the AO card.
Step 7.1: and setting a high-speed data acquisition unit to start data acquisition, and outputting a ramp signal waveform in an acquisition window.
Step 7.2: then, a switching button on the standby side of the hot engine of the redundant controller or a switching button on an upper monitoring picture is pressed, so that the controller is switched.
Step 7.3: the ramp signal waveform at this time is disturbed. And stopping the data acquisition of the high-speed data acquisition unit after the ramp signal is recovered.
And 8: and analyzing slope disturbance data of the high-speed data acquisition unit during switching.
Step 8.1: the first ramp value after switching X2 and the last ramp value before switching X1 are found.
Step 8.2: and calculating the controller synchronization time. Synchronization time (X2-X1)/Δ X Δ t
And step 9: and (5) repeating the step (7) and the step (8), and after the synchronization time is calculated for multiple times, taking the average value as a synchronization performance reference value.
Step 10: and switching the DPU in the normal output process of the DO card.
Step 10.1: and setting a high-speed data acquisition device to start data acquisition, and outputting the square wave signal waveform in an acquisition window.
Step 10.2: then, a switching button on the standby side of the hot engine of the redundant controller or a switching button on an upper monitoring picture is pressed, so that the controller is switched.
Step 10.3: the square wave signal waveform at this time is disturbed. And stopping the data acquisition of the high-speed data acquisition unit after the square wave signal is recovered.
Step 11: and analyzing square wave disturbance data of the high-speed data acquisition unit during switching.
Step 11.1: and finding the first square wave value after switching and the last square wave value before switching.
Step 11.2: and judging the synchronization correctness of the controller. When the two square wave values of step 11.1 are not consistent, the synchronization accuracy is poor. When the two square wave values of step 11.1 are consistent, the synchronization accuracy is good.
Step 12: and (5) repeating the step (10) and the step (11), after multiple comparisons, judging that the synchronization correctness of the controller is good if the synchronization correctness is always good, and otherwise, judging that the synchronization correctness is poor.
The method for testing and judging the synchronization performance of the real-time control system with the redundancy mechanism comprises the steps of collecting 1-2 orders of magnitude higher than the requirement on the resolution, decoupling the synchronization time and the switching time, directly verifying the influence of the synchronization performance on the output of a card, and combining the synchronization time and the synchronization correctness to judge the overall synchronization performance. By configuring the types and the number of the clamping pieces, designing a ramp signal and a square wave signal, carrying out high-speed data acquisition, configuring sampling resolution, analyzing sampling data and the like, the acquired signals are more reasonable, the conclusion is more accurate and comprehensive, and the method is more suitable for judging the synchronization performance of the redundancy controller.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (10)
1. A real-time control system synchronization performance test system with a redundancy mechanism is characterized by comprising:
the controller comprises a main control CPU and an auxiliary control CPU, and the main control CPU is responsible for control strategy calculation and control output; the auxiliary control CPU takes over the main control CPU for control when the main control CPU is in fault, restarted or stopped, and switches to a standby state for redundant hot standby after the main control CPU is recovered;
the AO fastener is respectively connected with the main control CPU and the auxiliary control CPU, and the AO fastener is an analog quantity output fastener and is used for collecting and outputting the current output by the controller;
the DO clamping piece is respectively connected with the main control CPU and the auxiliary control CPU, and is a digital output clamping piece and used for collecting and outputting the minimum voltage or the maximum voltage output by the controller;
the data acquisition unit is used for receiving output signals of the AO card and the DO card;
and the monitoring software is used for downloading the configuration in the system and setting the parameters.
2. A method for testing the synchronous performance test system of the real-time control system with redundancy mechanism according to claim 1, comprising:
performing a synchronized time acquisition step, the synchronized time acquisition step comprising: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of the controller in the normal output process of the AO card, analyzing slope disturbance data acquired by a high-speed data acquisition unit during switching, and calculating the synchronization time of the controller;
repeatedly executing the synchronization time acquisition step to acquire a plurality of synchronization time data, and taking the average value of the synchronization time data as a synchronization performance reference value;
executing a synchronization correctness judging step, wherein the synchronization correctness judging step comprises the following steps: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of the controller in the normal output process of the DO card, analyzing square wave disturbance data of a high-speed data acquisition unit during switching, and judging the synchronous correctness of the controller according to the square wave disturbance data;
and repeating the step of judging the synchronization correctness, and judging that the synchronization correctness of the controller is good if the synchronization correctness is always good after multiple comparisons, or judging that the synchronization correctness is poor.
3. The test method of claim 2, wherein: carrying out redundancy switching on a main control CPU and an auxiliary control CPU of a controller in the normal output process of an AO card, comprising the following steps: data are collected through a high-speed data collector, and a switching instruction is sent to a controller, so that a main control CPU (central processing unit) and an auxiliary control CPU of the controller perform redundancy switching; during switching, the ramp signal waveform is disturbed, and after the ramp signal waveform is recovered, the data acquisition of the high-speed data acquisition device is stopped.
4. The test method of claim 2, wherein: the method for analyzing the slope disturbance data of the high-speed data acquisition unit during switching comprises the following steps:
acquiring a first ramp value X2 after switching and a last ramp value X1 before switching, wherein the ramp signal is delta X of delta t increment of each execution cycle;
and calculating the synchronous time of the controller, wherein the synchronous time is (X2-X1)/delta X delta t.
5. The test method of claim 2, wherein: the method for redundancy switching of the main control CPU and the auxiliary control CPU of the controller in the normal output process of the DO card piece comprises the following steps: data are collected through a high-speed data collector, and a switching instruction is sent to a controller, so that a main control CPU (central processing unit) and an auxiliary control CPU of the controller perform redundancy switching; during switching, the waveform of the square wave signal is disturbed, and after the waveform of the square wave signal is recovered, the data acquisition of the high-speed data acquisition device is stopped.
6. The test method of claim 2, wherein: analyzing square wave disturbance data of a high-speed data acquisition unit during switching, comprising the following steps:
acquiring a first square wave value after switching and a last square wave value before switching;
and judging the synchronous correctness of the controller, wherein the synchronous correctness is poor when the two acquired square wave values are inconsistent, and the synchronous correctness is good when the two square wave values are consistent.
7. The test method of claim 2, wherein: and switching buttons are arranged on the standby side of the controller heat engine and in the monitoring software and are used for switching control of the main control CPU and the auxiliary control CPU.
8. The method of testing of claim 2, further comprising: before data are collected through the high-speed data collector, the operation period of a slope, an AO card piece, a switching instruction and a DO card piece is set through monitoring software to be the minimum operation period delta t which can be achieved by the controller.
9. The method of testing of claim 4, further comprising: before data is collected through the high-speed data collector, the ramp signal is set to be increased by a fixed value delta x every operation period through monitoring software.
10. The method of testing of claim 4, further comprising: before data is collected through the high-speed data collector, the collection resolution of the high-speed data collector is set to be 0.1 ms.
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