CN114003014B - Method and system for testing redundant switching time of controller - Google Patents
Method and system for testing redundant switching time of controller Download PDFInfo
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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
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
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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
- G05B2219/24—Pc safety
- G05B2219/24065—Real time diagnostics
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- Safety Devices In Control Systems (AREA)
- Testing Electric Properties And Detecting Electric Faults (AREA)
Abstract
The invention discloses a test system for redundant switching time of a controller, which comprises the following components: the controller comprises a main control CPU and an auxiliary control CPU; the AO card is respectively connected with the main control CPU and the auxiliary control CPU, and the A O card is an analog output card; the DO card is respectively connected with the main control CPU and the auxiliary control CPU, is a digital quantity output card and is used for collecting and outputting the minimum voltage or the maximum voltage output by the controller; the data acquisition device is used for receiving output signals of the AO card and the DO card; the variable resistance box is used for converting the current output by the AO clamping piece into voltage and connecting the voltage to the high-speed data acquisition device; the step-down module is used for reducing the voltage output by the DO card part and outputting the voltage to the high-speed data acquisition unit; the method provided by the invention has the advantages that the output stop and start time points are more accurate, the collected voltage signals are output voltage signals of the clamping piece, an output relay is not needed, the collected signals are more reasonable, and the obtained redundancy switching time is more accurate.
Description
Technical Field
The invention relates to a method and a system for testing redundancy switching time of a controller, and belongs to the technical field of controllers.
Background
The real-time control system is usually a real-time system for controlling the production process, and the system is required to collect field data in real time and process the collected data in time so as to automatically control corresponding execution mechanisms, so that certain parameters (such as temperature, pressure, azimuth and the like) can be changed according to a preset rule, thereby ensuring the quality of products and improving the yield.
The redundant switching time of the controller is tens of milliseconds, the time resolution of the historical data record is usually hundreds of milliseconds to seconds, and the switching time cannot be accurately judged through the historical data of the state of the controller.
When the switching time of the controllers is measured by adopting a digital square wave alone, firstly, the specific time point when the first controller stops outputting cannot be known accurately, and the time point can be distributed at any position from the beginning to the end of the last pulse width of the square wave before switching; and secondly, the specific time point when the second controller outputs for the first time cannot be known accurately, and the time point can be distributed at any position from the beginning to the end of the square wave pulse width after the square wave pulse width is taken over.
When the SOE clamping piece of the other pair of redundant controllers is adopted to collect digital quantity output without the aid of the high-speed data collector, the relay response time of the digital quantity output clamping piece can generate errors on the measurement result.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a method and a system for testing the redundant switching time of a controller.
In order to achieve the above purpose, the invention is realized by adopting the following technical scheme:
in a first aspect, the present invention provides a system for testing a controller redundancy switching time, including:
the controller comprises a main control CPU and an auxiliary control CPU, wherein the main control CPU is responsible for controlling policy calculation and control output; when the main control CPU fails, restarts or stops, the auxiliary control CPU takes over the main control CPU to control, and after the main control CPU is recovered, the auxiliary control CPU is switched to a standby state to carry out redundant heat standby;
the AO card is respectively connected with the main control CPU and the auxiliary control CPU, is an analog output card and is used for collecting and outputting the current output by the controller;
the DO card is respectively connected with the main control CPU and the auxiliary control CPU, is a digital quantity output card and is used for collecting and outputting the minimum voltage or the maximum voltage output by the controller;
the data acquisition device is used for receiving output signals of the AO card and the DO card;
the variable resistance box is used for converting the current output by the AO clamping piece into voltage and connecting the voltage to the high-speed data acquisition device;
the step-down module is used for outputting the voltage output by the DO card to the high-speed data collector after step-down.
Furthermore, the main control CPU and the auxiliary control CPU perform state and data synchronization through a special redundant data network.
Furthermore, the main control CPU and the auxiliary control CPU are respectively provided with a communication bus, and the AO card part and the DO card part realize parallel communication with the main control CPU and the auxiliary control CPU through the communication buses respectively.
In a second aspect, the present invention provides a test method of the test system for controller redundancy switching time according to any one of the above, including:
the high-speed data acquisition device acquires data and sends a switching instruction to the controller, so that the main control CPU and the auxiliary control CPU of the controller perform redundancy switching; when switching, the waveform of the ramp signal is disturbed, the switching instruction variable is turned over, and after the waveform of the ramp signal is recovered, the data acquisition of the high-speed data acquisition device is stopped;
positioning a switched data area according to the position of the switching instruction variable turning, and amplifying the data area;
recording the time T1 of the last output of the slope value before switching in the data area, and recording the time T2 of the last output of the slope value after switching in the data area;
the controller redundancy switching time Δt, Δt=t2-T1 is calculated.
Further, a switching button is arranged on the standby side of the controller heat engine and used for switching control of the main control CPU and the auxiliary control CPU.
Further, the method further comprises: before data are collected by the high-speed data collector, the operation period of the slope, the AO card, the switching instruction and the DO card is set to be the minimum operation period which can be achieved by the controller.
Further, the method further comprises: the ramp signal is set to be incremented by a fixed value per operational cycle prior to data acquisition by the high-speed data acquisition unit.
Further, the method further comprises: the acquisition resolution of the high-speed data acquisition unit is set to 0.1ms before data is acquired by the high-speed data acquisition unit.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the testing method for the redundant switching time of the controllers, when the redundant controllers are switched, the specific time point when the first controller stops outputting and the specific time point when the second controller outputs for the first time are rapidly positioned, so that the switching time of the redundant controllers is calculated.
2. The invention makes the collected signals more reasonable by configuring the types and the quantity of the clamping pieces, designing the slope signals, utilizing the switching instruction, converting the collected signals, configuring the sampling resolution and the like, and the obtained time points before and after switching are more accurate, thereby being more suitable for comparing the switching performance of the redundant controllers.
Drawings
FIG. 1 is a schematic diagram of a system for testing controller redundancy switching time according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of current-to-voltage conversion provided by an embodiment of the present invention;
FIG. 3 is a schematic diagram of a buck module according to an embodiment of the present invention;
fig. 4 is a schematic diagram of data collection of the high-speed data collector according to the embodiment of the invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for more clearly illustrating the technical aspects of the present invention, and are not intended to limit the scope of the present invention.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first", "a second", etc. may explicitly or implicitly include one or more such feature. In the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication 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 in a specific case.
Example 1
The embodiment introduces a test system for redundant switching time of a controller, which includes:
the controller comprises a main control CPU and an auxiliary control CPU, wherein the main control CPU is responsible for controlling policy calculation and control output; when the main control CPU fails, restarts or stops, the auxiliary control CPU takes over the main control CPU to control, and after the main control CPU is recovered, the auxiliary control CPU is switched to a standby state to carry out redundant heat standby;
the AO card is respectively connected with the main control CPU and the auxiliary control CPU, is an analog output card and is used for collecting and outputting the current output by the controller;
the DO card is respectively connected with the main control CPU and the auxiliary control CPU, is a digital quantity output card and is used for collecting and outputting the minimum voltage or the maximum voltage output by the controller;
the data acquisition device is used for receiving output signals of the AO card and the DO card;
the variable resistance box is used for converting the current output by the AO clamping piece into voltage and connecting the voltage to the high-speed data acquisition device;
the step-down module is used for outputting the voltage output by the DO card to the high-speed data collector after step-down.
As shown in fig. 1, the system for testing the redundant switching time of the controller provided in this embodiment specifically includes: the system comprises a pair of redundant control processing units, an AO clamping piece, a DO clamping piece, a resistance changing box, a depressurization module and a high-speed data acquisition device.
The redundant control processing units comprise a main control CPU and an auxiliary control CPU, wherein one of the redundant control processing units is responsible for controlling policy calculation and control output for the main control CPU; the other is an auxiliary control CPU, and the heat engine is used for standby; when the main control CPU fails, is restarted or is stopped, the auxiliary control CPU immediately takes over to become the main control CPU, and the original main control CPU becomes the auxiliary control CPU to carry out redundant heat standby after recovery.
And the main CPU and the auxiliary CPU perform state and data synchronization through a special redundant data network.
As shown in fig. 2, the AO clamp is an analog output clamp, outputs a current value, and the resistor box is set to a fixed value to convert the output into a voltage value.
As shown in fig. 3, the DO card is a digital output card, the output of the relay is an on-off value, the output of the relay is a voltage value, and in order to reduce the error caused by the response time of the relay, the voltage value output of the relay is taken to determine the output time of the DO card. Meanwhile, the voltage value can be adjusted to a proper range through the voltage reduction module for adapting to the high-speed data collector.
The main control CPU and the auxiliary control CPU are respectively provided with a communication bus and are connected with the AO card and the DO card, and the main control CPU and the auxiliary control CPU can realize parallel communication between the AO card and the DO card.
The high-speed data collector is independent of equipment outside the control system, and can collect data from any signal source. The high-speed data acquisition device receives output signals of the AO card and the DO card at the same time, and can realize data acquisition with 0.1ms resolution. In the switching process of the redundant controller, the outputs of the AO card and the DO card can be accurately captured.
The AO card, DO card, main control CPU and auxiliary control CPU can achieve 1ms level through the communication cycle of the bus, and logic in the CPU can be rapidly output to the card.
The calculation period of the AO card and the DO card in the controller is set to be the minimum operation period which can be achieved by the controller, and the slope signal output by the AO card is accumulated to be a fixed value in each calculation period.
The DO card part one-channel outputs a controller switching instruction variable, the AO card part one-channel outputs a logic operation slope variable, the last output period before the controller redundancy switching outputs a slope variable value, and the first output period after the controller redundancy switching outputs the controller switching instruction variable and the slope variable value. And whether the DO card output controller is used for switching variable values or not is also used for rapidly positioning the switching positions, so that collected data of the high-speed data collector can be analyzed conveniently. The data collected by the high-speed data collector is amplified as shown in fig. 4.
The controller redundancy switching time=the first output time T2 of the AO card after redundancy switching and the last output time T1 of the AO card before redundancy switching. As shown by Δt in fig. 4, i.e., Δt=t2-T1.
Example 2
The application process of the test method for the controller redundancy switching time provided by the embodiment specifically relates to the following steps:
step 1: the controller only has one AO card and one DO card, and is used for accelerating the output speed of the controller to the AO card and the DO card, and the output speed can reach 1ms level.
Step 2: the AO fastener outputs current, and the current that will be output by AO fastener is connected to the resistance box, is connected to high-speed data acquisition unit with the voltage at resistance box both ends behind the resistance box. Such as: the output of the AO clamping piece is generally 4-20 mA, the resistance box can be set to be 250 omega, and the output is 1-5V.
Step 3: and the DO card outputs voltage, the voltage output by the DO card is connected to the voltage reducing module, and the voltage passing through the voltage reducing module is connected to the high-speed data acquisition unit. Such as: the DO card output is generally 0-24V, the ratio of the resistance value of the resistor 1 to the resistance value of the resistor 2 is set to be 4:1, and the DO card output is 0-4.8V.
Step 4: setting the operation cycle of the slope, the AO card, the switching instruction and the DO card as the minimum operation cycle which can be achieved by the controller. Such as: the current controller can reach 5-10 ms.
Step 5: the ramp signal is set to be increased by a fixed value per operation cycle. Such as: the ramp is incremented by 1 per operation cycle.
Step 6: the acquisition resolution of the high-speed data acquisition device is set to be 0.1ms, and the resolution is 1 to 2 orders of magnitude lower than the switching time, so that the timeliness of acquisition can be ensured.
Step 7: and performing a switching experiment in the normal output process of the data of the AO card and the DO card.
Step 7.1: and setting a high-speed data acquisition unit to start to acquire data, and outputting a ramp signal waveform in an acquisition window.
Step 7.2: then a switch button on the standby side of the redundant controller heat engine is pressed, causing the controller to switch.
Step 7.3: the ramp signal waveform is disturbed at this time, and the switching command variable is inverted. And after the waveform of the slope signal is recovered, stopping the data acquisition of the high-speed data acquisition unit.
Step 8: and analyzing disturbance data of the high-speed data collector during switching.
Step 8.1: and according to the position of the switching instruction variable turning, the switching data area is quickly positioned. The data area is enlarged for analysis.
Step 8.2: the last output time of the ramp value before switching in the data area is recorded and is set as T1. The time of last output of the slope value after switching in the recording data area, that is, the time of switching command variable inversion, is set as T2.
Step 8.3: calculating the redundant switching time of the controller, and setting the redundant switching time as delta T, namely: Δt=t2-T1.
The method for calculating the redundant switching time of the controller by adopting square wave sampling has larger calculation error area, and cannot locate the specific time point of the last output before the switching of the controller and the specific time point of the first output after the switching of the controller, thereby leading to larger test data error. The key point of the invention is to find a method, which can rapidly and accurately locate the specific time point when the first controller stops outputting and the specific time point when the second controller outputs for the first time, thereby calculating the switching time of the redundant controllers. Through the aspects of configuring the types and the quantity of the clamping pieces, designing the slope signals, utilizing the switching instruction, carrying out the conversion of the acquisition signals, configuring the sampling resolution ratio and the like, the acquired signals are more reasonable, the obtained time points before and after switching are more accurate, and the switching performance of the redundant controllers is more suitable to be compared.
The foregoing is merely a preferred embodiment of the present invention, and it should be noted that modifications and variations could be made by those skilled in the art without departing from the technical principles of the present invention, and such modifications and variations should also be regarded as being within the scope of the invention.
Claims (8)
1. A system for testing controller redundancy switching time, comprising:
the controller comprises a main control CPU and an auxiliary control CPU, wherein the main control CPU is responsible for controlling policy calculation and control output; when the main control CPU fails, restarts or stops, the auxiliary control CPU takes over the main control CPU to control, and after the main control CPU is recovered, the auxiliary control CPU is switched to a standby state to carry out redundant heat standby;
the AO card is respectively connected with the main control CPU and the auxiliary control CPU, is an analog output card and is used for collecting and outputting the current output by the controller;
the DO card is respectively connected with the main control CPU and the auxiliary control CPU, is a digital quantity output card and is used for collecting and outputting the minimum voltage or the maximum voltage output by the controller;
the data acquisition device is used for receiving output signals of the AO card and the DO card;
the variable resistance box is used for converting the current output by the AO clamping piece into voltage and connecting the voltage to the high-speed data acquisition device;
the step-down module is used for reducing the voltage output by the DO card part and outputting the voltage to the high-speed data acquisition unit;
the switching module is used for acquiring data through the high-speed data acquisition unit and sending a switching instruction to the controller so that the main control CPU and the auxiliary control CPU of the controller perform redundancy switching; when switching, the waveform of the ramp signal is disturbed, the switching instruction variable is turned over, and after the waveform of the ramp signal is recovered, the data acquisition of the high-speed data acquisition device is stopped;
the amplifying module is used for positioning the switched data area according to the position of the switching instruction variable turnover and amplifying the data area;
the recording module is used for recording the time T1 of the last output of the slope value before switching in the data area and the time T2 of the last output of the slope value after switching in the data area;
and the calculating module is used for calculating the controller redundancy switching time delta T, wherein delta T=T2-T1.
2. The system for testing controller redundancy switch time of claim 1, wherein: and the main control CPU and the auxiliary control CPU perform state and data synchronization through a special redundant data network.
3. The system for testing controller redundancy switch time of claim 1, wherein: the AO card and the DO card realize parallel communication with the main control CPU and the auxiliary control CPU through the communication buses respectively.
4. A test method of the test system for controller redundancy switch time according to any one of claims 1 to 3, comprising:
the high-speed data acquisition device acquires data and sends a switching instruction to the controller, so that the main control CPU and the auxiliary control CPU of the controller perform redundancy switching; when switching, the waveform of the ramp signal is disturbed, the switching instruction variable is turned over, and after the waveform of the ramp signal is recovered, the data acquisition of the high-speed data acquisition device is stopped;
positioning a switched data area according to the position of the switching instruction variable turning, and amplifying the data area;
recording the time T1 of the last output of the slope value before switching in the data area, and recording the time T2 of the last output of the slope value after switching in the data area;
the controller redundancy switching time Δt, Δt=t2-T1 is calculated.
5. The method of testing according to claim 4, wherein: and the standby side of the controller heat engine is provided with a switching button for switching control of the main control CPU and the auxiliary control CPU.
6. The method of testing of claim 4, further comprising: before data are collected by the high-speed data collector, the operation period of the slope, the AO card, the switching instruction and the DO card is set to be the minimum operation period which can be achieved by the controller.
7. The method of testing of claim 4, further comprising: the ramp signal is set to be incremented by a fixed value per operational cycle prior to data acquisition by the high-speed data acquisition unit.
8. The method of testing of claim 4, further comprising: the acquisition resolution of the high-speed data acquisition unit is set to 0.1ms before data is acquired by the high-speed data acquisition unit.
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