CN114690716A - Design method of DCS system circuit board card service life automatic diagnosis alarm system - Google Patents
Design method of DCS system circuit board card service life automatic diagnosis alarm system Download PDFInfo
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- CN114690716A CN114690716A CN202011619548.6A CN202011619548A CN114690716A CN 114690716 A CN114690716 A CN 114690716A CN 202011619548 A CN202011619548 A CN 202011619548A CN 114690716 A CN114690716 A CN 114690716A
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- 238000003745 diagnosis Methods 0.000 title claims abstract description 66
- 238000013461 design Methods 0.000 title claims abstract description 44
- 238000000034 method Methods 0.000 title claims abstract description 38
- 238000004458 analytical method Methods 0.000 claims abstract description 11
- 238000001514 detection method Methods 0.000 claims description 20
- 230000006870 function Effects 0.000 claims description 18
- 238000004891 communication Methods 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 16
- 230000035882 stress Effects 0.000 claims description 12
- 238000012423 maintenance Methods 0.000 claims description 8
- 238000004422 calculation algorithm Methods 0.000 claims description 7
- 239000003990 capacitor Substances 0.000 claims description 3
- 230000005059 dormancy Effects 0.000 claims description 3
- 230000006353 environmental stress Effects 0.000 claims description 3
- 230000000737 periodic effect Effects 0.000 claims description 3
- 230000002035 prolonged effect Effects 0.000 claims description 3
- 230000009286 beneficial effect Effects 0.000 abstract description 2
- 238000005259 measurement Methods 0.000 abstract description 2
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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]
- G05B19/41845—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 system universality, reconfigurability, modularity
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention belongs to the technical field of instrument and instrument appearance and analysis and measurement control in a DCS system, and particularly relates to a design method for automatically diagnosing and alarming the service life of a circuit board card of the DCS system. The method comprises the following steps: step one, establishing a board card service life model; step two, determining a hardware architecture; step three, determining a software architecture; and step four, determining the service life automatic diagnosis process of the circuit board card of the DCS system. The technical scheme of the invention has the beneficial effects that the element-level service life model is established, so that the service life of the element is predicted more accurately than the service life of the prior board-level service life.
Description
Technical Field
The invention belongs to the technical field of instrument and instrument appearance and analysis and measurement control in a DCS (distributed control system), and particularly relates to a design method of an automatic diagnosis and alarm system for the service life of a circuit board card of the DCS.
Background
With the rapid development of nuclear power construction business in China, the safety and reliability of a Digital Control System (DCS) known as a 'nervous system' of a nuclear power plant are more and more concerned by people.
In order to improve the safety and reliability of the DCS, the DCS is generally designed into a multiple redundancy system and comprises dozens of circuit boards, the service lives of the circuit boards are different, and great difficulty is brought to field maintenance.
The design of the prior circuit board card does not have a service life diagnosis function, is mostly obtained based on MTBF analysis, and cannot faithfully reflect the real service life condition of the field board card.
There is a need for a method that improves the authenticity and accuracy of the diagnosis of the lifetime of a circuit board.
Disclosure of Invention
The invention aims to solve the technical problem of providing a design method of an automatic diagnosis and alarm system for the service life of a circuit board card of a DCS system, thereby simplifying the hardware structure, not influencing the normal function of the board card and reducing the workload of field equipment maintenance personnel.
In order to realize the purpose, the invention adopts the technical scheme that:
a design method of an automatic diagnosis and alarm system for the service life of a circuit board card of a DCS comprises the following steps:
step one, establishing a board card service life model
Counting data in the board card service life model;
establishing a board storage life model and a working life model according to different types of boards by adopting corresponding calculation algorithms, and generating life-stress data of the boards;
step two, determining hardware architecture
The DCS system circuit board card service life automatic diagnosis hardware architecture comprises a diagnosis MCU circuit, an EEPROM storage circuit, an RTC circuit, a power supply circuit and a diagnosis circuit;
step three, determining a software framework
The DCS system circuit board service life automatic diagnosis software architecture comprises a board service life-stress database module, an actual stress diagnosis module, a service life statistics module, a service life criterion module, a communication module, an alarm module and a low power consumption design module;
step four, determining the automatic diagnosis process of the service life of the circuit board card of the DCS:
(1) data downloading: downloading the service life-stress database of the board card model determined in the first step into the EEPROM storage circuit determined in the second step, and establishing a retrieval index, wherein the corresponding software module is a service life-stress database module;
(2) communication function: sending the actual environmental stress, the service life statistical data, the residual service life and the alarm information to an upper control system as data backup in idle time through a control network of the DCS;
acquiring DCS system time and calibrating local time;
acquiring upper-layer control data of a DCS;
the corresponding software module is a communication module;
(3) low power consumption design function: the service life of the circuit board card of the DCS is controlled by the low-power-consumption design module to automatically diagnose the periodic dormancy of the hardware, so that the service life of the hardware for automatically diagnosing the service life of the circuit board card of the DCS is prolonged; the corresponding software module is a low-power design module.
(4) Collecting the stress of the actual working condition: acquiring environment temperature, CPU load rate, bus load and drive load information and setting a service life threshold value through the diagnosis circuit of the DCS system circuit board card service life automatic diagnosis hardware determined in the step two; the corresponding software module is an actual stress diagnosis module;
(5) establishing a board card service life log: counting working condition information including power-on time, fuse power-on times, FLASH erasing times, connector plugging times, relay action times and electrolytic capacitor duration, and establishing a board card working life log; the corresponding software module is a service life counting module;
(6) and (3) judging the service life: periodically detecting actual stress data, searching the board model service life-stress database obtained in the step four (1), judging whether the residual service life is lower than a set reminding threshold value, modifying the residual service life when the service life is not lower than the set reminding threshold value, and updating a working log; when the service life is lower than the set reminding threshold, executing a step four (7); the corresponding software module is a service life judging module;
(7) and (4) alarming: when the residual service life obtained in the step four (6) is lower than a set reminding threshold value, starting an alarm function to remind maintenance personnel of preparing;
when the residual service life obtained in the step (6) is lower than the set replacement threshold value, starting an alarm function to warn maintenance personnel to replace the board card;
the alarm information is sent to an upper control system through a DCS control bus;
the corresponding software modules are an alarm module and a communication module.
Further, in the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the first step, the statistical data includes: original failure rate data of a factory, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis and failure rate prediction conventional reliability analysis data.
Further, according to the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS, in the second step, the diagnosis MCU circuit is responsible for independently operating the diagnosis algorithm, and the normal function of the original system is not affected.
Further, in the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the second step, the EEPROM storage circuit is responsible for storing data in the service life-stress database.
Further, according to the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the second step, the RTC circuit is responsible for providing a real-time clock and recording a work log of the board card.
Further, according to the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the second step, the power supply circuit is responsible for supplying power to other hardware in the automatic diagnosis hardware for the service life of the circuit board card of the DCS system.
Further, in the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the second step, the diagnosis circuit is responsible for obtaining the actual working condition information and performing diagnosis.
Further, in the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the second step, the diagnosis circuit includes a temperature detection circuit, an input power detection circuit, a communication bus load detection, a CPU load detection, a memory read-write frequency detection, and an IO load.
Further, in the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system, in the fourth step (7), the reminding threshold is set to 10%, and the replacement threshold is set to 2%.
The technical scheme of the invention has the beneficial effects that:
1. a component-level life model is established, so that the life of the component is predicted more accurately than the calculation of the prior board-level life.
2. The actual working condition information of the board card is obtained in real time, and the reliability is more reliable than the reliability prediction of a pure theory.
3. Can be combined with a DCS functional circuit, thereby saving the cost.
Drawings
FIG. 1 is a schematic diagram of the diagnostic process of the present method.
Detailed Description
The technical scheme of the invention is explained in detail in the following by combining the drawings and the specific embodiment.
As shown in fig. 1, the design method of the automatic diagnosis and alarm system for the service life of the circuit board card of the DCS system of the invention comprises the following steps:
step one, establishing a board card service life model
Counting data in the board card service life model;
the statistical data includes: original failure rate data of a factory, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis and failure rate prediction conventional reliability analysis data;
establishing a board storage life model and a working life model according to different types of boards by adopting corresponding calculation algorithms, and generating life-stress data of the boards;
step two, determining hardware architecture
The DCS system circuit board card service life automatic diagnosis hardware architecture comprises a diagnosis MCU circuit, an EEPROM storage circuit, an RTC circuit, a power supply circuit and a diagnosis circuit;
the diagnosis MCU circuit is responsible for independently operating a diagnosis algorithm and does not influence the normal function of the original system; the EEPROM storage circuit is responsible for storing data in the life-stress database; the RTC circuit is responsible for providing a real-time clock and recording a working log of the board card; the power supply circuit is responsible for providing power for other hardware in the DCS system circuit board card service life automatic diagnosis hardware; the diagnosis circuit is responsible for acquiring and diagnosing actual working condition information; the diagnosis circuit comprises a temperature detection circuit, an input power supply detection circuit, a communication bus load detection circuit, a CPU load detection circuit, a memory read-write frequency detection circuit and an IO load;
step three, determining a software architecture
The DCS system circuit board service life automatic diagnosis software architecture comprises a board service life-stress database module, an actual stress diagnosis module, a service life statistics module, a service life criterion module, a communication module, an alarm module and a low power consumption design module;
step four, determining the automatic diagnosis process of the service life of the circuit board card of the DCS:
(1) data downloading: downloading the service life-stress database of the board card model determined in the first step into the EEPROM storage circuit determined in the second step, and establishing a retrieval index, wherein the corresponding software module is a service life-stress database module;
(2) communication function: sending the actual environmental stress, the service life statistical data, the residual service life and the alarm information to an upper control system as data backup in idle time through a control network of the DCS;
acquiring DCS system time and calibrating local time;
acquiring upper-layer control data of a DCS;
the corresponding software module is a communication module;
(3) low power consumption design function: the service life of the circuit board card of the DCS is controlled by the low-power-consumption design module to automatically diagnose the periodic dormancy of the hardware, so that the service life of the hardware for automatically diagnosing the service life of the circuit board card of the DCS is prolonged; the corresponding software module is a low-power design module.
(4) Collecting the stress of the actual working condition: acquiring environment temperature, CPU load rate, bus load and drive load information and setting a service life threshold value through the diagnosis circuit of the DCS system circuit board card service life automatic diagnosis hardware determined in the step two; the corresponding software module is an actual stress diagnosis module;
(5) establishing a board card working life log: counting working condition information including power-on time, fuse power-on times, FLASH erasing times, connector plugging times, relay action times and electrolytic capacitor duration, and establishing a board card working life log; the corresponding software module is a service life counting module;
(6) and (3) judging the service life: periodically detecting actual stress data, searching the board model service life-stress database obtained in the step four (1), judging whether the residual service life is lower than a set reminding threshold value, modifying the residual service life when the service life is not lower than the set reminding threshold value, and updating a working log; when the service life is lower than the set reminding threshold, executing a step four (7); the corresponding software module is a service life judging module;
(7) and (4) alarming: when the residual service life obtained in the step four (6) is lower than the set reminding threshold, starting an alarm function to remind maintenance personnel to prepare;
when the residual service life obtained in the step (6) is lower than the set replacement threshold value, starting an alarm function to warn maintenance personnel to replace the board card;
in this embodiment, the reminding threshold is set to 10%, and the replacement threshold is set to 2%.
The alarm information is sent to an upper control system through a DCS control bus;
the corresponding software modules are an alarm module and a communication module.
Claims (10)
1. A design method for automatic diagnosis and alarm of the service life of a circuit board card of a DCS is characterized by comprising the following steps:
step one, establishing a board card service life model
Counting data in the board card service life model;
establishing a board storage life model and a working life model according to different types of boards by adopting corresponding calculation algorithms, and generating life-stress data of the boards;
step two, determining a hardware architecture
The DCS system circuit board card service life automatic diagnosis hardware architecture comprises a diagnosis MCU circuit, an EEPROM storage circuit, an RTC circuit, a power supply circuit and a diagnosis circuit;
step three, determining a software architecture
The DCS system circuit board service life automatic diagnosis software architecture comprises a board service life-stress database module, an actual stress diagnosis module, a service life statistics module, a service life criterion module, a communication module, an alarm module and a low power consumption design module;
step four, determining the automatic diagnosis process of the service life of the circuit board card of the DCS:
(1) data downloading: downloading the service life-stress database of the board card model determined in the first step into the EEPROM storage circuit determined in the second step, and establishing a retrieval index, wherein the corresponding software module is a service life-stress database module;
(2) communication function: sending the actual environmental stress, the service life statistical data, the residual service life and the alarm information to an upper control system as data backup in idle time through a control network of the DCS;
acquiring DCS system time and calibrating local time;
acquiring upper-layer control data of a DCS;
the corresponding software module is a communication module;
(3) low power consumption design function: the service life of the circuit board card of the DCS is controlled by the low-power-consumption design module to automatically diagnose the periodic dormancy of the hardware, so that the service life of the hardware for automatically diagnosing the service life of the circuit board card of the DCS is prolonged; the corresponding software module is a low-power design module.
(4) Collecting stress of actual working conditions: acquiring environment temperature, CPU load rate, bus load and drive load information and setting a service life threshold value through the diagnosis circuit of the DCS system circuit board card service life automatic diagnosis hardware determined in the step two; the corresponding software module is an actual stress diagnosis module;
(5) establishing a board card working life log: counting working condition information including power-on time, fuse power-on times, FLASH erasing times, connector plugging times, relay action times and electrolytic capacitor duration, and establishing a board card working life log; the corresponding software module is a service life counting module;
(6) and (3) judging the service life: periodically detecting actual stress data, searching the board model service life-stress database obtained in the step four (1), judging whether the residual service life is lower than a set reminding threshold value, modifying the residual service life when the service life is not lower than the set reminding threshold value, and updating a working log; when the service life is lower than the set reminding threshold, executing a step four (7); the corresponding software module is a service life judging module;
(7) and (4) alarming: when the residual service life obtained in the step four (6) is lower than the set reminding threshold, starting an alarm function to remind maintenance personnel to prepare;
when the residual service life obtained in the step (6) is lower than the set replacement threshold value, starting an alarm function to warn maintenance personnel to replace the board card;
the alarm information is sent to an upper control system through a DCS control bus;
the corresponding software modules are an alarm module and a communication module.
2. The design method of claim 1, wherein the design method comprises the following steps: in the first step, the statistical data includes: original failure rate data of a factory, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis and failure rate prediction conventional reliability analysis data.
3. The design method of claim 1, wherein the design method comprises the following steps: and in the second step, the diagnosis MCU circuit is responsible for independently operating the diagnosis algorithm without influencing the normal function of the original system.
4. The design method of claim 1, wherein the design method comprises the following steps: and in the second step, the EEPROM storage circuit is responsible for storing the data in the life-stress database.
5. The design method of claim 1, wherein the design method comprises the following steps: in the second step, the RTC circuit is responsible for providing a real-time clock and recording the working log of the board card.
6. The design method of claim 1, wherein the design method comprises the following steps: and in the second step, the power supply circuit is responsible for providing power for other hardware in the DCS system circuit board card service life automatic diagnosis hardware.
7. The design method of claim 1, wherein the design method comprises the following steps: and in the second step, the diagnosis circuit is responsible for acquiring and diagnosing the actual working condition information.
8. The design method of claim 7 for automatic diagnosis and alarm of the service life of the circuit board card of the DCS system, which is characterized in that: in the second step, the diagnosis circuit comprises a temperature detection circuit, an input power supply detection circuit, a communication bus load detection circuit, a CPU load detection circuit, a memory read-write frequency detection circuit and an IO load.
9. The design method for automatic diagnosis and alarm of service life of circuit board card of DCS system as claimed in claim 1, characterized by: in the fourth step (7), the reminding threshold value is set to be 10%, and the replacement threshold value is set to be 2%.
10. The design method for automatic diagnosis and alarm of service life of circuit board card of DCS system as claimed in claim 1, characterized by: in the first step, the statistical data includes: original failure rate data of a factory, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis and failure rate prediction conventional reliability analysis data;
in the second step, the diagnosis MCU circuit is responsible for independently operating the diagnosis algorithm without influencing the normal function of the original system; the EEPROM storage circuit is responsible for storing data in the life-stress database; the RTC circuit is responsible for providing a real-time clock and recording a working log of the board card; the power supply circuit is responsible for providing power for other hardware in the DCS system circuit board card service life automatic diagnosis hardware; the diagnosis circuit is responsible for acquiring and diagnosing actual working condition information; the diagnosis circuit comprises a temperature detection circuit, an input power supply detection circuit, a communication bus load detection circuit, a CPU load detection circuit, a memory read-write frequency detection circuit and an IO load;
in the fourth step (7), the reminding threshold value is set to be 10%, and the replacement threshold value is set to be 2%.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116069565A (en) * | 2023-03-15 | 2023-05-05 | 北京城建智控科技股份有限公司 | Method and device for replacing board card |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116069565A (en) * | 2023-03-15 | 2023-05-05 | 北京城建智控科技股份有限公司 | Method and device for replacing board card |
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