CN115328065A - Method for automatically migrating control unit functions applied to industrial control system - Google Patents
Method for automatically migrating control unit functions applied to industrial control system Download PDFInfo
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- CN115328065A CN115328065A CN202211127404.8A CN202211127404A CN115328065A CN 115328065 A CN115328065 A CN 115328065A CN 202211127404 A CN202211127404 A CN 202211127404A CN 115328065 A CN115328065 A CN 115328065A
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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], computer integrated manufacturing [CIM]
- G05B19/41865—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], computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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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
Abstract
The invention belongs to the technical field of industrial control systems, and particularly relates to a method for automatically migrating control unit functions applied to an industrial control system. The invention provides an industrial control system comprising DCS and PLC, which realizes the capability of automatically, quickly and undisturbed transferring the logic function of a control unit from one control unit to another non-specific control unit under specific conditions. The system realizes the automatic migration capability through a migration service module, a shared storage unit, a self-diagnosis service module and the like.
Description
Technical Field
The invention belongs to the technical field of industrial control systems, and particularly relates to a method for automatically migrating control unit functions applied to an industrial control system.
Background
In an industrial control system, a plurality of control stations are often deployed, which respectively undertake different computing tasks and cooperate with each other to complete an overall control function. The control station consists of a control unit, an I/O module and the like, wherein the control unit (also called a controller, an industrial controller, a main control module, an MCU, a CPU unit) based on the embedded system is a core component of the control station and bears the logical operation task of the whole system.
In industrial control system products (such as DCS and PLC) of the existing industrial control system manufacturers, 1 control unit is arranged in one control station or is configured by adopting single master control; or 2 (or more) control units with hot standby redundancy (i.e. master-slave redundancy) or cold standby redundancy are deployed to improve the system availability. However, the firmware and configuration software (software for implementing control logic functions, configured and developed by engineering software developers according to engineering requirements) in the redundant control units are bound to specific physical control units, and once the system is put into operation, the logic control functions of the control units are determined. When the logic control function of the system is changed, only operations with local and small-range influences such as parameter modification, variable forcing, patching and the like can be performed under the online operation condition of the system; if the logic control function of the system is upgraded and modified, even completely reassembled and other operations which have obvious influence, the system needs to be maintained by shutdown or offline and the like, so that the uninterrupted operation of the system is damaged.
Disclosure of Invention
Therefore, the invention provides a method for automatically migrating the functions of control units applied to an industrial control system, which realizes that the logic control function of each control unit can be undisturbed, quickly and automatically migrated to any other redundant idle control unit in the system on the premise that the industrial control system is in uninterrupted operation, namely the function and the role of the control unit are undisturbed and replaced by another control unit.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a method for automatic migration of control unit functions applied to an industrial control system, wherein the industrial control system is provided with a plurality of control units and implements the following steps: besides the non-idle control units which respectively execute the automatic control functions, the industrial control system is also provided with at least 1 redundant idle control unit to form an available control unit pool; under the condition of migration triggering, taking a non-idle control unit to be migrated as a source control unit, taking a target control unit out of an available control unit pool, acquiring an application program corresponding to the source control unit, loading the application program to the target control unit, and synchronizing state data of the source control unit to the target control unit. The invention aims at industrial control systems including DCS and PLC, and realizes the capability of automatically, quickly and undisturbed transferring the logic function of the control unit from one control unit to another non-specific control unit under specific conditions.
As a preferred scheme of the migration method, the migration trigger may actively request: and the non-idle control unit actively requests to outwards migrate the non-idle control unit as a source control unit according to the self fault or abnormal state.
As a preferred scheme of the migration method, the migration trigger may systematically judge: the industrial control system carries out health state judgment and fault prediction on each non-idle control unit through self diagnosis, and judges whether to execute migration on a certain non-idle control unit.
As a preferred solution of the migration method, the migration trigger may be manually instructed to: the migration of a certain non-idle control unit is triggered by a manual instruction.
On the other hand, an industrial control system is provided, which adopts the above method for automatic migration of control unit functions applied to the industrial control system.
In another aspect, an industrial control system is provided, including:
the industrial control system is provided with a plurality of control units, wherein the industrial control system is provided with at least 1 redundant idle control unit besides non-idle control units for respectively executing automatic control functions, and an available control unit pool is formed;
the migration service module is used for confirming the legality of the migration triggering condition and authorizing the execution of the migration action, taking a non-idle control unit to be migrated as a source control unit, taking a target control unit out of the available control unit pool, and synchronizing the state data of the source control unit to the target control unit;
the shared storage unit is used for storing the application program of the control function executed by the non-idle control unit for a long time and storing and periodically updating the state data of the non-idle control unit; and acquiring the application program and the state data corresponding to the source control unit from the migration process and loading the application program and the state data to the target control unit.
As a preferable scheme of the industrial control system, a human-computer interface or an engineer station is accessed, and the migration of a certain non-idle control unit is triggered through a manual instruction.
The optimal scheme of the industrial control system comprises a self-diagnosis service module, wherein the self-diagnosis service module is used for judging the health state and predicting the fault of each non-idle control unit through self-diagnosis and judging whether to execute migration on a certain non-idle control unit.
In a preferred embodiment of the industrial control system, the shared storage unit stores necessary status data, and if the target control unit fails to synchronize the status data from the source control unit, the target control unit synchronizes the status data from the shared storage unit.
As the preferable scheme of the industrial control system, hot plugging of the control units is supported, and the newly added control units are automatically added into the available control unit pool after detection.
In summary, the present invention has the following advantages and advantages compared with the prior art. The invention is suitable for the following typical scenes and other similar scenes in the field of 3 types of industrial control:
1. when hardware maintenance or software change or upgrade, test or experiment and other conditions affecting or possibly affecting the normal operation of a certain control unit in the system are required, the automatic migration function can enable the logic control function of the control unit to be rapidly, undisturbed and automatically migrated to other redundant idle control units, and the system is kept to operate uninterruptedly.
2. When the system automatically detects and judges that a certain control unit has a certain degree of fault or abnormity, or predicts that a fault and failure risk exists, the system automatically starts the migration action and rapidly completes the migration, thereby avoiding adverse consequences caused by the fault of the control unit and timely sending an alarm to operating personnel and maintenance personnel.
3. In order to avoid potential faults and sleeping faults in the control unit in operation, the system actively selects the control unit at random or according to a certain rule to execute automatic migration at regular or irregular intervals as verification and test of the function of the control unit.
Drawings
The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention.
FIG. 1 is a system architecture and migration diagram of the present invention.
FIG. 2 is a system architecture and migration diagram according to an embodiment of the present invention.
Detailed Description
To make the objects, technical solutions and advantages of the present invention more apparent, the following detailed description of the principles, features and the like of the present invention is made with reference to the following examples and accompanying drawings, and the exemplary embodiments and descriptions of the present invention are only used for explaining the present invention, and are not used as limiting the scope of the present invention.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one of ordinary skill in the art that: it is not necessary to employ these specific details to practice the present invention. In other instances, well-known structures, circuits, materials, or methods have not been described in detail so as not to obscure the present invention.
Throughout the description, references to "one embodiment," "an embodiment," "one example," or "an example" mean: the particular features, structures, or characteristics described in connection with the embodiment or example are included in at least one embodiment of the invention. Thus, the appearances of the phrase "one embodiment," "an embodiment," "one example" or "an example" in various places throughout this specification are not necessarily all referring to the same embodiment or example. Furthermore, the particular features, structures, or characteristics may be combined in any suitable combination and/or sub-combination in one or more embodiments or examples. Further, those of ordinary skill in the art will appreciate that the illustrations provided herein are for illustrative purposes and are not necessarily drawn to scale. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
The following discloses many different embodiments or examples for implementing the subject technology described. The following describes particular embodiments of one or more arrangements of features for simplicity of disclosure, but the illustrated embodiments are not intended to be limiting of the present disclosure, and the first and second features set forth in the following description may be combined to include embodiments that are directly connected, or may form additional features, and further, may include the use of one or more additional intervening features to indirectly connect or combine the first and second features to each other such that the first and second features may not be directly connected. In the description of the present specification, "a plurality" means at least two, e.g., two, three, etc., unless explicitly defined otherwise.
The terms used in the present specification are those general terms which are currently widely used in the art in consideration of functions related to the present disclosure, but they may be changed according to the intention of a person having ordinary skill in the art, precedent, or new technology in the art. Also, specific terms may be selected by the applicant, and in this case, their detailed meanings will be described in the detailed description of the present disclosure. Therefore, the terms used in the specification should not be construed as simple names, but rather based on the meanings of the terms and the overall description of the present disclosure.
Flowcharts or text are used in this specification to illustrate operational steps performed in accordance with embodiments of the present application. It should be understood that the operational steps in the embodiments of the present application are not necessarily performed in the exact order recited. Rather, the various steps may be processed in reverse order or simultaneously, as desired. Meanwhile, other operations may be added to or removed from these processes.
Example 1
The present embodiment provides a method for automatically migrating control unit functions applied to an industrial control system, where the industrial control system includes a plurality of control units and implements the following steps:
besides non-idle control units which respectively execute each automatic control function, the industrial control system is also provided with at least 1 redundant idle control unit to form an available control unit pool; under the condition of migration triggering, taking a non-idle control unit to be migrated as a source control unit, taking a target control unit out of an available control unit pool, acquiring an application program corresponding to the source control unit, loading the application program to the target control unit, and synchronizing state data of the source control unit to the target control unit.
The present embodiments relate to the ability to implement automatic, fast, and undisturbed migration of logic functions of control units from one control unit to another, non-specific control unit under specific conditions for typical industrial control systems including DCS (digital control system), PLC (programmable logic controller).
Wherein the type of trigger migration:
1) Actively requesting: the non-idle control unit actively requests itself to be used as a source control unit to be outwards transferred according to self faults or abnormal states, for example, under the condition that faults of different degrees occur, and a transfer service module judges and selects a target control unit.
2) And (3) system judgment: the industrial control system self-diagnosis judges the health state of each non-idle control unit, predicts the fault and judges whether to execute the migration to a certain non-idle control unit by monitoring the fault. If so, selecting a target control unit for the target control unit.
3) Manual instruction: the operator or the maintenance personnel trigger the migration of a certain non-idle control unit through a manual instruction, and can select a target control unit automatically selected by the migration service module or manually designate the target control unit.
On the basis, the embodiment also provides an industrial control system, namely the method for automatically migrating the control unit function applied to the industrial control system is adopted.
Example 2
In the industrial control system provided by the embodiment, as shown in fig. 1, for a typical industrial control system including a DCS (digital control system) and a PLC (programmable logic controller), the system has a migration service module, a shared memory unit, and a self-diagnosis service module, which implement the capability of automatically, quickly, and undisturbed migration of logic functions of a control unit from one control unit to another non-specific control unit.
The industrial control system specifically includes:
the industrial control system is provided with a plurality of control units, and at least 1 redundant idle control unit is arranged in the industrial control system besides non-idle control units which respectively execute each automatic control function, so that an available control unit pool which is uniformly scheduled by a system migration service module is formed;
the migration service module is used for confirming the legality of the migration triggering condition and authorizing the execution of the migration action, taking a non-idle control unit to be migrated as a source control unit, taking a target control unit out of the available control unit pool, and synchronizing the state data of the source control unit to the target control unit;
the shared storage unit is used for storing the application program of the control function executed by the non-idle control unit for a long time and storing and periodically updating the state data of the non-idle control unit; and acquiring the application program and the state data corresponding to the source control unit from the migration process and loading the application program and the state data to the target control unit.
The system is provided with a migration service module, schedules and manages the migration actions of all control units, and comprises the following steps: judging the execution of the migration action, selecting a source and a target according to a certain rule, authorizing to acquire an application program and state data and executing synchronization, managing the switching of the control unit and other types of modules (such as I/O modules) and the like.
The system is provided with a uniform shared storage unit for storing application programs and necessary state data of all the control units. The application program refers to application software and codes which are generated after the engineer station (or a configuration tool) is configured, undertake logic control tasks and run in the control unit; the state data refers to data related to the operation states of components such as control stations, control units and the like in the system, and the data is periodically acquired from real-time operation data of the control units of the system or is triggered to be acquired under specific conditions. The shared storage unit supports storage high availability designs that are not limited to redundant configurations, disk arrays, and the like.
As a selectable migration condition triggering mode, the industrial control system can be accessed to a human-computer interface or an engineer station, and migration of a certain non-idle control unit is triggered through a manual instruction. Or self-diagnosis is carried out by the self-diagnosis service module, the health state judgment and the fault prediction are carried out on each non-idle control unit, and whether the migration is carried out on a certain non-idle control unit is judged.
As an alternative status data synchronization method, the shared storage unit stores necessary status data, and if the target control unit fails to synchronize the status data from the source control unit, the target control unit synchronizes from the shared storage unit. During the migration process, the underlying software (firmware, boot software, driver, etc.) common to each control unit is no longer migrated. The upper application software (configuration software) and the state data are migrated, and the data flow direction is as follows: the target control unit reads and loads application software from the shared storage unit; the target control unit synchronizes the state data from the source control unit, and if the synchronization fails due to factors such as a failure of the source control unit, the target control unit synchronizes the state data from the shared storage unit.
The system is provided with a uniform shared storage unit for storing application programs and necessary state data of all the control units. The application program refers to application software and codes which are generated after the engineer station (or a configuration tool) is configured, undertake logic control tasks and run in the control unit; the state data refers to data related to the operation states of components such as control stations, control units and the like in the system, and the data is acquired periodically from real-time operation data of the control units of the system or is triggered to be acquired under specific conditions. The shared storage unit supports storage high availability designs that are not limited to redundant configurations, disk arrays, and the like.
As an alternative implementation mode, the industrial control system supports hot plug of the control unit, and the newly added control unit is automatically added into the available control unit pool after detection.
Example 3
In addition to embodiments 1 and 2, the present embodiment is directed to a control system according to the present invention, which includes 5 control units, each numbered 1-5. Wherein, the No. 1-3 control units respectively execute different control functions (non-idle control units), and the No. 4-5 control units are redundant idle control units.
Under a certain trigger condition, taking the control unit itself fault alarm active request migration as an example, the execution sequence is as follows:
1) The No. 2 control unit sends out a self device temperature high alarm, so that the No. 2 control unit actively requests the migration to the migration service module.
2) The migration service module confirms the validity of the request and confirms the passing.
3) The migration service module takes a target control unit from the pool of available control units (in this case, the control units No. 4 and No. 5), where No. 4 is taken as an example.
4) The migration service module grants synchronous action and resource access authority for No. 2 and No. 4 control units.
5) And the No. 4 control unit acquires the application program corresponding to the No. 2 control unit from the shared storage unit and loads the application program.
6) It is confirmed that the control unit No. 2 can complete the status data synchronization with the control unit No. 4, and start and complete the data synchronization.
7) The No. 4 control unit runs the application program and loads the state data to be put into operation, but the output function is shielded (locked).
8) After the migration service module confirms that the control unit No. 4 is successfully operated, the output shielding of the control unit No. 4 is cancelled, the output of the control unit No. 2 is shielded, and the migration service module updates related data. At which point the migration action is complete.
9) And sending self equipment temperature high alarm according to the No. 2 control unit, and intervening maintenance of the No. 2 control unit by operation and maintenance personnel. And after the maintenance is finished, adding the No. 2 control unit into the available control unit pool.
As will be appreciated by one skilled in the art, embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and so forth) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
The above-mentioned embodiments, objects, technical solutions and advantages of the present invention are further described in detail, it should be understood that the above-mentioned embodiments are merely preferred embodiments of the present invention, and are not intended to limit the scope of the present invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (10)
1. A method for automatic migration of control unit functions applied to an industrial control system, the industrial control system having a plurality of control units, the method comprising: besides non-idle control units which respectively execute each automatic control function, the industrial control system is also provided with at least 1 redundant idle control unit to form an available control unit pool; under the condition of migration triggering, taking a non-idle control unit to be migrated as a source control unit, taking a target control unit out of an available control unit pool, acquiring an application program corresponding to the source control unit, loading the application program to the target control unit, and synchronizing state data of the source control unit to the target control unit.
2. The method for automatic migration of control unit functions applied to an industrial control system according to claim 1, wherein the migration trigger can actively request: and the non-idle control unit actively requests to outwards migrate the non-idle control unit as a source control unit according to the self fault or abnormal state.
3. The method for automatic migration of control unit functions applied to an industrial control system according to claim 1, wherein the migration trigger can be systematically determined by: the industrial control system carries out health state judgment and fault prediction on each non-idle control unit through self diagnosis, and judges whether to execute migration on a certain non-idle control unit.
4. The method for automatic migration of control unit functions applied to an industrial control system according to claim 1, characterized in that the migration trigger is manually instructed to: the migration of some non-idle control unit is triggered by a manual instruction.
5. An industrial control system, characterized in that the method for automatic migration of control unit functions applied to the industrial control system according to any one of claims 1 to 4 is adopted.
6. An industrial control system, comprising:
the industrial control system is provided with a plurality of control units, wherein the industrial control system is provided with at least 1 redundant idle control unit besides non-idle control units for respectively executing automatic control functions, and an available control unit pool is formed;
the migration service module is used for confirming the legality of the migration triggering condition and authorizing the execution of the migration action, taking a non-idle control unit to be migrated as a source control unit, taking a target control unit out of the available control unit pool, and synchronizing the state data of the source control unit to the target control unit;
the shared storage unit is used for storing the application program of the control function executed by the non-idle control unit for a long time and storing and periodically updating the state data of the non-idle control unit; and acquiring the application program and the state data corresponding to the source control unit from the migration process and loading the application program and the state data to the target control unit.
7. The industrial control system of claim 6, wherein: and accessing a human-machine interface or an engineer station, and triggering the migration of a certain non-idle control unit through a manual instruction.
8. The industrial control system of claim 6, wherein: the self-diagnosis service module is used for judging the health state and predicting the fault of each non-idle control unit through self-diagnosis and judging whether to execute migration on a certain non-idle control unit.
9. The industrial control system of claim 6, wherein: the shared storage unit stores necessary state data, and if the target control unit fails to synchronize the state data from the source control unit, the target control unit synchronizes from the shared storage unit.
10. The industrial control system of claim 6, wherein: and supporting the hot plug of the control unit, and automatically adding the newly added control unit into the available control unit pool after detection.
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