CN116719270A - Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field - Google Patents
Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field Download PDFInfo
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- CN116719270A CN116719270A CN202310888128.5A CN202310888128A CN116719270A CN 116719270 A CN116719270 A CN 116719270A CN 202310888128 A CN202310888128 A CN 202310888128A CN 116719270 A CN116719270 A CN 116719270A
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- 238000000034 method Methods 0.000 title claims abstract description 18
- 238000013500 data storage Methods 0.000 claims abstract description 14
- 230000001360 synchronised effect Effects 0.000 claims abstract description 6
- 230000003287 optical effect Effects 0.000 claims abstract description 5
- 238000012545 processing Methods 0.000 claims abstract description 5
- 230000005540 biological transmission Effects 0.000 claims description 8
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000004891 communication Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009776 industrial production Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/052—Linking several PLC's
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/14—Plc safety
- G05B2219/14014—Redundant processors and I-O
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- 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]
Abstract
The invention discloses a hot standby redundant control system and a method for a PLC system in the industrial control field, wherein the hot standby redundant control system comprises a main controller and a standby controller; the main controller and the standby controller are communicated through an optical cable; the main controller includes: program input module, redundant hot standby system overhead module, program execution module, data storage and exchange module, program output module; the program enters the main controller through the program input module, is processed by the redundant hot standby system overhead module, is executed by the program executing module and is output by the program output module, and the data after the program execution is stored in the data storage and exchange module. The method comprises the following steps: s1, reading input information; s2, processing non-redundant parts which do not need to be synchronized in the input information; s3, executing a redundant part; s4, outputting information. The invention effectively solves the problem that the whole system stops operating due to the failure of the main controller in the prior art.
Description
Technical Field
The invention relates to the field of industrial control, in particular to a hot standby redundancy control system and method for a PLC (programmable logic controller) system in the field of industrial control.
Background
In the field of industrial control, especially in the field of digital instrument control of nuclear power plants and the like, a large number of high-low level signals or voltage-current signals can be output to control and drive external equipment, the shutdown control is participated in, important logic operation and the like are participated in, and the safe operation of the nuclear power plants is concerned.
By "redundant" system, it is meant that the entire PLC control system consists of 2 identical sets of systems, one of which is not required during normal operation of the system. In a hot standby (hot) system, 2 CPUs are directly connected together through a communication interface, all in a powered-on state.
In industrial application, one set of controller module can meet the requirement of the whole PLC system under the condition of no fault occurrence. However, if the redundancy heat standby scheme is not adopted, when the controller module fails, the whole PLC system stops working normally, and the system can continue working normally only after waiting for a technician to repair. This can seriously affect the industrial production efficiency and even in some cases even cause safety accidents. In industrial applications, it is therefore necessary to use redundancy alternatives when setting up PLC systems.
Disclosure of Invention
The invention provides a hot standby redundant control system of a PLC (programmable logic controller) system in the industrial control field, which comprises a main controller and a standby controller; the main controller and the standby controller are communicated through an optical cable.
Further, the main controller includes: program input module, redundant hot standby system overhead module, program execution module, data storage and exchange module, program output module; the program enters the main controller through the program input module, is processed by the redundant hot standby system overhead module, is executed by the program executing module and is output by the program output module, and the data after the program execution is stored in the data storage and exchange module.
Further, the standby controller includes: program input module, redundant hot standby system overhead module, program execution module, data storage and exchange module, program output module; the program enters the main controller through the program input module, is processed by the redundant hot standby system overhead module, is output by the program output module after the first section of the input program is executed by the program execution module, and the data after the program execution is stored in the data storage and exchange module.
A hot standby redundancy control method of a PLC system in the industrial control field comprises the following steps: s1, reading input information; s2, processing non-redundant parts which do not need to be synchronized in the input information; s3, executing a redundant part; s4, outputting information.
Further, the main controller further comprises a data transmission step with the standby controller: the standby state information acquired from the standby controller is analyzed, and the redundant backup data is copied to the CPU of the standby controller after the redundant portion is executed.
Further, the standby controller further comprises a data transmission step with the main controller: the main status information acquired from the main controller is analyzed, and the standby system information is copied to the CPU of the main controller after the redundant part is executed.
Further, the program in the standby controller executes only the first segment of the program input by the user.
Further, there is a MAST to scan the program when the program is running as a whole, and the scan time T spent for the scan is: scan time T > redundant hot standby overhead time t1+program execution time T2.
The invention provides a hot standby redundant control system and a hot standby redundant control method for a PLC (programmable logic controller) system in the industrial control field, which effectively solve the problem that the whole system stops operating due to the failure of a main controller in the prior art.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to the structures shown in these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of a method for providing a hot standby redundancy control system and method for a PLC system in the industrial control field;
fig. 2 is a system module structure diagram of a PLC system hot standby redundancy control system and method in the industrial control field.
Detailed Description
It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
The following detailed description of embodiments of the invention, taken in conjunction with the accompanying drawings, illustrates only some, but not all embodiments, and for the sake of clarity, illustration and description not related to the invention is omitted in the drawings and description.
The technical scheme of the present invention is selected from the following detailed description in order to more clearly understand the technical features, objects and advantageous effects of the present invention. It will be apparent that the described embodiments are some, but not all, embodiments of the invention and should not be construed as limiting the scope of the invention which can be practiced. All other embodiments, which can be made by a person of ordinary skill in the art based on the embodiments of the present invention without making any inventive effort, are within the scope of the present invention.
As shown in FIG. 2, the invention provides a hot standby redundant control system of a PLC system in the industrial control field, which comprises a main controller and a standby controller; the main controller and the standby controller are communicated through an optical cable.
Wherein, main control unit includes: program input module, redundant hot standby system overhead module, program execution module, data storage and exchange module, program output module; the program enters the main controller through the program input module, is processed by the redundant hot standby system overhead module, is executed by the program executing module and is output by the program output module, and the data after the program execution is stored in the data storage and exchange module.
The standby controller includes: program input module, redundant hot standby system overhead module, program execution module, data storage and exchange module, program output module; the program enters the main controller through the program input module, is processed by the redundant hot standby system overhead module, is output by the program output module after the first section of the input program is executed by the program execution module, and the data after the program execution is stored in the data storage and exchange module.
As shown in fig. 1, a hot standby redundancy control method for a PLC system in the industrial control field includes the following steps: s1, reading input information; s2, processing non-redundant parts which do not need to be synchronized in the input information; s3, executing a redundant part; s4, outputting information.
Wherein the main controller further comprises a data transmission step with the standby controller: the standby state information acquired from the standby controller is analyzed, and the redundant backup data is copied to the CPU of the standby controller after the redundant portion is executed.
The standby controller further comprises a data transmission step with the main controller: the main status information acquired from the main controller is analyzed, and the standby system information is copied to the CPU of the main controller after the redundant part is executed. Wherein the program when executed only performs the first segment of the input program.
The main controller firstly reads in input information, then firstly processes non-redundant programs which do not need to be synchronized, then analyzes standby state information acquired from the standby CPU, and can learn the running state, storage space and other data of the standby controller at the moment from the standby state information, thereby executing related operations of a redundant part, copying the data which need to be redundant to the standby CPU, and finally finishing information output by the main controller and entering the next cycle period. The operation flow of the standby controller in the unified period with the main controller is basically consistent, the input information is read first, then the non-redundant program which does not need to be synchronized is processed first, then the information acquired from the main controller is analyzed, however, the standby controller does not perform processing operation after analyzing the acquired data, only copies the information to the main controller, and finally completes the output to enter the next cycle period.
And the main controller and the standby controller are communicated through an optical cable, so that data transmission is completed. Variables and non-positioning variables in the state RAM of the main controller need to be transmitted to the standby controller in real time, so that the input and output states of the main controller and the standby controller are consistent. The data of the remaining non-transfer areas, such as module configuration related data, need not be transferred to the standby controller. The network scan (communication between the main controller and the standby controller) exchanges data between 2 controllers and runs in parallel with the application. And after entering the input driving program, the main controller completes the overhead of the redundant hot standby system, and the overhead time of the redundant hot standby system is determined by the size of the database. And then the main controller enters an application program execution stage, and synchronously performs data transmission with the standby controller at the moment, and finally completes the output driver. The standby controller performs the same relevant operations, except that the standby controller performs only the first segment, i.e. the input sampling phase, when the application is executing. As shown in FIG. 2, the scanning time T is greater than the redundant hot standby overhead time T1+the application execution time T2, and the scanning time is greater than the data exchange time, so that the whole redundant hot standby system can stably operate.
The invention can ensure the long-term stable operation of the whole PLC system, can switch to the standby controller in time even when the main controller fails, and can keep the input and output states of the whole PLC system unchanged, and the PLC system can not stop operating due to the failure of the main controller. The method can be applied to a nuclear power plant safety digital instrument control system or other industrial control industries to realize long-term stable operation of the control system. When a PLC control system is arranged in a nuclear power plant or a factory, redundant hot standby configuration is considered firstly, two sets of controllers (a main controller and a standby controller) are used, when a hot standby CPU is empty, a program is automatically downloaded into the hot standby PLC at the first time, no configuration is carried out in the hot standby CPU, no additional programming tool is needed, and no manual operation is needed.
The redundant system can structurally adopt 2 complete PLC control systems, and can divide a rack into 2 areas and install 2 sets of modules (including CPU, I/O and the like). The 2 CPUs are connected by a cable, and the switching between the working system and the standby system is realized through a switching instruction of the PLC.
The foregoing is merely a preferred embodiment of the invention, and it is to be understood that the invention is not limited to the form disclosed herein but is not to be construed as excluding other embodiments, but is capable of numerous other combinations, modifications and environments and is capable of modifications within the scope of the inventive concept, either as taught or as a matter of routine skill or knowledge in the relevant art. And that modifications and variations which do not depart from the spirit and scope of the invention are intended to be within the scope of the appended claims.
Claims (8)
1. A hot standby redundant control system of a PLC system in the industrial control field is characterized by comprising a main controller and a standby controller; the main controller and the standby controller are communicated through an optical cable.
2. The industrial control field PLC system hot standby redundancy control system of claim 1, wherein the master controller comprises: the system comprises a main program input module, a main redundancy hot standby system overhead module, a main program execution module, a main data storage and exchange module and a main program output module; the program enters the main controller through the main program input module, is processed by the main redundancy heat standby system overhead module, is executed by the main program executing module and is output by the main program output module, and the data after the program execution is stored in the main data storage and exchange module.
3. The industrial control field PLC system hot standby redundant control system of claim 1, wherein said standby controller comprises: the system comprises a standby program input module, a standby redundancy heat standby system overhead module, a standby program execution module, a standby data storage and exchange module and a standby program output module; the program enters the standby controller through the standby program input module, is processed by the standby redundancy heat standby system overhead module, is output by the standby program output module after the standby program execution module executes the first section of the input program, and the data after the program execution is stored in the standby data storage and exchange module.
4. A hot standby redundancy control method for an industrial control field PLC system, based on the industrial control field PLC system hot standby redundancy control system as claimed in any one of claims 1-3, comprising the following steps: s1, reading input information; s2, processing non-redundant parts which do not need to be synchronized in the input information; s3, executing a redundant part; s4, outputting information.
5. The method for controlling redundancy of a PLC system in an industrial control field according to claim 4, wherein the main controller further comprises a data transmission step with the standby controller: the standby state information acquired from the standby controller is analyzed, and the redundant backup data is copied to the CPU of the standby controller after the redundant portion is executed.
6. The method for controlling redundancy of a PLC system in an industrial control field according to claim 4, wherein the backup controller further comprises a data transmission step with the main controller: the main status information acquired from the main controller is analyzed, and the standby system information is copied to the CPU of the main controller after the redundant part is executed.
7. The method for hot standby redundancy control of an industrial personal area PLC system according to claim 6, wherein the program in the standby controller is executed by executing only the first section of the program input by the user.
8. The method for controlling redundancy of a PLC system in an industrial control field according to claim 4, wherein a MAST is present to scan the whole program, and the scan time T spent for the scan is: scan time T > redundant hot standby overhead time t1+program execution time T2.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310888128.5A CN116719270A (en) | 2023-07-19 | 2023-07-19 | Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310888128.5A CN116719270A (en) | 2023-07-19 | 2023-07-19 | Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field |
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| CN116719270A true CN116719270A (en) | 2023-09-08 |
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| CN202310888128.5A Pending CN116719270A (en) | 2023-07-19 | 2023-07-19 | Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field |
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- 2023-07-19 CN CN202310888128.5A patent/CN116719270A/en active Pending
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