CN116954176A - Industrial production flow dynamic control method and system - Google Patents
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- 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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Abstract
The invention discloses a dynamic control method and a dynamic control system for an industrial production process, which relate to the technical field of dynamic control of the industrial production process and comprise an information acquisition module, a server, a comparison module, a comprehensive analysis module and an early warning module; and the information acquisition module acquires performance information and communication information when a central processing unit in the PLC for controlling the catalytic cracking process runs. According to the invention, the running state of the central processor in the PLC for controlling the catalytic cracking process is monitored, when the running state of the central processor has abnormal hidden danger, related staff is prompted to check that the central processor may have abnormality, and the possible problem of the central processor is found in time, so that the central processor is maintained in advance, the central processor is ensured to accurately control the catalytic cracking process, the quality of products is further ensured, and the catalytic cracking in the oil refining process is accurately and efficiently controlled.
Description
Technical Field
The invention relates to the technical field of dynamic control of industrial production processes, in particular to a dynamic control method and a dynamic control system of an industrial production process.
Background
Refining refers to the process of breaking down, converting and refining raw petroleum (also known as crude oil) into different kinds of petroleum products through a series of physical and chemical processes. Crude oil is a natural resource formed deep in the subsurface and contains a variety of hydrocarbons ranging from light liquid hydrocarbons to heavy waxy materials.
Oil refining processes typically use PLCs (programmable logic controllers) to enable automation control and monitoring, such as crude oil processing, desulfurization and denitrification, catalytic cracking, etc., which converts heavy crude oil into lighter products, such as gasoline, and the PLCs can control the temperature, pressure, and catalyst supply of the catalytic cracking reactor to control the rate of reaction and product quality.
A PLC, i.e., a programmable logic controller, is an electronic device specifically designed for industrial automation control, designed to monitor, control, and automate various tasks and operations in an industrial process. The PLC is mainly used for replacing the traditional relay control system, provides a more flexible, efficient and programmable control mode, takes a Central Processing Unit (CPU) as a brain of the PLC and is responsible for executing preset control logic, and the CPU receives input signals and generates output signals after logic operation so as to control the action of an actuator.
The prior art has the following defects: however, when the central processing unit in the PLC controlling the catalytic cracking process has abnormal operation, the related staff cannot find out in time, and the abnormal operation may cause the central processing unit to precisely control the catalytic cracking process (the catalytic cracking process needs precise temperature, pressure, flow and other parameters to be controlled, and the abnormal operation may cause the parameters to be unable to be precisely adjusted), thereby affecting the quality of the product, and when the quality of the product has obvious abnormality, the related staff can find out the problem of the abnormal operation possibly existing in the central processing unit, and find out that the problem has serious hysteresis, so that the PLC is inconvenient to precisely and efficiently control the catalytic cracking in the oil refining process.
The above information disclosed in the background section is only for enhancement of understanding of the background of the disclosure and therefore it may include information that does not form the prior art that is already known to a person of ordinary skill in the art.
Disclosure of Invention
The invention aims to provide a dynamic control method and a system for an industrial production process, which monitor the running state of a central processing unit in a PLC (programmable logic controller) for controlling a catalytic cracking process, and prompt related staff to check possible abnormality of the central processing unit when the running state of the central processing unit has potential abnormality hazards, so as to timely find possible problems of the central processing unit, thereby maintaining the central processing unit in advance, ensuring the central processing unit to accurately control the catalytic cracking process, further ensuring the quality of products, and realizing accurate and efficient control of catalytic cracking in the oil refining process, so as to solve the problems in the background art.
In order to achieve the above object, the present invention provides the following technical solutions: the industrial production flow dynamic control system comprises an information acquisition module, a server, a comparison module, a comprehensive analysis module and an early warning module;
the information acquisition module acquires performance information and communication information of the central processing unit in the PLC for controlling the catalytic cracking process during operation, and transmits the performance information and the communication information of the central processing unit during operation to the server after the acquisition;
the server comprehensively analyzes the processed performance information and communication information in the running process of the central processing unit for controlling the catalytic cracking process to generate an influence index, and transmits the influence index to the comparison module;
the comparison module is used for comparing and analyzing an influence index generated when a central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold value to generate a high influence signal and a low influence signal, and transmitting the signals to the comprehensive analysis module;
and the comprehensive analysis module is used for establishing a data set for comprehensive analysis of an influence index corresponding to the generated high influence signal and an influence index generated during the operation of a subsequent central processing unit after receiving the high influence signal generated during the operation of the central processing unit for controlling the catalytic cracking process, generating an influence degree signal, transmitting the signal to the early warning module, and sending different early warning prompts or not sending the early warning prompts through the early warning module.
Preferably, the performance information of the CPU during operation includes frequency oscillation stability coefficient and clock frequency abnormal floating coefficient, and after acquisition, the information acquisition module sums the frequency oscillation stability coefficient generated by the CPU during operationThe abnormal floating coefficient of the clock frequency is respectively calibrated to be PL δ and SZδ The communication information generated by the CPU during operation comprises abnormal hiding coefficients of communication data transmission rate, and after acquisition, the information acquisition module marks the abnormal hiding coefficients of the communication data transmission rate generated by the CPU during operation as TSJ δ 。
Preferably, the logic for obtaining the stability factor of the frequency oscillation is as follows:
a101, acquiring actual working frequencies of different moments in T time in the running process of the central processing unit, and calibrating the actual working frequencies to be Pl v V represents the number of the actual working frequency at different moments in the T time in the running process of the central processing unit, v=1, 2, 3, 4, … … and n, wherein n is a positive integer;
a102, calculating standard deviations of actual working frequencies at different moments in T time in the running process of the central processing unit, and calibrating the standard deviations of the actual working frequencies as R, wherein the standard deviations are as follows:
； wherein ,the calculation formula is obtained for the average value of the actual working frequency of the CPU at different moments in the T time in the running process of the CPU: / >
A103, calculating a frequency oscillation stability coefficient, wherein the calculated expression is as follows:
preferably, the logic for clock frequency anomaly floating coefficient acquisition is as follows:
b101, obtaining the clock frequency reference value of the CPU controlling the catalytic cracking process and calibrating the clock frequency reference value as SZ Ginseng radix ；
B102, obtaining the actual clock frequency generated in the running process of the CPU in the unit time of T time, and calibrating the actual clock frequency as SZ x X represents the number of the actual clock frequency generated in the running process of the central processing unit in the unit time of T time, and x=1, 2, 3, 4, … … and m are positive integers;
and B103, calculating a clock frequency abnormal floating coefficient generated at the time T in the running process of the central processing unit, wherein the calculated expression is as follows:
preferably, the logic for obtaining the abnormal concealing coefficient of the communication data transmission rate is as follows:
c101, obtaining the optimal communication data transmission rate reference range when the CPU controlling the catalytic cracking process runs, and calibrating the optimal communication data transmission rate reference range as V TX min ～V TX max ；
C102, acquiring actual average communication data transmission rates of different time periods in T time in the running process of the central processing unit, and calibrating the actual average communication data transmission rates as V TX y Y represents the number of the actual average communication data transmission rate in different time periods of T time in the running process of the central processing unit, y=1, 2, 3, 4, … … and p are positive integers;
c103, comparing the obtained actual average communication data transmission rate with the reference range of the optimal communication data transmission rate, defining the actual average communication data transmission rate which is not in the reference range of the optimal communication data transmission rate as an abnormal communication data transmission rate, and recalibrating the abnormal communication data transmission rate as V TX w W represents the number of abnormal communication data transmission rates, w=1, 2, 3, 4, … …, q being a positive integer;
and C104, calculating abnormal hiding coefficients of the communication data transmission rate, wherein the calculated expression is as follows: in the formula ,/>
Preferably, the server obtains a frequency oscillation stability factor PL δ Abnormal clock frequency floating coefficient SZ δ Communication data transmission rate abnormality concealment coefficient TSJ δ Then, a data analysis model is established to generate an influence index mu, and the following formula is adopted:
wherein k1, k2, k3 are the frequency oscillation stability coefficients PL, respectively δ Abnormal clock frequency floating coefficient SZ δ Communication data transmission rate abnormality concealment coefficient TSJ δ And k1, k2, k3 are all greater than 0.
Preferably, the comparison module compares the impact index generated when the central processing unit controlling the catalytic cracking process runs with a preset impact index reference threshold, if the impact index is greater than or equal to the impact index reference threshold, a high impact signal is generated through the comparison module and is transmitted to the comprehensive analysis module, and if the impact index is less than the impact index reference threshold, a low impact signal is generated through the comparison module and is transmitted to the comprehensive analysis module.
Preferably, after the comprehensive analysis module receives a high influence signal generated during the operation of a central processing unit controlling the catalytic cracking process, a data set is established between an influence index corresponding to the generated high influence signal and an influence index generated during the operation of a subsequent central processing unit, and the data set is calibrated as P, so that P= { mu ] is obtained u ) U represents the number of the impact index within the data set, u=1, 2, 3, 4, … …, s being a positive integer;
aggregating dataComparing the influence index in the range with the influence index reference threshold, and recalibrating the influence index larger than or equal to the influence index reference threshold to mu j J represents the number of the impact index greater than or equal to the impact index reference threshold in the data set, j=1, 2, 3, 4, … …, i being a positive integer;
calibrating the impact index reference threshold to mu Ginseng radix By influencing the index mu j And an impact index reference threshold μ Ginseng radix Calculating an influence degree index, and calibrating the influence degree index as mu Index number The calculation formula is as follows: where s represents the total number of impact indices within the data set.
Preferably, the degree of influence index generated in the data set is compared with a degree of influence index gradient threshold YZ 1 and YZ2 Performing comparison, wherein YZ 1 ＜YZ 2 The following is generated:
if mu is Index number ＞YZ 2 Generating a high-influence degree signal through the comprehensive analysis module, transmitting the signal to the early warning module, and sending out a high-risk early warning prompt through the early warning module;
if YZ 1 ＜μ Index number ≤YZ 2 Generating a signal with medium influence degree through the comprehensive analysis module, transmitting the signal to the early warning module, and sending out a medium risk early warning prompt through the early warning module;
if mu is Index number ≤YZ 1 And generating a low-level influence degree signal through the comprehensive analysis module, transmitting the signal to the early warning module, and sending out an early warning prompt without the early warning module.
A dynamic control method for industrial production flow comprises the following steps:
Collecting performance information and communication information of a central processing unit in a PLC for controlling the catalytic cracking process during operation, and processing the performance information and the communication information of the central processing unit during operation after the performance information and the communication information are collected;
comprehensively analyzing the processed performance information and communication information of a central processing unit controlling the catalytic cracking process during operation to generate an influence index;
comparing and analyzing an influence index generated when a central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold value to generate a high influence signal and a low influence signal;
after receiving a high influence signal generated when a central processing unit controlling a catalytic cracking process runs, establishing a data set for comprehensively analyzing an influence index corresponding to the generated high influence signal and an influence index generated when a subsequent central processing unit runs, generating an influence degree signal, and sending different early warning prompts or not sending early warning prompts to the influence degree signal through an early warning module.
In the technical scheme, the invention has the technical effects and advantages that:
according to the invention, through monitoring the running state of the central processor in the PLC for controlling the catalytic cracking process, when the running state of the central processor has abnormal hidden danger, related staff is prompted to check that the central processor is likely to be abnormal, and the possible problem of the central processor is found in time, so that the central processor is maintained in advance, the central processor is ensured to accurately control the catalytic cracking process, the quality of products is further ensured, and the catalytic cracking in the oil refining process is accurately and efficiently controlled;
When detecting that the running state of the central processing unit has abnormal hidden trouble, the application further analyzes the degree of the abnormal hidden trouble of the central processing unit, thereby facilitating maintenance personnel to infer possible problems of the central processing unit according to the condition of the degree of the abnormal hidden trouble of the central processing unit, and improving the maintenance efficiency of the central processing unit;
when the application detects that the central processing unit has slight abnormal hidden trouble, the application does not send out early warning prompt, eliminates the sudden slight abnormal hidden trouble when the central processing unit operates, and in this way, the trust degree of related staff on early warning can be improved, the central processing unit can be ensured to operate stably and efficiently, and the catalytic cracking process can be ensured to operate stably and efficiently.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments described in the present application, and other drawings may be obtained according to these drawings for those skilled in the art.
FIG. 1 is a schematic diagram of a dynamic control method and system for industrial production process according to the present application.
FIG. 2 is a flow chart of a dynamic control method and system for industrial production process according to the present invention.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. However, the exemplary embodiments may be embodied in many forms and should not be construed as limited to the examples set forth herein; rather, these example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the example embodiments to those skilled in the art.
The invention provides an industrial production flow dynamic control system as shown in figure 1, which comprises an information acquisition module, a server, a comparison module, a comprehensive analysis module and an early warning module;
the information acquisition module acquires performance information and communication information of the central processing unit in the PLC for controlling the catalytic cracking process during operation, and transmits the performance information and the communication information of the central processing unit during operation to the server after the acquisition;
the performance information of the CPU during operation includes frequency oscillation stability coefficient and clock frequency abnormal floating coefficient, and after acquisition, the information acquisition module respectively marks the frequency oscillation stability coefficient and clock frequency abnormal floating coefficient generated by the CPU during operation as PL δ and SZδ ；
Frequency oscillation refers to fluctuation of the working frequency of the central processing unit, and may cause unstable execution speed and time of the control system, thereby affecting accuracy and stability of the control strategy, and the following reasons why frequency oscillation affects control:
the instruction execution speed is unstable: the frequency oscillation can cause the working frequency of the central processing unit to fluctuate in a short time, which affects the execution speed of the instruction, and the unstable instruction execution speed can cause the actual execution time of the control program to be inconsistent with the expected time, thereby affecting the execution of the control strategy;
control period is inaccurate: the control system typically performs operations within a fixed control period to ensure stable control, and frequency oscillations may cause the control period to vary such that the control operations cannot be performed at desired intervals;
the timing operation is unstable: many control strategies involve timing operations, such as periodically reading sensor data, adjusting actuators, etc., which may be unstable by frequency oscillations, affecting the intended behavior of the control program;
data synchronization problem: the different components in the control system may need to operate synchronously at a specific point in time to ensure cooperative work, and frequency oscillation may cause data synchronization problems of the different components, affecting the overall performance of the control system;
Response time variation: the control system needs to respond to external changes within a specific time, and frequency oscillation can cause the response time of the control system to change, thereby affecting the processing capacity of the control system for the catalytic cracking process change;
therefore, the working frequency of the central processing unit controlling the catalytic cracking process is monitored, and the problem of potential abnormality caused by the fluctuation of the working frequency of the central processing unit in the running process can be found in time;
the logic for obtaining the frequency oscillation stability coefficient is as follows:
a101, acquiring actual working frequencies of different moments in T time in the running process of the central processing unit, and calibrating the actual working frequencies to be Pl v V represents the running process of the CPUThe numbers of the actual working frequencies at different moments in the T time, v=1, 2, 3, 4, … … and n, wherein n is a positive integer;
it should be noted that some third party monitoring tools may be integrated with a specific PLC system to provide a wider performance monitoring function, where the tools may display information such as actual operating frequency, for example, the Wonderware HMI/SCADA software may provide real-time data monitoring and reporting functions, and may be used to monitor the actual operating frequency of the central processor;
A102, calculating standard deviations of actual working frequencies at different moments in T time in the running process of the central processing unit, and calibrating the standard deviations of the actual working frequencies as R, wherein the standard deviations are as follows:
； wherein ,the calculation formula is obtained for the average value of the actual working frequency of the CPU at different moments in the T time in the running process of the CPU: />
The larger the representation value of the standard deviation R of the actual working frequency generated in the T time in the running process of the central processing unit is, the larger the oscillation of the actual working frequency in the T time in the running process of the central processing unit is, otherwise, the smaller the oscillation of the actual working frequency in the T time in the running process of the central processing unit is;
a103, calculating a frequency oscillation stability coefficient, wherein the calculated expression is as follows:
the calculation expression of the frequency oscillation stability coefficient shows that the larger the expression value of the frequency oscillation stability coefficient generated when the central processing unit for controlling the catalytic cracking process runs in the T time is, the lower the accuracy of the central processing unit for controlling the catalytic cracking process is, and the higher the accuracy of the central processing unit for controlling the catalytic cracking process is;
clock frequency refers to the clock speed of the central processing unit, that is, the number of clock cycles executed per second, which is the basis for the central processing unit to execute instructions, affects the execution speed and time interval of the instructions, is critical to the accuracy of the control process, and is why clock frequency anomalies affect the control:
Instruction execution speed: the clock frequency of the central processing unit determines the number of clock cycles executed in each second, namely the instruction execution speed, if the clock frequency is abnormal, the instruction execution speed may be accelerated or slowed down, so that the execution speed of a control algorithm also changes, and the instantaneity and the accuracy of a control strategy are affected;
timing operation inaccuracy: many control strategies involve timing operations, such as periodically reading sensor data, adjusting actuators, etc., which may be inaccurate due to clock frequency anomalies, affecting the intended behavior of the control program;
data synchronization problem: different components in the control system may need to operate synchronously at a specific time point to ensure cooperative work, and if the clock frequency is abnormal, the data synchronization problem of the different components may be caused, so that the overall performance of the control system is affected;
control stability: the control system needs to execute operations according to a specific sampling period to ensure stable control, and if the clock frequency is abnormal, the sampling period may change, so that the stability of the control system is affected;
response time variation: the control system needs to respond to external changes within a specific time, and abnormal clock frequency can cause the response time of the control system to change, thereby affecting the processing capacity of the control system for the catalytic cracking process change;
Therefore, the clock frequency of the central processing unit controlling the catalytic cracking process is monitored, and the problem that the clock frequency has abnormal hidden trouble in the running process of the central processing unit can be found in time;
the logic for obtaining the abnormal floating coefficient of the clock frequency is as follows:
b101, obtaining the clock frequency reference value of the CPU controlling the catalytic cracking process and calibrating the clock frequency reference value as SZ Ginseng radix ；
It should be noted that, the clock frequency reference value during the running of the central processing unit is a specifically defined maximum allowable clock frequency required by the control system, so as to ensure the real-time performance and stability of the control system, when determining the clock frequency, the control system needs to be tested and evaluated, so that the stability and accuracy of the control system can be ensured while the selected frequency meets the requirement, therefore, the setting of the clock frequency reference value is not particularly limited, and can be adjusted according to the actual test and evaluation results of the control system in different scenes;
b102, obtaining the actual clock frequency generated in the running process of the CPU in the unit time of T time, and calibrating the actual clock frequency as SZ x X represents the number of the actual clock frequency generated in the running process of the central processing unit in the unit time of T time, and x=1, 2, 3, 4, … … and m are positive integers;
It should be noted that, the PLC system provides special programming and monitoring software, which generally includes a real-time monitoring function, and may display performance parameters of the central processing unit, such as clock frequency, for example, siemens STEP 7, rockwell Studio 5000, etc.;
and B103, calculating a clock frequency abnormal floating coefficient generated at the time T in the running process of the central processing unit, wherein the calculated expression is as follows:
the calculation expression of the clock frequency abnormal floating coefficient shows that the larger the expression value of the clock frequency abnormal floating coefficient generated when the central processing unit controlling the catalytic cracking process runs in the T time is, the lower the accuracy of the central processing unit controlling the catalytic cracking process is, and the higher the accuracy of the central processing unit controlling the catalytic cracking process is otherwise;
the communication information generated by the CPU during operation comprises abnormal hiding coefficients of communication data transmission rate, and after acquisition, the information acquisition module marks the abnormal hiding coefficients of the communication data transmission rate generated by the CPU during operation as TSJ δ ；
The abnormal slow or fast transmission rate of the central processing unit in the PLC controlling the catalytic cracking process during the communication data transmission may cause that the central processing unit cannot accurately control the catalytic cracking process, and the real-time performance, stability and accuracy of the control system may be affected by the rate problem of the communication data transmission, so that the accurate control of the catalytic cracking process is affected, which may happen due to the following situations:
Data synchronization problem: the different components in the control system generally need to exchange and synchronize data at specific time points to ensure cooperative work, and if the communication data transmission speed is slow or fast, the data synchronization problem can be caused, so that the overall performance of the control system is affected;
real-time performance of a control algorithm: the control system may make decisions based on the real-time sensor data and execute a control algorithm that may obtain delayed real-time data if the data transmission rate is slow, thereby affecting the real-time response to changes in the catalytic cracking process;
control period is unstable: the control system generally performs operations according to a fixed control period to ensure stable control, and if the data transmission rate becomes slow or fast, the control period may be changed, so that the control operation cannot be performed at an expected time interval;
data processing delay: abnormal changes in data transmission rate may cause delays in data processing, which may affect the real-time and accuracy of the control system, thereby affecting control of the catalytic cracking process;
control command transfer delay: the delay in the transmission of control commands may cause delays in the operation of the actuator, thereby affecting the real-time adjustment of the catalytic cracking process;
Therefore, the communication data transmission rate of the central processing unit controlling the catalytic cracking process is monitored, and the problem of potential anomaly caused by the communication data transmission rate of the central processing unit in the running process can be found in time;
the logic for acquiring the abnormal hiding coefficient of the communication data transmission rate is as follows:
c101, obtaining the optimal communication data transmission rate reference range when the CPU controlling the catalytic cracking process runs, and calibrating the optimal communication data transmission rate reference range as V TX min ～V TX max ；
It should be noted that, performing a benchmark test to evaluate the system performance under different communication rates, by gradually increasing or decreasing the communication rate, observing the response time, the control accuracy and the stability of the system, in the test process, a communication rate range can be found to optimize the system performance, and the reference range of the optimal communication data transmission rate during the operation of the central processing unit for controlling the catalytic cracking process is not particularly limited herein, and can be adjusted according to the equipment specification, the system requirement, the reliability requirement and the like;
c102, acquiring actual average communication data transmission rate of different time periods (the time in the time period can be equal or unequal or in a crossed form, not specifically limited herein) of T time in the running process of the CPU, and calibrating the actual average communication data transmission rate as V TX y Y represents the number of the actual average communication data transmission rate in different time periods of T time in the running process of the central processing unit, y=1, 2, 3, 4, … … and p are positive integers;
it should be noted that some system monitoring software can monitor and report system performance parameters, including communication data transmission rate, and these software can provide visualization of real-time and historical data, for example Nagios is an open-source network monitoring tool, which can be used to monitor network equipment and system performance, and support configuration and monitor parameters such as actual average communication data transmission rate;
c103, actual to be acquiredComparing the average communication data transmission rate with the reference range of the optimal communication data transmission rate, defining the actual average communication data transmission rate which is not in the reference range of the optimal communication data transmission rate as an abnormal communication data transmission rate, and recalibrating the abnormal communication data transmission rate as V TX w W represents the number of abnormal communication data transmission rates, w=1, 2, 3, 4, … …, q being a positive integer;
and C104, calculating abnormal hiding coefficients of the communication data transmission rate, wherein the calculated expression is as follows: in the formula ,/>
The calculation expression of the abnormal hidden coefficient of the communication data transmission rate shows that the larger the expression value of the abnormal hidden coefficient of the communication data transmission rate generated when the central processing unit for controlling the catalytic cracking process runs in the T time is, the lower the accuracy of the central processing unit for controlling the catalytic cracking process is, and otherwise, the higher the accuracy of the central processing unit for controlling the catalytic cracking process is;
The server comprehensively analyzes the processed performance information and communication information in the running process of the central processing unit for controlling the catalytic cracking process to generate an influence index, and transmits the influence index to the comparison module;
the server obtains the frequency oscillation stability coefficient PL δ Abnormal clock frequency floating coefficient SZ δ Communication data transmission rate abnormality concealment coefficient TSJ δ Then, a data analysis model is established to generate an influence index mu, and the following formula is adopted:
wherein k1, k2, k3 are the frequency oscillation stability coefficients PL, respectively δ Abnormal clock frequency floating coefficient SZ δ Communication data transmission rate abnormality concealment coefficient TSJ δ K1, k2, k3 are all greater than 0;
as can be seen from the calculation formula, the larger the frequency oscillation stability coefficient generated when the central processing unit controlling the catalytic cracking process operates in the T time, the larger the clock frequency abnormal floating coefficient and the larger the communication data transmission rate abnormal hiding coefficient are, namely the larger the expression value of the influence index mu generated when the central processing unit controlling the catalytic cracking process operates in the T time is, the lower the accuracy of the central processing unit controlling the catalytic cracking process is indicated, the smaller the frequency oscillation stability coefficient generated when the central processing unit controlling the catalytic cracking process operates in the T time is, the smaller the clock frequency abnormal floating coefficient and the smaller the communication data transmission rate abnormal hiding coefficient are, namely the smaller the expression value of the influence index mu generated when the central processing unit controlling the catalytic cracking process operates in the T time is indicated, and the higher the accuracy of the central processing unit controlling the catalytic cracking process is indicated;
The comparison module is used for comparing and analyzing an influence index generated when a central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold value to generate a high influence signal and a low influence signal, and transmitting the signals to the comprehensive analysis module;
the comparison module compares and analyzes the influence index generated when the central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold, if the influence index is greater than or equal to the influence index reference threshold, a high influence signal is generated through the comparison module, the signal is transmitted to the comprehensive analysis module, and if the influence index is smaller than the influence index reference threshold, a low influence signal is generated through the comparison module, and the signal is transmitted to the comprehensive analysis module;
the comprehensive analysis module is used for establishing a data set for comprehensive analysis of an influence index corresponding to the generated high influence signal and an influence index generated by the subsequent central processing unit during operation after receiving the high influence signal generated by the central processing unit during operation of the catalytic cracking process, generating an influence degree signal, transmitting the signal to the early warning module, and sending different early warning prompts or not sending the early warning prompts through the early warning module;
After the comprehensive analysis module receives a high influence signal generated during the running of a central processing unit for controlling the catalytic cracking process, a data set is established between an influence index corresponding to the generated high influence signal and an influence index generated during the running of a subsequent central processing unit, and the data set is calibrated as P, so that P= { mu ] is obtained u U represents the number of the impact index within the data set, u=1, 2, 3, 4, … …, s being a positive integer;
comparing the impact index in the data set with an impact index reference threshold, and recalibrating the impact index greater than or equal to the impact index reference threshold to mu j J represents the number of the impact index greater than or equal to the impact index reference threshold in the data set, j=1, 2, 3, 4, … …, i being a positive integer;
calibrating the impact index reference threshold to mu Ginseng radix By influencing the index mu j And an impact index reference threshold μ Ginseng radix Calculating an influence degree index, and calibrating the influence degree index as mu Index number The calculation formula is as follows: where s represents the total number of impact indices within the data set;
the calculation formula shows that the larger the expression value of the influence degree index generated in the data set is, the more seriously the control accuracy of the central processing unit on the catalytic cracking process is influenced, otherwise, the less seriously the control accuracy of the central processing unit on the catalytic cracking process is influenced;
Gradient threshold YZ of the impact degree index generated in the data set 1 and YZ2 Performing comparison, wherein YZ 1 ＜YZ 2 The following is generated:
if mu is Index number ＞YZ 2 The comprehensive analysis module generates a high-influence degree signal and transmits the signal to the early warning module, the early warning module sends out a high-risk early warning prompt, and when the early warning module sends out the high-risk early warning prompt, the central processing unit is proved to seriously influence the control accuracy of the catalytic cracking process;
if YZ 1 ＜μ Index number ≤YZ 2 The comprehensive analysis module is used for generating a signal with medium influence degree, transmitting the signal to the early warning module, and sending a medium risk early warning prompt through the early warning module, wherein when the early warning module sends the medium risk early warning prompt, the central processing unit is shown that the control accuracy of the catalytic cracking process is seriously influenced, but the severity is lower than that of the high risk early warning prompt;
if mu is Index number ≤YZ 1 The comprehensive analysis module is used for generating a low-level influence degree signal and transmitting the signal to the early warning module, the early warning module is not used for sending out early warning prompts, and when the early warning module is used for sending out low-risk early warning prompts, the central processing unit is indicated that the control accuracy of the catalytic cracking process is not seriously influenced, and the influence is slight;
According to the invention, through monitoring the running state of the central processor in the PLC for controlling the catalytic cracking process, when the running state of the central processor has abnormal hidden danger, related staff is prompted to check that the central processor is likely to be abnormal, and the possible problem of the central processor is found in time, so that the central processor is maintained in advance, the central processor is ensured to accurately control the catalytic cracking process, the quality of products is further ensured, and the catalytic cracking in the oil refining process is accurately and efficiently controlled;
when detecting that the running state of the central processing unit has abnormal hidden trouble, the invention further analyzes the degree of the abnormal hidden trouble of the central processing unit, thereby facilitating maintenance personnel to infer possible problems of the central processing unit according to the condition of the degree of the abnormal hidden trouble of the central processing unit, and improving the maintenance efficiency of the central processing unit;
when the invention detects that the central processing unit has slight abnormal hidden trouble, the invention does not send out early warning prompt, eliminates the sudden slight abnormal hidden trouble when the central processing unit operates, and in this way, the trust degree of related staff on early warning can be improved, the central processing unit can be ensured to operate stably and efficiently, and the catalytic cracking process can be ensured to operate stably and efficiently.
The invention provides a dynamic control method of an industrial production process as shown in fig. 2, which comprises the following steps:
collecting performance information and communication information of a central processing unit in a PLC for controlling the catalytic cracking process during operation, and processing the performance information and the communication information of the central processing unit during operation after the performance information and the communication information are collected;
comprehensively analyzing the processed performance information and communication information of a central processing unit controlling the catalytic cracking process during operation to generate an influence index;
comparing and analyzing an influence index generated when a central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold value to generate a high influence signal and a low influence signal;
after receiving a high influence signal generated when a central processing unit controlling a catalytic cracking process runs, establishing a data set for comprehensively analyzing an influence index corresponding to the generated high influence signal and an influence index generated when a subsequent central processing unit runs, generating an influence degree signal, and sending different early warning prompts or no early warning prompt to the influence degree signal through an early warning module;
the embodiment of the invention provides an industrial production process dynamic control method, which is realized by the industrial production process dynamic control system, and the specific method and process of the industrial production process dynamic control method are detailed in the embodiment of the industrial production process dynamic control system, and are not repeated here.
The above formulas are all formulas with dimensions removed and numerical values calculated, the formulas are formulas with a large amount of data collected for software simulation to obtain the latest real situation, and preset parameters in the formulas are set by those skilled in the art according to the actual situation.
The above embodiments may be implemented in whole or in part by software, hardware, firmware, or any other combination. When implemented in software, the above-described embodiments may be implemented in whole or in part in the form of a computer program product. The computer program product comprises one or more computer instructions or computer programs. When the computer instructions or computer program are loaded or executed on a computer, the processes or functions described in accordance with embodiments of the present application are produced in whole or in part. The computer may be a general purpose computer, a special purpose computer, a computer network, or other programmable apparatus. The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another computer-readable storage medium, for example, the computer instructions may be transmitted from one website site, computer, server, or data center to another website site, computer, server, or data center by wired or wireless means (e.g., infrared, wireless, microwave, etc.). The computer readable storage medium may be any available medium that can be accessed by a computer or a data storage device such as a server, data center, etc. that contains one or more sets of available media. The usable medium may be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. The semiconductor medium may be a solid state disk.
It should be understood that, in various embodiments of the present application, the sequence numbers of the foregoing processes do not mean the order of execution, and the order of execution of the processes should be determined by the functions and internal logic thereof, and should not constitute any limitation on the implementation process of the embodiments of the present application.
Those of ordinary skill in the art will appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, or combinations of computer software and electronic hardware. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the solution. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present application.
In the several embodiments provided by the present application, it should be understood that the disclosed systems and methods may be implemented in other ways. For example, the embodiments described above are merely illustrative, e.g., the division of the elements is merely a logical functional division, and there may be additional divisions in actual implementation, e.g., multiple elements or components may be combined or integrated into another system, or some features may be omitted, or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be an indirect coupling or communication connection via some interfaces, devices or units, which may be in electrical, mechanical or other form.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in the embodiments of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit.
The functions, if implemented in the form of software functional units and sold or used as a stand-alone product, may be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application may be embodied essentially or in a part contributing to the prior art or in a part of the technical solution, in the form of a software product stored in a storage medium, comprising several instructions for causing a computer device (which may be a personal computer, a server, a network device, etc.) to perform all or part of the steps of the method according to the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a read-only memory (ROM), a random access memory (random access memory, RAM), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
The foregoing is merely illustrative of the present application, and the present application is not limited thereto, and any person skilled in the art will readily recognize that variations or substitutions are within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
While certain exemplary embodiments of the present application have been described above by way of illustration only, it will be apparent to those of ordinary skill in the art that modifications may be made to the described embodiments in various different ways without departing from the spirit and scope of the application. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive of the scope of the application, which is defined by the appended claims.
Claims (10)
1. The industrial production flow dynamic control system is characterized by comprising an information acquisition module, a server, a comparison module, a comprehensive analysis module and an early warning module;
the information acquisition module acquires performance information and communication information of the central processing unit in the PLC for controlling the catalytic cracking process during operation, and transmits the performance information and the communication information of the central processing unit during operation to the server after the acquisition;
The server comprehensively analyzes the processed performance information and communication information in the running process of the central processing unit for controlling the catalytic cracking process to generate an influence index, and transmits the influence index to the comparison module;
the comparison module is used for comparing and analyzing an influence index generated when a central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold value to generate a high influence signal and a low influence signal, and transmitting the signals to the comprehensive analysis module;
and the comprehensive analysis module is used for establishing a data set for comprehensive analysis of an influence index corresponding to the generated high influence signal and an influence index generated during the operation of a subsequent central processing unit after receiving the high influence signal generated during the operation of the central processing unit for controlling the catalytic cracking process, generating an influence degree signal, transmitting the signal to the early warning module, and sending different early warning prompts or not sending the early warning prompts through the early warning module.
2. The industrial process dynamic control system according to claim 1, wherein the performance information of the CPU during operation includes a frequency oscillation stability coefficient and a clock frequency abnormal floating coefficient, and the information acquisition module respectively calibrates the frequency oscillation stability coefficient and the clock frequency abnormal floating coefficient generated by the CPU during operation to PL after acquisition δ and SZδ The communication information generated by the CPU during operation comprises abnormal hiding coefficients of communication data transmission rate, and after acquisition, the information acquisition module marks the abnormal hiding coefficients of the communication data transmission rate generated by the CPU during operation as TSJ δ 。
3. The industrial process dynamic control system of claim 2, wherein the logic for obtaining the frequency oscillation stability factor is as follows:
a101, acquiring actual working frequencies of different moments in T time in the running process of the central processing unit, and calibrating the actual working frequencies to be Pl v V represents the number of the actual working frequency at different moments in the T time in the running process of the central processing unit, v=1, 2, 3, 4, … … and n, wherein n is a positive integer;
a102, calculating standard deviations of actual working frequencies at different moments in T time in the running process of the central processing unit, and calibrating the standard deviations of the actual working frequencies as R, wherein the standard deviations are as follows:
wherein ,the calculation formula is obtained for the average value of the actual working frequency of the CPU at different moments in the T time in the running process of the CPU: />
A103, calculating a frequency oscillation stability coefficient, wherein the calculated expression is as follows:
4. a dynamic control system for industrial process according to claim 3, wherein the logic for obtaining the abnormal floating coefficient of the clock frequency is as follows:
B101, obtaining the clock frequency reference value of the CPU controlling the catalytic cracking process and calibrating the clock frequency reference value as SZ Ginseng radix ；
B102, obtaining the actual clock frequency generated in the running process of the CPU in the unit time of T time, and calibrating the actual clock frequency as SZ x X represents the number of the actual clock frequency generated in the running process of the central processing unit in the unit time of T time, and x=1, 2, 3, 4, … … and m are positive integers;
and B103, calculating a clock frequency abnormal floating coefficient generated at the time T in the running process of the central processing unit, wherein the calculated expression is as follows:
5. the industrial process dynamic control system of claim 4, wherein the logic for obtaining the communication data transmission rate anomaly concealment coefficients comprises:
c101, obtaining the optimal communication data transmission rate reference range when the CPU controlling the catalytic cracking process is running, and communicating the optimal data transmission rate reference rangeThe reference range of the signal data transmission rate is marked as V TX min ～V TX max ；
C102, acquiring actual average communication data transmission rates of different time periods in T time in the running process of the central processing unit, and calibrating the actual average communication data transmission rates as V TX y Y represents the number of the actual average communication data transmission rate in different time periods of T time in the running process of the central processing unit, y=1, 2, 3, 4, … … and p are positive integers;
c103, comparing the obtained actual average communication data transmission rate with the reference range of the optimal communication data transmission rate, defining the actual average communication data transmission rate which is not in the reference range of the optimal communication data transmission rate as an abnormal communication data transmission rate, and recalibrating the abnormal communication data transmission rate as V TX w W represents the number of abnormal communication data transmission rates, w=1, 2, 3, 4, … …, q being a positive integer;
and C104, calculating abnormal hiding coefficients of the communication data transmission rate, wherein the calculated expression is as follows: in the formula ,/>
6. The industrial process dynamic control system according to claim 5, wherein the server obtains a frequency oscillation stability factor PL δ Abnormal clock frequency floating coefficient SZ δ Communication data transmission rate abnormality concealment coefficient TSJ δ Then, a data analysis model is established to generate an influence index mu, and the following formula is adopted:
wherein k1, k2, k3 are the frequency oscillation stability coefficients PL, respectively δ Abnormal clock frequency floating coefficient SZ δ Communication data transmission rate abnormality concealment coefficient TSJ δ And k1, k2, k3 are all greater than 0.
7. The industrial process dynamic control system of claim 6, wherein the comparison module compares the impact index generated by the cpu controlling the catalytic cracking process with a predetermined impact index reference threshold, generates a high impact signal by the comparison module if the impact index is greater than or equal to the impact index reference threshold, and transmits the signal to the integrated analysis module, and generates a low impact signal by the comparison module if the impact index is less than the impact index reference threshold, and transmits the signal to the integrated analysis module.
8. The industrial process dynamic control system according to claim 7, wherein after the comprehensive analysis module receives the high impact signal generated by the cpu during the operation of the cpu for controlling the catalytic cracking process, a data set is established between the impact index corresponding to the generated high impact signal and the impact index generated by the subsequent cpu during the operation, and the data set is calibrated to be P, so that p= { μ u U represents the number of the impact index within the data set, u=1, 2, 3, 4, … …, s being a positive integer;
Comparing the impact index in the data set with an impact index reference threshold, and recalibrating the impact index greater than or equal to the impact index reference threshold to mu j J represents the number of the impact index greater than or equal to the impact index reference threshold in the data set, j=1, 2, 3, 4, … …, i being a positive integer;
calibrating the impact index reference threshold to mu Ginseng radix By influencing the index mu j And an impact index reference threshold μ Ginseng radix Calculating the degree of influence meansNumber and index the degree of influence as mu Index number The calculation formula is as follows: where s represents the total number of impact indices within the data set.
9. The industrial process dynamic control system of claim 8, wherein the impact level index generated in the data set is compared with the impact level index gradient threshold YZ 1 and YZ2 Performing comparison, wherein YZ 1 ＜YZ 2 The following is generated:
if mu is Index number ＞YZ 2 Generating a high-influence degree signal through the comprehensive analysis module, transmitting the signal to the early warning module, and sending out a high-risk early warning prompt through the early warning module;
if YZ 1 ＜μ Index number ≤YZ 2 Generating a signal with medium influence degree through the comprehensive analysis module, transmitting the signal to the early warning module, and sending out a medium risk early warning prompt through the early warning module;
If mu is Index number ≤YZ 1 And generating a low-level influence degree signal through the comprehensive analysis module, transmitting the signal to the early warning module, and sending out an early warning prompt without the early warning module.
10. An industrial process dynamic control method, implemented by an industrial process dynamic control system according to any one of claims 1-9, comprising the steps of:
collecting performance information and communication information of a central processing unit in a PLC for controlling the catalytic cracking process during operation, and processing the performance information and the communication information of the central processing unit during operation after the performance information and the communication information are collected;
comprehensively analyzing the processed performance information and communication information of a central processing unit controlling the catalytic cracking process during operation to generate an influence index;
comparing and analyzing an influence index generated when a central processing unit controlling the catalytic cracking process runs with a preset influence index reference threshold value to generate a high influence signal and a low influence signal;
after receiving a high influence signal generated when a central processing unit controlling a catalytic cracking process runs, establishing a data set for comprehensively analyzing an influence index corresponding to the generated high influence signal and an influence index generated when a subsequent central processing unit runs, generating an influence degree signal, and sending different early warning prompts or not sending early warning prompts to the influence degree signal through an early warning module.
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