CN117032118A - Soft PLC system based on industrial Internet of things - Google Patents
Soft PLC system based on industrial Internet of things Download PDFInfo
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- CN117032118A CN117032118A CN202311029091.7A CN202311029091A CN117032118A CN 117032118 A CN117032118 A CN 117032118A CN 202311029091 A CN202311029091 A CN 202311029091A CN 117032118 A CN117032118 A CN 117032118A
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- 230000005540 biological transmission Effects 0.000 claims abstract description 5
- 238000012545 processing Methods 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 10
- 238000013480 data collection Methods 0.000 claims description 6
- 230000008569 process Effects 0.000 claims description 4
- 238000012544 monitoring process Methods 0.000 claims description 3
- 230000000007 visual effect Effects 0.000 claims description 3
- 230000006855 networking Effects 0.000 claims 1
- 230000006870 function Effects 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
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- 238000011160 research Methods 0.000 description 1
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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
- G05B19/418—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]
- G05B19/41845—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS], computer integrated manufacturing [CIM] characterised by system universality, reconfigurability, modularity
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31094—Data exchange between modules, cells, devices, processors
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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 soft PLC system based on the industrial Internet of things comprises a cloud platform server and a control station, wherein the cloud platform server is provided with a load balancing unit, an OPC UA data acquisition control instance unit, a message middleware unit, a dynamic cache unit, a soft PLC instance unit, a control scheduling application unit and a scheduling center unit; the control site comprises a cloud platform connection application, an OPC UA server, a sensor and an actuator, wherein the control site and the cloud platform server perform data transmission according to an OPC UA communication protocol, and one control site corresponds to one or more soft PLC instance units.
Description
Technical Field
The invention relates to a PLC control system, in particular to a soft PLC system based on industrial Internet of things.
Background
PLCs can be classified into hard PLCs and soft PLCs. The hard PLC is an instruction for realizing the PLC by hardware or a special ASIC chip in a strict sense; and the soft PLC uses a PC or an embedded controller as a hardware supporting platform, and the basic function of the hard PLC is realized by using software.
At present, in the fields of discrete manufacturing, flow industrial manufacturing and the like, an industrial control system generally adopts a hard PLC control system, a field bus control technology is utilized to connect a PLC controller and field equipment, an upper computer system is utilized to monitor and control the hard PLC control system, and acquired data information is transmitted to a management layer of an enterprise. The system thus constructed requires a long time for data exchange, and communication between each other is extremely inconvenient.
Secondly, because the number of PLC brands applied in the hard PLC control system is large, the hardware and the software used by each brand are very different and cannot be compatible, and great inconvenience is brought to staff; meanwhile, the capability of information exchange between the hard PLC automatic control systems is not strong, and some PLC brands have no autonomous upper computer software and can only be controlled by upper computers of other brands. Because of the difficulty in compatibility of PLCs of various brands, critical operational information cannot be fully integrated into the control master.
With the advent and development of soft PLC, how to apply soft PLC technology to fields of discrete manufacturing, flow industrial manufacturing, etc. to solve the problems existing in hard PLC has been the focus of research.
Disclosure of Invention
Aiming at the problems, the invention provides the soft PLC system based on the industrial Internet of things, which has the advantages of strong compatibility, good interaction capability, capability of integrating and summarizing all information, fast data transmission and convenient communication.
The invention is realized in the following way: the soft PLC system based on the industrial Internet of things comprises a cloud platform server and a control station, wherein the cloud platform server is provided with a load balancing unit, an OPC UA data acquisition control instance unit, a message middleware unit, a dynamic cache unit, a soft PLC instance unit, a control scheduling application unit and a scheduling center unit; the control site comprises cloud platform connection application, an OPC UA server, a sensor and an actuator, wherein the control site and the cloud platform server perform data transmission according to an OPC UA communication protocol, and one control site corresponds to one or more soft PLC instance units;
the load balancing unit receives data collected from all control stations and transmits the collected data to the OPC UA data collection instance unit;
the OPC UA data acquisition control instance unit is used for ensuring that data can be transmitted by using an OPC UA communication protocol, receiving all data from the load balancing unit and transmitting the data to the message middleware unit;
the message middleware unit can store all data from the OPC UA data acquisition control instance unit into a database, and simultaneously, the data required to be processed by the soft PLC instance unit is written into the dynamic cache unit;
the dynamic cache unit stores control processing commands from the soft PLC instance unit and data of the message middleware unit;
the soft PLC instance unit is used for executing a control program, reading data of the dynamic cache unit, outputting a control processing command, and transmitting the control processing command to the executor for execution through the OPC UA data acquisition control instance unit, the load balancing unit and the OPC UA server of the control site in sequence;
the control scheduling application unit is responsible for loading a control program into the soft PLC instance unit and designating an execution mode of the program;
the dispatching center unit is responsible for monitoring the running condition of each software unit of the system and summarizing and displaying the running information.
Preferably, the OPC UA server of the control station will tag the data collected by the sensor, and the station tags of different control stations are different.
Preferably, the load balancing unit may set up a plurality of parallel bypasses to transmit data to the soft PLC instance unit, where the parallel bypasses include an OPC UA data acquisition control instance unit, a message middleware unit, and a dynamic buffer unit.
Preferably, the cloud server is further provided with a visualization application unit and a system management application unit.
A control method of a soft PLC system based on industrial Internet of things comprises the following steps:
1) Firstly, loading a control program in a soft PLC instance unit;
2) The method comprises the steps that various sensors of all control sites collect data and collect the collected data to OPC UA servers of all control sites;
3) Each OPC UA server marks the collected data on site labels of own control sites, and transmits the data to a load balancing unit on the cloud platform server through cloud platform connection application on the cloud platform server by OPC UA protocol, and the load balancing unit judges whether parallel bypasses are required to be opened according to the current collected data quantity of each control site and transmits the data to an OPC UA data collection example unit;
4) Transmitting the data of the OPC UA data acquisition example unit to a message middleware unit;
5) The message middleware unit stores all data into a database, and simultaneously, writes the data which needs to be processed by the soft PLC instance unit into the dynamic cache unit;
6) Each soft PLC instance unit reads and processes the data with the corresponding site tag in the dynamic cache unit, feeds back a control processing command to the OPC UA data acquisition control instance unit, and stores the control processing command to the dynamic cache unit;
7) The OPC UA data acquisition control instance unit transmits the received control processing command to the load balancing module;
8) The load balancing module transmits a control processing command to the corresponding OPC UA server through a cloud platform connection application on the OPC UA server of the corresponding control site according to the OPC UA communication protocol;
9) The OPC UA server controls the corresponding actuator to execute the control processing command.
The invention has the advantages that:
(1) The invention controls the field device by constructing the high-efficiency and real-time communication network, effectively integrates enterprise management and field control, and greatly improves the working efficiency of the control system and the reliability of various devices.
(2) Compared with the traditional hardware PLC, the invention is easier to deploy and improve, has strong compatibility and good interaction capability, and can solve the problems of more hard PLC brands, poor compatibility between hardware and software of each brand and complex daily maintenance work of operation and maintenance personnel.
(3) The redundancy cost of the invention is far lower than that of a hardware PLC system, and the system construction cost can be greatly saved.
Drawings
FIG. 1 is a general frame diagram of a system of the present invention;
FIG. 2 is a block diagram of a system with a soft PLC instance unit embedded in an industrial personal computer according to the present invention;
FIG. 3 is a diagram of a deployment architecture of the soft PLC instance module of the present invention on a cloud or industrial personal computer;
fig. 4 is a diagram of a deployment architecture of the soft PLC instance module of the present invention on an embedded system.
Detailed Description
Referring to fig. 1, an industrial internet of things-based soft PLC system includes a cloud platform server and a control site, and functions of internal operation of the system, application programs and services of an extended system, and the like are implemented by a PaaS platform, which uses a micro-service architecture. The cloud platform server is further provided with a visual application unit and a system management application unit, wherein an operator can modify a control program applied to the soft PLC instance unit through the visual application unit, and the system management application unit is used for user account management and performing operations such as adding, deleting, modifying, inquiring and the like on data of a database. The control site comprises cloud platform connection application, an OPC UA server, a sensor and an actuator, wherein the OPC UA server of the control site can label data collected by the sensor, and site labels of different control sites are different. And the control site and the cloud platform server perform data transmission according to an OPC UA communication protocol, and one control site corresponds to one or more soft PLC instance units.
The load balancing unit receives data collected from all control stations and transmits the collected data to the OPC UA data collection instance unit.
The OPC UA data acquisition control instance unit is used for ensuring that data can be transmitted by using an OPC UA communication protocol, receiving all data from the load balancing unit and transmitting the data to the message middleware unit, the load balancing unit can be provided with a plurality of parallel bypasses for transmitting the data to the soft PLC instance unit, and the parallel bypasses comprise the OPC UA data acquisition control instance unit, the message middleware unit and the dynamic cache unit.
The message middleware unit can store all data from the OPC UA data acquisition control instance unit into a database, and simultaneously, write the data which needs to be processed by the soft PLC instance unit into the dynamic cache unit.
The dynamic caching unit stores the control processing command from the soft PLC instance unit and the data of the message middleware unit, and can ensure that the cache values of the incoming data and the control processing command of the soft PLC instance unit are always up to date. Thus, when a soft PLC instance unit fails, the newly generated soft PLC instance unit can easily continue controlling computations based on the values stored in the cache.
The soft PLC instance unit is used for executing a control program, reading data of the dynamic cache unit, outputting a control processing command, and transmitting the control processing command to the executor for execution through the OPC UA data acquisition control instance unit, the load balancing unit and the OPC UA server of the control site in sequence.
The control scheduling application unit is responsible for loading a control program into the soft PLC instance unit and designating an execution mode of the program, wherein the execution mode comprises a cyclic execution mode and a triggering execution mode.
The dispatching center unit is responsible for monitoring the running condition of each software unit of the system and summarizing and displaying the running information.
Referring to fig. 2, for a control site where a hard PLC control system exists originally, the control site can be modified, the soft PLC instance unit in the present invention is directly embedded into an industrial personal computer, and the hard PLC control system of the control site is modified into a soft PLC control system, so that the problems of more applied PLC brands, incompatibility of various brands, and weak information exchange capability in the hard PLC control system are solved.
The soft PLC instance unit is programmed by using the programming environment of the IEC61131-3 standard, and a given control algorithm is realized, so that in order to enable the hardware equipment to be programmed by using the programming environment based on the IEC61131-3 standard, a runtime system must be transplanted in the corresponding equipment. CODESYS Runtime System is an industrial-level real-time operating system kernel that can transform any embedded device or PC-based device into an industrial controller conforming to the IEC61131-3 standard by porting a runtime system on a hardware platform. The soft PLC instance unit is developed secondarily based on CODESYS Runtime System, is provided with an operating system interface, is customized with a driver and integrated additional functions, and is connected with an external system.
Referring to fig. 3, when the soft PLC instance unit is deployed on a cloud server or an industrial personal computer, codesys runtime system is used as an application program deployed in an operating system, when a real-time task occurs, the system defaults to execute the real-time task first, and when no real-time task occurs, the system runs the task in the kernel of the operating system. In this case, the actual working form of a large number of process tasks during the running of the system can be kept unchanged, so that the input environment is provided for the real-time signals while the tasks of the system are accurately executed. Referring to fig. 4, when the soft PLC instance unit is deployed on the embedded system, CODESYS Runtime system is no longer an operating system application, and directly invokes resources (such as clock resources, memory resources, relays, etc.) of the hardware platform through the underlying hardware driver, so as to complete a control function, which plays an equivalent role to the conventional hardware PLC. The code SYS code executing mechanism is compiling execution, namely IEC codes written in the code SYS IDE are compiled into machine codes through an integrated compiler, and then the machine codes are deployed into a system provided with the code SYS run time through a network cable or a serial port. Plcheandler is used to establish communications between third party clients and PLCs developed based on the codec sys, and plcheandler encapsulates the complete underlying communication protocol and provides an API interface. The API interface provides access to all available functions and services.
A control method of a soft PLC system based on industrial Internet of things comprises the following steps:
1) Firstly, loading a control program in a soft PLC instance unit;
2) The method comprises the steps that various sensors of all control sites collect data and collect the collected data to OPC UA servers of all control sites;
3) Each OPC UA server marks the collected data on site labels of own control sites, and transmits the data to a load balancing unit on the cloud platform server through cloud platform connection application on the cloud platform server by OPC UA protocol, and the load balancing unit judges whether parallel bypasses are required to be opened according to the current collected data quantity of each control site and transmits the data to an OPC UA data collection example unit;
4) Transmitting the data of the OPC UA data acquisition example unit to a message middleware unit;
5) The message middleware unit stores all data into a database, and simultaneously, writes the data which needs to be processed by the soft PLC instance unit into the dynamic cache unit;
6) Each soft PLC instance unit reads and processes the data with the corresponding site tag in the dynamic cache unit, feeds back a control processing command to the OPC UA data acquisition control instance unit, and stores the control processing command to the dynamic cache unit;
7) The OPC UA data acquisition control instance unit transmits the received control processing command to the load balancing module;
8) The load balancing module transmits a control processing command to the corresponding OPC UA server through a cloud platform connection application on the OPC UA server of the corresponding control site according to the OPC UA communication protocol;
9) The OPC UA server controls the corresponding actuator to execute the control processing command.
Claims (5)
1. Soft PLC system based on industry thing networking, including cloud platform server and control website, its characterized in that: the cloud platform server is provided with a load balancing unit, an OPC UA data acquisition control instance unit, a message middleware unit, a dynamic cache unit, a soft PLC instance unit, a control scheduling application unit and a scheduling center unit; the control site comprises cloud platform connection application, an OPC UA server, a sensor and an actuator, wherein the control site and the cloud platform server perform data transmission according to an OPC UA communication protocol, and one control site corresponds to one or more soft PLC instance units;
the load balancing unit receives data collected from all control stations and transmits the collected data to the OPC UA data collection instance unit;
the OPC UA data acquisition control instance unit is used for ensuring that data can be transmitted by using an OPC UA communication protocol, receiving all data from the load balancing unit and transmitting the data to the message middleware unit;
the message middleware unit can store all data from the OPC UA data acquisition control instance unit into a database, and simultaneously, the data required to be processed by the soft PLC instance unit is written into the dynamic cache unit;
the dynamic cache unit stores control processing commands from the soft PLC instance unit and data of the message middleware unit;
the soft PLC instance unit is used for executing a control program, reading data of the dynamic cache unit, outputting a control processing command, and transmitting the control processing command to the executor for execution through the OPC UA data acquisition control instance unit, the load balancing unit and the OPC UA server of the control site in sequence;
the control scheduling application unit is responsible for loading a control program into the soft PLC instance unit and designating an execution mode of the program;
the dispatching center unit is responsible for monitoring the running condition of each software unit of the system and summarizing and displaying the running information.
2. The industrial internet of things-based soft PLC system according to claim 1, wherein: the OPC UA server of the control site can label the data collected by the sensor, and the site labels of different control sites are different.
3. The industrial internet of things-based soft PLC system according to claim 1, wherein: the load balancing unit can be provided with a plurality of parallel bypasses for transmitting data to the soft PLC instance unit, and the parallel bypasses comprise an OPC UA data acquisition control instance unit, a message middleware unit and a dynamic cache unit.
4. The industrial internet of things-based soft PLC system according to claim 1, wherein: and the cloud server is also provided with a visual application unit and a system management application unit.
5. The control method of the industrial internet of things-based soft PLC system according to claim 1, wherein: comprises the following steps:
1) Firstly, loading a control program in a soft PLC instance unit;
2) The method comprises the steps that various sensors of all control sites collect data and collect the collected data to OPC UA servers of all control sites;
3) Each OPC UA server marks the collected data on site labels of own control sites, and transmits the data to a load balancing unit on the cloud platform server through cloud platform connection application on the cloud platform server by OPC UA protocol, and the load balancing unit judges whether parallel bypasses are required to be opened according to the current collected data quantity of each control site and transmits the data to an OPC UA data collection example unit;
4) Transmitting the data of the OPC UA data acquisition example unit to a message middleware unit;
5) The message middleware unit stores all data into a database, and simultaneously, writes the data which needs to be processed by the soft PLC instance unit into the dynamic cache unit;
6) Each soft PLC instance unit reads and processes the data with the corresponding site tag in the dynamic cache unit, feeds back a control processing command to the OPC UA data acquisition control instance unit, and stores the control processing command to the dynamic cache unit;
7) The OPC UA data acquisition control instance unit transmits the received control processing command to the load balancing module;
8) The load balancing module transmits a control processing command to the corresponding OPC UA server through a cloud platform connection application on the OPC UA server of the corresponding control site according to the OPC UA communication protocol;
9) The OPC UA server controls the corresponding actuator to execute the control processing command.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117687351A (en) * | 2024-02-02 | 2024-03-12 | 中广核工程有限公司 | Control system, method, computer equipment and storage medium for power station supporting facility |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117687351A (en) * | 2024-02-02 | 2024-03-12 | 中广核工程有限公司 | Control system, method, computer equipment and storage medium for power station supporting facility |
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