WO2020047951A1 - 一种悬挂自行输送小车的多级安全冗余控制系统 - Google Patents

一种悬挂自行输送小车的多级安全冗余控制系统 Download PDF

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WO2020047951A1
WO2020047951A1 PCT/CN2018/110765 CN2018110765W WO2020047951A1 WO 2020047951 A1 WO2020047951 A1 WO 2020047951A1 CN 2018110765 W CN2018110765 W CN 2018110765W WO 2020047951 A1 WO2020047951 A1 WO 2020047951A1
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sensor
motion controller
safety
priority
sensors
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French (fr)
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楼佩煌
郭大宏
钱晓明
张沪松
张炯
胡泊
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Nanjing University of Aeronautics and Astronautics
Miracle Automation Engineering Co Ltd
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Nanjing University of Aeronautics and Astronautics
Miracle Automation Engineering Co Ltd
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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
    • G05B9/00—Safety arrangements
    • G05B9/02—Safety arrangements electric
    • G05B9/03—Safety arrangements electric with multiple-channel loop, i.e. redundant control systems

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  • the invention belongs to the field of industrial field production transportation control, and particularly relates to a multi-level safety redundant control system for a suspension self-conveying trolley.
  • Suspension self-conveying trolley also called Electric Monorail System (EMS)
  • EMS Electric Monorail System
  • EMS Electric Monorail System
  • the material is transported or moved on a predetermined track by a self-propelled trolley device according to a predetermined control program.
  • Suspension self-conveying trolleys are mostly used for conveying materials at industrial sites, especially new energy automobile assembly production lines. Their operating conditions are complex, not only working at high altitudes, but also suspending automobile frames weighing more than 1000kg. Any safety accident may bring Serious life safety hazards and property damage.
  • New energy vehicles have large capacity changes, and their models are flexible and changeable. They are mostly upgraded from existing models. They are especially suitable for assembly and production using EMS, which is a suspension self-conveying trolley (hereinafter referred to as EMS), because the EMS production cycle is flexible and variable. In the early stage, the investment is small, and the process and production capacity can be adjusted flexibly according to the technical upgrade in the later stage.
  • EMS suspension self-conveying trolley
  • control system of domestic EMS mostly depends on imports, and stays in a single controller to process sensor signals and task instructions.
  • unexpected failures such as program running, electromagnetic interference, mechanical vibration, etc.
  • the motor of the execution unit is still operating incorrectly, even if the probability of failure is extremely low, once it occurs, it will cause a temporary loss of control of the execution unit, which is extremely harmful to life and property.
  • the present invention aims to provide a multi-level safety redundant control system for hanging a self-conveying trolley to improve system safety and stability.
  • the technical solution of the present invention is:
  • a multi-level safety redundant control system for a suspension self-conveying trolley includes a task input module, a motion controller, a safety processor, a low-priority sensor, a medium-priority sensor, a high-priority sensor, and a driving device for an execution component; a task;
  • the input module inputs task instructions to the motion controller, and the motion controller generates driving instructions according to the task instructions, and transmits the driving instructions to the driving device of the execution component, and controls the execution component to perform the corresponding task; low priority sensors, medium priority sensors, and high Priority sensors collect their own sensing signals and transmit them to the security processor.
  • the security processor first performs data fusion processing based on health assessment on the signals collected by each sensor, and makes decisions based on the processing results.
  • the security processor first prohibits the motion controller from transmitting driving instructions to the driving device of the execution component through the I / O signal hardware flow control, and then the security processor sends the control instruction corresponding to the decision taken to the driving device of the execution component; Controller and Safety Division There is information interaction between the controllers.
  • the motion controller and the safety processor regularly send their respective parameter information to each other, and back up each other's parameter information. When one of them fails and restarts, it can obtain the parameter information before the failure from the other;
  • the motion controller and the security processor are watchdogs. When one of them A fails, and the other B finds that A has not sent the parameter information according to the original rules, B first disables the A pair through the hardware flow control of the I / O signal.
  • the control of the execution unit sends an emergency stop command to the driving unit of the execution unit.
  • the low-priority sensor includes a voltage sensor, a temperature sensor, and a humidity sensor, which are respectively used to detect a change in the input voltage of the EMS cart, and the temperature and humidity of the working environment;
  • the medium-priority sensor includes a first vibration sensor and a remote sensor.
  • the distance laser ranging sensor is respectively used to detect the mechanical vibration at the bottom of the EMS trolley lifting structure and the EMS trolley long-distance obstacle;
  • the high-priority sensor includes a second vibration sensor, a short-range laser ranging sensor, and a safety edge, wherein The second vibration sensor and the short-range laser ranging sensor are respectively used to detect the mechanical vibration on the top of the lifting structure of the EMS trolley and the short-distance obstacle of the EMS trolley.
  • the safety touch edge is a pressure-sensitive switch fixed on the edge of the forward direction of the EMS trolley. For detecting collision or squeeze signals.
  • the decision made by the security processor according to the result of the data fusion processing includes: continued operation, alarming and feedback to the MES system or ERP system, deceleration operation, and emergency shutdown.
  • the signals collected by each sensor are quantified, and then the quantized signals are used to calculate the health of the EMS car according to the following formula:
  • h j is the health degree corresponding to decision j
  • ⁇ j is the correction coefficient of decision j
  • ⁇ i is the influence factor of sensor i on health
  • x i is the quantized value of the signal collected by sensor i
  • f i (x i ) is the health of the EMS car by sensor i
  • n is the total number of sensors that need to be considered for decision j;
  • the sensors that need to be considered for alarm and feedback to the MES system or ERP system are low-priority sensors, the sensors that need to be considered for deceleration are medium-priority sensors, and the sensors that need to be considered for emergency shutdown are high-priority sensors;
  • the health degree h j of each decision corresponds to a pre-set alert value H j . If the health degree h j is lower than the alert value H j , the decision is triggered; if an alarm is reported and fed back to the MES system or ERP system, the deceleration operation and If none of the three emergency stop decisions are triggered, the operation will continue.
  • the parameter information in the information interaction between the motion controller and the security processor includes task parameters and self-running parameters in the motion controller, and various sensor acquisition parameters and self-running parameters in the security processor.
  • the motion controller and the security processor are set to be watchdogs with each other. It is assumed that the high-security embedded controllers on the market now fail (running, electromagnetic interference, failure caused by mechanical vibration, etc.). The probability is 0.01%, then the two sides are watchdog control methods for each other, and the probability that the two parts fail at the same time and cause the execution part to lose control is 0.0001%, which is much higher than the existing single controller control safety and stability;
  • the multi-sensor data fusion processing based on the health evaluation of the EMS car of the present invention avoids the "one-to-one" feedback of a single sensor to the processor in the past, and the "multi-to-one" feedback and multi-sensor fusion are beneficial to the processor Comprehensive calculation and evaluation of the health of the EMS, solved the dependence of the EMS on a single sensor, and greatly improved the reliability of equipment operation;
  • the motion controller and the safety processor are set to back up their respective operating parameters.
  • the other party B can send the operating parameters before A to A; assuming that A cannot
  • maintenance personnel can also obtain various operating parameters before fault A from B.
  • Such beneficial effects are as follows: it is convenient for maintenance personnel to obtain data before operation to troubleshoot the cause, and After externally resetting A's hardware and inputting parameters through task instructions, A can continue to complete the work before the failure without re-dispatching tasks and scheduling, saving valuable time for downtime maintenance.
  • Figure 1 is a block diagram of the system composition of the present invention
  • FIG. 4 is a multi-sensor data fusion flowchart in the embodiment.
  • the present invention proposes a multi-level safety redundant control system for a suspension self-conveying trolley.
  • the system includes a task input module, a motion controller, a safety processor, a low priority sensor, a medium priority sensor, and a high priority. Drives for level sensors and actuators.
  • the suspension self-conveying trolley system provided in this embodiment runs on a production line for manufacturing and assembling a new energy vehicle.
  • the mechanical structure is shown in FIG. 2.
  • the control method proposed by the present invention includes four control strategies:
  • Control strategy 1 The task input module inputs task instructions to the motion controller, and the motion controller generates driving instructions according to the task instructions, and transmits the driving instructions to the driving device of the execution unit, and controls the execution unit to perform the corresponding task.
  • the MES manufacturing enterprise production process execution system
  • ERP enterprise resource planning
  • Control Strategy 2 Low-priority sensors, medium-priority sensors, and high-priority sensors collect their respective sensing signals and transmit them to the security processor.
  • the security processor first performs data fusion based on the health assessment of the signals collected by each sensor. Process and make decisions based on the processing results. If measures are required on the execution unit, the safety processor first prohibits the motion controller from transmitting drive instructions to the drive unit of the execution unit through I / O signal hardware flow control, and then the safety processor sends The driving device of the execution unit sends a control instruction corresponding to the adopted decision.
  • the so-called health degree refers to the possibility of being in a safe state.
  • EMS car which is a highly integrated mechatronics device carrying many sensors and driving equipment
  • its safety is very important. Since its own weight is as high as hundreds of kilograms or even tons, and it belongs to high-altitude operations, if an accident occurs, the consequences must be unimaginable.
  • the ideal working environment temperature of the EMS car is -20 ° C to + 40 ° C, and the health is close to 100%. Outside this range, the health has Decrease regularly.
  • This data is determined by the actual operation test results and the ideal working environment temperature of all the components in the EMS cart components.
  • Figure 3 is the distribution function of the equipment health degree with respect to the ambient temperature. This function is only qualitative and not an exact value. Then the working environment temperature defines the health of the EMS car as f T (x T ), where x T is the quantized value of the temperature sensor output data.
  • the present invention considers the impact of multiple sensors (factors) on the health of the EMS cart:
  • h j is the health degree corresponding to decision j
  • ⁇ j is the correction coefficient of decision j
  • ⁇ i is the influence factor of sensor i on health
  • x i is the quantized value of the signal collected by sensor i
  • f i (x i ) is the health of the EMS car by sensor i
  • n is the total number of sensors that need to be considered for decision j.
  • the low-priority sensor includes a voltage sensor, a temperature sensor, and a humidity sensor, which are respectively used to detect changes in the input voltage of the EMS cart, and the temperature and humidity of the working environment;
  • the medium-priority sensor includes a first vibration sensor and Long-distance laser ranging sensors are used to detect mechanical vibration at the bottom of the EMS trolley lifting structure and long-distance obstacles of the EMS trolley, respectively;
  • the high-priority sensor includes a second vibration sensor, a short-range laser ranging sensor, and a safety edge, The second vibration sensor and the short-range laser ranging sensor are respectively used to detect the mechanical vibration on the top of the EMS trolley lifting structure and the short-distance obstacle of the EMS trolley.
  • the safety touch edge is a pressure-sensitive switch fixed on the edge of the forward direction of the EMS trolley. Used to detect collision or squeeze signals.
  • Decisions made by the security processor based on the results of the data fusion process include: continue operation, alarm and feedback to the MES system or ERP system, deceleration operation, and emergency shutdown. Deceleration operation includes deceleration of the traveling motor and deceleration of the lifting motor.
  • the sensors that need to be considered for alarm and feedback (decision) to the MES system or ERP system are low priority sensors, the sensors that need to be considered for deceleration operation (decision) are medium priority sensors, and the sensors that need to be considered for emergency stop (decision) are high Priority sensor.
  • the health degree h j of each decision corresponds to a pre-set alert value H j .
  • Control strategy three There is information interaction between the motion controller and the safety processor.
  • the motion controller and the safety processor regularly send their respective parameter information to each other and back up each other's parameter information. When one of them fails and restarts, it can Obtain the parameter information before the fault from the other party.
  • the motion controller and the safety processor periodically send each other's operating state parameters and peripheral device parameters, including the command input for the task, the parameters of the motion motor, and the parameters of each sensor, etc., according to the agreed protocol.
  • beneficial effects are: 1. If one party fails, the hardware is reset and restarted quickly, and then the other party transfers the pre-failure data to it, and it can quickly connect to the production cycle; 2. In the case of 1, if the hardware cannot be reset, Is the controller failure caused by vibration or electromagnetic interference, then after the shutdown, maintenance personnel can obtain data from the other party to determine what caused the failure, import the data after the fault is removed, and can continue to maintain the original production Beat and continue production.
  • Control strategy four The motion controller and the security processor are watchdogs. When one of the A fails and the other B finds that A has not sent the parameter information according to the original rules, B first passes the I / O signal hardware flow. The control prohibits A from controlling the execution unit, and then sends an emergency stop instruction to the driving unit of the execution unit.
  • the so-called watchdogs that is, A receives B's data at an agreed time interval, and B receives A's data at an agreed time interval.
  • B When a party (assuming it is A) does not read B's information at the agreed time, then B must be Some kind of failure occurred.
  • A immediately failed the communication port of B through hardware flow control. (Hardware flow control does not need to go through the user program accordingly, that is, the communication port can be enabled or disabled when the program runs.)
  • the motor only orders to A, and then A immediately sends an emergency stop instruction to the actuator drive unit to ensure safe stopping.

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Abstract

一种悬挂自行输送小车的多级安全冗余控制系统，其中，任务输入模块将任务指令输入运动控制器，运动控制器根据任务指令生成驱动指令，并传送给执行部件的驱动装置；低、中、高优先级传感器分别采集传感信号并传送给安全处理器，安全处理器进行基于健康度评估的数据融合处理，并根据处理结果进行决策，若需要对执行部件采取措施，则首先安全处理器通过I/O信号硬件流控制禁止运动控制器向执行部件的驱动装置传送驱动指令，然后由安全处理器向执行部件的驱动装置发送所采取决策对应的控制指令；运动控制器和安全处理器定时备份对方的参数信息；运动控制器与安全处理器互为看门狗。该多级安全冗余控制系统提高了系统安全性和稳定性，避免发生重大人身和财产损失。

Description

一种悬挂自行输送小车的多级安全冗余控制系统 技术领域
本发明属于工业现场生产输送控制领域，特别涉及了一种悬挂自行输送小车的多级安全冗余控制系统。
背景技术
悬挂自行输送小车，又叫电动自行小车系统(Electrified Monorail System,EMS)，是一种集机械、电子、电气、计算机于一体的高技术输送、搬运控制系统，它将生产、仓储等过程中的物料通过自行小车装置在预定的轨道上，按照预定的控制程序进行输送或搬运。悬挂自行输送小车多用于工业现场输送物料，尤其是新能源汽车装配生产线，其运行工况复杂，不仅在高空工作，还要悬吊重达1000kg以上的汽车车架，任何安全意外都可能带来严重的生命安全危害和财产损失。
新能源汽车由于其产能变化大，车型灵活多变，多由现有车型升级改款而来，特别适合采用EMS即悬挂自行输送小车(后面简称EMS)来装配生产，因为EMS生产节拍灵活可变，前期投入小，后期根据技术升级可灵活调整工序和产能。
目前国内EMS的控制系统多依赖进口，而且多停留在单控制器处理传感器信号和任务指令，单一处理器在遇到不可预料的故障(如程序跑飞，电磁干扰，机械振动导致失效等)时，执行部件电机仍在错误地运转，即使发生故障的概率极低，可一旦发生，会导致执行部件的暂时失控，对生命财产安全危害极大。
发明内容
为了解决上述背景技术提出的技术问题，本发明旨在提供一种悬挂自行输送小车的多级安全冗余控制系统，提高系统安全性和稳定性。
为了实现上述技术目的，本发明的技术方案为：
一种悬挂自行输送小车的多级安全冗余控制系统，包括任务输入模块、运动控制器、安全处理器、低优先级传感器、中优先级传感器、高优先级传感器和执行部件的驱动装置；任务输入模块将任务指令输入运动控制器，运动控制器根据任务指令生成驱动指令，并将驱动指令传送给执行部件的驱动装置，控制执行部件执行相应任务；低优先级传感器、中优先级传感器和高优先级传感器分别采集各自的传感信号并传送给安全处理器，安全处理器首先对各传感器采集的信号进行基于健康度评估的数据融合处理，并根据处理结果进行决策，若需要对执行部件采取措施，则首先安全处理器通过I/O信号硬件流控制禁止运动控制器向执行部件的驱动装置传送驱动指令，然后由安全处理器向执行部件的驱动装置发送所采取决策对应的控制指令；运动控制器与安全处理器之间存在信息交互，运动控制器和安全处理器定时将各自的参数信息发送给对方，互相备份对方的参数信息，当其中一方发生故障重启后，能够向另一方获取故障前的参数信息；运动控制器与安全处理器互为看门狗，当其中一方A发生故障，另一方B发现A未按原定规则将参数信息发送过来，则B先通过I/O信号硬件流控制禁止A对执行部件的控制，再向执行部件的驱动装置发送紧急停车的指令。
进一步地，所述低优先级传感器包括电压传感器、温度传感器和湿度传感器，分别用于检测EMS小车的输入电压变化、工作环境的温度和湿度；所述中优先级传感器包括第一振动传感器和远距离激光测距传感器，分别用于检测EMS小车升降结构底部的机械振动和EMS小车远距离障碍物；所述高优先级传感器包括第二振动传感器、近距离激光测距传感器和安全触边，其中第二振动传感器和近距离激光测距传感器分别用于检测EMS小车升降结构顶部的机械振动和EMS 小车近距离障碍物，安全触边为固定在EMS小车前进方向边棱上的压敏开关，用于检测碰撞或挤压信号。
进一步地，安全处理器根据数据融合处理结果进行的决策包括：继续运行、报警并向MES系统或ERP系统反馈、减速运行以及紧急停车。
进一步地，所述基于健康度评估的数据融合处理的过程如下：
首先将各传感器采集的信号进行量化，然后将量化后的信号根据下式计算出EMS小车的健康度：
Figure PCTCN2018110765-appb-000001
上式中，h j为决策j对应的健康度，ε j为决策j的修正系数，δ i为传感器i对健康度的影响因子，x i为传感器i采集信号的量化值，f i(x i)为传感器i对EMS小车的健康度，n为决策j需要考虑的传感器总数；
报警并向MES系统或ERP系统反馈所需要考虑的传感器为低优先级传感器，减速运行所需要考虑的传感器为中优先级传感器，紧急停车需要考虑的传感器为高优先级传感器；
每个决策的健康度h j对应一个预先设定的警戒值H j，若健康度h j低于警戒值H j，则触发该决策；若报警并向MES系统或ERP系统反馈、减速运行以及紧急停车这三个决策均未触发，则继续运行。
进一步地，运动控制器与安全处理器信息交互中的参数信息包括运动控制器中的任务参数和自身运行参数以及安全处理器中的各传感器采集参数和自身运行参数。
采用上述技术方案带来的有益效果：
(1)本发明中将运动控制器和安全处理器设置成互为看门狗，假设现在市面上高安全性的嵌入式控制器发生故障(跑飞、电磁干扰、机械振动导致失效等) 的概率为0.01％，那么双方互为看门狗的控制方法，双方同时失效导致执行部件失控的概率就为0.0001％，比现有的单一控制器控制安全性和稳定性提高很多；
(2)本发明基于EMS小车健康度评估的多传感器数据融合处理，避免了过去单个传感器对处理器的“一对一”的反馈，“多对一”的反馈和多传感器融合有利于处理器综合计算评估EMS的健康度，解决了EMS对单一传感器的依赖性问题，大大提高了设备运行的可靠性；
(3)本发明中设置运动控制器和安全处理器互相备份各自运行参数，当一方A暂时故障，自复位以后，另一方B可以把A故障前的运行参数发给A；假设A故障后无法完成自复位的操作，那么维保人员也可以从B处获得A故障前的各种运行参数，这样的有益效果一是：方便维保人员获得运行前的数据排查故障的原因，二是可以在外部人工给A硬件复位后，将参数通过任务指令输入进去，那么A就可以继续完成故障前的工作，无需重新分派任务和调度，节约了停工维修的宝贵时间。
附图说明
图1是本发明系统组成框图；
图2是实施例中EMS系统的机械结构图；
图3是实施例中健康度关于环境温度的分布函数图；
图4是实施例中多传感器数据融合流程图。
具体实施方式
以下将结合附图，对本发明的技术方案进行详细说明。
本发明提出了一种悬挂自行输送小车的多级安全冗余控制系统，如图1所示，包括任务输入模块、运动控制器、安全处理器、低优先级传感器、中优先级 传感器、高优先级传感器和执行部件的驱动装置。
本实施例提供的悬挂自行输送小车系统运行于一条新能源汽车整车制造装配的生产流水线，机械结构如图2所示。汽车制造装配的生产流水线，一旦发生安全事故，其严重后果除了造成产品的损失和人员的伤亡外，还会影响整个车间的生产节拍，生产任务会受到极大的影响。
本发明提出的控制方法包括四项控制策略：
控制策略一：任务输入模块将任务指令输入运动控制器，运动控制器根据任务指令生成驱动指令，并将驱动指令传送给执行部件的驱动装置，控制执行部件执行相应任务。
针对策略一，MES(制造企业生产过程执行系统)或者ERP(企业资源计划)系统通过工业总线或者工业wifi等给运动控制器发送依次到工位A，B，C，D完成工装，那么运动控制器分析处理了这段任务指令后，依次给执行电机驱动器发送对应的前进，停止，升降等指令。
控制策略二：低优先级传感器、中优先级传感器和高优先级传感器分别采集各自的传感信号并传送给安全处理器，安全处理器首先对各传感器采集的信号进行基于健康度评估的数据融合处理，并根据处理结果进行决策，若需要对执行部件采取措施，则首先安全处理器通过I/O信号硬件流控制禁止运动控制器向执行部件的驱动装置传送驱动指令，然后由安全处理器向执行部件的驱动装置发送所采取决策对应的控制指令。
所谓健康度即指处于安全状态的可能性程度，对EMS小车这种载有很多传感器和驱动设备的机电一体化高度融合的设备而言，其设备安全性十分重要。由于自重高达数百kg甚至上吨，而且属于高空作业，它一旦发生事故，后果必定不堪设想。
以环境温度为例说明单一传感器(因素)对EMS小车健康度的影响，EMS 小车的理想工作环境温度为-20℃至+40℃，健康度接近100％，在这个范围之外，健康度有规律地降低。这个数据是由实际运行测试结果和EMS小车组成部件中所有零部件的理想工作环境温度所确定。图3是设备健康度关于环境温度的分布函数，此函数只是定性，非精确数值。那么工作环境温度对EMS小车的健康度定义为f T(x T)，x T为温度传感器输出数据经量化后的数值。
本发明考虑多传感器(因素)对EMS小车健康度的影响：
Figure PCTCN2018110765-appb-000002
上式中，h j为决策j对应的健康度，ε j为决策j的修正系数，δ i为传感器i对健康度的影响因子，x i为传感器i采集信号的量化值，f i(x i)为传感器i对EMS小车的健康度，n为决策j需要考虑的传感器总数。
在本实施例中，低优先级传感器包括电压传感器、温度传感器和湿度传感器，分别用于检测EMS小车的输入电压变化、工作环境的温度和湿度；所述中优先级传感器包括第一振动传感器和远距离激光测距传感器，分别用于检测EMS小车升降结构底部的机械振动和EMS小车远距离障碍物；所述高优先级传感器包括第二振动传感器、近距离激光测距传感器和安全触边，其中第二振动传感器和近距离激光测距传感器分别用于检测EMS小车升降结构顶部的机械振动和EMS小车近距离障碍物，安全触边为固定在EMS小车前进方向边棱上的压敏开关，用于检测碰撞或挤压信号。
安全处理器根据数据融合处理结果进行的决策包括：继续运行、报警并向MES系统或ERP系统反馈、减速运行以及紧急停车。减速运行包括行走电机的减速和升降电机的减速。报警并向MES系统或ERP系统反馈(决策)所需要考虑的传感器为低优先级传感器，减速运行(决策)所需要考虑的传感器为中优先级传感器，紧急停车(决策)需要考虑的传感器为高优先级传感器。每个决策的 健康度h j对应一个预先设定的警戒值H j，若健康度h j低于警戒值H j，则触发该决策；若报警并向MES系统或ERP系统反馈、减速运行以及紧急停车这三个决策均未触发，则继续运行。该过程如图4所示。
控制策略三：运动控制器与安全处理器之间存在信息交互，运动控制器和安全处理器定时将各自的参数信息发送给对方，互相备份对方的参数信息，当其中一方发生故障重启后，能够向另一方获取故障前的参数信息。
运动控制器和安全处理器相互定时地，按照约定的协议，发送各自的运行状态参数以及外围设备参数，包括任务输入的指令，运动电机的参数，各传感器的参数等。这样的有益效果有：1、若有一方故障，迅速硬件复位重启，然后另一方将故障前数据传送给它，它就可以迅速衔接上生产节拍；2、在1的情况下如果不能硬件复位，是振动或者电磁干扰导致的控制器失效，那么可以在停车后，由维保人员从另一方获取数据，判断是什么原因引起的故障，在故障排除后将数据导入，即可继续保持原来的生产节拍，继续生产。
控制策略四：运动控制器与安全处理器互为看门狗，当其中一方A发生故障，另一方B发现A未按原定规则将参数信息发送过来，则B先通过I/O信号硬件流控制禁止A对执行部件的控制，再向执行部件的驱动装置发送紧急停车的指令。
所谓互为看门狗，即A按约定时间间隔接收B的数据，B按约定时间间隔接收A的数据，当某一方(假设是A)按约定时间没有读取到B的信息，那么B一定发生了某种故障，此时为了系统的安全性，A立即通过硬件流控制B的通信端口失效(硬件流控制不需要经过用户程序相应，即程序跑飞时也能使通信端口有效或者失效)，此时电机只听命于A，然后A立即向执行部件驱动装置发送急停指令，确保安全停车。这样的有益效果是：假设A和B都是高安全性的嵌入式控制器，发生故障的概率为0.01％，即一万次运行中出现一次故障，虽然可 能在其生产生命周期中都不一定会发生一次故障，但是一旦发生了，就会造成EMS和悬吊的汽车损坏和人员受伤，还会打断生产节拍，影响产能造成大额的经济损失。那么如果A和B采用这种互为看门狗的冗余控制方法，即使一方故障了，另一方能立即发现，并禁止其通信，然后令电机停止。这样发生事故的概率就降为0.01％*0.01％＝0.0001％，即双方同时发生故障的情况，这样就大大提高了安全性和稳定性，这对于汽车生产装配线来说是非常重要的。
实施例仅为说明本发明的技术思想，不能以此限定本发明的保护范围，凡是按照本发明提出的技术思想，在技术方案基础上所做的任何改动，均落入本发明保护范围之内。

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  1. 一种悬挂自行输送小车的多级安全冗余控制系统，其特征在于：包括任务输入模块、运动控制器、安全处理器、低优先级传感器、中优先级传感器、高优先级传感器和执行部件的驱动装置；任务输入模块将任务指令输入运动控制器，运动控制器根据任务指令生成驱动指令，并将驱动指令传送给执行部件的驱动装置，控制执行部件执行相应任务；低优先级传感器、中优先级传感器和高优先级传感器分别采集各自的传感信号并传送给安全处理器，安全处理器首先对各传感器采集的信号进行基于健康度评估的数据融合处理，并根据处理结果进行决策，若需要对执行部件采取措施，则首先安全处理器通过I/O信号硬件流控制禁止运动控制器向执行部件的驱动装置传送驱动指令，然后由安全处理器向执行部件的驱动装置发送所采取决策对应的控制指令；运动控制器与安全处理器之间存在信息交互，运动控制器和安全处理器定时将各自的参数信息发送给对方，互相备份对方的参数信息，当其中一方发生故障重启后，能够向另一方获取故障前的参数信息；运动控制器与安全处理器互为看门狗，当其中一方A发生故障，另一方B发现A未按原定规则将参数信息发送过来，则B先通过I/O信号硬件流控制禁止A对执行部件的控制，再向执行部件的驱动装置发送紧急停车的指令。
  2. 根据权利要求1所述悬挂自行输送小车的多级安全冗余控制系统，其特征在于：所述低优先级传感器包括电压传感器、温度传感器和湿度传感器，分别用于检测EMS小车的输入电压变化、工作环境的温度和湿度；所述中优先级传感器包括第一振动传感器和远距离激光测距传感器，分别用于检测EMS小车升降结构底部的机械振动和EMS小车远距离障碍物；所述高优先级传感器包括第二振动传感器、近距离激光测距传感器和安全触边，其中第二振动传感器和近距离激光测距传感器分别用于检测EMS小车升降结构顶部的机械振动和EMS小车近距离障碍物，安全触边为固定在EMS小车前进方向边棱上的压敏开关，用于 检测碰撞或挤压信号。
  3. 根据权利要求1或2所述悬挂自行输送小车的多级安全冗余控制系统，其特征在于：安全处理器根据数据融合处理结果进行的决策包括：继续运行、报警并向MES系统或ERP系统反馈、减速运行以及紧急停车。
  4. 根据权利要求3所述悬挂自行输送小车的多级安全冗余控制系统，其特征在于：所述基于健康度评估的数据融合处理的过程如下：
    首先将各传感器采集的信号进行量化，然后将量化后的信号根据下式计算出EMS小车的健康度：
    Figure PCTCN2018110765-appb-100001
    上式中，h j为决策j对应的健康度，ε j为决策j的修正系数，δ i为传感器i对健康度的影响因子，x i为传感器i采集信号的量化值，f i(x i)为传感器i对EMS小车的健康度，n为决策j需要考虑的传感器总数；
    报警并向MES系统或ERP系统反馈所需要考虑的传感器为低优先级传感器，减速运行所需要考虑的传感器为中优先级传感器，紧急停车需要考虑的传感器为高优先级传感器；
    每个决策的健康度h j对应一个预先设定的警戒值H j，若健康度h j低于警戒值H j，则触发该决策；若报警并向MES系统或ERP系统反馈、减速运行以及紧急停车这三个决策均未触发，则继续运行。
  5. 根据权利要求3所述悬挂自行输送小车的多级安全冗余控制系统，其特征在于：运动控制器与安全处理器信息交互中的参数信息包括运动控制器中的任务参数和自身运行参数以及安全处理器中的各传感器采集参数和自身运行参数。
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