技术领域technical field
本实用新型涉及分布式控制系统的冗余构架，具体涉及一种PAS100控制系统的总体冗余构架。The utility model relates to a redundant framework of a distributed control system, in particular to an overall redundant framework of a PAS100 control system.
背景技术Background technique
PAS100控制系统是基于DCS构架设计的过程自动化控制系统，采用模块化设计思想和开放性的设计理念，使得该系统具备良好的开放性和扩展性，适用于石油、化工、冶金、轻工、能源和环保等行业的过程自动化控制。现有DCS系统（即集散型控制系统或分布式控制系统）采用多级分层结构，综合了常规仪表控制系统和计算机集中控制的优点，弥补了它们各自的不足，具备分散控制、集中操作、分级管理、配置灵活以及组态方便等特点，其可靠性是DCS系统的关键指标。为了提高DCS系统的可靠性，因此需对DCS系统进行冗余设置。不同厂家的DCS系统的冗余位置、程度和具体实现方式都有所不同，常见的系统冗余实现方式是部件冗余。基于成本因素考虑和针对具体行业应用需求不同，不同厂家的部件冗余的实现级别和方式也有所不同，有的采用全部部件冗余，也有采用部分部件冗余的。从理论上来说，系统的冗余设计实现冗余的位置越多、冗余的程度越高，系统的安全性和可靠性就越好。但是从系统的设计和实现角度来说，也会增加了系统的复杂度、设计的难度和产品的成本，而高复杂度必然导致更多不可预见的问题，增加了一些潜在的风险。从经济角度考虑，过高的冗余度会大大增加系统的成本，甚至是一种浪费。如：现有控制系统的控制层与输入输出层间之间采用以太网和Modbus/TCP协议进行通信，技术难度相对大，成本高，并且控制器冗余必然通信模块冗余、网络冗余。因此目前急需开发一种设计合理的冗余架构，该冗余架构安全性和可靠性，且成本低。The PAS100 control system is a process automation control system based on the DCS architecture design. It adopts the modular design concept and the open design concept, which makes the system have good openness and scalability, and is suitable for petroleum, chemical industry, metallurgy, light industry, energy, etc. Process automation control in industries such as environmental protection and environmental protection. The existing DCS system (distributed control system or distributed control system) adopts a multi-level hierarchical structure, which combines the advantages of conventional instrument control systems and computer centralized control, and makes up for their respective shortcomings. It has decentralized control, centralized operation, Hierarchical management, flexible configuration and convenient configuration, etc., its reliability is the key indicator of the DCS system. In order to improve the reliability of the DCS system, it is necessary to set up redundancy for the DCS system. The redundancy location, degree and specific implementation methods of the DCS systems of different manufacturers are different. The common system redundancy implementation method is component redundancy. Based on cost considerations and different application requirements for specific industries, different manufacturers have different implementation levels and methods of component redundancy. Some use all component redundancy, and some use partial component redundancy. Theoretically speaking, the more redundant positions of the system's redundant design and the higher the degree of redundancy, the better the security and reliability of the system. However, from the perspective of system design and implementation, it will also increase the complexity of the system, the difficulty of design and the cost of the product, and the high complexity will inevitably lead to more unforeseen problems and increase some potential risks. From an economic point of view, excessive redundancy will greatly increase the cost of the system, and even be a waste. For example, Ethernet and Modbus/TCP protocols are used for communication between the control layer and the input and output layers of the existing control system. The technical difficulty is relatively high, the cost is high, and the redundancy of the controller must be the redundancy of the communication module and the network. Therefore, there is an urgent need to develop a reasonably designed redundant architecture, which is safe, reliable, and low in cost.
发明内容Contents of the invention
本实用新型的目的是为了克服现有技术的不足，提供一种PAS100控制系统的总体冗余构架，该冗余构架合理，综合考虑PAS100控制系统的时效性、安全性、可靠性，且成本低，保证PAS100控制系统能正常运行。The purpose of this utility model is to overcome the deficiencies of the prior art and provide an overall redundant framework of the PAS100 control system. The redundant framework is reasonable, comprehensively considering the timeliness, safety and reliability of the PAS100 control system, and low in cost , to ensure the normal operation of the PAS100 control system.
本实用新型的目的可以通过以下技术方案实现：The purpose of this utility model can be realized through the following technical solutions:
一种PAS100控制系统的总体冗余构架，包括PAS100控制系统的监控层、控制层和输入输出层，其特征在于：所述控制层设有至少一组互为冗余的主控制器和备用控制器，所述主控制器和备用控制器按1:1冗余，所述主控制器执行控制决策，实现与监控层和输入输出层的数据交互,所述备用控制器实时同步主控制器的程序和数据并监控主控制器的运行状态；所述控制层的主控制器和备用控制器均采用两条互为冗余的主通信网络和备用通信网络与监控层进行网络通信；所述输入输出层设有多个输入输出模块组，所述各输入输出模块组内设有多个IO模块以及两个互为冗余的主通信模块和备用通信模块，各输入输出模块组的主通信模块和备用通信模块均设有四个通信接口，其中两个通信接口用于实现对控制器的通信冗余，另外两个通信接口用于实现对输入输出模块组内IO模块的通信冗余，各输入输出模块组的主通信模块和备用通信模块分别通过两条互为冗余的主通信总线和备用通信总线与控制层的主控制器和备用控制器进行数据交互。An overall redundant framework of a PAS100 control system, comprising a monitoring layer, a control layer and an input and output layer of the PAS100 control system, characterized in that: the control layer is provided with at least one group of mutually redundant main controllers and backup control The main controller and the standby controller are redundant at 1:1, the main controller executes control decisions, and realizes data interaction with the monitoring layer and the input and output layer, and the standby controller synchronizes the data of the main controller in real time program and data and monitor the operating status of the main controller; the main controller and the backup controller of the control layer both use two mutually redundant main communication networks and a backup communication network to communicate with the monitoring layer; the input The output layer is provided with a plurality of input and output module groups, and each input and output module group is provided with a plurality of IO modules and two mutually redundant main communication modules and standby communication modules, and the main communication module of each input and output module group Both the communication module and the standby communication module are equipped with four communication interfaces, two of which are used to realize the communication redundancy of the controller, and the other two communication interfaces are used to realize the communication redundancy of the IO modules in the input and output module group. The main communication module and the backup communication module of the input-output module group perform data interaction with the main controller and the backup controller of the control layer respectively through two mutually redundant main communication buses and backup communication buses.
所述控制层的主控制器和备用控制器均由电源模块、CPU模块和公共底座构成，所述电源模块和CPU模块通过接插件固定于公共底座上，通过公共底座的底板实现互联，所述CPU模块设有通信网络接口和通信总线接口，主控制器和备用控制器之间通过CPU模块的通信网络接口进行数据交互，CPU模块的通信网络接口用于与监控层进行的通信；CPU模块的通信总线接口用于与输入输出层各输入输出模块组的通信模块进行数据交互。Both the main controller and the backup controller of the control layer are composed of a power supply module, a CPU module and a common base, and the power supply module and the CPU module are fixed on the common base through connectors, and are interconnected through the bottom plate of the common base. The CPU module is equipped with a communication network interface and a communication bus interface. The main controller and the standby controller perform data interaction through the communication network interface of the CPU module. The communication network interface of the CPU module is used for communication with the monitoring layer; The communication bus interface is used for data interaction with the communication modules of each input and output module group of the input and output layer.
所述主控制器的电源模块和CPU模块与备用控制器的电源模块和CPU模块相互独立。The power module and CPU module of the main controller are independent from the power module and CPU module of the standby controller.
所述主控制器和备用控制器的CPU模块均设有两个通信总线接口，两个通信总线接口均为RS485总线接口，所述控制层的主控制器和备用控制器分别通过两条互为冗余的RS485总线和Modbus通信协议与输入输出层的主通信模块和备用通信模块进行数据交互。The CPU modules of the main controller and the standby controller are all provided with two communication bus interfaces, and the two communication bus interfaces are RS485 bus interfaces, and the main controller and the standby controller of the control layer are respectively connected to each other through two communication bus interfaces. Redundant RS485 bus and Modbus communication protocol exchange data with the main communication module and standby communication module of the input and output layer.
所述主控制器和备用控制器的CPU模块均设有两个用于与监控层连接的通信网络接口，所述控制层的主控制器和备用控制器分别通过两个互为冗余的主通信网络和备用通信网络与监控层进行网络通信。The CPU modules of the master controller and the backup controller are all provided with two communication network interfaces for connecting with the monitoring layer, and the master controller and the backup controller of the control layer respectively pass two mutually redundant master The communication network and the backup communication network communicate with the monitoring layer.
所述两个用于与监控层连接的通信网络接口均为RJ45以太网接口，所述控制层的主控制器和备用控制器分别通过两个互为冗余的主以太网和备用以太网与监控层进行网络通信。The two communication network interfaces that are used to connect with the monitoring layer are RJ45 Ethernet interfaces, and the main controller and the standby controller of the control layer are connected to each other through two mutually redundant main Ethernets and standby Ethernets. The monitoring layer performs network communication.
所述主控制器与备用控制器之间采用光纤进行，用于冗余控制器之间数据交互。An optical fiber is used between the main controller and the standby controller for data exchange between redundant controllers.
所述输入输出层设有最多八个输入输出模块组，所述各输入输出模块组内均设有最多八个IO模块和两个互为冗余的主通信模块和备用通信模块。The input and output layer is provided with a maximum of eight input and output module groups, and each of the input and output module groups is provided with a maximum of eight IO modules and two mutually redundant main communication modules and backup communication modules.
所述各输入输出模块组的主通信模块和备用通信模块均通过两条互为冗余的主通信总线和备用通信总线与输入输出模块组内IO模块进行实时数据交互。The main communication module and the backup communication module of each input-output module group perform real-time data interaction with the IO modules in the input-output module group through two mutually redundant main communication buses and backup communication buses.
所述各输入输出模块组内的主通信模块和备用通信模块分别通过两条互为冗余的RS485总线和Modbus协议与输入输出模块组内各IO模块的进行数据交互。The main communication module and the standby communication module in each input and output module group perform data interaction with each IO module in the input and output module group through two mutually redundant RS485 buses and Modbus protocol respectively.
本实用新型的有益效果：本实用新型的控制层按1:1冗余原理设置为至少一组互为冗余的主控制器和备用控制器，通过主控制器执行控制决策，实现与监控层和输入输出层的数据交互,通过备用控制器实时同步主控制器的程序和数据并监控主控制器的运行状态，实现了控制层的控制器冗余，若主控制器出现异常，则主控制器切换为备用状态。当备用控制器未检测到主控制器的存在或者监测到主控制发生故障，则备用控制器切换为主状态，保证了控制器的正常运行；输入输出层的各输入输出模块组内设有多个IO模块以及两个互为冗余的主通信模块和备用通信模块，实现了通信模块冗余；主通信模块和备用通信模块均设有四个通信接口，其中两个通信接口用于实现对控制器的通信冗余，另外两个通信接口用于实现对输入输出模块组内IO模块的通信冗余，各通信模块实时读取IO模块的输入模块数据，并将数据打包发送给控制器，通信模块解包控制输出命令并分别发送到各IO模块的输出模块，通信模块分担控制器的与输入输出层的通信任务，提高了控制器的工作效率。主通信模块和备用通信模块分别通过两条互为冗余的主通信总线和备用通信总线与控制层的主控制器和备用控制器进行数据交互，实现了总线冗余。通信模块与控制器采用总线通信，相对于以太网和Modbus/TCP协议进行通信，技术难度相对低，运行成本低，并且采用两个通信模块和两条总线，保障了输入输出层与控制层的正常通信。本实用新型基于全局考虑，由于控制器是系统的核心部件，一旦控制器发生故障，整个控制回路的功能都将失效；网络和总线是连接系统各功能部件的媒介，且网络和总线易受外接因素影响，发生故障的可能性相对较高，网络的安全性和可靠性设计要求高，而IO模块的故障，对系统功能的影响是局部的，同时IO模块故障可以通过其它方法予以解决，因此本实用新型提出了一种总体冗余方案，且采用1:1冗余原理，有效且简单、配置灵活，易于实现，充分考虑了不同层级的数据流量和通信速率，采用以太网、光纤和RS485总线技术实现不同层级的通信冗余；充分考虑了工控行业和集散型控制系统的特点，符合该行业和本领域的应用需求；减小了系统整体设计的复杂性，具有很好的一致性和实用性，使用方便、可靠性好、通用性高，符合较高的时效性、可靠性和安全性；且成本低。Beneficial effects of the utility model: the control layer of the utility model is set as at least one group of mutually redundant master controllers and backup controllers according to the principle of 1:1 redundancy, and the control decision-making is executed by the master controller to realize the monitoring layer Interact with the data of the input and output layer, synchronize the program and data of the main controller in real time through the standby controller and monitor the running status of the main controller, and realize the controller redundancy of the control layer. If the main controller is abnormal, the main control switches to the standby state. When the standby controller does not detect the existence of the main controller or detects that the main controller fails, the standby controller switches to the main state to ensure the normal operation of the controller; each input and output module group of the input and output layer is equipped with multiple One IO module and two mutually redundant main communication modules and backup communication modules realize the communication module redundancy; the main communication module and the backup communication module are equipped with four communication interfaces, two of which are used to realize communication The communication redundancy of the controller, and the other two communication interfaces are used to realize the communication redundancy of the IO modules in the input and output module group. Each communication module reads the input module data of the IO module in real time, and sends the data to the controller in a package. The communication module unpacks the control output command and sends it to the output module of each IO module respectively, and the communication module shares the communication task between the controller and the input and output layer, which improves the working efficiency of the controller. The main communication module and the standby communication module perform data interaction with the main controller and the standby controller of the control layer respectively through two mutually redundant main communication buses and the standby communication bus, thereby realizing bus redundancy. The communication module and the controller adopt bus communication. Compared with Ethernet and Modbus/TCP protocol for communication, the technical difficulty is relatively low, and the operating cost is low. Moreover, two communication modules and two buses are used to ensure the communication between the input and output layers and the control layer. Normal communication. The utility model is based on overall considerations. Since the controller is the core component of the system, once the controller fails, the functions of the entire control loop will fail; the network and the bus are the media connecting the various functional components of the system, and the network and the bus are easily affected by external connections. Influenced by various factors, the possibility of failure is relatively high, and the security and reliability design requirements of the network are high. However, the failure of the IO module has a partial impact on the system function. At the same time, the failure of the IO module can be solved by other methods, so The utility model proposes an overall redundancy scheme, and adopts the principle of 1:1 redundancy, which is effective and simple, flexible in configuration, easy to implement, fully considers the data flow and communication rate of different levels, and adopts Ethernet, optical fiber and RS485 Bus technology realizes communication redundancy at different levels; fully considers the characteristics of industrial control industry and distributed control system, meets the application requirements of this industry and this field; reduces the complexity of the overall system design, and has good consistency and Practical, easy to use, good reliability, high versatility, high timeliness, reliability and safety; and low cost.
所述控制层的主控制器和备用控制器均由电源模块、CPU模块和公共底座构成，电源模块和CPU模块通过接插件固定于公共底座上，通过公共底座的底板实现互联，硬件更简单，成本也相对较低。CPU模块设有通信网络接口和通信总线接口，主控制器和备用控制器之间通过CPU模块的通信网络进行数据交互，CPU模块的通信网络接口用于与监控层进行通信；CPU模块的通信总线接口用于与输入输出层各输入输出模块组的通信模块进行数据交互。CPU模块通过自身集成的通信接口采用通信总线和Modbus协议与输入输出模块组的通信模块进行通信，技术难度相对低，成本低，具有高可靠性和稳定性。Both the main controller and the standby controller of the control layer are composed of a power supply module, a CPU module and a common base, the power supply module and the CPU module are fixed on the common base through connectors, and interconnected through the bottom plate of the common base, the hardware is simpler, The cost is also relatively low. The CPU module is equipped with a communication network interface and a communication bus interface. The main controller and the standby controller perform data interaction through the communication network of the CPU module. The communication network interface of the CPU module is used to communicate with the monitoring layer; the communication bus of the CPU module The interface is used for data interaction with the communication modules of each input and output module group of the input and output layer. The CPU module uses the communication bus and Modbus protocol to communicate with the communication module of the input and output module group through its own integrated communication interface, which has relatively low technical difficulty, low cost, high reliability and stability.
所述主控制器的电源模块和CPU模块与备用控制器的电源模块和CPU模块相互独立，若其中一台控制器出现故障，另外一台控制器不受影响，系统仍然能正常运行，同时系统管理或维护工作人员可以根据系统的错误提示信息对故障控制器实现在线更换。The power supply module and the CPU module of the main controller are independent of the power supply module and the CPU module of the standby controller. If one of the controllers fails, the other controller will not be affected, and the system can still operate normally. Management or maintenance personnel can replace the faulty controller online according to the error message of the system.
所述控制层的主控制器和备用控制器分别通过两条互为冗余的RS485总线和Modbus通信协议与输入输出层的主通信模块和备用通信模块进行数据交互，采用冗余RS-485总线稳定性高，易实现，成本相对低，且冗余配置更为灵活。The main controller and the standby controller of the control layer perform data interaction with the main communication module and the standby communication module of the input and output layer respectively through two mutually redundant RS485 buses and the Modbus communication protocol, and adopt redundant RS-485 buses High stability, easy implementation, relatively low cost, and more flexible redundant configuration.
主控制器和备用控制器均采用两条互为冗余的主通信网络和备用通信网络与监控层进行网络通信，实现了网络冗余，保证了网络的畅通。Both the main controller and the backup controller use two mutually redundant main communication networks and a backup communication network to communicate with the monitoring layer, realizing network redundancy and ensuring the smooth flow of the network.
所述输入输出层设有最多八个输入输出模块组，所述各输入输出模块组内均设有最多八个IO模块和两个互为冗余的主通信模块和备用通信模块。实用于中小型控制系统，满足一般和常见的冗余需求，满足市场上用户对控制系统的冗余要求，且成本低。The input and output layer is provided with a maximum of eight input and output module groups, and each of the input and output module groups is provided with a maximum of eight IO modules and two mutually redundant main communication modules and backup communication modules. It is suitable for small and medium-sized control systems, meets general and common redundancy requirements, and meets the redundancy requirements of users in the market for control systems, and has low cost.
附图说明Description of drawings
图1是本实用新型控制系统的原理框图；Fig. 1 is the functional block diagram of the utility model control system;
图2是本实用新型控制器的结构示意图；Fig. 2 is the structural representation of controller of the present utility model;
图3是本实用新型控制层中两冗余控制器的连接示意图；Fig. 3 is the connection schematic diagram of two redundant controllers in the utility model control layer;
图4是本实用新型通信模块的结构示意图；Fig. 4 is a schematic structural diagram of the communication module of the present invention;
图5是IO模块与通信模块的连接示意图；Figure 5 is a schematic diagram of the connection between the IO module and the communication module;
图6是总线冗余连接示意图；Fig. 6 is a schematic diagram of bus redundancy connection;
图7是监控层与控制层之间的冗余网络连接示意图；Fig. 7 is a schematic diagram of a redundant network connection between the monitoring layer and the control layer;
图8是监控层与控制层之间的非冗余网络连接的示意图。Fig. 8 is a schematic diagram of a non-redundant network connection between the monitoring layer and the control layer.
具体实施方式Detailed ways
下面结合附图对本实用新型作进一步地说明。Below in conjunction with accompanying drawing, the utility model is described further.
参见图1至图8所示，一种PAS100控制系统的总体冗余构架，PAS100控制系统按照DCS架构设计，主要分为3个层次，包括监控层、控制层和输入输出层。Referring to Figures 1 to 8, an overall redundant architecture of the PAS100 control system. The PAS100 control system is designed according to the DCS architecture and is mainly divided into three levels, including the monitoring layer, control layer, and input and output layers.
所述控制层的主要部件是控制器，主要功能是实现输入输出层中输入模块数据的采集，根据组态程序执行控制逻辑，并控制输入输出层中输出模块数据的输出。控制器是运行控制软件、执行控制逻辑，并通过一定的通信机制和策略实现与输入输出层各模块以及监控层各节点的数据信息的交互。控制器是控制系统控制决策执行的核心部件，其稳定性和可靠性对整个系统是至关重要的。理论和实践都证明，冗余技术是一种可以提高系统的稳定性和可靠性的有效方法。由于控制器在控制系统中具有极高的重要性，因此控制层设有至少一组互为冗余的主控制器和备用控制器，主控制器和备用控制器按1:1冗余。参见图1所示，本实施例中，控制层设有一组互为冗余的主控制器和备用控制器，主控制器和备用控制器按1:1冗余。The main component of the control layer is the controller, whose main function is to realize the collection of input module data in the input and output layer, execute the control logic according to the configuration program, and control the output of the output module data in the input and output layer. The controller is to run the control software, execute the control logic, and realize the interaction with the data information of each module of the input and output layer and each node of the monitoring layer through a certain communication mechanism and strategy. The controller is the core component of the control system to control decision-making, and its stability and reliability are crucial to the entire system. Both theory and practice have proved that redundancy technology is an effective method that can improve the stability and reliability of the system. Because the controller is extremely important in the control system, the control layer is provided with at least one set of mutually redundant main controllers and backup controllers, and the main controller and the backup controller are 1:1 redundant. Referring to FIG. 1 , in this embodiment, the control layer is provided with a group of mutually redundant master controllers and backup controllers, and the master controller and backup controllers are redundant at a ratio of 1:1.
参见2所示，控制器1A和控制器1B均由电源模块1、CPU模块2和公共底座3构成，电源模块1和CPU模块2通过接插件固定于公共底座3上，并通公共底座3的底板实现互联。电源模块1为控制器供电，CPU模块基于工业级X86核心板设计，是控制器的核心。所述CPU模块2设有三个通信网络接口和两个通信总线接口，CPU模块的其中一通信网络接口用于主控制器和备用控制器之间的数据交互，另两个通信网络接口用于与监控层进行通信；CPU模块的两个通信总线接口用于与输入输出层各输入输出模块组的通信模块进行数据交互。参见图3所示，本实施例中：CPU模块设有两个RJ45以太网接口、一个光纤以太网接口和两个RS485总线接口。两个RJ45以太网接口分别是RJ45-1，RJ45-2，两个RS485总线接口分别是RS485-1，RS485-2，两个RJ45以太网接口用于与监控层通信，光纤以太网接口用于主控制器与备用控制器之间的数据交互，两个RS485总线接口用于实现与输入输出层各输入输出模块组的通信和数据交互，为最佳实施例。Referring to 2, the controller 1A and the controller 1B are both composed of a power module 1, a CPU module 2 and a common base 3. The power module 1 and the CPU module 2 are fixed on the common base 3 through connectors, and connected to the The backplane interconnects. The power supply module 1 supplies power to the controller, and the CPU module is designed based on the industrial-grade X86 core board, which is the core of the controller. The CPU module 2 is provided with three communication network interfaces and two communication bus interfaces, wherein one of the communication network interfaces of the CPU module is used for data interaction between the main controller and the standby controller, and the other two communication network interfaces are used for communicating with The monitoring layer communicates; the two communication bus interfaces of the CPU module are used for data interaction with the communication modules of each input and output module group of the input and output layer. Referring to Fig. 3, in this embodiment: the CPU module is provided with two RJ45 Ethernet interfaces, one optical fiber Ethernet interface and two RS485 bus interfaces. The two RJ45 Ethernet interfaces are RJ45-1 and RJ45-2, and the two RS485 bus interfaces are RS485-1 and RS485-2. The two RJ45 Ethernet interfaces are used for communication with the monitoring layer, and the optical fiber Ethernet interface is used for For the data interaction between the main controller and the standby controller, two RS485 bus interfaces are used to realize the communication and data interaction with each input and output module group of the input and output layer, which is the best embodiment.
正常情况下，控制器1A为主控制器，控制器1B为备用控制器。此种情况下，控制器1A执行控制决策，实现与监控层和输入输出层的数据交互；控制器1B实时同步主控制器的程序和数据并监控主控制器的运行状态。若主控制器出现异常，则主控制器切换为备用状态。当备用控制器未检测到主控制器的存在或者监测到主控制发生故障，则备用控制器切换为主状态。Normally, controller 1A is the master controller, and controller 1B is the standby controller. In this case, the controller 1A executes control decisions to realize data interaction with the monitoring layer and the input and output layer; the controller 1B synchronizes the program and data of the main controller in real time and monitors the operating status of the main controller. If the main controller is abnormal, the main controller will switch to the standby state. When the backup controller does not detect the existence of the master controller or detects that the master controller fails, the backup controller switches to the master state.
所述主控制器和备用控制器的电源和CPU都相互独立。若主控制器和备用控制器中的一台出现故障，可以切断该控制器的电源对该控制器进行更换，另外一台控制器不受影响，系统仍然能正常运行，同时系统管理或维护工作人员可以根据系统的错误提示信息对故障控制器实现在线更换。The power supply and CPU of the main controller and the backup controller are independent of each other. If one of the main controller and the standby controller fails, the power of the controller can be cut off to replace the controller, and the other controller will not be affected, and the system can still operate normally. At the same time, the system management or maintenance work Personnel can replace the faulty controller online according to the error message of the system.
所述PAS100控制系统的控制层还可以设置为多组控制器，所述各组控制器可以配置为互为冗余的主控制器和备用控制器，也可以采用非冗余控制器，形成多组全冗余的控制器，或者形成冗余和非冗余混合的多组控制器。The control layer of the PAS100 control system can also be set as multiple groups of controllers, and each group of controllers can be configured as a mutually redundant master controller and a backup controller, or non-redundant controllers can be used to form multiple controllers. A fully redundant set of controllers, or a mix of redundant and non-redundant sets of controllers.
在控制器的所有工作任务中，与输入输出层的IO模块通过通信实现数据交互是最为耗时的一个工作任务。为了提高控制器工作效率，PAS100控制系统引入通信模块以分担控制器的与输入输出层的通信任务。Among all the work tasks of the controller, it is the most time-consuming work task to realize data interaction with the IO module of the input and output layer through communication. In order to improve the working efficiency of the controller, the PAS100 control system introduces a communication module to share the communication tasks between the controller and the input and output layers.
所述输入输出层用于控制现场信号测量以及PAS100控制系统控制信号的输出，输入输出层由最多八个输入输出模块组构成，每个输入输出模块组包括最多八个IO模块和两个互为冗余的主通信模块和备用通信模块。主通信模块和备用通信模块与IO模块安装在同一机架上组成一个输入输出模块组，主通信模块和备用通信模块统一处理组内IO模块的数据，并与控制器实现数据交互。各IO模块的功能是现场信号测量和输出系统控制信号到现场设备。主通信模块和备用通信模块是控制器实现与各输入输出模块组内数据通信的“信息集散中心”，在IO模块的输入过程中，通信模块实时读取组内各输入模块数据，并打成一个数据包发送给控制器；在IO模块的输出过程中，通信模块解析来自控制器的输出控制指令，然后分别控制各输出模块的输出。The input and output layer is used to control the field signal measurement and the output of the control signal of the PAS100 control system. The input and output layer is composed of a maximum of eight input and output module groups, and each input and output module group includes a maximum of eight IO modules and two mutual Redundant primary and backup communication modules. The main communication module and the standby communication module are installed on the same rack as the IO module to form an input and output module group. The main communication module and the standby communication module uniformly process the data of the IO modules in the group and realize data interaction with the controller. The function of each IO module is to measure field signals and output system control signals to field devices. The main communication module and the backup communication module are the "information collection and distribution centers" for the controller to realize data communication with each input and output module group. During the input process of the IO module, the communication module reads the data of each input module in the group in real time and writes it into A data packet is sent to the controller; during the output process of the IO module, the communication module analyzes the output control instructions from the controller, and then controls the output of each output module respectively.
本实施例中：输入输出层设有八个输入输出模块组，分别是第一、第二、第三、第四……第八输入输出模块组。每个输入输出模块组均包括八个IO模块IOX1、IOX2、IOX3、IOX4、IOX5、IOX6、IOX7、IOX8和两个互为冗余的主通信模块CPXA和备用通信模块CPXB。第一输入输出模块组由八个IO模块分别为IO11、IO12、IO13、IO14、IO15、IO16、IO17、IO18，以及主通信模块CP1A和备用通信模块CP1B,八个IO模块和两通信模块位于同一IO机架。第二输入输出模块组由八个IO模块分别为IO21、IO22、IO23、IO24、IO25、IO26、IO27、IO28，以及主通信模块CP2A和备用通信模块CP2B,八个IO模块和两通信模块位于同一IO机架。其余几个输入输出模块组的结构设置均相同，在此省略。主通信模块和备用通信模块均通过两条互为冗余的主通信总线和备用通信总线与输入输出模块组内IO模块进行实时数据交互。In this embodiment: the input and output layer is provided with eight input and output module groups, namely the first, second, third, fourth...eighth input and output module groups. Each input and output module group includes eight IO modules IOX1, IOX2, IOX3, IOX4, IOX5, IOX6, IOX7, IOX8 and two mutually redundant main communication modules CPXA and backup communication module CPXB. The first input and output module group consists of eight IO modules respectively IO11, IO12, IO13, IO14, IO15, IO16, IO17, IO18, as well as the main communication module CP1A and the backup communication module CP1B. The eight IO modules and the two communication modules are located in the same IO rack. The second input and output module group consists of eight IO modules respectively IO21, IO22, IO23, IO24, IO25, IO26, IO27, IO28, as well as the main communication module CP2A and the backup communication module CP2B. The eight IO modules and the two communication modules are located in the same IO rack. The structural settings of the remaining input and output module groups are the same and are omitted here. Both the main communication module and the backup communication module perform real-time data interaction with the IO modules in the input and output module group through two mutually redundant main communication buses and backup communication buses.
冗余通信模块的主从状态由控制器决定，即控制器与哪个通信模块进行数据通信则那个通信模块为主通信模块，另一个为备用通信模块。正常情况下，控制器与通信模块CPXA进行数据通信，此时，通信模块CPXA为主通信模块，通信模块CPXB为备用通信模块。此种情况下，主通信模块实现与控制器数据和输入输出模块组内各个IO模块的数据通信；备用通信模块实时监测主通信模块的数据和运行状态。若控制层的控制器检测到主通信模块出现异常，则控制器给出与主通信模块通信故障信息并将数据通信切换到备用通信模块。此时，备用通信模块切换为主状态,主通信模块切换为备用状态。The master-slave state of the redundant communication module is determined by the controller, that is, which communication module the controller communicates with is the master communication module, and the other is the standby communication module. Under normal circumstances, the controller performs data communication with the communication module CPXA. At this time, the communication module CPXA is the main communication module, and the communication module CPXB is the standby communication module. In this case, the main communication module implements data communication with the controller data and each IO module in the input and output module group; the standby communication module monitors the data and operating status of the main communication module in real time. If the controller at the control layer detects that the main communication module is abnormal, the controller will give communication failure information with the main communication module and switch the data communication to the standby communication module. At this time, the standby communication module switches to the main state, and the main communication module switches to the standby state.
所述主通信模块和备用通信模块相互独立，若其中任一一个通信模块出现故障，另外个不受影响，系统仍然能正常运行。又因为通信模块和IO模块均具备带电插拔功能，且插拔其中一个模块不会影响其它模块的运行，所以系统管理或维护工作人员根据系统的错误提示信息，可以在不影响系统运行的情况下对故障通信模块实现在线更换。The main communication module and the standby communication module are independent of each other, if any one of the communication modules fails, the other will not be affected, and the system can still operate normally. And because both the communication module and the IO module have the function of hot plugging, and plugging one of the modules will not affect the operation of other modules, so the system management or maintenance staff can use the error message of the system according to the error message of the system, without affecting the operation of the system. Realize online replacement of faulty communication modules.
参见图4所示：各输入输出模块组的主通信模块和备用通信模块均设有两个用于连接控制器的RS485通信接口和两个用于连接IO模块的RS485通信接口，两个用于连接控制器的RS485通信接口分别是RS485-U1和RS485-U2，两个用于连接IO模块的RS485通信接口分别是RS485-D1和RS485-D2，两个用于连接控制器的RS485通信接口实现对控制器的通信冗余，两个用于连接IO模块的RS485通信接口实现对输入输出模块组内IO模块的通信冗余。See Figure 4: the main communication module and standby communication module of each input and output module group are equipped with two RS485 communication interfaces for connecting to the controller and two RS485 communication interfaces for connecting to IO modules, two for The RS485 communication interfaces connected to the controller are RS485-U1 and RS485-U2, the two RS485 communication interfaces used to connect the IO modules are RS485-D1 and RS485-D2, and the two RS485 communication interfaces used to connect the controller are realized For the communication redundancy of the controller, two RS485 communication interfaces used to connect the IO modules realize the communication redundancy of the IO modules in the input and output module group.
各输入输出模块组内的主通信模块和备用通信模块通过两个RS485通信接口、两条互为冗余的主通信总线和备用通信总线依次与各IO模块连接，所述主通信总线和备用通信总线均采用RS485总线，通信协议采用Modbus通信协议，输入输出模块组的主通信模块和备用通信模块与输入输出模块组内各IO模块基于RS485总线的Modbus协议实现数据交互。实施技术难度更低，成本也相对于较低，且具有高可靠性和稳定性。The main communication module and standby communication module in each input and output module group are connected to each IO module in turn through two RS485 communication interfaces, two mutually redundant main communication buses and standby communication buses, and the main communication bus and standby communication The bus adopts RS485 bus, and the communication protocol adopts Modbus communication protocol. The main communication module and standby communication module of the input and output module group and each IO module in the input and output module group realize data interaction based on the Modbus protocol of RS485 bus. The implementation technology is less difficult, the cost is relatively low, and it has high reliability and stability.
参见图5所示，主通信模块和备用通信模块与八个IO模块之间通过内置于IO机架底板上的两条RS485总线实现连接。主通信模块通过RS485总线读写组内IO模块数据，备用通信模块通过监听该总线获取相应数据。如果两条RS485总线分别为RS485-1和RS485-2。正常情况下，RS485-1为主通信总线，RS485-2为备用通信总线，主通信模块和备用通信模块均通过主通信总线RS485-1与各IO模块通信。主通信模块通过主通信总线RS485-1读写IO模块数据，则备用通信模块监听该主通信总线RS485-1获取相应数据；主通信模块通过备用通信总线RS485-2读写IO数据，则备用通信模块监听备用通信总线RS485-2获取相应数据。即主通信模块的通信总线切换了，备用通信模块的通信总线也进行相应切换。若主通信模块和备用通信模块通过主通信总线RS485-1与某一IO模块通信失败，则启用备用通信总线RS485-2与该IO模块通信；若主通信模块和备用通信模块通过主通信总线RS485-1与输入输出模块组内各IO模块通信失败个数超过n(该值可设置，默认为4)，则备用通信总线RS485-2切换为主通信总线。由于RS485-1和RS485-2相互独立，若RS485-1和RS485-2其中任一一条通信总线发生故障或异常，或者主通信总线的某一节点发生故障或异常，备用通信总线不受影响，系统可以正常运行和工作。As shown in FIG. 5, the main communication module, the backup communication module and the eight IO modules are connected through two RS485 buses built into the bottom plate of the IO rack. The main communication module reads and writes the data of the IO modules in the group through the RS485 bus, and the standby communication module obtains corresponding data by monitoring the bus. If two RS485 buses are RS485-1 and RS485-2 respectively. Under normal circumstances, RS485-1 is the main communication bus, and RS485-2 is the backup communication bus. Both the main communication module and the backup communication module communicate with each IO module through the main communication bus RS485-1. The main communication module reads and writes IO module data through the main communication bus RS485-1, and the standby communication module monitors the main communication bus RS485-1 to obtain corresponding data; the main communication module reads and writes IO data through the standby communication bus RS485-2, then the standby communication module The module monitors the backup communication bus RS485-2 to obtain corresponding data. That is, the communication bus of the main communication module is switched, and the communication bus of the standby communication module is also switched accordingly. If the main communication module and the backup communication module fail to communicate with a certain IO module through the main communication bus RS485-1, then enable the backup communication bus RS485-2 to communicate with the IO module; if the main communication module and the backup communication module pass the main communication bus RS485 -1 If the number of communication failures with each IO module in the input and output module group exceeds n (this value can be set, the default is 4), then the backup communication bus RS485-2 will switch to the main communication bus. Since RS485-1 and RS485-2 are independent of each other, if any one of the communication buses of RS485-1 and RS485-2 fails or is abnormal, or a node of the main communication bus fails or is abnormal, the backup communication bus will not be affected , the system can run and work normally.
参见图6所示，各输入输出模块组的主通信模块和备用通信模块分别通过两个RS485通信接口、两条互为冗余的主通信总线和备用通信总线与控制层的主控制器和备用控制器进行数据交互，主通信总线和备用通信总线均采用RS485总线，通信协议采用Modbus通信协议，输入输出层的两通信模块与控制层的控制器之间基于RS485总线的Modbus协议实现数据交互。相对于以太网通信，该总线通信硬件更简单，实施技术难度更低，成本也相对于较低，且具有高可靠性和稳定性。Referring to Fig. 6, the main communication module and the standby communication module of each input and output module group communicate with the main controller and the standby communication module of the control layer respectively through two RS485 communication interfaces, two mutually redundant main communication buses and a standby communication bus. The controller performs data interaction. Both the main communication bus and the backup communication bus use the RS485 bus. The communication protocol adopts the Modbus communication protocol. The two communication modules at the input and output layer and the controller at the control layer realize data interaction based on the Modbus protocol of the RS485 bus. Compared with Ethernet communication, the bus communication hardware is simpler, the implementation technology is less difficult, the cost is relatively lower, and it has high reliability and stability.
控制层的主控制器和备用控制器与输入输出层的主通信模块和备用通信模块之间均通过两条RS485总线连接。如果两条RS485总线分别为RS485-A和RS485-B，正常情况下，RS485-A为主通信总线，RS485-B为备用通信总线，各控制器通过主通信总线RS485-A与各通信模块通信。若控制器通过主通信总线RS485-A与某一通信模块通信失败，则启用备用通信总线RS485-B与该通信模块通信；若控制器通过主通信总线RS485-A与通信模块失败个数超过n(该值可设置，默认为4)，则备用通信总线RS485-B切换为主通信总线。由于RS485-A和RS485-B相互独立，若其中任一一条通信总线发生故障或异常，或者主通信总线的某一节点发生故障或异常，备用通信总线不受影响，系统可以正常运行和工作。Both the main controller and the backup controller of the control layer are connected with the main communication module and the backup communication module of the input and output layer through two RS485 buses. If the two RS485 buses are RS485-A and RS485-B, under normal circumstances, RS485-A is the main communication bus, and RS485-B is the backup communication bus, and each controller communicates with each communication module through the main communication bus RS485-A . If the controller fails to communicate with a communication module through the main communication bus RS485-A, enable the backup communication bus RS485-B to communicate with the communication module; if the controller fails to communicate with the communication module through the main communication bus RS485-A, the number exceeds n (This value can be set, the default is 4), then the standby communication bus RS485-B is switched to the main communication bus. Since RS485-A and RS485-B are independent of each other, if any one of the communication buses fails or is abnormal, or a node of the main communication bus fails or is abnormal, the backup communication bus will not be affected, and the system can run and work normally .
控制层与输入输出层之间的通信总线冗余和各输入输出模块组内两通信模块与IO模块之间的通信总线冗余，构成PAS100控制系统的总线冗余，总线冗余保证了控制层与输入输出层之间及各输入输出模块组内两通信模块与IO模块之间的正常通信。The communication bus redundancy between the control layer and the input and output layer and the communication bus redundancy between the two communication modules and the IO module in each input and output module group constitute the bus redundancy of the PAS100 control system. The bus redundancy ensures that the control layer Normal communication between the input and output layer and between the two communication modules and the IO module in each input and output module group.
由于PAS100控制系统的通信模块与控制器之间采用RS-485总线通信，因此输入输出层的主通信模块和备用通信模块可以分别接入到两台主、备用控制器上，也可以单独接到任一台控制器上；通信模块与控制器之间可以采用冗余的双RS-485总线通信，也可以采用单RS-485总线通信，从而使得PAS100控制系统可以单独实现控制器冗余、通信模块冗余和总线冗余。Since the communication module of the PAS100 control system and the controller adopt RS-485 bus communication, the main communication module and the standby communication module of the input and output layer can be respectively connected to the two main and standby controllers, or can be connected to the On any controller; redundant dual RS-485 bus communication can be used between the communication module and the controller, or single RS-485 bus communication can be used, so that the PAS100 control system can independently realize controller redundancy and communication Module redundancy and bus redundancy.
所述监控层是运行于PC平台上的PAS-HMI监控软件、组态软件以及PAS-CONFIG等工具软件，用于系统监控、工程组态和调试。监控层设有服务器、多个操作站（1……n个操作站）和工程师站。The monitoring layer is PAS-HMI monitoring software, configuration software, PAS-CONFIG and other tool software running on the PC platform for system monitoring, engineering configuration and debugging. The monitoring layer is equipped with servers, multiple operation stations (1...n operation stations) and engineer stations.
参见图1和图7所示，该PAS100控制系统中，监控层与控制层之间的网络连接配置为冗余。控制层的主控制器和备用控制器均提供了对监控层的两个RJ45以太网接口，通过这两个RJ45以太网接口主控制器和备用控制器可以分别接入两条互为冗余的主通信网络和备用通信网络，主通信网络和备用通信网络均采用100M/1000M以太网，通用Modbus/TCP或专用SicModbus-UDP通信协议，最大网络节点数为247，实现了监控层与控制层之间的通信网络冗余。在网络冗余的系统中，其中一条网络默认作为主通信网络，另一条网络为备用通信网络，若主通信网络出现故障，则启用备用通信网络；若某一节点与主通信网络接口出现故障，则该节点启用与备用通信网络接口。Referring to Fig. 1 and Fig. 7, in the PAS100 control system, the network connection between the monitoring layer and the control layer is configured as redundant. Both the main controller and the standby controller of the control layer provide two RJ45 Ethernet interfaces to the monitoring layer, and through these two RJ45 Ethernet interfaces, the main controller and the standby controller can respectively access two mutually redundant The main communication network and the backup communication network, both the main communication network and the backup communication network adopt 100M/1000M Ethernet, general-purpose Modbus/TCP or special SicModbus-UDP communication protocol, the maximum number of network nodes is 247, and the connection between the monitoring layer and the control layer is realized. The communication network between them is redundant. In a system with network redundancy, one of the networks defaults as the main communication network, and the other network is the backup communication network. If the main communication network fails, the backup communication network will be enabled; if a node fails at the interface with the main communication network, The node is then enabled to interface with the backup communication network.
参见图8所示，所述监控层与控制层之间的网络连接也可以配置为非冗余网络。Referring to Fig. 8, the network connection between the monitoring layer and the control layer may also be configured as a non-redundant network.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201520543118.9UCN204904019U (en) | 2015-07-24 | 2015-07-24 | PAS100 control system's overall redundant framework |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201520543118.9UCN204904019U (en) | 2015-07-24 | 2015-07-24 | PAS100 control system's overall redundant framework |
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| CN204904019Utrue CN204904019U (en) | 2015-12-23 |
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| CN201520543118.9UExpired - LifetimeCN204904019U (en) | 2015-07-24 | 2015-07-24 | PAS100 control system's overall redundant framework |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105045181A (en)* | 2015-07-24 | 2015-11-11 | 重庆川仪自动化股份有限公司 | Overall redundant architecture of PAS 100 control system |
| CN112350909A (en)* | 2019-08-06 | 2021-02-09 | 中车株洲电力机车研究所有限公司 | Communication system and method based on RS485 bus |
| CN115562123A (en)* | 2022-10-21 | 2023-01-03 | 无锡市华星电力环保工程有限公司 | Flue gas purification redundancy control system based on DCS |
| CN116719270A (en)* | 2023-07-19 | 2023-09-08 | 成都天核科技有限公司 | Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105045181A (en)* | 2015-07-24 | 2015-11-11 | 重庆川仪自动化股份有限公司 | Overall redundant architecture of PAS 100 control system |
| CN112350909A (en)* | 2019-08-06 | 2021-02-09 | 中车株洲电力机车研究所有限公司 | Communication system and method based on RS485 bus |
| CN115562123A (en)* | 2022-10-21 | 2023-01-03 | 无锡市华星电力环保工程有限公司 | Flue gas purification redundancy control system based on DCS |
| CN116719270A (en)* | 2023-07-19 | 2023-09-08 | 成都天核科技有限公司 | Hot standby redundancy control system and method for PLC (programmable logic controller) system in industrial control field |
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