CN101546187B - Redundant PLC system - Google Patents
Redundant PLC system Download PDFInfo
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- CN101546187B CN101546187B CN2008100431863A CN200810043186A CN101546187B CN 101546187 B CN101546187 B CN 101546187B CN 2008100431863 A CN2008100431863 A CN 2008100431863A CN 200810043186 A CN200810043186 A CN 200810043186A CN 101546187 B CN101546187 B CN 101546187B
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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]
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Abstract
The invention discloses a redundant PLC system. In the system, real-time data is recorded periodically in redundant PLC1, redundant HMI compares the obtained real-time data with previously obtained data every 500 ms to determine whether the obtained real-time data and the previously obtained data are accordant or not; if the obtained real-time data is not in accordance with the previously obtained data, an alarm signal of interrupting connection is sent out; after the redundant PLC 1 detects a main CPU of the redundant PLC1 has failures, failure information is transferred to a redundant PLC2, so that the redundant HMI can receive an alarm signal of the main CPU in time; and the redundant HMI delays 2 seconds after the redundant HMI receives the alarm signal of interrupting connection and the alarm signal of the main CPU; and by time delay, if the two alarm signals still exist, the redundant HMI sends out an instruction of switching connection of connection link. The redundant PLC system can ensure that data of the HMI server can be updated in time after the main CPU in the redundant PLC system has failures, and improves real time of data response, real time response performance when the redundant control system is failed.
Description
Technical field
The present invention relates to automation field, particularly relate to a kind of redundant PLC (programmable logic controller (PLC)) system.
Background technology
In the control of important process flow process, need continual monitoring electromechanical equipment, control system usually can be selected redundant PLC system; And it is incorporate system software package that HMI (man-machine interface) monitored picture software that redundant PLC system adopts and redundant PLC system itself do not resemble DCS (the collective and distributive type control system DISTRIBUTEDCONTROL SYSTEM) control system.The Citect V6.0 monitoring software of the supporting Australian CITECT of the S7 of Siemens Company series redundant PLC system company for example.Citect V6.0 monitoring software is configured to two main and auxiliary server systems of HMI that redundant heat is equipped with mode, forms the binary channels physical connection with redundant PLC system, guarantees the real-time stabilization of data.The host CPU of HMI master server and redundant PLC system is set up the communication link transceive data under the normal condition, the HMI secondary sever carries out backed up in synchronization from the real-time copy data of HMI master server, and the auxilliary CPU of redundant PLC system keeps synchronously by synchronous optical fiber and host CPU real time data.In case after the host CPU of redundant PLC system broke down, auxilliary CPU switched to running status rapidly, take over all working task that host CPU is finished control program.But the HMI master server can not be fast and the auxilliary CPU of redundant PLC system set up communication link, cause the main and auxiliary server data of HMI not upgrade in time or be not connected on the auxilliary CPU.For this situation, need restart the main and auxiliary server of HMI, to seek the host CPU (i.e. Yun Hang CPU) of redundant PLC system again and set up communication link, this process needs the time more than 5 minutes at least.Beyond thought incident may will take place in 5 minutes in some important quick response technique production procedure, therefore need shorten the time that is connected with HMI communication again fast after the host CPU fault of redundant PLC system as much as possible.
Summary of the invention
The technical problem to be solved in the present invention provides a kind of redundant PLC system, make in the redundant PLC system after the host CPU fault fast and the HMI server reconnects, the HMI server data can upgrade in time, improves the real-time of data response, and the real-time response performance during the redundancy control system fault.
For solving the problems of the technologies described above, redundant PLC system of the present invention is provided with two cover redundant PLC subsystems, i.e. redundant PLC 1 and redundant PLC 2, and every cover redundant PLC subsystem all has host CPU and auxilliary CPU; Described two cover redundant PLC subsystems are connected with redundant HMI by the network switch, and redundant HMI has master server and secondary sever; During normal the operation, the master server while of redundant HMI connects with the host CPU of redundant PLC 1 and redundant PLC 2, realizes that the real time datas between HMI and the two cover redundant PLC subsystems are mutual, and the control of production procedure;
Real time data of every at least 250ms record in redundant PLC 1, redundant HMI compares the every 500ms of resulting real time data with the data that received before, judge whether unanimity; If consistent, then between redundant PLC 1 and the redundant HMI be connected normal; If inconsistent then sending connects the alerting signal of interrupting;
After redundant PLC 1 detects its host CPU and breaks down, this failure message is delivered in the redundant PLC 2 of normal operation, make redundant HMI in time receive the host CPU alerting signal of redundant PLC 1;
Redundant HMI receives and connected after the alerting signal of interrupting and the host CPU alerting signal time-delay 2 seconds, and through time-delay, if above-mentioned 2 alerting signals still exist, then redundant HMI sends and switches the instruction that communication link connects; Behind the handover success, the operation CPU of redundant HMI and redundant PLC 1 is normal communication again.
The operation CPU of redundant HMI and redundant PLC 1 behind the normal communication, with mark position 1, continues to less real time data of every 250ms record again in the redundant PLC 1 in redundant HMI, redundant HMI receives this real time data in real time, and system normally moves; Executive routine among the redundant HMI is arranged to per 2 seconds run-downs.
Adopt after the present invention, improved the performance of whole redundant system, reduced total system fault-time.When the host CPU operation of redundant PLC system was broken down, the response of system's real time data still can have stable guarantee, has improved system reliability.
Owing to improved the performance of whole redundant system, the identical control system in this area had higher using value.
The present invention is not at concrete control system, control program module and control method, and when running into different control system, as long as adopt corresponding software to programme again, following dress gets final product.
Description of drawings
The present invention is further detailed explanation below in conjunction with accompanying drawing and embodiment:
Fig. 1 is redundant PLC system and redundant HMI structural representation;
Fig. 2 is a control procedure synoptic diagram of the present invention.
Embodiment
As shown in Figure 1, in redundant PLC system of the present invention, two cover redundant PLC subsystems are set, i.e. redundant PLC 1 and redundant PLC 2, every cover redundant PLC subsystem all has host CPU and auxilliary CPU.Described two cover redundant PLC subsystems are connected with redundant HMI by the network switch, and redundant HMI has master server and secondary sever.During normal the operation, the master server while of redundant HMI connects with the host CPU of redundant PLC 1 and redundant PLC 2, realizes that the real time data between HMI and the PLC is mutual, and the control of production procedure.
The effect of the network switch in system be with the Ethernet card of redundant PLC system and and the Ethernet card of redundant HMI be joined together to form independently network.The network address all is arranged on the same network segment, and arbitrary server of redundant HMI and arbitrary CPU of redundant PLC system communicate.
Referring to shown in Figure 2, real time data of every at least 250ms record in redundant PLC 1, redundant HMI compares the every 500ms of resulting real time data with the data that received before, judge whether unanimity; If consistent, then between redundant PLC 1 and the redundant HMI be connected normal; Prove then that as if inconsistent redundant HMI can't obtain the PLC real time data, the malunion of redundant HMI and redundant PLC 1 is normal, sends to connect the alerting signal of interrupting, and guarantees the correctness of switching command.Whether the communication link that can in time find to grasp redundant PLC 1 like this normal, as switch signal that communication link connects according to one of.
After redundant PLC 1 detects its host CPU and breaks down, this failure message is delivered in the redundant PLC 2 of another normal operation, the host CPU alerting signal of the redundant PLC 1 that the communication link by redundant PLC 2 and redundant HMI is in time received redundant HMI to break down is as switching two of signal foundation that communication link connects.
Redundant HMI receives and connected after the alerting signal of interrupting and the host CPU alerting signal time-delay 2 seconds, and through time-delay, if above-mentioned 2 alerting signals still exist, judging then that redundant HMI need send switches the instruction that communication link connects.Behind the handover success, the operation CPU of redundant HMI and redundant PLC 1 (the auxilliary CPU in the redundant PLC 1 of host CPU fault promptly occurring) is normal communication again; And in redundant HMI with Reflector position 1 (when the host CPU reparation of breaking down or change re-power operation after, when cpu fault information disappears with the reset of fault recovery zone bit), continue to less real time data of every 250ms record in the redundant PLC 1, redundant HMI receives this real time data in real time, and system normally moves.
Executive routine among the redundant HMI is arranged to per 2 seconds run-downs, and the auxilliary CPU of redundant PLC 1 and redundant HMI are connected fast, guarantees that the real time data of recovering the HMI picture in 5 seconds shows and renewal.
Set the program that at least one calculates the real time data circulation change in redundant PLC 1, a cpu fault determining program, a cpu fault information are transmitted signal procedure; The PLC real time data that in redundant HMI, is provided with judgement at least and is received whether self-consistentency program, switch the program that communicates to connect; Said procedure is concentrated and is placed at least one data field; After the program module operation of redundant PLC 1, said procedure all starts.
At least set up a data block to use the district as the data of handoff functionality in redundant PLC system, the data that will be used to judge, switch execution, instruct are placed on these data and use in the district.
The present invention can be in 5 second time, and the host CPU of redundant PLC 1 back of breaking down is reconnected with redundant HMI fast, improves the response real-time of data.When the host CPU of redundant PLC 1 because fault when out of service, redundant HMI master server is being less than being connected of automatically switch in time of 5 seconds main and auxiliary CPU and redundant HMI, do not need manually to restart redundant HMI or its program module, the master server of redundant HMI and the auxilliary CPU of the normal redundant PLC 1 that moves are connected fast.The present invention is owing to adopt the monitoring of redundant PLC 1 fault host CPU to be connected dynamic tracking with the program module of redundant HMI, confirm to automatically switch after single cpu breaks down, avoided after host CPU breaks down in the redundant PLC 1, the program module of redundant HMI long-time (more than 5 minutes) is new data or the situation that redundant HMI program network connects fault occurs more not.Therefore, the present invention has improved after the host CPU fault of redundant PLC 1 system and the switching time between the redundant HMI, has improved the response real-time of control data.Redundant PLC 2 also can be adopted to use the same method and control simultaneously.The present invention can use on the redundant PLC system of 2 above different brands and redundant HMI, the real-time response performance when improving the redundancy control system fault.
The auxilliary CPU of redundant PLC breaks down generally speaking, and not being connected of redundant HMI and redundant PLC can be interrupted, but also can stop the generation of fortuitous event by method of the present invention.
Claims (4)
1. redundant PLC system is characterized in that: two cover redundant PLC subsystems are set, i.e. and redundant PLC 1 and redundant PLC 2, every cover redundant PLC subsystem all has host CPU and auxilliary CPU; Described two cover redundant PLC subsystems are connected with redundant HMI by the network switch, and redundant HMI has master server and secondary sever; During normal the operation, the master server while of redundant HMI connects with the host CPU of redundant PLC 1 and redundant PLC 2, realizes that the real time datas between HMI and the two cover redundant PLC subsystems are mutual, and the control of production procedure; Described HMI is meant man-machine interface;
Real time data of every at least 250ms record in redundant PLC 1, redundant HMI compares the every 500ms of resulting real time data with the data that received before, judge whether unanimity; If consistent, then between redundant PLC 1 and the redundant HMI be connected normal; If inconsistent then sending connects the alerting signal of interrupting;
After redundant PLC 1 detects its host CPU and breaks down, this failure message is delivered in the redundant PLC 2 of normal operation, make redundant HMI in time receive the host CPU alerting signal of redundant PLC 1;
Redundant HMI receives and connected after the alerting signal of interrupting and the host CPU alerting signal time-delay 2 seconds, and through time-delay, if above-mentioned 2 alerting signals still exist, then redundant HMI sends and switches the instruction that communication link connects; Behind the handover success, the operation CPU of redundant HMI and redundant PLC 1 is normal communication again.
2. redundant PLC system as claimed in claim 1, it is characterized in that: the operation CPU of redundant HMI and redundant PLC 1 is again behind the normal communication, in redundant HMI with mark position 1, continue to less real time data of every 250ms record in the redundant PLC 1, redundant HMI receives this real time data in real time, and system normally moves; Executive routine among the redundant HMI is arranged to per 2 seconds run-downs.
3. redundant PLC system as claimed in claim 1 is characterized in that: set the program that at least one calculates the real time data circulation change in redundant PLC 1, a cpu fault determining program, a cpu fault information are transmitted signal procedure; The PLC real time data that in redundant HMI, is provided with judgement at least and is received whether self-consistentency program, switch the program that communicates to connect; Said procedure is concentrated and is placed at least one data field; After the program module operation of redundant PLC 1, said procedure all starts.
4. redundant PLC system as claimed in claim 1 is characterized in that: set up a data block to use the district as the data of handoff functionality in described redundant PLC system at least, the data that will be used to judge, switch execution, instruct are placed on these data and use in the district.
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| CN2008100431863A CN101546187B (en) | 2008-03-25 | 2008-03-25 | Redundant PLC system |
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| CN2008100431863A CN101546187B (en) | 2008-03-25 | 2008-03-25 | Redundant PLC system |
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| CN101546187A CN101546187A (en) | 2009-09-30 |
| CN101546187B true CN101546187B (en) | 2010-12-08 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| TWI454870B (en) * | 2012-02-03 | 2014-10-01 | Delta Electronics Inc | System and method for redundancy control |
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| CN102231073B (en) * | 2011-05-30 | 2013-12-11 | 北京和利时***工程有限公司 | Network redundancy communication method, apparatus and system thereof |
| CN103473920B (en) * | 2012-06-06 | 2017-05-24 | 攀钢集团攀枝花钢钒有限公司 | Anti-interference method and system for detection signal |
| CN102819252B (en) * | 2012-08-13 | 2015-05-13 | 国电南京自动化股份有限公司 | Method for realizing multi-redundancy of process control station in distributed control system |
| JP5638042B2 (en) * | 2012-08-20 | 2014-12-10 | ファナック株式会社 | Numerical control device with maintenance function when HMI is abnormal |
| CN102866690B (en) * | 2012-09-18 | 2015-09-23 | 南京国电南自美卓控制***有限公司 | Redundancy switching method between Redundant process control station in scattered control system |
| CN102866698B (en) * | 2012-09-29 | 2015-06-17 | 南京国电南自美卓控制***有限公司 | Human machine interface (HMI) redundant communication method for distributed control system controller |
| CN103838186A (en) * | 2012-11-20 | 2014-06-04 | 中核建中核燃料元件有限公司 | Automatic control system of dry method device |
| CN105334729A (en) * | 2015-11-27 | 2016-02-17 | 王先宏 | Method for redundancy switch of two independent PLC systems in railway locomotive depot signal control |
| EP3428748B1 (en) * | 2017-07-13 | 2020-08-26 | Siemens Aktiengesellschaft | Method and assembly for operating two redundant systems |
| WO2019034971A1 (en) * | 2017-08-13 | 2019-02-21 | Si-Ga Data Security (2014) Ltd. | A threat detection system for industrial controllers |
| CN113495522B (en) * | 2020-03-19 | 2022-12-13 | 南京南瑞继保电气有限公司 | Method and device for determining on-duty state of PLC in environment and equipment monitoring system |
| CN113495484A (en) * | 2021-06-21 | 2021-10-12 | 宝信软件(武汉)有限公司 | Multi-switching system for industrial water treatment circulation control |
| CN115576187A (en) * | 2022-11-23 | 2023-01-06 | 浙江中控研究院有限公司 | Multi-redundancy-design PLC control system and system control method |
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| CN101546187A (en) | 2009-09-30 |
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