CN110632912B - DCS power system fault diagnosis method - Google Patents
DCS power system fault diagnosis method Download PDFInfo
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- CN110632912B CN110632912B CN201910990477.1A CN201910990477A CN110632912B CN 110632912 B CN110632912 B CN 110632912B CN 201910990477 A CN201910990477 A CN 201910990477A CN 110632912 B CN110632912 B CN 110632912B
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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
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0221—Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
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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
- G05B2219/20—Pc systems
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- G05B2219/24065—Real time diagnostics
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Abstract
The invention discloses a DCS power system fault diagnosis method, wherein each power module is provided with a power diagnosis module for detecting a corresponding power module parameter and judging the state of each power module, and a control center diagnoses and prewarns each power module according to the detected power parameters, so as to grasp the real-time condition of each power module in time and realize the real-time monitoring of the power modules.
Description
Technical Field
The invention relates to the technical field of industrial automation control, in particular to a DCS power system fault diagnosis method.
Background
At present, a DCS system is popularized in various industries, such as pharmaceutical industry, water treatment industry and petrochemical industry, a power supply on the DCS system is used as a core of the whole DCS control system, the quality of the power supply directly affects the stable operation of the whole DCS system, a traditional DCS power supply is generally used as an independent individual to participate in the power supply of the DCS system, the whole DCS system is generally powered by a hot standby redundancy mode, a hot standby power supply is in a hot standby state while a main power supply supplies power, and when the main power supply fails, the hot standby power supply can be switched into the main power supply within a minimum control period. However, the traditional method cannot evaluate the power quality of each node in the whole DCS system, and cannot give early warning to hidden potential faults on some nodes in advance, so that maintenance personnel can know hidden dangers of the whole system power network in advance.
Specifically, the power supply redundancy of some DCS systems adopts a mode that 2 power supplies are output in parallel through diodes, each power supply node supplied with power cannot be monitored in a distributed mode, the distributed power supply diagnosis method adopts an independent industrial bus technology, meanwhile, an MCU is required to participate in diagnosis, and the distributed power supply diagnosis method is difficult to modify on the original basis.
Therefore, how to detect the power supply on the DCS system and obtain the state of the power supply in real time is a problem to be solved urgently at present.
Disclosure of Invention
The invention aims to provide a DCS power system fault diagnosis method, wherein each power module is provided with a power diagnosis module for detecting a corresponding power module parameter, judging the state of each power module, diagnosing and prewarning each power module according to the parameters, and timely mastering the real-time condition of each power module so as to realize the real-time monitoring of the power modules.
The above object of the present invention is achieved by the following technical solutions:
a DCS power system fault diagnosis method, the DCS system includes at least one power module, control center, diagnoses each power module, including the following steps:
s1, initializing the system;
s2, initializing interrupt configuration;
s3, initializing data;
s4, judging whether the RAM is verified or not, if so, entering the next step, and if not, turning to S9;
s5, judging whether to request to report fault diagnosis data, if not, entering the next step, if yes, turning to S10;
s6, judging whether the fault diagnosis tree is updated or not, if not, entering the next step, and if so, turning to S11;
s7, judging whether the analog quantity data acquisition is finished, if so, entering the next step, and if not, waiting for the acquisition to be finished;
s8, processing ADC data, calculating data of each diagnosis item, and turning to S5;
s9, alarming by the fault of the diagnosis module, and turning to S12;
s10, processing communication, and turning to S12;
s11, updating the fault tree;
and S12, ending.
The invention is further configured to: the power supply diagnosis system is characterized by further comprising power supply diagnosis modules, the number of the power supply diagnosis modules is the same as that of the power supply modules, the power supply diagnosis modules are arranged between each power supply module and the control center respectively, each power supply diagnosis module is used for detecting corresponding power supply module parameters and judging the state of each power supply module, the detected parameters, states and addresses of each power supply module are transmitted to the control center through a bus, and the control center diagnoses and warns each power supply module.
The invention is further configured to: in step S4, the RAM data in the power supply diagnostic module is verified.
The invention is further configured to: the diagnosis item parameters detected by each power supply diagnosis module comprise: input power, input voltage, input current, peak voltage, peak current, ripple peak value, Buck controller switching frequency, power supply conversion efficiency and heat loss detection and analysis.
The invention is further configured to: each power supply diagnosis module carries out detection and comprises the following steps:
a1, comparing the detected parameters with corresponding set values to obtain comparison results;
a2, judging whether the comparison result is abnormal, if so, entering the next step, otherwise, selecting the next parameter, and turning to A1;
a3, evaluating a fault symptom mode;
a4, matching with the types in the fault library, if the types can be matched with the types in the fault library, entering the next step, and if the types cannot be matched, updating the fault library;
a5, internal evaluation, and analysis of failure modes possibly caused by faults;
and A6, reporting the fault information and the failure mode to a control center.
The invention is further configured to: and the control center transmits the fault information and the failure modes of the power supply diagnosis modules to diagnosis and early warning software for analysis.
The invention is further configured to: the power supply diagnosis module comprises a central processing unit, a power supply voltage monitoring unit, a power supply current monitoring unit, a peak voltage monitoring unit, a peak current I/V conversion circuit, a heat loss monitoring unit, a ripple small signal detection circuit, a pulse width frequency detection circuit, an input and output power consumption monitoring circuit and an SPI communication interface circuit, wherein the central processing unit is respectively connected with the power supply voltage monitoring unit, the power supply current monitoring unit, the peak voltage monitoring unit, the peak current I/V conversion circuit, the heat loss monitoring unit, the ripple small signal detection circuit, the pulse width frequency detection circuit, the input and output power consumption monitoring circuit and the SPI communication interface circuit, and each circuit respectively monitors one performance parameter of a power supply.
The invention is further configured to: the central processor and the control center realize communication through at least one of SPI, UART and CAN interfaces.
The invention is further configured to: the control center comprises a controller and an upper computer, diagnosis and early warning software is arranged in the upper computer, and the controller transmits various data detected by the power supply diagnosis module to the diagnosis and early warning software for processing to obtain a processing result and perform early warning according to the processing result.
Compared with the prior art, the beneficial technical effects of this application do:
1. according to the power supply monitoring system, the power supply parameter diagnosis module is arranged on each power supply module, so that the parameters of each power supply module are detected, the real-time condition of each power supply module is mastered in time, and the real-time monitoring of the power supply modules is realized;
2. furthermore, different power supply parameters are detected independently, detection parameters can be set according to conditions, and corresponding detection of the power supply module is achieved;
3. furthermore, the diagnosis and early warning software integrates various information of the control station and the power supply diagnosis module, and comprehensive diagnosis of the system is realized.
Drawings
FIG. 1 is a schematic diagram of a DCS system architecture for a specific embodiment of the present application;
FIG. 2 is a schematic view of a DCS system control flow of an embodiment of the present application;
FIG. 3 is a schematic view of a DCS system control flow of another embodiment of the present application;
FIG. 4 is a schematic diagram of a supply voltage monitoring architecture of an embodiment of the present application;
fig. 5 and 6 are schematic diagrams of a power supply current monitoring circuit according to an embodiment of the present application;
FIG. 7 is a schematic diagram of a pulse width frequency detection circuit according to an embodiment of the present application;
FIG. 8 is a schematic diagram of a heat loss monitoring unit according to an embodiment of the present application;
fig. 9 is a schematic diagram of a maximum value sampling recording circuit according to an embodiment of the present application.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings.
The invention relates to a DCS system with power failure diagnosis function, as shown in figure 1, the DCS system comprises at least one main station (MN) node and at least one slave station (CN) node, each main station is provided with a plurality of slave stations, each node comprises a power supply module and a power supply diagnosis module, and each power supply module is used as a slave station (CN) node in the whole DCS system and has a unique ID. Each power supply module is electrically connected with the control center through a bus, power supply diagnosis modules are respectively arranged between each power supply module and the control center, each power supply diagnosis module is used for detecting a corresponding power supply module parameter, judging the state of each power supply module according to the detection result, transmitting the detected parameters, states and addresses of each power supply module to the control center through the bus, and the control center diagnoses and pre-warns each power supply module through diagnosis and pre-warning software.
In one embodiment of the present application, the parameters detected by the power supply diagnostic module include: input power, input voltage, input current, peak voltage, peak current, ripple peak value, Buck controller switching frequency, power supply conversion efficiency and heat loss detection and analysis.
In an embodiment of the present application, the DCS power system fault diagnosis method, as shown in fig. 2, includes the following steps:
s1, initializing the system;
s2, initializing interrupt configuration;
s3, initializing data;
s4, judging whether the RAM is verified or not, if so, entering the next step, and if not, turning to S9;
s5, judging whether to request to report fault diagnosis data, if not, entering the next step, if yes, turning to S10;
s6, judging whether the fault diagnosis tree is updated or not, if not, entering the next step, and if so, turning to S11;
s7, judging whether the analog quantity data acquisition is finished, if so, entering the next step, and if not, waiting for the acquisition to be finished;
s8, processing ADC data, calculating data of each diagnosis item, and turning to S5;
s9, alarming by the fault of the diagnosis module, and turning to S12;
s10, processing communication, and turning to S12;
s11, updating the fault tree;
and S12, ending.
In step S4, the control chip MCU in the power supply diagnostic module reads the RAM on the module, and then performs CRC16 check on the data in the whole RAM area, and after the check is passed, the RAM on the power supply diagnostic module is considered to be normal.
In step S5, the MCU in the power supply diagnosis module reports the fault diagnosis data if there is a fault according to the determination result of the diagnosis data, and does not report if there is no fault.
In step S6, the power supply diagnosis module compares the diagnosed fault with the fault type in the fault library, and if the fault already exists, then the internal evaluation is performed; if the fault does not exist, the fault tree is updated.
In step S7, the power supply diagnostic module performs data acquisition on the diagnostic items, and after the data acquisition of all the diagnostic items is completed, performs step S8, and if the data acquisition of all the diagnostic items is not completed, continues to perform the data acquisition of the corresponding diagnostic items until the data acquisition of all the diagnostic items is completed.
The power supply diagnosis module performs detection, as shown in fig. 3, and includes the following steps:
a1, comparing the detected parameters with corresponding set values to obtain comparison results;
a2, judging whether the comparison result is abnormal, if so, entering the next step, otherwise, selecting the next parameter, and turning to A1;
a3, evaluating a fault symptom mode;
a4, matching with the types in the fault library, if the types can be matched with the types in the fault library, entering the next step, and if the types cannot be matched, updating the fault library;
a5, internal evaluation, and analysis of failure modes possibly caused by faults;
and A6, reporting the fault information and the failure mode to a control center.
Specifically, in step a1, each detected parameter is compared with its corresponding set value, and the comparison result between each parameter and the set value is obtained.
In step a2, the power supply diagnosis module determines whether an abnormality occurs according to the comparison result of each parameter, and if the comparison result meets the condition, the power supply is considered to be normal, and if the comparison result does not meet the condition, the power supply is considered to be abnormal.
In step a3, when a power supply abnormality occurs, a failure symptom mode is evaluated according to the type of the parameter in which the abnormality occurs.
Step A4, step A5, the failure symptom mode of the assessment is compared with the failure mode in the failure storehouse stored in the power diagnosis module, if the comparison is not up, the failure storehouse is updated, add the new failure mode into the failure storehouse; if the comparison is carried out, internal evaluation is carried out, and failure modes possibly caused by faults are analyzed.
In step a6, when the master station accesses a faulty slave station, the power supply diagnosis module of the slave station reports the fault failure mode to the master station, that is, the controller, the master station transmits all the slave station node fault information and the fault failure modes that may be caused to the diagnosis and early warning software, and the diagnosis and early warning software performs fault diagnosis and early warning according to the fault parameters and the fault failure modes.
In one embodiment of the present application, the power supply diagnosis module includes a central processing unit, a power supply voltage monitoring unit, a power supply current monitoring unit, a peak voltage monitoring unit, a peak current I/V conversion circuit, a heat loss monitoring unit, a ripple small signal detection circuit, a pulse width frequency detection circuit, an input/output power consumption monitoring circuit, and an SPI communication interface circuit, wherein the central processing unit is respectively connected to the power supply voltage monitoring unit, the power supply current monitoring unit, the peak voltage monitoring unit, the peak current I/V conversion circuit, the heat loss monitoring unit, the ripple small signal detection circuit, the pulse width frequency detection circuit, the input/output power consumption monitoring circuit, and the SPI communication interface circuit, and each unit circuit respectively monitors a performance parameter of the power supply.
The central processor and the control center realize communication through at least one of SPI, UART and CAN interfaces.
In a specific embodiment of the present application, the supply voltage monitoring unit includes a voltage divider circuit and a follower circuit, and is configured to step down the supply voltage, and then perform impedance isolation using the follower circuit, and then input the impedance isolation to the central processing unit.
Specifically, the supply voltage monitoring unit is shown in fig. 4, where Vin represents a sampled value of an input voltage, and after the sampled value is divided by resistors R207 and R219, the Vin input voltage is divided into a voltage range acceptable by an ADC inside the single chip. The DZ200 is used for voltage stabilization. L302, C329, R304 and C331 constitute a second-level low-pass filter for filtering the detected sampling voltage, and an operational amplifier U306A constitutes a voltage follower circuit for increasing input impedance to form ADC _ V voltage, and the voltage directly enters an ADC port of the central processing unit for ADC sampling.
In a specific embodiment of the present application, the supply current monitoring unit includes a sampling circuit, an amplifying circuit, and a voltage bias circuit, where the sampling circuit is configured to sample a magnitude of the supply current, the amplifying circuit is configured to amplify a sampled current signal, and the voltage bias circuit is configured to bias the amplified current signal, and transmit the bias signal to the central controller.
Specifically, as shown in fig. 5 and 6, the supply current monitoring unit, i.e., the I/V conversion circuit, is configured such that the sampling resistor RT is connected in series to the main loop of the Vin input power supply, the VB and VD sampling networks are voltages at two ends of the RT sampling resistor, and the amplification circuit for instruments, which is composed of U305A, U305B and U306B, has balanced impedance at two input ends, high resistance and low input bias current ratio.
In order to ensure that the voltage value in the whole measurement range is between 0.5 and 1 times of the ADC sampling reference as much as possible, as shown in FIG. 5, a voltage bias circuit consisting of R325, R328 and R332 is added, and the output voltage of the voltage bias circuit is the sampling voltage input to the ADC acquisition port of the singlechip.
In one embodiment of the present application, the pulse width frequency detection circuit includes an isolation circuit for isolating the PWM signal of the power supply and transmitting the isolated PWM signal to the central controller.
Specifically, as shown in fig. 7, the isolation circuit includes a logic gate circuit.
In a specific embodiment of the present application, the heat loss monitoring unit includes a sampling circuit, a filter circuit, and a voltage follower circuit, the sampling circuit is configured to collect a temperature of the power module, the filter circuit is configured to filter a detected temperature value, and the voltage follower circuit is configured to implement impedance isolation between the detection circuit and the central controller.
Specifically, as shown in fig. 8, the thermal loss monitoring unit is a sampling resistor, and forms a voltage dividing circuit with a resistor R4 to divide the voltage VCC to obtain a sampling voltage, the inductor L1, the capacitor C1, the inductor R1, and the capacitor C2 form a two-stage low-pass filter, and the DZ is used for stabilizing the voltage value of Rtemp within a range. U3A then follows the voltage, increasing the input impedance at the input of the ADC. And finally, the obtained voltage is Temp _ check, and the voltage enters an ADC sampling port of the singlechip to be subjected to ADC sampling. And finally obtaining a temperature value through the ADC sampling value, and modeling through the temperature value and the input power and the output power so as to obtain the heat loss.
In a specific embodiment of the present application, the ripple small signal detection circuit includes a signal attenuation circuit, an isolation circuit, an amplification circuit, and an AD conversion circuit, wherein an input of the isolation circuit is connected to the signal attenuation circuit, an output of the isolation circuit is connected to the amplification circuit, an output of the amplification circuit is connected to the AD conversion circuit, the signal attenuation circuit reduces the detection signal, the isolation circuit prevents the dc signal from passing through the ac signal, and then the detection signal is transmitted to the amplification circuit for amplification, and finally the amplified analog data is converted into digital data and then transmitted to the control center.
Specifically, the isolation circuit includes a capacitor, and the AD conversion circuit includes an AD conversion chip.
In a specific embodiment of this application, peak voltage monitor unit includes the bleeder circuit, first maximum value sampling record circuit includes the second grade follower circuit, be provided with voltage memory circuit between the second grade follower circuit, the input voltage signal after will passing through the bleeder circuit, after first grade follower circuit, transmit to voltage memory circuit and save, when the input voltage signal increases, to saving the increased voltage value in the voltage memory circuit, when the input voltage signal reduces, voltage memory circuit keeps the maximum value of input voltage signal, the second grade follower circuit carries out impedance isolation, transmit the input voltage signal maximum value of saving to the control center.
Specifically, as shown in fig. 9, the first maximum value sampling recording circuit includes amplifiers U3A, U3B, diodes D1, D2, and a capacitor C5, the amplifier U3B, as a first-stage follower circuit, follows the sampled value after sampling voltage division, and stores the sampled value after passing through a voltage storage circuit composed of a diode D2 and a capacitor C5, because of the presence of the diode D2, when the input sampled value increases, the value on the capacitor C5 increases, and when the input sampled value decreases, the value on the capacitor C5 remains the maximum value, and then passes through a second-stage follower circuit, and transmits the maximum value on the capacitor C5 to the control center.
In a specific embodiment of the application, the peak current I/V conversion circuit includes a differential circuit, an amplifying circuit, and a maximum value sampling recording circuit, which are connected in sequence, the differential circuit converts the sampled voltage value into a current value, and after the current value is amplified by the amplifying circuit, the current value is sampled by the maximum value sampling recording circuit, and the current value is transmitted to the control center.
Specifically, the amplifying circuit adopts an instrument amplifying circuit, and the amplifying accuracy is improved.
In a specific embodiment of this application, SPI communication interface circuit includes four ways, and the SPI interface connection through resistance and control center respectively, resistance are used for current-limiting and decoupling, and SPI communication interface circuit is used for with outside module integration.
The embodiments of the present invention are preferred embodiments of the present invention, and the scope of the present invention is not limited by these embodiments, so: all equivalent changes made according to the structure, shape and principle of the invention are covered by the protection scope of the invention.
Claims (9)
1. A DCS power system fault diagnosis method is provided, the DCS system comprises at least one power module and a control center, and the DCS power system fault diagnosis method is characterized in that: each power module has a unique ID, and the diagnosis of each power module includes the steps of:
s1, initializing the system;
s2, initializing interrupt configuration;
s3, initializing data;
s4, judging whether the power supply module passes the RAM verification, if so, entering the next step, and if not, turning to S9;
s5, judging whether to request to report fault diagnosis data according to whether the power module has faults, if not, entering the next step, and if yes, turning to S10;
s6, comparing the diagnosed fault with the fault type in the fault library, judging whether the fault diagnosis tree is updated, if not, entering the next step, and if yes, turning to S11;
s7, judging whether the analog quantity data acquisition is finished, if so, entering the next step, and if not, waiting for the acquisition to be finished;
s8, processing ADC data, calculating data of each diagnosis item, and turning to S5;
s9, alarming by the fault of the diagnosis module, and turning to S12;
s10, processing communication, and turning to S12;
s11, updating the fault tree;
and S12, ending.
2. The DCS power system fault diagnosis method of claim 1, wherein: the power supply diagnosis system is characterized by further comprising power supply diagnosis modules, the number of the power supply diagnosis modules is the same as that of the power supply modules, the power supply diagnosis modules are arranged between each power supply module and the control center respectively, each power supply diagnosis module is used for detecting corresponding power supply module parameters and judging the state of each power supply module, the detected parameters, states and addresses of each power supply module are transmitted to the control center through a bus, and the control center diagnoses and warns each power supply module.
3. The DCS power system fault diagnosis method of claim 2, wherein: in step S4, the RAM data in the power supply diagnostic module is verified.
4. The DCS power system fault diagnosis method of claim 2, wherein: the diagnosis item parameters detected by each power supply diagnosis module comprise: input power, input voltage, input current, peak voltage, peak current, ripple peak value, Buck controller switching frequency, power supply conversion efficiency and heat loss detection and analysis.
5. The DCS power system fault diagnosis method of claim 2, wherein: each power supply diagnosis module carries out detection and comprises the following steps:
a1, comparing the detected parameters with corresponding set values to obtain comparison results;
a2, judging whether the comparison result is abnormal, if so, entering the next step, otherwise, selecting the next parameter, and turning to A1;
a3, evaluating a fault symptom mode;
a4, matching with the types in the fault library, if the types can be matched with the types in the fault library, entering the next step, and if the types cannot be matched, updating the fault library;
a5, internal evaluation, and analysis of failure modes possibly caused by faults;
and A6, reporting the fault information and the failure mode to a control center.
6. The DCS power system fault diagnosis method of claim 2, wherein: and the control center transmits the fault information and the failure modes of the power supply diagnosis modules to diagnosis and early warning software for analysis.
7. The DCS power system fault diagnosis method of claim 2, wherein: the power supply diagnosis module comprises a central processing unit, a power supply voltage monitoring unit, a power supply current monitoring unit, a peak voltage monitoring unit, a peak current I/V conversion circuit, a heat loss monitoring unit, a ripple small signal detection circuit, a pulse width frequency detection circuit, an input and output power consumption monitoring circuit and an SPI communication interface circuit, wherein the central processing unit is respectively connected with the power supply voltage monitoring unit, the power supply current monitoring unit, the peak voltage monitoring unit, the peak current I/V conversion circuit, the heat loss monitoring unit, the ripple small signal detection circuit, the pulse width frequency detection circuit, the input and output power consumption monitoring circuit and the SPI communication interface circuit, and each circuit respectively monitors one performance parameter of a power supply.
8. The DCS power system fault diagnosis method of claim 7, wherein: the central processor and the control center realize communication through at least one of SPI, UART and CAN interfaces.
9. The DCS power system fault diagnosis method of claim 1, wherein: the control center comprises a controller and an upper computer, diagnosis and early warning software is arranged in the upper computer, and the controller transmits various data detected by the power supply diagnosis module to the diagnosis and early warning software for processing to obtain a processing result and perform early warning according to the processing result.
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| CN114977492B (en) * | 2022-05-11 | 2024-05-17 | 中海油能源发展装备技术有限公司 | Power supply monitoring and diagnosing method for offshore platform central control system |
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| DE102009013229A1 (en) * | 2009-03-17 | 2010-09-23 | Siemens Aktiengesellschaft | Diagnostic procedure for a fieldbus system designed according to the AS-Interface standard |
| CN204116932U (en) * | 2014-10-21 | 2015-01-21 | 内蒙古包钢钢联股份有限公司 | Expedition pump station control system |
| CN106483472A (en) * | 2015-08-20 | 2017-03-08 | 陕西千山航空电子有限责任公司 | A kind of power system failure diagnostic method based on airborne power supply management and control device |
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| CN108735321A (en) * | 2018-06-22 | 2018-11-02 | 江苏核电有限公司 | A kind of control loop power supply is in alarm device and its verification method |
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