CN111103811A - Control system semi-physical simulation platform - Google Patents
Control system semi-physical simulation platform Download PDFInfo
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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
- G05B17/00—Systems involving the use of models or simulators of said systems
- G05B17/02—Systems involving the use of models or simulators of said systems electric
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/058—Safety, monitoring
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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
- G05B2219/10—Plc systems
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Abstract
The invention discloses a semi-physical simulation platform of a control system, which comprises a real PLC control subsystem, a virtual simulation subsystem and a modeling subsystem; the real PLC control subsystem is built according to an industrial field real control system to be simulated, a control program and a monitoring program in the industrial field real control system to be simulated are set, and the control program is executed based on an output signal sent by the virtual simulation subsystem; the virtual simulation subsystem is used for driving a virtual model provided by the modeling subsystem and sending an output signal of the virtual model to the real PLC control subsystem; the modeling subsystem is used for constructing a virtual model and injecting the virtual model into the simulation subsystem. The semi-physical hybrid simulation platform can meet the simulation requirement of an industrial control system which adopts a PLC as a controller, can develop modeling work from two aspects of the physical mechanism and data analysis of the industrial system, and has better adaptability, expansibility and reusability.
Description
Technical Field
The invention relates to the technical field of PLC (programmable logic controller) industrial control, in particular to a semi-physical simulation platform of a control system.
Background
In the field of industrial automatic control, a control system based on a PLC (programmable logic controller) generally exists, and in the engineering practice of the automatic system, various requirements such as improvement of the structure and process design of the system, optimization of a control algorithm, development of operation training and the like exist all the time. However, since it is too costly to construct an industrial control system including real physical objects, simulation by computer technology becomes the first strategy to be studied. In the fields of aircrafts, ship driving and the like, semi-physical simulation plays an important role in personnel training, but in the field of industrial automatic control, particularly, simulation platforms and tools for PLC control systems are rarely reported, and the main reason is that the industrial systems relate to various physical objects and physical processes such as machines, electricity, solids, gases, liquids and the like, the system interior and the system are mutually associated and coupled, and an open, expandable and high-adaptability simulation platform is needed.
Chinese patent publication No. CN109100955A discloses a semi-physical simulation control test platform and a test method thereof, the test platform includes: the system comprises a laboratory controller I, a computer, mathematical software on the computer and a virtual controlled object obtained by modeling an industrial field real controlled object through the mathematical software. When the controller I carries out simulation control on the virtual controlled object through the computer, the control parameters can be repeatedly adjusted on the controller I for optimization, and the optimized control parameters can be provided for a field controller II for controlling the real controlled object in an industrial field. However, the controller I and the computer running the virtual controlled object adopt TCPIP communication, and the PLC controller and the controlled object in the real system communicate in a bus manner through a hardware IO interface, so the method can only optimize the control parameters of the control system, and cannot completely simulate information interaction between the controller and the controlled object, and the information interaction process relates to the control timing and control logic of control software, and is an important component of the control program.
The invention discloses a semi-physical simulation test method, a device and a system, which is disclosed by Chinese invention patent with publication number CN107678307A, and the semi-physical simulation test method comprises the steps of receiving a test item selected by a user, wherein the test item is associated with a test item identifier, calling a test program in a test kit corresponding to the item, generating and sending a test instruction to a corresponding controller, so that the controller sends an execution instruction to a data acquisition device, calling a motion parameter sent by the data acquisition device from a server according to the test item identifier, wherein the data acquisition device comprises an evaluation program in the test kit corresponding to a lower computer calling the test item identifier loaded with a real-time simulation model, analyzing and calculating the motion parameter, and obtaining a test result. The virtual simulation object of the invention is limited to a robot model, and the structure of the semi-physical simulation test method of the invention is also different from the real structure of a general PLC industrial control system, so the method of the invention is not suitable for the simulation of the PLC-based industrial automation system.
Disclosure of Invention
In view of the above problems, an object of the present invention is to provide a semi-physical simulation platform for a control system, which can meet the simulation requirements of a class of industrial control systems using a PLC as a controller, can perform modeling work from two aspects of physical mechanism and data analysis of the industrial system, and has good adaptability, expansibility and reusability.
In order to achieve the purpose, the invention adopts the following technical scheme: a control system semi-physical simulation platform comprises a real PLC control subsystem, a virtual simulation subsystem and a modeling subsystem; the real PLC control subsystem is built according to an industrial field real control system to be simulated, a control program and a monitoring program in the industrial field real control system to be simulated are set, and the control program is executed based on an output signal sent by the virtual simulation subsystem; the virtual simulation subsystem is used for driving a virtual model provided by the modeling subsystem and sending an output signal of the virtual model to the real PLC control subsystem; the modeling subsystem is used for constructing the virtual model and injecting the virtual model into the simulation subsystem.
Furthermore, the real PLC control subsystem comprises an upper computer, more than one real physical PLC controllers, first signal input modules and first signal output modules, wherein the number of the first signal input modules corresponds to the number of the real physical PLC controllers; each real physical PLC controller is connected with the upper computer through a bus, connected with the corresponding first signal input module and first signal output module through a backboard bus or a PLC expansion module, and connected with the virtual simulation subsystem through cables; each real physical PLC controller is loaded with a control program and used for executing the control program according to the output signal of the virtual model in the virtual simulation subsystem; and the upper computer is loaded with a monitoring program and is used for monitoring the control program loaded in the real physical PLC.
Furthermore, the upper computer, each real physical PLC controller, the first signal input module and the first signal output module are consistent with the settings of the real industrial field control system to be simulated.
Further, the control program loaded in the real physical PLC controller and the monitoring program loaded in the upper computer are consistent with the control program and the monitoring program operated in the real industrial field control system to be simulated.
Furthermore, the virtual simulation subsystem comprises a simulation server and more than one second signal input module, a second signal output module and a signal conversion module, and the number of the second signal input module, the number of the second signal output module and the number of the signal conversion module are consistent with the number of real physical PLC controllers in the real PLC control subsystem; each second signal input module receives a control instruction of each real PLC control subsystem, the control instruction is input to a virtual model stored in the simulation server after being subjected to signal conversion by the signal conversion module, and a signal output by the virtual model is output to a corresponding real physical PLC controller in the real PLC control subsystem through the second signal output module after being subjected to signal conversion by the signal conversion module.
Furthermore, each second signal input module is connected with a corresponding first signal output module in the real PLC control subsystem through a cable, and each second signal output module is connected with a corresponding first signal input module in the real PLC control subsystem through a cable.
Further, the modeling subsystem comprises a model building module and a historical database; the model building module is used for building a virtual model of the industrial field control system to be simulated; the historical database is used for storing historical operation data of the industrial field control system to be simulated.
Furthermore, the virtual model constructed by the modeling subsystem comprises two types, namely, starting from the mechanism analysis of the physical object, constructing the virtual model of the physical object; and the other is a virtual model established by using historical operating data of the industrial field control system to be simulated.
Due to the adoption of the technical scheme, the invention has the following advantages: 1. the control system semi-physical simulation platform provided by the invention divides the whole platform into a real PLC control subsystem, a virtual simulation subsystem and a modeling subsystem, so that the decoupling between the interior of the system and the system is realized, each system can be independently modified, and the expandability and the applicability are effectively enhanced. 2. The real PLC control subsystem is completely consistent with the real industrial field system to be simulated, and the control program and the monitoring program in the real PLC control subsystem are completely consistent with the program operated in the real industrial field system to be simulated, so that the obtained related parameters are more easily and directly applied to the industrial field control system. 3. According to the invention, the real PLC control subsystem and the virtual simulation subsystem are connected through a cable, so that information interaction between the controller and the controlled object can be completely simulated, and the obtained control parameters are more suitable for an industrial field control system. 4. The virtual model constructed by the modeling subsystem can be implanted into the virtual simulation subsystem and is communicated and interacted with the PLC control subsystem, wherein the virtual model can be established by starting from physical object mechanism analysis, and can also be established by utilizing historical data of a real system, so that a platform and a test environment can be provided for the optimization design, control algorithm improvement and the like of an industrial system. Therefore, the invention can be widely applied to the technical field of PLC industrial control.
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FIG. 1 is sample 1 of one embodiment of the present invention;
FIG. 2 is another embodiment of the present invention, sample 2;
in the figures, the various reference numerals are as follows: 1. a real PLC control subsystem; 2. a virtual simulation subsystem; 3. a modeling subsystem; 4. an upper computer; 5. a bus; 6. a true physical PLC controller; 7. a first signal input module; 8. a first signal output module; 9. a second signal output module; 10. a second signal input module; 11. a cable; 12. a signal conversion module; 13. a network; 14. a simulation server; 15. a simulation modeling tool; 16. a model building module; 17. a history database.
Detailed Description
The invention is described in detail below with reference to the figures and examples.
As shown in fig. 1, the semi-physical simulation platform for the control system provided by the invention comprises a real PLC control subsystem 1, a virtual simulation subsystem 2 and a modeling subsystem 3. The real PLC control subsystem 1 is built according to an industrial field real control system to be simulated, a control program and a monitoring program in the industrial field real control system to be simulated are set, and the control program is executed based on an output signal sent by the virtual simulation subsystem 2; the virtual simulation subsystem 2 is used for driving a virtual model provided by the modeling subsystem 3 and sending an output signal of the virtual model to the real PLC control subsystem 1; the modeling subsystem 3 adopts a simulation modeling tool or builds a virtual model through two modes of historical data analysis of a real control system and the like, and injects the built virtual model into the virtual simulation subsystem 2.
Further, the real PLC control subsystem 1 includes an upper computer 4, more than one real physical PLC controllers 6, first signal input modules 7 and first signal output modules 8, the number of which corresponds to the number of the real physical PLC controllers 6. Each real physical PLC controller 6 is connected with the upper computer 4 through a bus 5, is connected with a corresponding first signal input module 7 and a corresponding first signal output module 8 through a backboard bus or a PLC extension module, and is connected with the virtual simulation subsystem 2 through a cable, wherein each first signal input module 7 and each first signal output module 8 are connected with the virtual simulation subsystem 2 through a cable; each real physical PLC controller 6 is loaded with a control program and used for executing the control program according to the output signal of the virtual model in the virtual simulation subsystem 2; the upper computer is loaded with a monitoring program for monitoring the control program in the real physical PLC controller 6.
Further, the upper computer 4, the real physical PLC controller 6, the first signal input module 7 and the first signal output module 8 are completely consistent with the real control system of the industrial field to be simulated; the control program in the real physical PLC controller 6 and the monitoring program loaded in the upper computer 4 are completely consistent with the program running in the real industrial field control system to be simulated.
Further, the adaptability of the real PLC control subsystem 1 is realized by flexibly assembling or expanding the real physical PLC controller 6 with the signal input module 7 and the signal output module 8, so that the system can be adapted to different industrial control systems.
Further, the virtual simulation subsystem 2 includes a simulation server 14 and one or more second signal input modules 10, second signal output modules 9, and signal transformation modules 12. Wherein, the number of the second signal input modules 10, the second signal output modules 9 and the signal transformation modules 12 is the same as the number of the real physical PLC controllers 6 in the real PLC control subsystem 1. The second signal input module 10 is connected with the corresponding first signal output module 8 in the real PLC control subsystem 1 through a cable 11, and the second signal output module 9 is connected with the corresponding first signal input module 7 in the real PLC control subsystem 1 through a cable 11; the second signal input module 10 receives a control instruction of the real PLC control subsystem, performs signal transformation by the signal transformation module 12, and inputs the control instruction to the virtual model stored in the simulation server 14 through the network 13, and the signal output by the virtual model is subjected to signal transformation by the signal transformation module 12 and then output to the corresponding real physical PLC controller 6 in the real PLC control subsystem 1 through the second signal output module 9.
Further, the virtual simulation server 14 may run different types of simulation platform software, and the virtual model is driven to run by the simulation platform software, wherein the simulation platform software includes but is not limited to analog, Modelica, and the like.
Further, the modeling subsystem comprises a model building module 16 and a historical database 17, wherein the model building module 16 is used for deploying various physical fields of temperature, fluid, structural mechanics, electricity and the like and multi-agent based simulation modeling tools 15, including but not limited to ANSYS, FLUENT, MATLAB and the like, and uploading the built virtual model to the simulation server 14 of the virtual simulation subsystem 2 through a network; the historical database 17 is used to store a large amount of data of the real industrial system operation.
Further, the model construction module 16 may construct two types of virtual models, one is to construct a black box virtual model of a physical object starting from the mechanism analysis of the physical object; and secondly, establishing a virtual model by using historical operating data of the real industrial system.
A first embodiment of the invention is shown in fig. 1 and described below.
1) Establishing a real PLC control subsystem 1, wherein the real PLC control subsystem 1 comprises an upper computer 4, a real PLC controller 6, a signal input module 7, a signal output module 8 and the like; the upper computer 4 and the PLC controller 6 are connected by a bus 5, and the bus 5 is usually a Profibus DP bus if S7-300 or S7-400 PLC of siemens is adopted. Then, injecting an industrial field real control program and a monitoring program into a PLC controller 6 and an upper computer 4 in the real PLC control subsystem 1;
2) establishing a virtual simulation subsystem 2, wherein the virtual simulation subsystem 2 comprises a signal output module 9, a signal input module 10, a signal transformation module 12 and a simulation server 14, a signal input module 7 of a real PLC control subsystem 1 is directly connected with the signal output module 9 in the virtual simulation subsystem 2 through a cable 11, and a signal output module 8 in the real PLC control subsystem 1 is directly connected with the signal input module 10 in the virtual simulation subsystem 2 through the cable 11; the signal input module 10 and the signal output module 9 are connected with the signal conversion module 12, and the signals after conversion processing are communicated with the simulation server 14 through the network 13.
3) A modeling subsystem 3 is established, the modeling subsystem 3 including a simulation modeling software tool 15, a model building module 16, and a historical database 17. The simulation modeling software tool 15 is selected as follows: the multi-agent modeling software may preferably be analog, the mathematical equation-based modeling tool may preferably be Modelica, the physical field modeling tool may preferably be a modeling tool such as Fluent, ANSYS, etc., and the electromechanical device modeling tool may preferably be Modelica. Furthermore, the data provided by the historical database 17 may be used for modeling. The virtual model generated on model build module 16 may be uploaded to virtual simulation server 14 for a simulation run. Taking Building heating ventilation air conditioning system modeling as an example, preferably Building a virtual model of electromechanical devices such as a fan, a water pump, a valve, a cold machine and the like in a Building library of the Modelica, and communicating with a signal input and output module of the real PLC control subsystem 1 through a connector module in the Modelica.
Fig. 2 shows a second embodiment of the present invention. The difference between example 2 and example 1 mainly includes two aspects: firstly, the real PLC control subsystems 1 are different, and in embodiment 2, the scale of the real PLC control subsystem 1 is expanded by increasing the number of the PLC controllers 6, the signal input modules 7 and the signal output modules 8 in the real PLC control subsystem 1; and secondly, the modeling subsystem 3 is different, and the modeling subsystem 3 can also carry out simulation by carrying out mechanism modeling through a simulation modeling tool under the condition of no historical data.
A specific embodiment is given above, but the invention is not limited to the described embodiment. The basic idea of the present invention lies in the above solution, and it is obvious to those skilled in the art that it is not necessary to spend creative efforts to design various modified models, formulas and parameters according to the teaching of the present invention. Variations, modifications, substitutions and alterations may be made to the embodiments without departing from the principles and spirit of the invention, and still fall within the scope of the invention.
Claims (8)
1. A control system semi-physical simulation platform is characterized in that: the system comprises a real PLC control subsystem, a virtual simulation subsystem and a modeling subsystem;
the real PLC control subsystem is built according to an industrial field real control system to be simulated, a control program and a monitoring program in the industrial field real control system to be simulated are set, and the control program is executed based on an output signal sent by the virtual simulation subsystem;
the virtual simulation subsystem is used for driving a virtual model provided by the modeling subsystem and sending an output signal of the virtual model to the real PLC control subsystem;
the modeling subsystem is used for constructing the virtual model and injecting the virtual model into the simulation subsystem.
2. The semi-physical simulation platform of a control system according to claim 1, wherein: the real PLC control subsystem comprises an upper computer, more than one real physical PLC controllers, first signal input modules and first signal output modules, wherein the number of the first signal input modules corresponds to the number of the real physical PLC controllers;
each real physical PLC controller is connected with the upper computer through a bus, connected with the corresponding first signal input module and first signal output module through a backboard bus or a PLC expansion module, and connected with the virtual simulation subsystem through cables;
each real physical PLC controller is loaded with a control program and used for executing the control program according to the output signal of the virtual model in the virtual simulation subsystem;
and the upper computer is loaded with a monitoring program and is used for monitoring the control program loaded in the real physical PLC.
3. The semi-physical simulation platform of a control system according to claim 2, wherein: the upper computer, each real physical PLC controller, the first signal input module and the first signal output module are consistent with the real control system of the industrial field to be simulated.
4. The semi-physical simulation platform of a control system according to claim 2, wherein: and the control program loaded in the real physical PLC controller and the monitoring program loaded in the upper computer are consistent with the control program and the monitoring program operated in the real industrial field control system to be simulated.
5. The semi-physical simulation platform of a control system according to claim 2, wherein: the virtual simulation subsystem comprises a simulation server and more than one second signal input module, a second signal output module and a signal transformation module, and the number of the second signal input module, the number of the second signal output module and the number of the signal transformation module are consistent with the number of real physical PLC controllers in the real PLC control subsystem;
each second signal input module receives a control instruction of each real PLC control subsystem, the control instruction is input to a virtual model stored in the simulation server after being subjected to signal conversion by the signal conversion module, and a signal output by the virtual model is output to a corresponding real physical PLC controller in the real PLC control subsystem through the second signal output module after being subjected to signal conversion by the signal conversion module.
6. The semi-physical simulation platform of a control system according to claim 5, wherein: each second signal input module is connected with a corresponding first signal output module in the real PLC control subsystem through a cable, and each second signal output module is connected with a corresponding first signal input module in the real PLC control subsystem through a cable.
7. The semi-physical simulation platform of a control system according to claim 1, wherein: the modeling subsystem comprises a model building module and a historical database; the model building module is used for building a virtual model of the industrial field control system to be simulated; the historical database is used for storing historical operation data of the industrial field control system to be simulated.
8. The semi-physical simulation platform of a control system according to claim 7, wherein: the virtual model constructed by the modeling subsystem comprises two types, namely, starting from the mechanism analysis of a physical object, constructing the virtual model of the physical object; and the other is a virtual model established by using historical operating data of the industrial field control system to be simulated.
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| CN112182867A (en) * | 2020-09-21 | 2021-01-05 | 上海机电工程研究所 | Aircraft hybrid simulation test method and system |
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| CN112182867A (en) * | 2020-09-21 | 2021-01-05 | 上海机电工程研究所 | Aircraft hybrid simulation test method and system |
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