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CN-121979325-A - High-reliability multi-sensor redundant temperature control system and fault switching system

CN121979325ACN 121979325 ACN121979325 ACN 121979325ACN-121979325-A

Abstract

The invention discloses a high-reliability multi-sensor redundant temperature control system and a fault switching system, which relate to the technical field of industrial automatic control and comprise a multi-sensor redundant temperature acquisition module, a multi-channel signal isolation and preprocessing module, a redundant control logic operation core module, a two-way temperature control execution driving module, a fault on-line diagnosis and positioning module, a non-disturbance fault switching control module, a full-flow state monitoring and storage module, a multi-terminal interaction and linkage control module and a safety interlocking protection module; the system can realize multi-path independent temperature acquisition, closed-loop temperature control operation, full-link fault diagnosis and positioning, main-standby link undisturbed switching, running state monitoring storage and hierarchical safety interlocking protection, the invention adopts a full-link redundancy architecture, the intelligent control system has the advantages of rapid fault identification and undisturbed switching capacity, dual safety protection of software and hardware, stable and reliable operation, capability of avoiding single-point fault risks, and suitability for industrial temperature control scenes with high reliability requirements.

Inventors

  • WU JUN
  • ZHANG YONGLIN

Assignees

  • 南京欧能机械有限公司

Dates

Publication Date
20260505
Application Date
20260402

Claims (10)

  1. 1. The high-reliability multi-sensor redundant temperature control system and the fault switching system are characterized by comprising the following modules: The multi-sensor redundant temperature acquisition module adopts at least three temperature measurement sensing units with the same specification, the temperature measurement sensing units are distributed at core temperature measurement points of a temperature controlled object, each sensing unit adopts an electrical isolation design, acquisition links are mutually independent, and an acquisition signal linearly corresponding to a temperature value is output; The multichannel signal isolation and preprocessing module adopts a multichannel independent electrical isolation structure to carry out synchronous filtering, linearization correction and noise reduction processing on each channel of acquisition signals so as to complete signal analog-to-digital conversion; the redundant control logic operation core module adopts a two-way heterogeneous control chip architecture, the main control core and the standby control core synchronously operate a temperature control algorithm, closed-loop logic operation is executed based on multi-channel temperature acquisition data and a set temperature control threshold value, a temperature control adjustment instruction is generated, the operation states of the main core and the standby core are synchronous in real time, and operation results are checked mutually; the two-way temperature control execution driving module adopts a two-way independent redundant driving circuit to receive control operation instructions and drive the execution elements, and the two driving links are mutually independent and respectively correspond to the main temperature control execution elements and the standby temperature control execution elements; The fault on-line diagnosis and positioning module is internally provided with a multidimensional fault diagnosis algorithm, acquires the running state data of each path of sensing link, the control core and the driving link in real time, compares the normal running parameter threshold value to perform fault identification, and generates a fault type and grade judgment result; The undisturbed fault switching control module triggers the switching of the main link and the standby link when the main link fails according to the fault diagnosis result, and isolates and locks the state of the failed link; The full-flow state monitoring and storing module is used for collecting temperature data, control instructions, running states and fault event data of the system operation in real time, locally storing the data and supporting history backtracking inquiry; The multi-terminal interaction and linkage control module establishes communication connection with the upper computer control system and the field operation terminal, uploads the running state of the system to the distributed control system, and executes multi-equipment linkage control; the safety interlocking protection module is internally provided with a multi-stage safety interlocking logic, and triggers a safety protection action when a system fails, cuts off the output of a failure loop and triggers an acousto-optic early warning signal.
  2. 2. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, further comprising a multi-sensor space layout adapting module, wherein the module optimizes the installation point position and the arrangement distance of the sensing unit according to the thermal field distribution simulation result of the temperature controlled object, embeds a space temperature gradient compensation algorithm, and corrects thermal field deviation of the collected data of each point position.
  3. 3. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, further comprising a two-way power supply redundant power supply module, wherein the module adopts a two-way independent alternating current-direct current power supply architecture, the two-way power supplies are mutually hot standby, when a single-way power supply fails, the power supply is automatically switched to the other power supply for power supply, and an overvoltage, overcurrent, overheat and short-circuit protection circuit is arranged in the module to protect a power supply loop in real time.
  4. 4. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, wherein the redundancy control logic operation core module is internally provided with a multi-path temperature data dynamic fusion unit, and generates an effective temperature reference value of temperature control through multi-link data weighted fusion calculation, wherein the calculation formula is as follows: Wherein For the effective value of the temperature after the fusion, For the total number of redundant sensing units, Is the first The dynamic weight coefficients of the road sensing units, Is the first The real-time temperature acquisition value of the road sensing unit is equal to 1, and the sum of all dynamic weight coefficients is equal to 1.
  5. 5. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, wherein a multi-dimensional fault feature library is arranged in the fault on-line diagnosis and positioning module, the full-link fault hierarchical diagnosis is carried out on the sensing link, the control core and the driving loop, and the fault type, the fault point location and the fault level are determined based on the fault feature matching result.
  6. 6. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, wherein a main-standby link state pre-synchronization unit is built in the undisturbed fault switching control module, operation data, an operation state and control parameters of a main-standby control core are synchronized in real time, the standby link state pre-loading is completed before the fault switching, a smooth transition algorithm is adopted to carry out incremental connection on control output instructions, and after the switching is completed, the main-standby link role redefinition and state verification are executed, and the fault link is electrically isolated and state locked.
  7. 7. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, wherein the fault on-line diagnosis and positioning module is further provided with a system fault risk quantification evaluation unit, and the overall fault risk level of the system is generated through multi-dimensional fault feature weighted calculation, and the calculation formula is as follows: Wherein To quantify the value of the risk of a system failure, As a total number of fault signature dimensions, Is the first The risk weighting coefficient of the term failure feature, Is the first The deviation degree value of the item fault characteristic parameter relative to the normal threshold value is calculated, risk weight distribution is adaptively adjusted by the unit based on the system operation time length, the environment working condition and the historical fault condition, and the multidimensional fault characteristic is subjected to weighted fusion, so that quantitative evaluation of the system fault risk is realized.
  8. 8. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1 are characterized in that the full-process state monitoring and storage module is further internally provided with a device health state assessment unit, the unit is used for constructing a device health state quantitative assessment model based on temperature data stability, control action execution precision, fault occurrence frequency and parameter drift amplitude of long-term operation of the system, quantitatively assessing the aging degree of a sensing element, performance attenuation of an executing element and control core operation state to generate maintenance reminding information, and performing desensitization storage and compliance export on operation data to generate a system full life cycle operation report.
  9. 9. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, wherein the multi-terminal interaction and linkage control module further comprises a multi-protocol industrial communication adapting unit which adapts various industrial field buses and Ethernet communication protocols and is in communication connection with a programmable logic controller, a distributed control system and a data acquisition and monitoring control system, so that remote setting of temperature control parameters, real-time uploading of running states and remote issuing of control instructions are realized, and the unit is provided with a three-level operation authority hierarchical control mechanism for operation checking, parameter setting and system management, and multi-user hierarchical operation and full-flow operation log preservation are performed.
  10. 10. The high-reliability multi-sensor redundant temperature control system and the fault switching system according to claim 1, wherein a safety interlocking protection module is internally provided with a grading overtemperature interlocking protection logic, the grading overtemperature interlocking protection logic divides a multi-level protection level based on an overtemperature amplitude and a heating rate, corresponding triggering early warning, power reduction operation, emergency shutdown and fault loop cutting protection actions, the module adopts a hardware-level independent interlocking protection circuit and forms a double protection framework with a software control logic, the hardware interlocking circuit independently executes the emergency protection actions of overtemperature, short circuit and out-of-control faults, the interlocking protection action events are uploaded to an upper computer system, and multi-terminal acousto-optic early warning is triggered.

Description

High-reliability multi-sensor redundant temperature control system and fault switching system Technical Field The invention relates to the technical field of industrial automatic control, in particular to a high-reliability multi-sensor redundant temperature control system and a fault switching system. Background In the whole industrial production process, accurate and stable control of temperature parameters is a core link for guaranteeing production safety, product quality and stable operation of equipment, and in a plurality of high-end industrial fields such as precision equipment manufacturing, chemical synthesis reaction, power equipment operation, new energy storage, rail transit vehicle-mounted equipment and the like, a controlled object has strict requirements on continuity, accuracy and reliability of temperature control, temperature control deviation, control interruption or out of control can not only lead to product precision not reaching standards, production process interruption, but also possibly cause serious consequences such as equipment damage, safety production accidents and the like. Along with the continuous acceleration of industrial high-end and intelligent transformation processes in China, the industrial field has higher requirements on the long-term operation stability, fault coping capacity and continuous uninterrupted operation capacity of the temperature control system, the traditional single-link temperature control system only adopts the architecture design of single-path sensing acquisition, single control core and single driving link, and single-point faults occur in any link, so that the control failure of the whole temperature control system can be directly caused, and the high reliability requirement of the high-end industrial scene on the temperature control system can not be met. The prior temperature control system with redundant design still has a plurality of technical defects in architecture design and control logic, most products only increase standby temperature measuring elements in sensing acquisition links, the redundant design of all links of acquisition, control, driving and power supply is not realized, a control core still adopts a single-chip architecture, once the control core has program run-out and hardware damage faults, the whole system still falls into a paralysis state, meanwhile, the multi-channel sensing data fusion capability of the prior system is insufficient, multi-channel acquisition data is processed by adopting a simple average value calculation mode, the data weight cannot be dynamically adjusted according to the running state of the sensing links, and the final temperature control precision is directly influenced and even the wrong control action is caused when the single-channel sensing data has deviation and drift. The fault diagnosis capability of the existing system is weak, only simple signal interruption faults can be identified, full-link layered diagnosis of a sensing link, a control core and a driving loop cannot be realized, the point position and the type of the fault cannot be accurately positioned, the fault identification response speed is low, and the problem that fault disposal is not timely is easily caused is solved. Meanwhile, the existing system is imperfect in fault switching design, the problems of control output interruption and parameter jump easily occur in the switching process of the main link and the standby link, the temperature of a controlled object can be greatly fluctuated, undisturbed smooth switching can not be realized, and the continuity and the stability of the temperature control process are seriously influenced. The existing temperature control system also has obvious short boards in the aspects of safety protection and intelligent adaptation, the safety interlocking protection of most products only depends on software control logic, when a software program fails, the safety protection function can be failed synchronously, an independent hardware-level interlocking protection architecture is lacking, double safety protection cannot be formed, and obvious potential safety hazards exist. The existing system lacks the equipment health state evaluation capability of full life cycle, can not identify potential hidden troubles of aging of a sensing element and performance attenuation of an executive element according to long-term operation data, can only perform passive treatment after faults occur, not only increases site operation and maintenance cost, but also can not avoid fault shutdown risks in advance, meanwhile, the existing system has insufficient linkage adaptation capability with an industrial site distributed control system and a data acquisition system, has poor communication protocol compatibility, can not realize remote control and multi-equipment linkage control of temperature control parameters, and is difficult to adapt to the intelligent control requirement of a modern industrial auto