CN-121985055-A - Cross-system cooperative communication system and method based on multiple serial port servers

CN121985055ACN 121985055 ACN121985055 ACN 121985055ACN-121985055-A

Abstract

The invention relates to a cross-system cooperative communication system and a method based on a multi-serial server, and relates to the technical field of communication of a distributed control system, wherein the device comprises a multi-serial server main body, a serial port adaptation module, a protocol conversion module, a data scheduling module, a DCS interface adaptation module, a redundancy backup module and a fault diagnosis module; the method realizes cross-system cooperative communication through serial port equipment access adaptation, multi-protocol unified conversion, DCS priority scheduling, dual-machine redundancy backup and fault self-healing. The invention supports the expansion of multiple serial ports such as RS232/485/422 and the like, is compatible with industrial protocols such as Modbus, profibus, OPC UA and the like, can seamlessly butt-joint a DCS main controller with a PLC, a sensor, an actuator and other external DCS subsystems of different manufacturers, has data transmission delay less than or equal to 10ms and failure switching time less than or equal to 500ms, remarkably improves the reliability, instantaneity and expansibility of cross-platform coordination of the DCS system, and is suitable for industrial control scenes such as chemical industry, electric power, metallurgy and the like.

Inventors

CHENG XIAOWEI
LI HAIYONG
ZHU XIANGKE
SHEN XIAOSONG
ZHOU XUEZHENG
YANG XIUCHENG
YANG JIANFENG
JIANG YOUMING
LI XIANFA

Assignees

重庆大唐国际石柱发电有限责任公司

Dates

Publication Date: 20260505
Application Date: 20251224

Claims (9)

1. A multi-serial server-based cross-system cooperative communication device, comprising: a multi-serial server main body serving as a device core operation and control carrier; The serial port adaptation module is integrated in the multi-serial port server main body, comprises at least 8 paths of configurable serial port interfaces, supports serial port type switching of RS232, RS485 and RS422, and is used for accessing serial port peripheral equipment of a DCS system and serial port communication ports of a different manufacturer subsystem; The protocol conversion module is embedded in the multi-serial port server main body and pre-stores an industrial communication protocol library, wherein the protocol library comprises Modbus RTU/TCP, profibus DP, OPC UA, HART and FF protocols and is used for converting heterogeneous protocol data of different serial port devices and subsystems into standard protocol data compatible with a DCS system; The data scheduling module is electrically connected with the protocol conversion module, adopts a priority queue scheduling mechanism and divides data transmission priority according to the importance of the DCS control instruction so as to ensure the real-time transmission of key data; the DCS interface adapting module is respectively and electrically connected with the data scheduling module and the DCS main controller, supports Profibus DP, etherNet/IP and OPC UA DCS standard communication interfaces and is used for realizing seamless butt joint of the device and a DCS system; the redundant backup module comprises a main multi-serial server and a secondary multi-serial server, wherein the main multi-serial server and the secondary multi-serial server are connected through a heartbeat detection link, and are used for synchronizing communication configuration and data caching in real time, and the secondary multi-serial server is automatically switched to when the main multi-serial server fails; The fault diagnosis module is respectively and electrically connected with the serial port adaptation module, the protocol conversion module and the data scheduling module, realizes fault identification through link connectivity detection, data CRC (cyclic redundancy check) and protocol analysis integrity verification, and generates a fault alarm signal to be fed back to the DCS monitoring center.
2. The cross-system cooperative communication device based on the multi-serial server according to claim 1, wherein the multi-serial server main body adopts an industrial ARM Cortex-A9 processor, the main frequency is more than or equal to 800MHz, a 512MB DDR3 memory and an 8GB flash memory are built in the multi-serial server main body, 24 hours uninterrupted operation is supported, the working temperature range is-40 ℃ to 85 ℃, and the multi-serial server main body is suitable for industrial severe environments.
3. The multi-serial server-based cross-system cooperative communication device according to claim 1, wherein the serial port adaptation module is internally provided with an electrostatic protection circuit and a surge suppression circuit, the protection level accords with IEC 61000-4-2 standard, and the device is suitable for industrial strong electromagnetic interference environments.
4. The multi-serial server-based cross-system cooperative communication device according to claim 1, wherein the protocol conversion module adopts an embedded Linux system architecture, supports online upgrade of a protocol analysis algorithm, and supports remote update of analysis logic of a newly-added industrial protocol through a DCS system.
5. The multi-serial server based cross-system collaborative communication apparatus according to claim 1, wherein the data scheduling module prioritizes data transmissions into control instruction priority > status feedback priority > log data priority.
6. The multi-serial server-based cross-system cooperative communication device according to claim 1, wherein the switching delay of the redundant backup module is less than or equal to 500ms, so as to ensure that data cache is not lost in the switching process and ensure the continuity of control instructions of a DCS system.
7. A cross-system cooperative communication method based on multiple serial port servers, which is applied to the device of any one of claims 1 to 6, and is characterized by comprising the following steps: s1, serial port equipment access and parameter configuration, namely connecting serial port peripheral equipment of a DCS (distributed control system) and a different manufacturer subsystem through a serial port adaptation module, configuring serial port baud rate, data bit and check bit parameters, and matching serial port communication parameters of access equipment; s2, protocol conversion and data standardization, wherein a protocol conversion module reads the communication protocol type of the access equipment, calls a corresponding analysis algorithm in a protocol library and converts heterogeneous protocol data into standard protocol data compatible with a DCS system; S3, cross-system data scheduling and transmission, wherein the data scheduling module ranks the standardized data according to a preset priority, preferentially transmits DCS control instructions and emergency state data, transmits the data to the DCS main controller through the DCS interface adaptation module, and simultaneously receives downlink instructions of the DCS main controller and forwards the downlink instructions to corresponding serial port equipment; S4, redundant backup and fault processing, wherein the redundant backup module monitors the running state of the main multi-serial server in real time through a heartbeat detection link, and synchronizes communication configuration and data caching; And S5, data interaction feedback, namely processing after the DCS main controller receives data, generating a control feedback instruction, transmitting the control feedback instruction to the data scheduling module through the DCS interface adaptation module, and transmitting the control feedback instruction to the corresponding serial port equipment after protocol conversion to complete cross-system cooperative communication closed loop.
8. The cross-system cooperative communication method based on multiple serial port servers according to claim 7, wherein in step S3, the data scheduling module controls data transmission flow by adopting a sliding window mechanism to avoid data congestion of the DCS master controller, and the window size is dynamically adjusted according to the communication bandwidth of the DCS system.
9. The method for collaborative communication across systems based on multiple serial servers according to claim 7, wherein in step S4, the failure recognition type of the failure diagnosis module includes serial link disconnection, packet loss of data transmission, failure of protocol resolution, failure of server hardware, and the alarm signal includes a failure location, a failure type and a failure occurrence time stamp.

Description

Cross-system cooperative communication system and method based on multiple serial port servers Technical Field The invention belongs to the technical field of communication of a distributed control system, and particularly relates to a cross-system cooperative communication system and method based on a multi-serial server. Background The Distributed Control System (DCS) is a core control unit for industrial production (such as chemical industry, electric power and metallurgy) and is responsible for realizing centralized monitoring and distributed control of the production process. In practical application, the DCS system often needs to perform data interaction with various serial devices (such as sensors, actuators, and PLCs) and DCS subsystems of different manufacturers, so as to realize full-flow cooperative control. However, the communication of the existing DCS system has the following technical drawbacks: 1. The serial port resources are insufficient, namely the number of the original serial ports of the traditional DCS main controller is limited (usually 2-4 paths), and the simultaneous access requirement of multiple serial port devices can not be met; 2. the protocol compatibility is poor, namely serial devices and DCS subsystems of different manufacturers adopt heterogeneous communication protocols (such as Modbus, profibus, HART and the like), and a unified protocol conversion mechanism is lacked, so that cross-system data cannot be directly interacted; 3. The real-time performance and the reliability are insufficient, the DCS control instruction needs to be transmitted preferentially in industrial production, but the existing communication mode lacks a priority scheduling mechanism, key data delay is easy to occur, the redundancy backup design is avoided, the communication is interrupted due to the failure of a server, and the production safety is affected; 4. The existing communication device lacks a specific fault diagnosis function, cannot quickly locate faults of links such as serial links, protocol analysis and the like, and increases maintenance cost. Therefore, a need exists for a cross-system collaborative communication system and method that adapts to DCS system requirements, has multi-serial port expansion, multi-protocol compatibility, high reliable redundancy, and real-time scheduling capabilities. Disclosure of Invention The invention aims to provide a cross-system cooperative communication system and method based on a multi-serial server, which are used for solving the technical problems of incompatibility of communication protocols between an existing DCS system and multi-type serial equipment and between different manufacturer subsystems, insufficient serial resources, poor data transmission instantaneity and weak fault redundancy capability. The invention provides a cross-system cooperative communication device based on a multi-serial server, which comprises: a multi-serial server main body serving as a device core operation and control carrier; The serial port adaptation module is integrated in the multi-serial port server main body, comprises at least 8 paths of configurable serial port interfaces, supports serial port type switching of RS232, RS485 and RS422, and is used for accessing serial port peripheral equipment of a DCS system and serial port communication ports of a different manufacturer subsystem; The protocol conversion module is embedded in the multi-serial port server main body and pre-stores an industrial communication protocol library, wherein the protocol library comprises Modbus RTU/TCP, profibus DP, OPC UA, HART and FF protocols and is used for converting heterogeneous protocol data of different serial port devices and subsystems into standard protocol data compatible with a DCS system; The data scheduling module is electrically connected with the protocol conversion module, adopts a priority queue scheduling mechanism and divides data transmission priority according to the importance of the DCS control instruction so as to ensure the real-time transmission of key data; the DCS interface adapting module is respectively and electrically connected with the data scheduling module and the DCS main controller, supports Profibus DP, etherNet/IP and OPC UA DCS standard communication interfaces and is used for realizing seamless butt joint of the device and a DCS system; the redundant backup module comprises a main multi-serial server and a secondary multi-serial server, wherein the main multi-serial server and the secondary multi-serial server are connected through a heartbeat detection link, and are used for synchronizing communication configuration and data caching in real time, and the secondary multi-serial server is automatically switched to when the main multi-serial server fails; The fault diagnosis module is respectively and electrically connected with the serial port adaptation module, the protocol conversion module and the data scheduling module, realizes fa