CN-121995837-A - Cloud edge cooperative virtual controller architecture, adaptation and implementation method

CN121995837ACN 121995837 ACN121995837 ACN 121995837ACN-121995837-A

Abstract

The invention discloses a cloud edge cooperative virtual controller architecture, an adaptation and an implementation method, and relates to the technical field of industrial automation control. The virtual controller adopts a three-layer architecture of a cloud/upper engineering layer, an edge control layer and a field device layer, an industrial control software and an industrial control mechanism are used for constructing a core control unit to realize high-real-time and high-stability control of an industrial field, an operation mechanism corrects the defects of the traditional logic sequence and ensures the control reliability through a closed loop flow of upper computer programming configuration, edge run time starting initialization, program downloading verification and real-time communication coordination, and a protocol adaptation module supports interconnection, intercommunication and conversion of a plurality of industrial protocols such as Modbus, etherCAT, profinet and the like. The invention does not need to rely on a complex hardware architecture, solves the problems of poor protocol compatibility, insufficient instantaneity and low deployment flexibility of the traditional controller through deep cooperative optimization of software and industrial-grade hardware, is applicable to various industrial automation scenes, and meets the severe requirements of industrial sites in protocol communication success rate and control response performance through third party detection and verification.

Inventors

XIA CHANGQING
YU JISONG
ZHAO JINLONG
LI DONG
ZENG PENG
XU CHI
YU HAIBIN

Assignees

中国科学院沈阳自动化研究所

Dates

Publication Date: 20260508
Application Date: 20260122

Claims (8)

1. Cloud edge cooperative virtual controller architecture, its characterized in that includes: The cloud/upper engineering layer is provided with industrial control software and special supporting software, is used for configuring hardware resources meeting the requirements of control logic development and simulation through the industrial control software, and performs data interaction with the edge control layer through a TCP/IP protocol; The edge control layer is used for carrying out logic operation on the physical quantity data collected by the field device layer, generating a control instruction and sending the control instruction to the field device layer through a special industrial interface; The field device layer is used for collecting physical quantity data of the industrial field, sending the physical quantity data to the edge control layer through the special industrial interface and executing corresponding actions according to the control instruction pair.
2. The cloud-edge cooperative virtual controller architecture according to claim 1, wherein the industrial control software supports multiple programming languages and has control logic programming, simulation debugging, communication parameter configuration, IO mapping, device status monitoring and fault alarm functions.
3. The cloud-edge cooperative virtual controller architecture of claim 1, wherein the edge control layer comprises: The run time environment is used for initializing a protocol adaptation module, checking and loading a control program, processing acquired data, generating a control instruction, maintaining a communication link and feeding back fault information; The protocol adaptation module is used for identifying communication characteristics of corresponding protocols through a plurality of protocol special adaptation components, performing format conversion on protocol data sent by the field device layer and maintaining a communication link between the protocol data and the field device layer; The data buffer unit is used for temporarily storing the collected field device data and the control instruction to be issued.
4. The cloud-edge cooperative virtual controller architecture of claim 1, wherein the field device layer comprises: the sensor is used for collecting physical quantity data of an industrial field; The executor is used for executing the control instruction issued by the edge control layer; and the IO module is used for expanding the input/output interface of the equipment.
5. The implementation method of the cloud edge cooperative virtual controller architecture is characterized by comprising the following steps of: 1) Control logic programming is carried out in industrial control software of a cloud/upper engineering layer, communication parameters, IO mapping relation and starting parameters are configured according to industrial control requirements, and the logic correctness of a program is verified through off-line simulation; 2) Starting a run time environment of an edge control layer, initializing a protocol adaptation module, detecting a connection state among the modules and communication link connectivity with a cloud/upper engineering layer, feeding back fault information if abnormality exists, and continuously retrying until the state is normal; 3) Only when the run time is started and the communication link is communicated, downloading the written control program to the industrial personal computer of the edge control layer through a TCP/IP protocol, and checking the integrity of the program by the industrial personal computer; 4) The run time environment loads and executes a control program passing verification, sensor data of a field device layer are collected in real time through a protocol adaptation module, and a control instruction is generated according to control logic calculation; 5) And simultaneously, the equipment running state data is fed back to the cloud/upper engineering layer to realize real-time monitoring and fault alarm.
6. The method for implementing a cloud-edge cooperative virtual controller architecture according to claim 5, wherein the protocol adaptation module designs dedicated adaptation logic for Modbus, etherCAT, profinet industrial protocols respectively, automatically identifies a protocol type of a field device, and invokes a corresponding protocol library to complete data format conversion, communication link establishment and fault handling, wherein the adaptation logic specifically comprises: For Modbus protocol adaptation, configuring communication parameters through ModbusTCP master-slave station mode, setting address, port, response timeout and reconnection mechanism of the adaptation industry scene, realizing data interaction through function code configuration, and establishing association between protocol data and control logic variables through IO mapping; for EtherCAT protocol adaptation, configuring synchronous unit allocation, process data mapping and starting parameters of master and slave stations, realizing equipment management and real-time data transmission by adopting the EtherCAT protocol, and supporting interaction of digital quantity and analog quantity; and for the Profinet protocol adaptation, configuring communication parameters and real-time communication types of the master station and the slave station, setting a sending period and a watchdog mechanism, and realizing mapping and collaborative interaction of input and output data through IO configuration.
7. Control system based on cloud limit cooperation virtual controller framework, characterized by comprising: The dependent task scene construction module is used for constructing a control logic programming environment in a cloud/upper engineering layer, configuring communication parameters and IO mapping relation, and verifying the correctness of the program through off-line simulation; the run time starting initialization module is used for starting an edge control layer run time environment, initializing the multi-protocol adaptation module and detecting equipment connection, a communication link and hardware resource states; the program downloading verification module is used for transmitting a control program through a TCP/IP protocol, verifying the integrity of the program by adopting a verification algorithm and storing the verification algorithm; The real-time control execution module is used for loading a control program, collecting and processing field device data, generating and issuing a control instruction; The data feedback monitoring module is used for receiving the execution result of the equipment, judging the execution state and feeding back to the cloud/upper engineering layer to realize real-time monitoring and fault alarm; And the multi-protocol adaptation module is used for carrying out the adaptation and data conversion of Modbus, etherCAT, profinet protocols.
8. A computer readable storage medium, wherein a computer program is stored on the storage medium, and when the computer program is executed by a processor, the method for implementing the cloud-edge cooperative virtual controller architecture according to claim 5 or 6 is implemented.

Description

Cloud edge cooperative virtual controller architecture, adaptation and implementation method Technical Field The invention relates to the technical field of industrial automation control, in particular to a cloud edge cooperative virtual controller architecture, an adaptation and an implementation method, which are suitable for industrial scenes such as flow industry, discrete industry and the like which need multi-protocol cooperation and high real-time control. Background The manufacturing industry is accelerated to be flexible and intelligent, the traditional Programmable Logic Controller (PLC) gradually exposes various limitations in complex industrial scenes, namely, firstly, poor protocol compatibility, most of traditional PLCs adopt a closed architecture, only support specific brands or few types of industrial protocols, and are difficult to realize cooperative work of different protocol devices, so that the phenomenon of 'information island' of an industrial field is prominent, the improvement of production efficiency is restricted, secondly, the design of operation logic is unreasonable, and part of the existing virtual controller scheme has the logic defect that the program is installed before the environment is started during run time, the problems of program loading failure, abnormal control logic execution and the like are easily caused, the system operation stability is affected, thirdly, the deployment flexibility is low, the hardware and the software of the traditional PLCs are highly bound, the control logic or the expansion function is required to be matched and replaced, the deployment cost is high, the period is long, the dynamic requirement of flexible production is difficult to be adapted, fourthly, the protocol adaptation capability is insufficient, the existing virtual controller is designed for a single or few industrial protocols, and the special adaptation logic for the main stream is lacked, and the data interaction and the real-time difficulty is guaranteed. The virtual controller (vPLC) simulates the traditional PLC function through software and combines with an industrial grade hardware carrier, so that a new technical path is provided for solving the problems, but the existing virtual controller still has the defects of limited protocol adaptation types, insufficient suitability of an operation mechanism and an industrial site, difficulty in meeting the strict industrial requirements in stability and the like. Therefore, the cloud-edge cooperative virtual controller architecture, the adaptation and the operation mechanism are provided, the cooperative control of the multi-protocol equipment is realized through three-layer architecture design, reasonable operation logic sequence and dedicated protocol adaptation logic, the real-time performance and the reliability of the system are improved, and the blank of the prior art is filled. Disclosure of Invention The invention aims to provide a cloud edge cooperative virtual controller architecture, an adaptation and an implementation method, which realize cooperative control of multi-protocol equipment and improve the real-time performance and reliability of a system through three-layer architecture design, reasonable operation logic sequence and exclusive protocol adaptation logic. The technical scheme adopted by the invention for achieving the purpose is as follows: Cloud edge cooperative virtual controller architecture includes: The cloud/upper engineering layer is provided with industrial control software and special supporting software, is used for configuring hardware resources meeting the requirements of control logic development and simulation through the industrial control software, and performs data interaction with the edge control layer through a TCP/IP protocol; The edge control layer is used for carrying out logic operation on the physical quantity data collected by the field device layer, generating a control instruction and sending the control instruction to the field device layer through a special industrial interface; The field device layer is used for collecting physical quantity data of the industrial field, sending the physical quantity data to the edge control layer through the special industrial interface and executing corresponding actions according to the control instruction pair. The industrial control software supports multiple programming languages and has the functions of control logic programming, simulation debugging, communication parameter configuration, IO mapping, equipment state monitoring and fault alarming. The edge control layer includes: The run time environment is used for initializing a protocol adaptation module, checking and loading a control program, processing acquired data, generating a control instruction, maintaining a communication link and feeding back fault information; The protocol adaptation module is used for identifying communication characteristics of corresponding protocols t