CN-122018408-A - Universal industrial controller and fault response efficiency improving system thereof

CN122018408ACN 122018408 ACN122018408 ACN 122018408ACN-122018408-A

Abstract

The invention discloses a general industrial controller and a fault response efficiency improving system thereof, belonging to the technical field of industrial automation control, which are characterized in that firstly, core operation and protocol parameters of industrial equipment are acquired and accessed to complete equipment adaptation analysis to generate equipment control instructions and module scheduling instructions, then, based on the module scheduling instructions, the adaptation switching of multi-type industrial communication interfaces is completed to realize the protocol conversion and the bidirectional transmission of control signals and equipment feedback signals.

Inventors

Lv Zheqi
LIU ZHE
ZHAO HAOPENG
YANG KUN
Wen Dongyao
LIU CHUNYU
Lai Youguo
LIU HAO
CHEN XUANXI
ZENG XIANGDONG
MA JIAPEI
LI BO

Assignees

吉林建筑科技学院

Dates

Publication Date: 20260512
Application Date: 20260228

Claims (10)

1. A universal industrial controller, comprising: The self-adaptive main control module is used for collecting core operation and protocol parameters of the access industrial equipment, completing equipment adaptation analysis and generating equipment control instructions and module scheduling instructions; The multi-protocol communication module is used for completing the adaptive switching of multi-type industrial communication interfaces based on the module scheduling instruction output by the adaptive main control module and realizing the protocol conversion and the bidirectional transmission of control signals and equipment feedback signals; the fault pre-detection module is used for acquiring real-time operation data of the controller and the equipment through the multi-protocol communication module based on a module scheduling instruction output by the self-adaptive main control module, completing data preprocessing, anomaly identification, hidden danger tracing and outputting a fault pre-detection report; and the safety protection module is used for acquiring safety related signals of the controller and the equipment based on the module scheduling instruction output by the self-adaptive main control module, completing risk assessment and executing corresponding protection actions.
2. The universal industrial controller of claim 1, wherein the adaptive master control module comprises: The device parameter acquisition unit acquires core parameters of the access industrial device, realizes comprehensive acquisition of parameters through a built-in multi-interface acquisition circuit and outputs a device parameter acquisition set; The parameter analysis and adaptation unit analyzes the control requirement and the communication standard of the equipment through a preset multi-protocol analysis algorithm and parameter matching model based on the equipment parameter collection set output by the equipment parameter collection unit, screens out a control parameter threshold and a communication protocol for adapting the equipment, and outputs a parameter analysis result and an adaptation instruction; And the main control scheduling unit is used for calling a corresponding control logic algorithm to generate a device operation control instruction based on the parameter analysis result and the adaptation instruction output by the parameter analysis and adaptation unit, scheduling the cooperation of the multi-protocol communication module, the fault pre-detection module and the safety protection module, receiving feedback data of each module in real time, dynamically adjusting the control instruction, and outputting the device control instruction and the module scheduling instruction.
3. The universal industrial controller of claim 1, wherein the multi-protocol communication module comprises: the communication interface unit integrates various industrial common communication interfaces so as to output an interface switching signal and a communication preparation state signal after receiving a module scheduling instruction output by the self-adaptive main control module; The protocol conversion unit is used for converting a control instruction of the controller into a protocol signal which can be recognized by the equipment based on the interface switching signal and the communication preparation state signal which are output by the communication interface unit and combining communication protocol adaptation parameters, converting operation data and fault signals of the equipment into standard signals which can be processed by the controller, and outputting the control signals and equipment feedback signals after protocol conversion; and the data transmission unit is used for outputting encrypted transmission data and transmission state feedback by adopting an encryption transmission algorithm based on the control signal and the equipment feedback signal which are output by the protocol conversion unit and are subjected to protocol conversion.
4. The universal industrial controller of claim 1, wherein the fault pre-detection module comprises: the operation data acquisition unit is used for acquiring the operation parameters of the controller and the real-time operation parameters of the equipment based on the module scheduling instruction output by the self-adaptive main control module and outputting a real-time operation data acquisition set; The data preprocessing unit is used for removing abnormal data and interference data by adopting filtering, denoising and normalizing algorithms based on the real-time operation data acquisition set output by the operation data acquisition unit and outputting preprocessed effective operation data; the abnormal feature identification unit is used for identifying abnormal features in the data based on the preprocessed effective operation data output by the data preprocessing unit and combining a preset fault feature library, judging whether fault hidden danger exists or faults occur or not, and outputting an abnormal feature identification result; the fault hidden danger tracing unit is used for tracing the generation source of the abnormal characteristics and outputting a fault hidden danger tracing report by combining the historical operation data of the equipment with the cooperative operation record of the controller based on the abnormal characteristic identification result output by the abnormal characteristic identification unit; and the pre-detection result output unit is used for generating a fault pre-detection report based on the fault hidden danger tracing report output by the fault hidden danger tracing unit and the abnormal characteristic identification result output by the abnormal characteristic identification unit.
5. The universal industrial controller of claim 1, wherein the safety protection module comprises: The safety signal acquisition unit is used for acquiring safety related signals of the controller and the equipment based on a module scheduling instruction output by the self-adaptive main control module and outputting a safety signal acquisition set; The safety risk assessment unit is used for assessing the risk level corresponding to the safety signal based on the safety signal collection set output by the safety signal collection unit and combining a preset safety risk assessment model, judging whether a protective measure needs to be started or not, and outputting a safety risk assessment result and a protective starting instruction; And the protection execution unit starts corresponding protection measures based on the safety risk assessment result and the protection starting instruction output by the safety risk assessment unit, and simultaneously feeds back the protection execution state to the self-adaptive main control module and outputs a protection execution signal and a state feedback signal.
6. A fault response efficiency enhancement system for a universal industrial controller, in conjunction with the universal industrial controller of any of claims 1-5, comprising: The fault pre-judging and early-warning module is used for completing fault hidden danger analysis and early-warning grade judgment based on the fault pre-detection report and outputting early-warning execution signals and early-warning information synchronous data; the rapid fault positioning module is used for integrating the fault related total information based on the synchronous data of the early warning execution signal and the early warning information output by the fault pre-judging early warning module to complete fault feature matching, relevance analysis and positioning optimization and outputting a precise positioning result; The hierarchical fault disposal module is used for calling a corresponding disposal strategy based on the accurate positioning result output by the rapid fault positioning module and combining the early warning execution signal and the early warning information synchronous data output by the fault pre-judging early warning module, generating and executing a fault disposal instruction and outputting a disposal result verification report; And the multi-disc optimizing module is used for completing fault data archiving and optimizing analysis by combining the accurate positioning result output by the rapid fault positioning module based on the treatment result verification report output by the hierarchical fault treatment module and outputting a strategy updating signal and an optimizing parameter synchronization result.
7. The system for improving the failure response efficiency of a universal industrial controller according to claim 6, wherein the failure pre-judging and pre-warning module comprises: the pre-detection data receiving unit is used for checking the data based on the fault pre-detection report and outputting checked fault pre-detection data; The fault hidden danger analysis unit is used for analyzing the development trend of the fault hidden danger, the possible fault type and the influence range of the fault hidden danger and outputting a fault hidden danger analysis report based on the checked fault pre-detection data output by the pre-detection data receiving unit and combining a preset fault evolution model; The early warning grade judging unit is used for dividing faults and hidden dangers into four grades of I grade, II grade, III grade and IV grade based on the fault hidden danger analysis report and the fault pre-detection data output by the fault hidden danger analysis unit and outputting an early warning grade judging result and an early warning triggering instruction; And the early warning executing unit starts a corresponding early warning mode based on the early warning grade judging result and the early warning triggering instruction output by the early warning grade judging unit and outputs early warning executing signals and early warning information synchronous data.
8. The fault response efficiency enhancement system of a universal industrial controller as claimed in claim 6, the quick fault location module is characterized by comprising: the fault information receiving unit is used for integrating fault related information by combining a fault pre-detection report based on the pre-warning execution signal and the pre-warning information synchronous data output by the fault pre-judging pre-warning module and outputting an integrated fault information set; The fault feature matching unit is used for calling a preset fault feature database based on the integrated fault information set output by the fault information receiving unit, realizing the accurate matching of the fault feature and the fault position through a deep learning algorithm and outputting a preliminary fault positioning result; The fault correlation analysis unit is used for analyzing the correlation between the current fault and the controller and equipment based on the preliminary fault positioning result output by the fault feature matching unit and combining the fault hidden danger tracing report, and outputting a fault correlation analysis result; the positioning precision optimizing unit is used for correcting positioning errors based on the fault correlation analysis result output by the fault correlation analysis unit and combining real-time feedback data of equipment, determining the specific position of a fault and the correlation fault point and outputting a precision fault positioning result; And the positioning result output unit is used for synchronizing the accurate fault positioning result output by the positioning precision optimization unit to the grading fault handling module and the multiple disc optimization module and outputting the accurate positioning result.
9. The fault response efficiency enhancement system of a universal industrial controller as claimed in claim 6, characterized in that the hierarchical fault handling module comprises: The treatment strategy calling unit is used for calling a preset hierarchical treatment strategy library and outputting an adaptive fault treatment strategy by combining the early warning execution signal and the early warning information synchronous data output by the fault pre-judging early warning module based on the accurate positioning result output by the rapid fault positioning module; A treatment instruction generation unit that generates a specific fault treatment instruction in combination with the device control parameters of the controller based on the adapted fault treatment policy output by the treatment policy invocation unit, and outputs a fault treatment instruction set; A treatment instruction execution unit which transmits the fault treatment instruction set output by the treatment instruction generation unit to a controller and corresponding industrial equipment, performs fault treatment operation, monitors a treatment process in real time, and outputs a treatment execution state; and a treatment result verification unit which collects operation data of the controller and the equipment based on the treatment execution state output by the treatment instruction execution unit and outputs a treatment result verification report.
10. The fault response efficiency enhancement system of a universal industrial controller as claimed in claim 6, the multi-disc optimizing module is characterized by comprising: the fault data archiving unit is used for comprehensively archiving fault information, a treatment process and a treatment result based on the treatment result verification report output by the hierarchical fault treatment module and combining the accurate positioning result output by the rapid fault positioning module, establishing a fault archive and outputting an archived fault data set; The optimization analysis unit is used for outputting an optimization analysis report through a big data analysis algorithm based on the archived fault data set output by the fault data archiving unit; And the strategy updating unit is used for updating the fault characteristic database, the hierarchical treatment strategy library and the fault pre-judging model based on the optimization analysis report output by the optimization analysis unit, synchronizing the optimization parameters to the controller and outputting a strategy updating signal and an optimization parameter synchronization result.

Description

Universal industrial controller and fault response efficiency improving system thereof Technical Field The invention relates to the technical field of industrial automation control, in particular to a universal industrial controller and a fault response efficiency improving system thereof. Background Industrial controllers are core devices in industrial automation systems, often referred to as the "brain" or "central nerve" of the entire automation system. The system is special electronic equipment which is used for ‌ to collect site signals (such as temperature, pressure, position, switch state and the like) ‌, process and operate according to a preset program, logic or algorithm, and then ‌ outputs control instructions (such as a driving motor, a valve opening, a frequency converter adjusting and the like) ‌, so that automatic monitoring and accurate control of production equipment, production lines or the whole industrial process are realized. However, most of the current industrial controllers are specially designed, only industrial equipment with specific types and specific scenes is adapted, different controllers are required to be equipped for equipment with different industries and different specifications, the universality is poor, and the equipment investment and maintenance cost of enterprises are increased. Meanwhile, the fault response of the existing industrial controller mostly adopts a mode of 'passive detection after fault occurrence, manual investigation and disposal', the pre-judging and quick positioning capability is lacked, the fault response delay is high, the dynamic optimization mechanism is lacked in the fault disposal process, and the requirements of industrial production continuity and high precision are difficult to adapt. Disclosure of Invention In order to solve the technical problems, the invention provides the following technical scheme: A universal industrial controller, comprising: The self-adaptive main control module is used for collecting core operation and protocol parameters of the access industrial equipment, completing equipment adaptation analysis and generating equipment control instructions and module scheduling instructions; The multi-protocol communication module is used for completing the adaptive switching of multi-type industrial communication interfaces based on the module scheduling instruction output by the adaptive main control module and realizing the protocol conversion and the bidirectional transmission of control signals and equipment feedback signals; the fault pre-detection module is used for acquiring real-time operation data of the controller and the equipment through the multi-protocol communication module based on a module scheduling instruction output by the self-adaptive main control module, completing data preprocessing, anomaly identification, hidden danger tracing and outputting a fault pre-detection report; and the safety protection module is used for acquiring safety related signals of the controller and the equipment based on the module scheduling instruction output by the self-adaptive main control module, completing risk assessment and executing corresponding protection actions. As a preferable scheme of the universal industrial controller, the self-adaptive main control module comprises: The device parameter acquisition unit acquires core parameters of the access industrial device, realizes comprehensive acquisition of parameters through a built-in multi-interface acquisition circuit and outputs a device parameter acquisition set; The parameter analysis and adaptation unit analyzes the control requirement and the communication standard of the equipment through a preset multi-protocol analysis algorithm and parameter matching model based on the equipment parameter collection set output by the equipment parameter collection unit, screens out a control parameter threshold and a communication protocol for adapting the equipment, and outputs a parameter analysis result and an adaptation instruction; And the main control scheduling unit is used for calling a corresponding control logic algorithm to generate a device operation control instruction based on the parameter analysis result and the adaptation instruction output by the parameter analysis and adaptation unit, scheduling the cooperation of the multi-protocol communication module, the fault pre-detection module and the safety protection module, receiving feedback data of each module in real time, dynamically adjusting the control instruction, and outputting the device control instruction and the module scheduling instruction. As a preferable mode of the universal industrial controller according to the invention, the multi-protocol communication module includes: the communication interface unit integrates various industrial common communication interfaces so as to output an interface switching signal and a communication preparation state signal after receiving a module scheduling inst