PLC control system and control method

Abstract

The invention provides a PLC control system, and the system comprises a CPU module which executes application logic; the backboard modules are connected in series and are arranged to be communicated with the CPU module and the function modules, and each backboard module can be correspondingly connected with one function module; and the artificial intelligence module is one of the function modules, receives various data, performs data analysis processing on the data processing tasks with the data volume exceeding a preset data volume threshold value or the logic complexity exceeding a preset logic complexity threshold value, and forwards the obtained analysis data to the CPU module through the corresponding backboard module. According to the invention, the edge computing thought is applied to the PLC field, large-scale complex computing is migrated from the CPU module to the artificial intelligence module, the resource consumption of the CPU module is reduced, and the processing performance of the PLC control system is improved on the whole. The large-scale complex calculation is usually easy to generate faults, and the reliability and availability of the CPU module are also improved by independently carrying out the large-scale complex calculation through the artificial intelligence module.

Description

Technical Field

[0001] The present application relates to the field of industrial control technology, and more specifically, to a PLC control system and a control method. Background Art

[0002] With the rapid development and increasing popularity of artificial intelligence, the Internet of Things and industrial automation control technologies, in the field of industrial control systems, traditional programmable logic controllers (PLCs) are not only facing the large-scale development needs of multi-type and large-scale terminal device access, but also facing the development needs of shifting from programmable logic control to support artificial intelligence-based intelligent control and large-scale complex control.

[0003] The realization of high-speed backplane bus is a technical difficulty in the development of large-scale controllers. PLC systems usually use traditional serial communication technology to realize backplane bus. Serial bus can improve the reliability of automation equipment in harsh factory and industrial environments. Traditional serial communication technologies include CAN, I2C, UART, SPI, USB and PCIE, etc. Usually, many processors used as the main chips of PLC systems integrate peripheral components such as CAN, I2C, UART, SPI and USB. However, due to the slow speed caused by the integration of peripheral communications inside the processor, the high communication rate requirements of the high-speed backplane bus cannot be met at all; although the speed of PCIE can reach GBit / s, it is more expensive and has higher requirements for wiring, and requires an interface chip that specifically supports PCIE. Summary of the invention

[0004] In response to at least one defect or improvement need in the prior art, the present application provides a PLC control system and a control method, which can solve the problem that the current high-speed backplane bus cannot meet the requirements of large-scale data transmission and high communication rate in specific technical fields such as smelting at a relatively low cost, and at the same time, can improve the availability, reliability and intelligence capabilities of industrial controllers.

[0005] To achieve the above objectives, in a first aspect, the present application provides a PLC control system, comprising:

[0006] A CPU module, which is used to send domain data packets and execute application logic based on received analysis data;

[0007] A plurality of backplane modules connected in series, which are used to receive and forward the domain data packets, and also to send the received analysis data to the CPU module through the domain data packets; each backplane module can be connected to a corresponding functional module; the backplane module is configured to connect the CPU module and the functional module;

[0008] An artificial intelligence module, which is a type of the functional module, is used to receive relevant data in the domain data packet or receive terminal data sent by a connected terminal device, perform data analysis and processing on data processing tasks whose data volume exceeds a preset data volume threshold or whose logic complexity exceeds a preset logic complexity threshold, and forward the obtained analysis data to the CPU module through the corresponding backplane module.

[0009] Furthermore, the CPU module and the backplane module, as well as the backplane modules, are all based on the EtherCAT communication mechanism, using the EBUS bus for data exchange;

[0010] The backplane module and the functional module exchange data via TCP communication.

[0011] Furthermore, the artificial intelligence module includes:

[0012] Artificial intelligence module business module, which is used to analyze and process the received data to implement corresponding artificial intelligence business;

[0013] An artificial intelligence module embedded operating system adapted to the embedded operating system of the artificial intelligence module business module and bidirectionally connected to the artificial intelligence module business module;

[0014] An artificial intelligence module CPU processor, adapted to the CPU processor of the artificial intelligence module embedded operating system, and bidirectionally connected to the artificial intelligence module embedded operating system;

[0015] An artificial intelligence module GPU processor, adapted to the GPU processor of the artificial intelligence module embedded operating system, and bidirectionally connected to the artificial intelligence module embedded operating system;

[0016] The artificial intelligence module business module also includes:

[0017] An artificial intelligence module TCP client module, through which the artificial intelligence module performs TCP communication with the backplane module;

[0018] The artificial intelligence module access processing module is used to pre-process the received data; the artificial intelligence module access processing module supports the processing of different input data by downloading a new access processing model on the artificial intelligence module embedded operating system;

[0019] A data module, used to store data pre-processed by the processing module via the artificial intelligence module;

[0020] The analysis module is used to analyze and process the data pre-processed by the artificial intelligence module access processing module to obtain the analysis data; the analysis module adds a new analysis support function by downloading a new edge analysis model on the artificial intelligence module embedded operating system;

[0021] The post-processing module is used to send the analysis data through the artificial intelligence module TCP client module according to the data mapping rules.

[0022] Furthermore, the CPU module comprises:

[0023] CPU module EtherCAT master module, used to realize EtherCAT master function;

[0024] A real-time embedded operating system for a CPU module, adapted to the real-time embedded operating system of the CPU module, and bidirectionally connected to the EtherCAT master station module of the CPU module;

[0025] A CPU module CPU processor, adapted to the CPU module CPU processor, bidirectionally connected to the CPU module real-time embedded operating system;

[0026] The CPU module EtherCAT communication chip is bidirectionally connected with the CPU module CPU processor through the EtherCAT protocol, and is also bidirectionally connected with the backplane module through the EBUS bus.

[0027] Furthermore, the backplane module is an EtherCAT slave module corresponding to the CPU module EtherCAT master module, and is used to implement the EtherCAT slave function; the backplane module includes:

[0028] The backplane module EtherCAT communication chip is bidirectionally connected to the CPU module or other backplane modules via the EBUS bus;

[0029] The backplane module MCU processor is adapted to the CPU processor of the backplane module and realizes a bidirectional connection with the backplane module EtherCAT communication chip through FSMC;

[0030] Backplane module TCP server module, through which the backplane module performs TCP communication with the functional module.

[0031] Furthermore, the functional module also includes an IO module, which is configured to process digital and analog input and output information.

[0032] Furthermore, the functional module also includes a communication module, which is configured to support access of terminal devices containing a preset communication protocol.

[0033] In a second aspect, the present application provides a PLC control method based on the PLC control system described in any one of the above items, comprising:

[0034] The CPU module EtherCAT master module sets the scanning cycles of different backplane modules according to the EtherCAT domain data scanning mechanism, and classifies the backplane modules with the same scanning cycles into a unified domain; the CPU module EtherCAT master module generates corresponding domain data packets according to different scanning cycles, and sends them to the CPU module EtherCAT communication chip through the EtherCAT protocol; the CPU module EtherCAT communication chip transmits the received domain data packets through the EBUS bus according to the network topology;

[0035] The backplane module EtherCAT communication chip of each backplane module in the network topology checks the domain data packet to check whether there is message data sent to the backplane module to which it belongs; if there is, the data to be received is obtained from the domain data packet, and then the received data is cached in the memory of the backplane module EtherCAT communication chip, and at the same time, the data to be sent is taken out from the memory, and the data to be sent is written into the domain data packet, and finally the new domain data packet is forwarded to the next backplane module according to the network topology; after being processed sequentially according to this logic, the domain data packet is finally returned to the CPU module EtherCAT master station module, and the CPU module EtherCAT master station module processes the data in the domain data packet, thereby completing a cycle communication based on the CPU module and several backplane modules;

[0036] The backplane module TCP server module of the backplane module takes out the cache data from the corresponding backplane module EtherCAT communication chip through FSMC, and then sends it to the functional module connected to it through TCP;

[0037] The functional module sends the collected and processed data to the backplane module connected to it through its TCP client module, and the backplane module TCP server module of the backplane module caches the received data into the memory of the backplane module EtherCAT communication chip through FSMC.

[0038] Further, including:

[0039] The artificial intelligence module accesses the external terminal device through the network bridge device, and pre-processes the accessed terminal data through the artificial intelligence module access processing module, and then sends the pre-processed data to the analysis module for analysis and processing to obtain analysis data, and then sends the analysis data to the CPU module;

[0040] The CPU module performs logical operations based on the analyzed data, generates control instructions and sends them to the corresponding functional modules to achieve linkage control of the terminal equipment;

[0041] The analysis module can use different machine learning models to analyze the same pre-processed output data of the artificial intelligence module access processing module, and can also be set to apply different machine learning models to analyze and process the input data of different terminal devices;

[0042] and / or

[0043] The artificial intelligence module receives the real-time data of the process sent by the CPU module through the backplane module, pre-processes the received real-time data of the process through the artificial intelligence module access processing module, and then sends the pre-processed data to the data module for storage;

[0044] The analysis module analyzes and processes the pre-processed data, and sends the analysis data to the CPU module via the post-processing module, the artificial intelligence module, the TCP client module, and the backplane module;

[0045] The CPU module performs logical operations based on the analyzed data.

[0046] Further, including:

[0047] The artificial intelligence module obtains local data of a preset time window from the data module through the artificial intelligence module access processing module;

[0048] The artificial intelligence module access processing module sends the acquired local data to the analysis module for analysis and processing, and sends the analysis data to the CPU module via the post-processing module, the artificial intelligence module TCP client module and the backplane module;

[0049] The CPU module performs logical operations based on the analyzed data.

[0050] In general, the above technical solutions conceived by the present application can achieve the following beneficial effects compared with the prior art:

[0051] (1) This application applies the concept of edge computing to the PLC field, migrating large and complex calculations in specific technical fields such as smelting from the CPU module to the artificial intelligence module, reducing the resource consumption of the CPU module and improving the processing performance of the PLC control system as a whole. Large and complex calculations are usually prone to failure. By having the artificial intelligence module independently perform large and complex calculations, the reliability and availability of the CPU module are also improved.

[0052] (2) In the main data link (CPU module->each backplane module->CPU module), data processing is mainly completed by the EtherCAT communication chip with low hardware cost; in the branch data link (backplane module<-->various functional modules), the backplane module MCU processor realizes data transparent transmission between the CPU module and related functional modules through the backplane module TCP server module. Through the above settings, the maximum speed of the PLC control system can reach 100Mbit / s, and the fastest communication cycle can reach within 100μs; at the same time, based on the EtherCAT distributed clock synchronization mechanism, DC can be configured to achieve high-precision synchronization with a synchronization accuracy of <<1μs. In this way, it can be solved at a lower cost that the current high-speed backplane bus cannot meet the requirements of large-scale data transmission and high communication rate in specific technical fields such as smelting, and at the same time, it can improve the availability, reliability and intelligent capabilities of industrial controllers. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0054] Figure 1 A schematic block diagram of the core structure of a PLC control system provided in an embodiment of the present application;

[0055] Figure 2 A detailed structural schematic block diagram of a PLC control system provided in an embodiment of the present application;

[0056] Figure 3 A schematic block diagram of the structure of a CPU module provided in an embodiment of the present application;

[0057] Figure 4 A schematic block diagram of the structure of the backplane module provided in an embodiment of the present application;

[0058] Figure 5 A schematic block diagram of the structure of the IO module provided in the embodiment of the present application;

[0059] Figure 6 A schematic block diagram of the structure of an artificial intelligence module provided in an embodiment of the present application;

[0060] Figure 7 A schematic block diagram of the structure of a communication module provided in an embodiment of the present application. DETAILED DESCRIPTION

[0061] In order to make the purpose, technical solutions and advantages of the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application. In addition, the technical features involved in each embodiment of the present application described below can be combined with each other as long as they do not conflict with each other.

[0062] The terms "including" or "having" and any variations thereof in the specification, claims or drawings of the present application are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device including a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products or devices.

[0063] As described in the background technology section of the specification, the implementation of a high-speed backplane bus is a technical difficulty in the development of large-scale controllers. The existing PLC processors cannot meet the high communication rate requirements of high-speed backplane buses in specific technical fields such as smelting due to the slow speed caused by the integrated peripheral communication. Although the PCIE rate can reach GBit / s, it is costly and has high requirements for wiring, requiring an interface chip that specifically supports PCIE. In view of this, the present application proposes a PLC control system and control method, which can solve the problem that the current high-speed backplane bus cannot meet the requirements of large-scale data transmission and high communication rate in specific technical fields such as smelting at a relatively low cost. At the same time, it can improve the availability, reliability and intelligent capabilities of industrial controllers.

[0064] refer to Figure 1-Figure 7 An embodiment of the present application proposes a PLC control system, which may include at least: a CPU module, a plurality of backplane modules connected in series, an artificial intelligence module and a power supply module.

[0065] The power module is configured to convert AC power into DC power to power the PLC control system.

[0066] The CPU module is used to send domain data packets and execute application logic based on the received analysis data.

[0067] A plurality of backplane modules connected in series, the backplane modules are used to receive domain data packets and forward them, and also to send the received analysis data to the CPU module via domain data packets; each backplane module can be connected to a corresponding functional module; the backplane module is configured to connect the CPU module and the functional module.

[0068] The artificial intelligence module is a kind of functional module, which is used to receive relevant data in the domain data packet or receive terminal data sent by the connected terminal device, analyze and process data for data processing tasks whose data volume exceeds the preset data volume threshold or whose logic complexity exceeds the preset logic complexity threshold, and forward the obtained analysis data to the CPU module through the corresponding backplane module. The artificial intelligence module is configured to perform edge computing and artificial intelligence processing.

[0069] The CPU module and the backplane module are bidirectionally connected via EBUS; the backplane modules are bidirectionally connected via EBUS; the backplane module and the corresponding functional modules are bidirectionally connected via TCP; the power output end of the power module is connected to the power input end of the CPU module, and the power input end of the power module receives external AC power and outputs DC power, thereby powering the PLC control system.

[0070] This application applies the edge computing concept to the PLC field, migrating large and complex calculations in specific technical fields such as smelting from the CPU module to the artificial intelligence module, reducing the resource consumption of the CPU module and improving the processing performance of the PLC control system as a whole. Large and complex calculations are usually prone to failures. By having the artificial intelligence module independently perform large and complex calculations, the reliability and availability of the CPU module are also improved.

[0071] Furthermore, the CPU module and the backplane module, as well as the backplane modules, are based on the EtherCAT (Ethernet Control Automation Technology, an open architecture, Ethernet-based fieldbus system. The CAT in its name is the abbreviation of the first letter of Control Automation Technology. EtherCAT is a deterministic industrial Ethernet, which was first developed by Beckhoff in Germany. Automation generally requires a shorter data update time (or cycle time), low communication jitter during data synchronization, and low hardware cost for communication. The purpose of developing EtherCAT is to enable Ethernet to be used in automation applications.) communication mechanism, using the EBUS bus for data exchange. Data is exchanged between the backplane module and the functional module through TCP communication.

[0072] In the main data link of this application (CPU module->various backplane modules->CPU module), data processing is mainly completed by the EtherCAT communication chip with low hardware cost; in the branch data link (backplane module<-->various functional modules), the backplane module MCU processor realizes data transparent transmission between the CPU module and related functional modules through the backplane module TCP server module. Through the above settings, the maximum speed of the PLC control system can reach 100Mbit / s, and the fastest communication cycle can reach within 100μs; at the same time, based on the EtherCAT distributed clock synchronization mechanism, DC can be configured to achieve high-precision synchronization, and the synchronization accuracy is <<1μs. In this way, it can be solved at a lower cost that the current high-speed backplane bus cannot meet the requirements of large-scale data transmission and high communication rates in specific technical fields such as smelting, and at the same time, it can improve the availability, reliability and intelligent capabilities of industrial controllers.

[0073] In some embodiments, more specifically, reference Figure 3 , the CPU module can include an EtherCAT master module, a real-time embedded operating system, a CPU processor and an EtherCAT communication chip.

[0074] The EtherCAT master module is used to realize the EtherCAT master function.

[0075] The real-time embedded operating system is a real-time embedded operating system adapted to the CPU module.

[0076] The CPU processor can be either a domestic brand processor or an imported brand processor, but it must be compatible with its real-time embedded operating system, such as the LS2K1000LA processor and the SylixOS V3.6.3 real-time embedded operating system.

[0077] The EtherCAT communication chip can be a Beckhoff ET1100 chip or an FPGA chip that supports EtherCAT communication.

[0078] Its EtherCAT master module and real-time embedded operating system realize bidirectional connection; its real-time embedded operating system and CPU processor realize bidirectional connection; its CPU processor and EtherCAT communication chip realize bidirectional connection through EtherCAT protocol.

[0079] In some embodiments, more specifically, reference Figure 4 The backplane module can include an EtherCAT communication chip, an MCU processor, and a TCP Server module.

[0080] The EtherCAT communication chip and the MCU processor are bidirectionally connected via FSMC; the MCU processor and the TCP Server module are bidirectionally connected; and the EtherCAT communication chips are bidirectionally connected via EBUS.

[0081] The EtherCAT communication chip can be a Beckhoff ET1100 or ET1200 chip, or an FPGA chip supporting EBUS communication; the MCU processor can be any processor supporting FSMC, such as a related series of STM32.

[0082] The MCU processor of the backplane module and the MCU or CPU processor of various functional modules are bidirectionally connected through TCP.

[0083] In some embodiments, more specifically, reference Figure 6 The artificial intelligence module may include a business module, an embedded operating system, a CPU processor, and a GPU processor. The business module is bidirectionally connected to the embedded operating system, the embedded operating system is bidirectionally connected to the CPU processor, and the embedded operating system is bidirectionally connected to the GPU processor.

[0084] The business module of the artificial intelligence module is used to analyze and process the received data to implement the corresponding artificial intelligence business. The business module may include a TCP Client module, an access processing module, an analysis module, a post-processing module and a data module.

[0085] The artificial intelligence module performs TCP communication with the backplane module through its TCP Client module.

[0086] The access processing module of the artificial intelligence module is used to pre-process the received data; the access processing module of the artificial intelligence module supports the processing of different input data by downloading a new access processing model on the embedded operating system of the artificial intelligence module.

[0087] The data module is used to store data pre-processed by the access processing module of the artificial intelligence module.

[0088] The analysis module is used to analyze and process the data pre-processed by the access processing module of the artificial intelligence module to obtain analysis data.

[0089] The post-processing module is used to send the analysis data to the CPU module through the TCP Client module of the artificial intelligence module according to the data mapping rules, and is also used to send the video analysis data to the HMI (Human Machine Interface) through the network port.

[0090] The embedded operating system is an embedded operating system adapted to the business module of the artificial intelligence module, and is bidirectionally connected to the business module of the artificial intelligence module.

[0091] Its GPU processor can be NPU, TPU, etc., and its embedded operating system can be a series of embedded operating systems including Linux; its GPU processor and CPU processor must be adapted to its embedded operating system; its analysis module adds new analysis support by downloading new edge analysis models on its embedded operating system, and its access processing module supports the processing of different input data by downloading new access processing models on its embedded operating system.

[0092] In some embodiments, more specifically, reference Figure 2 , Figure 5 and Figure 7 , the functional modules may also include IO modules and communication modules.

[0093] The IO module includes a service module and an MCU processor, wherein the service module includes a TCP Client module and an access processing module; the service module is bidirectionally connected to the MCU processor. The IO module is configured to process digital and analog input and output information.

[0094] The communication module includes a TCP Client module and a protocol module, wherein the TCP Client module and the protocol module realize a bidirectional connection. The communication module can be a communication module supporting Profinet networking, or a communication module supporting EtherCAT, Profibus, Modbus and other networking. Each type of communication module supports a specific communication protocol. The communication module is configured to support the access of terminal devices containing specific communication protocols.

[0095] Through the bidirectional connection between backplane modules, and the bidirectional connection between backplane modules and functional modules such as IO modules, artificial intelligence modules and communication modules, in theory, no less than 100 IO / artificial intelligence / communication and other functional modules can be loaded, but based on comprehensive considerations such as performance and deployment implementation, the embodiment of this application limits the load to no more than 64 IO / artificial intelligence / communication and other functional modules. IO modules, artificial intelligence modules, and communication modules can be flexibly selected and deployed according to specific application scenarios.

[0096] The modular structural design based on the backplane module, IO module, artificial intelligence module and communication module realizes the reuse of functional modules well. Based on the low coupling and hot-swappable design of the IO module, artificial intelligence module, communication module and backplane module, when the IO module, artificial intelligence module or communication module fails, it will not affect the functional realization of other functional modules and can be quickly replaced under power, thereby improving the reliability, availability and maintainability of the PLC control system.

[0097] An embodiment of the present application further provides a PLC control method based on the aforementioned PLC control system, referring to Figure 1-Figure 4 The PLC control method includes: the EtherCAT master station module of the CPU module realizes the EtherCAT master station function (the main function of the EtherCAT master station is to control and manage the communication and data exchange of the entire EtherCAT network.

[0098] The EtherCAT master is responsible for sending control instructions to each EtherCAT slave device and receiving feedback data from the EtherCAT slave devices to ensure efficient operation of the entire network.

[0099] . ), configure the scanning cycles of different backplane modules (implementing EtherCAT slave function, the same as in the whole text) according to the EtherCAT domain data scanning mechanism, and classify the backplane modules with the same scanning cycle into the same domain. The EtherCAT master module of the CPU module generates corresponding domain data packets according to different scanning cycles, and sends them to the EtherCAT communication chip of the CPU module through the EtherCAT protocol. The EtherCAT communication chip of the CPU module transmits the received domain data packets through the EBUS bus according to the network topology. The EtherCAT communication chip of each backplane module in the network topology verifies the domain data packet to check whether there is message data sent to the backplane module to which it belongs. If there is, the data data1 to be received is obtained from the domain data packet, and then the data data1 is cached in the memory of its EtherCAT communication chip. At the same time, the data data2 to be sent is taken out from the memory, and the data data2 is written into the domain data packet. Finally, the domain data packet is forwarded to the next backplane module according to the network topology. With this forwarding logic, after processing in this order, the domain data packet is finally returned to the EtherCAT master module of the CPU module, and the EtherCAT master module of the CPU module processes the relevant series data2 in the domain data packet. In this way, a cycle communication based on the CPU module and a series of backplane modules is completed.

[0100] The TCP Server module of the backplane module takes out the cached data data1 from the corresponding EtherCAT communication chip through FSMC, and then sends it to the functional module connected to it, such as the IO module, artificial intelligence module or communication module through TCP; the functional module sends the collected and processed data data2 to the backplane module connected to it through its TCP Client module, and the TCP Server module of the backplane module caches the received data data2 into the memory of the EtherCAT communication chip through FSMC.

[0101] The above describes the process of high-performance data processing. It can be seen that in the main data link (CPU module->backplane module->CPU module), data processing is mainly completed by the hardware EtherCAT communication chip; in the branch data link (backplane module<-->IO module / artificial intelligence module / communication module), the MCU processor of the backplane module realizes data transparent transmission between the CPU module and related functional modules through the TCP Server module. Based on the above method, the maximum speed of the PLC control system can reach 100Mbit / s, and the fastest communication cycle can reach within 100μs; at the same time, based on the EtherCAT distributed clock synchronization mechanism, DC can be configured to achieve high-precision synchronization, with a synchronization accuracy of <<1μs.

[0102] In some embodiments, reference Figure 6 The PLC control method may also include: the artificial intelligence module accesses the terminal device through a network bridge device (such as a switch), preprocesses the accessed terminal data through the access processing module of the artificial intelligence module, and then sends the preprocessed data to the analysis module for analysis based on the machine learning model, and sends the analysis results to the CPU module via the post-processing module, the TCP Client module and the backplane module. The CPU module performs logical operations based on the analysis results and sends corresponding control instructions to the relevant IO module or communication module to realize the linkage control of the accessed terminal device. This method realizes edge intelligent control and improves the intelligent control capability.

[0103] The analysis module can use different machine learning models to analyze the same pre-processed output data of the access processing module. For example, in the smart construction site scenario, the same video input stream can be used to detect safety helmets and reflective clothing based on machine learning models. At the same time, the analysis module can also be configured to apply different machine learning models to analyze and process the input data of different terminal devices, such as applying a strip defect detection model to detect strip defects based on the input data of the terminal device, and applying a belt offset recognition model to detect belt offset in the belt conveyor system based on the input data of the terminal device. An analysis module can be connected to multiple terminal devices, and the input data of each terminal device can be configured with multiple machine learning models for analysis. At the same time, the output data analyzed and processed by the analysis module can be sent to the HMI through the network port by the post-processing module, so that the intelligent analysis results can be observed intuitively, and further, basic data can be provided for the self-optimization of the cloud-edge machine learning model, thereby further improving the machine learning model performance of the artificial intelligence module.

[0104] In some embodiments, reference Figure 6 The PLC control method may also include: the artificial intelligence module receives the process real-time data sent by the CPU module through the backplane module, pre-processes the received process real-time data through the access processing module, and then sends the pre-processed data to the data module for storage, and the analysis module performs analysis based on the complex rule model, and sends the analysis result to the CPU module via the post-processing module, the TCP Client module and the backplane module, and the CPU module performs logical operations according to the analysis result.

[0105] This method uses an independent artificial intelligence module to perform model analysis of complex rules. On the one hand, it improves the ability of the PLC control system to handle large and complex rule models. On the other hand, migrating large and complex calculations from the CPU module to the artificial intelligence module reduces the resource consumption of the CPU module, improves its processing capabilities, and improves the processing performance of the PLC control system as a whole. In addition, large and complex calculations are usually prone to failures. By having the artificial intelligence module independently perform large and complex calculations, the reliability and availability of the CPU module are also improved. The computing power based on the independent artificial intelligence module also provides a basis for edge distributed computing of the PLC control system. The implementation of this method improves the distributed edge computing capabilities, reliability and availability of the PLC control system as a whole.

[0106] In some embodiments, reference Figure 6, the PLC control method may also include: the artificial intelligence module obtains local data of a preset time window from the data module through the access processing module, the access processing module sends the obtained local data to the analysis module for model analysis based on complex rules, and sends the analysis results to the CPU module via the post-processing module, the TCP Client module and the backplane module, and the CPU module performs logical operations according to the analysis results. This method realizes rule-based analysis of historical data and further improves the edge computing capability of the PLC control system.

[0107] The analysis module can add new analysis support by downloading new edge analysis models (machine learning models, complex rule models) on the embedded operating system of the artificial intelligence module according to scenario requirements; the access processing module supports the processing of different input data by downloading new access processing models on the embedded operating system of the artificial intelligence module.

[0108] It should be noted that the functional modules in the various embodiments of the present application can be integrated into a processing module, or each module can exist physically separately, or two or more modules can be integrated into one module. The above-mentioned integrated modules can be implemented in the form of hardware or in the form of software functional modules. If the integrated modules are implemented in the form of software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on such an understanding, the technical solution of the present application is essentially or the part that contributes to the prior art or all or part of the technical solution can be embodied in the form of a software product.

[0109] Those skilled in the art will appreciate that the features described in the various embodiments and / or claims of the present application may be combined and / or combined in a variety of ways, even if such combinations and / or combinations are not explicitly described in the present application. In particular, without departing from the spirit and teachings of the present application, the technical features described in the various embodiments and / or claims of the present application may be combined and / or combined in a variety of ways, and all of these combinations and / or combinations fall within the scope of the present application.

[0110] Although the present application has been shown and described with reference to specific exemplary embodiments of the present application, it should be understood by those skilled in the art that various changes in form and details may be made to the present application without departing from the spirit and scope of the present application as defined by the appended claims and their equivalents. Therefore, the scope of the present application should not be limited to the above-mentioned embodiments, but should be determined not only by the appended claims, but also by the equivalents of the appended claims.

Claims

1. A PLC control system, characterized in that: include: A CPU module, which is used to send domain data packets and execute application logic based on received analysis data; A plurality of backplane modules connected in series, which are used to receive and forward the domain data packets, and also to send the received analysis data to the CPU module through the domain data packets; each backplane module can be connected to a corresponding functional module; the backplane module is configured to connect the CPU module and the functional module; An artificial intelligence module, which is a type of the functional module, is used to receive relevant data in the domain data packet or receive terminal data sent by a connected terminal device, perform data analysis and processing on data processing tasks whose data volume exceeds a preset data volume threshold or whose logic complexity exceeds a preset logic complexity threshold, and forward the obtained analysis data to the CPU module through the corresponding backplane module.

2. The PLC control system according to claim 1, characterized in that: The CPU module and the backplane module, as well as the backplane modules, are connected via an EtherCAT communication mechanism using an EBUS bus for data exchange. The backplane module and the functional module exchange data via TCP communication.

3. The PLC control system according to claim 2, characterized in that: The artificial intelligence module includes: Artificial intelligence module business module, which is used to analyze and process the received data to implement corresponding artificial intelligence business; An artificial intelligence module embedded operating system adapted to the embedded operating system of the artificial intelligence module business module and bidirectionally connected to the artificial intelligence module business module; An artificial intelligence module CPU processor adapted to the CPU processor of the artificial intelligence module embedded operating system and bidirectionally connected to the artificial intelligence module embedded operating system; An artificial intelligence module GPU processor, adapted to the GPU processor of the artificial intelligence module embedded operating system, and bidirectionally connected to the artificial intelligence module embedded operating system; The artificial intelligence module business module also includes: An artificial intelligence module TCP client module, through which the artificial intelligence module performs TCP communication with the backplane module; The artificial intelligence module access processing module is used to pre-process the received data; the artificial intelligence module access processing module supports the processing of different input data by downloading a new access processing model on the artificial intelligence module embedded operating system; A data module, used to store data pre-processed by the processing module via the artificial intelligence module; The analysis module is used to analyze and process the data pre-processed by the artificial intelligence module access processing module to obtain the analysis data; the analysis module adds a new analysis support function by downloading a new edge analysis model on the artificial intelligence module embedded operating system; The post-processing module is used to send the analysis data through the artificial intelligence module TCP client module according to the data mapping rules.

4. The PLC control system according to claim 3, characterized in that: The CPU module comprises: CPU module EtherCAT master module, used to realize EtherCAT master function; A real-time embedded operating system for a CPU module, adapted to the real-time embedded operating system of the CPU module, and bidirectionally connected to the EtherCAT master station module of the CPU module; A CPU module CPU processor, adapted to the CPU module CPU processor, bidirectionally connected to the CPU module real-time embedded operating system; The CPU module EtherCAT communication chip is bidirectionally connected with the CPU module CPU processor through the EtherCAT protocol, and is also bidirectionally connected with the backplane module through the EBUS bus.

5. The PLC control system according to claim 4, characterized in that: The backplane module is an EtherCAT slave module corresponding to the EtherCAT master module of the CPU module, and is used to realize the EtherCAT slave function; the backplane module includes: The backplane module EtherCAT communication chip is bidirectionally connected to the CPU module or other backplane modules via the EBUS bus; The backplane module MCU processor is adapted to the CPU processor of the backplane module and realizes a bidirectional connection with the backplane module EtherCAT communication chip through FSMC; Backplane module TCP server module, through which the backplane module performs TCP communication with the functional module.

6. The PLC control system according to any one of claims 1 to 5, characterized in that: The functional module also includes an IO module, which is configured to process digital and analog input and output information.

7. The PLC control system according to any one of claims 1 to 5, characterized in that: The functional module also includes a communication module, which is configured to support access of terminal equipment containing a preset communication protocol.

8. A PLC control method based on the PLC control system according to any one of claims 5 to 7, characterized in that: include: The CPU module EtherCAT master module sets the scanning cycles of different backplane modules according to the EtherCAT domain data scanning mechanism, and classifies the backplane modules with the same scanning cycles into a unified domain; the CPU module EtherCAT master module generates corresponding domain data packets according to different scanning cycles, and sends them to the CPU module EtherCAT communication chip through the EtherCAT protocol; the CPU module EtherCAT communication chip transmits the received domain data packets through the EBUS bus according to the network topology; The backplane module EtherCAT communication chip of each backplane module in the network topology checks the domain data packet to check whether there is message data sent to the backplane module to which it belongs; if there is, the data to be received is obtained from the domain data packet, and then the received data is cached in the memory of the backplane module EtherCAT communication chip, and at the same time, the data to be sent is taken out from the memory, and the data to be sent is written into the domain data packet, and finally the new domain data packet is forwarded to the next backplane module according to the network topology; after being processed sequentially according to this logic, the domain data packet is finally returned to the CPU module EtherCAT master station module, and the CPU module EtherCAT master station module processes the data in the domain data packet, thereby completing a cycle communication based on the CPU module and several backplane modules; The backplane module TCP server module of the backplane module takes out the cache data from the corresponding backplane module EtherCAT communication chip through FSMC, and then sends it to the functional module connected to it through TCP; The functional module sends the collected and processed data to the backplane module connected to it through its TCP client module, and the backplane module TCP server module of the backplane module caches the received data into the memory of the backplane module EtherCAT communication chip through FSMC.

9. The PLC control method according to claim 8, characterized in that: include: The artificial intelligence module accesses the external terminal device through the network bridge device, and pre-processes the accessed terminal data through the artificial intelligence module access processing module, and then sends the pre-processed data to the analysis module for analysis and processing to obtain analysis data, and then sends the analysis data to the CPU module; The CPU module performs logical operations based on the analyzed data, generates control instructions and sends them to the corresponding functional modules to achieve linkage control of the terminal equipment; The analysis module can use different machine learning models to analyze the same pre-processed output data of the artificial intelligence module access processing module, and can also be set to apply different machine learning models to analyze and process the input data of different terminal devices; and / or The artificial intelligence module receives the real-time data of the process sent by the CPU module through the backplane module, pre-processes the received real-time data of the process through the artificial intelligence module access processing module, and then sends the pre-processed data to the data module for storage; The analysis module analyzes and processes the pre-processed data, and sends the analysis data to the CPU module via the post-processing module, the artificial intelligence module, the TCP client module, and the backplane module; The CPU module performs logical operations based on the analyzed data.

10. The PLC control method according to claim 8 or 9, characterized in that: include: The artificial intelligence module obtains local data of a preset time window from the data module through the artificial intelligence module access processing module; The artificial intelligence module access processing module sends the acquired local data to the analysis module for analysis and processing, and sends the analysis data to the CPU module via the post-processing module, the artificial intelligence module TCP client module and the backplane module; The CPU module performs logical operations based on the analyzed data.

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