Plate glass production line cutting redundancy control method and system

Abstract

The invention provides a plate glass production line cutting redundancy control method and system, and the method comprises the steps: receiving plate glass production data, carrying out the optimization cutting calculation processing through a main server, so as to obtain a production line cutting scheme, and synchronously backing up the production line cutting scheme to a standby server; generating a control instruction based on the production line cutting scheme, transmitting the control instruction to main production line cutting control equipment through a preset communication path, and synchronously backing up the control instruction to standby production line cutting control equipment; and driving the plate glass production line cutting equipment to complete the cutting operation based on the control instruction, and automatically switching to the standby server and the standby production line cutting control equipment to maintain the continuity of the cutting operation when the main server and the main production line cutting control equipment break down. According to the plate glass production line cutting redundancy control method and system, continuous operation of the production line can be guaranteed, safety and integrity of data are guaranteed, and shutdown of the whole production line caused by single-point faults is avoided.

Description

Technical Field

[0001] The invention belongs to the technical field of industrial automation, and in particular relates to a cutting redundancy control method and system for a flat glass production line. Background Art

[0002] In the production process of flat glass, the optimization of the cutting system plays a vital role. It requires real-time calculation of the best cutting plan to improve production efficiency and material utilization. However, the traditional system relies on a single server for optimization calculation and data processing, and this architecture has the risk of single point failure. Once the equipment fails, the network connection is interrupted, or the operating system crashes, the entire production line may come to a standstill, resulting in huge economic losses. The modern flat glass manufacturing industry requires that the production line can run 24 hours a day without interruption, and any form of interruption may result in thousands of losses.

[0003] Therefore, how to provide a redundant control method for cutting a flat glass production line to improve the stability and reliability of the system has become one of the key issues that need to be urgently solved in the industry. Summary of the invention

[0004] The purpose of the present invention is to provide a redundant control method and system for cutting a flat glass production line, which can effectively meet the high requirements of continuity and real-time performance of the glass production line according to the specific needs of glass cutting, and avoid shutdown of the entire production line due to a single point failure.

[0005] In a first aspect, the present invention provides a method for redundant control of cutting of a flat glass production line, the method comprising the following steps: receiving flat glass production data, and performing optimized cutting calculation processing through a main server to obtain a production line cutting plan, and synchronously backing up the plan to a backup server; generating control instructions based on the production line cutting plan, and transmitting the control instructions to a main production line cutting control device through a preset communication path, and synchronously backing up the plan to a backup production line cutting control device; driving the flat glass production line cutting device to complete the cutting operation based on the control instructions, and automatically switching to the backup server and the backup production line cutting control device to maintain the continuity of the cutting operation when the main server and the main production line cutting control device fail.

[0006] In an implementation of the first aspect, generating control instructions based on the production line cutting plan and transmitting them to the main production line cutting control device through a preset communication path includes the following steps: setting main connection attribute parameters corresponding to the main server and backup connection attribute parameters corresponding to the main connection attribute parameters; converting the production line cutting plan into control instructions, and using the main connection parameters to establish a communication connection with the main production line cutting control device; wherein the main connection attribute parameters include a virtual IP address, port number, priority, and interface information.

[0007] In an implementation of the first aspect, the setting of the main connection attribute parameters corresponding to the main server and the backup connection attribute parameters corresponding to the main connection attribute parameters further includes the following steps: setting an application for server data monitoring; when the application detects abnormal data of the main server during execution, automatically switching to the backup server.

[0008] In an implementation of the first aspect, an application for server data monitoring includes the following steps: real-time monitoring of the operating status of the main server and the backup server through a heartbeat detection signal, wherein the heartbeat detection signal includes the load, memory usage, and network status of the main server and the backup server; real-time monitoring of the operating status of the main server and the backup server as well as the main production line cutting control device and the backup production line cutting control device by configuring the industrial switch as a ring network topology.

[0009] In an implementation of the first aspect, when both the main server and the backup server are in an abnormal state, the corresponding main production line cutting control device and the backup production line cutting control device enter a stand-alone mode and generate control instructions based on the last obtained production line cutting plan.

[0010] In a second aspect, the present invention provides a flat glass production line cutting redundant control system, the system comprising:

[0011] A power supply module, comprising a UPS main power supply and a UPS backup power supply, wherein the UPS main power supply is used to supply power to the main power supply, and the UPS backup power supply is used to supply power to the backup power supply;

[0012] A server module, connected to the power supply module, including a main server and a backup server, wherein the main server is used to receive flat glass production data and perform optimized cutting calculation processing through the main server to obtain a production line cutting plan, and the backup server is used to synchronously receive and back up the flat glass production data;

[0013] A controller module, connected to the server module and the power supply module, including a main production line cutting control device and a backup production line cutting control device, wherein the main production line cutting control device is used to generate a control instruction based on the production line cutting scheme and transmit the control instruction to the main production line cutting control device through a preset communication path, and the backup production line cutting control device is used to receive the same control instruction as a redundant backup;

[0014] A switch module, connected to the server module and the controller module, includes a main switch and a standby switch, wherein a ring network structure is formed between the main switch and the standby switch, and the main and standby switching of the flat glass production line cutting redundant control system is realized by real-time monitoring of the operating status of each module;

[0015] The execution module is connected to the controller module and is used to drive the flat glass production line cutting equipment to complete the cutting operation based on the control instruction.

[0016] In an implementation of the second aspect, a heartbeat detection module is configured between the primary server and the backup server; the heartbeat detection module is used to detect the operating status of the server module in real time by exchanging heartbeat signals through the TCP / IP protocol.

[0017] In an implementation of the second aspect, the server module is also configured with a mirrored redundant and striped storage hard disk array; the mirrored redundant and striped storage hard disk array is used to mirror the flat glass production data, and when an abnormal situation is detected, an automatic reading and backup operation is triggered.

[0018] In an implementation of the second aspect, the server module is also configured with a master database and a slave database; the master server is configured with a master database for real-time updating of the flat panel production data and the production line cutting plan; the backup server is configured with a backup database for synchronizing changes in the master database.

[0019] In an implementation of the second aspect, the system also includes a monitoring and alarm module; the monitoring and alarm module is connected to the server module and the controller module, and is used to monitor the operating status of the system in real time, and when a system failure or abnormality is detected, it prompts the operator through an audible and visual alarm, and records the fault information and operation log to facilitate troubleshooting and system maintenance.

[0020] As described above, the flat glass production line cutting redundancy control method and system of the present invention have the following beneficial effects:

[0021] (1) High availability: The redundant design of dual PCs and dual PLCs ensures that when any device fails, the system can quickly switch to the backup device to avoid production line stagnation. This design reduces production interruptions caused by single point failures, thereby ensuring production continuity and efficiency.

[0022] (2) Data security: RAID 10 hard disk redundancy and MySQL master-slave replication technology are used to ensure the integrity and consistency of production data. This redundant configuration can effectively prevent data loss and ensure that data can be quickly restored when hardware failure occurs.

[0023] (3) Flexibility and transparency: The application of virtual IP ensures that the connection between external devices and the system is not affected, and the switching process is transparent to the external system. Production equipment only needs to communicate through a fixed IP, without the need for additional network configuration.

[0024] (4) Strong risk resistance: The dual power supply and dual network card design effectively improves the stability of the system in the event of power fluctuations and network failures, reducing the risk of production interruption. This risk resistance is particularly important in industrial environments that operate for a long time.

[0025] (5) Improved production efficiency: The fast switching and continuous operation of the optimized calculation ensures efficient production in the event of equipment failure. This design enables efficient data processing and task scheduling during the cutting process, reducing production losses caused by failures.

[0026] (6) Reduced maintenance and management costs: Due to the system’s automated switching and fault detection mechanisms, the need for manual intervention is greatly reduced, thereby reducing equipment maintenance and management costs. This efficient operation and maintenance model enables enterprises to reduce costs while focusing resources on improving core competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a flow chart showing a method for controlling the cutting redundancy of a flat glass production line according to an embodiment of the present invention;

[0028] Figure 2a It is a diagram showing the data processing steps in one embodiment of the cutting redundancy control method of a flat glass production line of the present invention;

[0029] Figure 2b It is a diagram showing a path setting of a cutting redundancy control method of a flat glass production line according to an embodiment of the present invention;

[0030] Figure 3a It is a structural diagram of a redundant control system for cutting a flat glass production line according to an embodiment of the present invention;

[0031] Figure 3bIt is a structural diagram of a power supply module in one embodiment of a redundant control system for cutting a flat glass production line of the present invention;

[0032] Figure 3c It is a structural diagram of a server module in one embodiment of a redundant control system for cutting a flat glass production line of the present invention;

[0033] Figure 3d It is a structural diagram of a controller module and an execution module in one embodiment of a redundant control system for cutting a flat glass production line of the present invention;

[0034] Figure 3e It is a diagram showing the structure of a switch module in one embodiment of a redundant control system for cutting a flat glass production line of the present invention;

[0035] Figure 4 It is a working principle diagram of a redundant control system for cutting a flat glass production line according to the present invention in one embodiment; DETAILED DESCRIPTION

[0036] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.

[0037] It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and thus the drawings only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0038] The technical solutions in the embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0039] like Figure 1 As shown, in one embodiment, the flat glass production line cutting redundancy control method of the present invention includes steps S11 to S13.

[0040] Step S11, receiving flat glass production data, and performing optimized cutting calculation processing through the main server to obtain a production line cutting plan, and synchronously backing up the plan to the standby server.

[0041] like Figure 2aAs shown, the main server (PC1) receives real-time data from the production line through a network interface. Flat glass production includes key information such as the size, type, and quantity of flat glass. The received data is fed into the data processing module, which is responsible for parsing the data, extracting useful information, and converting it into a format suitable for processing by the optimization algorithm. The processed data is fed into the optimization algorithm module, which uses a specific algorithm to calculate the optimal cutting plan. The optimization algorithm considers factors such as material utilization, cutting speed, and tool wear to achieve dual optimization of production efficiency and cost. The optimization algorithm outputs the optimal cutting plan, which describes in detail how to cut each piece of flat glass.

[0042] Furthermore, the main server (PC1) synchronizes the optimized cutting plan to the backup server (PC2) in real time. The backup server (PC2) serves as a hot backup for the main server and can take over the service when the main server fails. When the main server fails, the backup server can quickly take over the service to ensure the continuity of the production line.

[0043] After troubleshooting, the main server needs to be rejoined to the cluster and data synchronization and status recovery are performed. Through the implementation of the above solution, flat glass production data can be effectively received and processed, an optimized cutting plan can be generated, and the synchronization and backup mechanism between the main server and the backup server can ensure the efficient operation of the production line and the security and reliability of the data.

[0044] Step S12: Generate control instructions based on the production line cutting plan, transmit them to the main production line cutting control device through a preset communication path, and synchronously back up them to the standby production line cutting control device.

[0045] Step S13, based on the control instruction, drive the flat glass production line cutting equipment to complete the cutting operation, and when the main server and the main production line cutting control equipment fail, automatically switch to the backup server and the backup production line cutting control equipment to maintain the continuity of the cutting operation.

[0046] like Figure 2b As shown, first set the connection attribute parameters and the application for server monitoring. The specific steps are as follows:

[0047] Step S121: Setting the main connection attribute parameters

[0048] Determine the main connection attribute parameters corresponding to the main server (PC1), including the virtual IP address, port number, priority and interface information. These parameters ensure that the communication connection with the main production line cutting control device can be established accurately.

[0049] Step S122: Setting backup connection attribute parameters

[0050] Set the backup connection attribute parameters corresponding to the main connection attribute parameters so that when the main server fails, it can quickly switch to the backup server (PC2).

[0051] Step S123: Set the application.

[0052] Design a graphical user interface (GUI) based server monitoring application to monitor the operating status of primary and standby servers. The program needs to be able to monitor the key performance indicators (KPIs) of the specified server in real time, including but not limited to central processing unit (CPU) load, memory usage, disk I / O, network connectivity and traffic statistics. In addition, the application can distinguish between primary and standby servers and provide an intuitive visualization interface for administrators to view and analyze server health status.

[0053] By implementing a heartbeat detection mechanism, the server activity is monitored by sending heartbeat signals regularly. The heartbeat signal contains information such as server load, memory usage, network status, etc., so that potential problems can be discovered in time.

[0054] The operating states of the main server and the backup server as well as the main production line cutting control device and the backup production line cutting control device are monitored in real time by configuring the industrial switch into a ring network topology structure.

[0055] Further, the production line cutting plan is converted, and the optimized production line cutting plan is converted into specific control instructions, which will guide the main production line cutting control device to operate. Using the main connection parameters, according to the set virtual IP address, port number and other information, a communication connection with the main production line cutting control device is established.

[0056] Furthermore, the backup is synchronized to the cutting control device of the backup production line. When the main server sends a control instruction to the cutting control device of the main production line, the same control instruction is synchronized to the cutting control device of the backup production line. Ensure that the cutting control device of the backup production line is in a standby state and is ready to take over the production task at any time.

[0057] Furthermore, the system’s performance indicators, such as response time and throughput, are continuously monitored. When the application detects abnormal data on the primary server during execution, it automatically switches to the backup server to ensure the continuity and stability of the production line.

[0058] Furthermore, when it is detected that both the main server and the backup server are not working properly, the control system will automatically trigger the stand-alone mode. In the stand-alone mode, the main production line cutting control equipment and the backup production line cutting control equipment will operate independently and no longer rely on the control instructions of the server. Before entering the stand-alone mode, the control system will save the last production line cutting plan received from the server. When the server cannot provide new control instructions, the equipment in the stand-alone mode will use the last obtained plan to guide production. According to the last obtained production line cutting plan, the equipment in the stand-alone mode will automatically generate corresponding control instructions. These control instructions will be sent directly to the actuators, such as cutting machines, conveyor belts, etc., to complete the cutting and handling of the glass.

[0059] By using the last acquired production line cutting plan, the equipment in stand-alone mode can ensure that production will not be interrupted due to server failure. Although it may not be possible to update the cutting plan in real time to adapt to production changes, at least the basic production process can be guaranteed to continue. Once the server resumes normal operation, the control system will reconnect to the server and synchronize the latest production line cutting plan. At this time, the equipment in stand-alone mode will stop using the last acquired plan and use the real-time data provided by the server for production.

[0060] The protection scope of the flat glass production line cutting redundant control method described in the embodiment of the present invention is not limited to the execution order of the steps listed in this embodiment. All solutions implemented by adding, reducing or replacing steps in the prior art based on the principles of the present invention are included in the protection scope of the present invention.

[0061] An embodiment of the present invention also provides a flat glass production line cutting redundant control system, which can implement the flat glass production line cutting redundant control method described in the present invention. However, the implementation device of the flat glass production line cutting redundant control system described in the present invention includes but is not limited to the structure of the flat glass production line cutting redundant control system listed in this embodiment. All structural deformations and replacements of the prior art made according to the principles of the present invention are included in the protection scope of the present invention.

[0062] like Figure 3a As shown, in one embodiment, the flat glass production line cutting redundant control system of the present invention includes:

[0063] The power supply module 31 includes a UPS main power supply and a UPS backup power supply, wherein the UPS main power supply is used to supply power to the main power supply, and the UPS backup power supply is used to supply power to the backup power supply;

[0064] The server module 32 is connected to the power supply module 31 and includes a main server and a backup server. The main server is used to receive the flat glass production data and perform optimized cutting calculation processing through the main server to obtain the production line cutting plan. The backup server is used to synchronously receive and back up the flat glass production data.

[0065] The controller module 33 is connected to the server module 32 and the power supply module 31, and includes a main production line cutting control device and a standby production line cutting control device. The main production line cutting control device is used to generate a control instruction based on the production line cutting scheme and transmit it to the main production line cutting control device through a preset communication path. The standby production line cutting control device is used to receive the same control instruction as a redundant backup.

[0066] The switch module 34 is connected to the server module 32 and the controller module 33, and includes a main switch and a backup switch. A ring network structure is formed between the main switch and the backup switch. The main and backup switches of the flat glass production line cutting redundant control system are switched by real-time monitoring of the operating status of each module.

[0067] The execution module 35 is connected to the controller module 33 and is used to drive the flat glass production line cutting equipment to complete the cutting operation based on the control instruction.

[0068] like Figure 3b As shown, the UPS system in the power supply module 31 plays a vital role in the flat glass production line cutting control system, and provides a stable and uninterrupted power supply for the server module 32, the controller module 33 and the industrial switch 34. The UPS system in the power supply module 31 adopts a power redundancy design and a power failure response mechanism, as follows:

[0069] (1) Power redundancy design: The UPS system implements power redundancy on key equipment. The primary and backup servers, primary and backup controllers, and industrial switches are all connected to the factory-level UPS uninterruptible power supply. This design ensures that even if there is a power outage in the factory power grid, the UPS system can immediately detect the power outage and automatically switch to battery power mode within milliseconds, so as not to affect the normal operation of the production line. Through this redundant design, the computing, control, and communication equipment on the production line can continue to work when the power supply of the power grid is unstable or completely out of power, ensuring the integrity of production data and the continuity of the cutting process.

[0070] (2) Power outage response mechanism: The UPS system not only provides instant power switching function, but also can maintain system operation for a sufficiently long period of time, which is usually referred to as "battery life". During the power outage, the UPS system provides the necessary power to the server module and control module, allowing them to continue to perform optimized computing and cutting tasks without causing data loss or task interruption due to power outage. In addition, the UPS system also provides a buffer time for power recovery. Even if the grid power supply is restored in a short time, the system has enough time to safely shut down or switch back to the grid power supply, avoiding the risk of equipment damage or data loss due to sudden power restoration. This power outage response mechanism is a very critical part of the production line automation system. It ensures the stability and reliability of the production process, reduces downtime caused by power problems, and improves production efficiency.

[0071] like Figure 3c As shown, the server module 21 adopts the following settings to achieve a redundant configuration:

[0072] (1) Dual server configuration

[0073] There are two servers with exactly the same functions in the system, namely PC1 and PC2. The same operating system and optimized cutting computing software are installed on both servers to ensure that they can perform the same tasks. The server hardware is configured with dual power supplies, dual network cards, and RAID 10 hard disk arrays. Dual power supplies ensure that even if one power supply fails, the other power supply can continue to supply power; RAID 10 hard disk arrays provide data redundancy and high-performance storage through disk mirroring and striping; dual network cards provide redundant paths for network connections.

[0074] Each PC server is equipped with dual power modules and connected to different power supply lines. This dual power design ensures that when one power module or power supply line fails, the system can quickly switch to another power module to ensure the continuity of power supply on the production line. The power module is integrated with a monitoring chip to detect the power status in real time. Once an abnormality is detected in a power supply, the system will automatically issue an alarm and switch to the backup power module.

[0075] The storage device of each PC server adopts RAID 10 configuration, which combines data mirroring redundancy (RAID1) and striped storage (RAID 0). In this configuration, data is written to multiple hard disks at the same time and backed up by mirroring. When any hard disk fails, RAID 10 can automatically read data from the mirrored hard disk to ensure data integrity and normal operation of the system. It also supports hot-swappable replacement, and operation and maintenance personnel can replace the failed hard disk while the system is running without stopping the system, thereby realizing rapid data recovery.

[0076] The master server (PC1) is configured as the MySQL master database, responsible for real-time updating of production data and optimization of calculation results. PC2 is configured as a slave database, synchronizing changes in the master database in real time. This master-slave replication mechanism ensures that when the master server fails, the slave server can take over seamlessly, ensuring high availability and data consistency of the system.

[0077] Each PC server is equipped with dual network cards, which are connected to different network switches. This way, even if one network path fails, the other path can still maintain communication. This redundant network channel design ensures high availability of network connections. If a network path of PC1 or PC2 fails, the system automatically switches to the backup network card to maintain stable communication with PLC devices and other network devices. This automatic switching mechanism reduces the risk of single point failures, improves the reliability of the entire system, and ensures that the flat glass production line can operate stably in a complex industrial environment.

[0078] Furthermore, the Gigabit Ethernet switch connection between the servers provides 1Gbps data transmission bandwidth, which ensures that production data can be synchronized in real time between the two servers to ensure data consistency.

[0079] (2) Virtual IP binding and switching

[0080] Virtual IP technology allows two servers to share an IP address, so that external devices only need to communicate with one IP address without knowing which server is processing the request. In the initial state, the virtual IP is bound to the primary server PC1, and all external production devices communicate with the system through this VIP. The backup server PC2 monitors the status of the primary server PC1 in real time, which is usually achieved through the heartbeat detection module. The heartbeat signal is a signal sent periodically to indicate that the server is operating normally.

[0081] If PC1 fails, the heartbeat detection module will detect the loss of the heartbeat signal within a short period of time and trigger an automatic switch to PC2. This process is called failover, which allows the system to quickly restore service when the primary server has problems without affecting the operation of the production line.

[0082] (3) Heartbeat monitoring module

[0083] Heartbeat detection software is installed on both PC1 and PC2. The software is responsible for monitoring the operating status of the server and sending heartbeat signals. The heartbeat signal is transmitted through the TCP / IP protocol to ensure stable communication at the network level. PC1 and PC2 are set to exchange heartbeat signals once a second. This high-frequency exchange can promptly detect any abnormalities in the other server. The heartbeat signal contains key information such as CPU load, memory usage, network status, etc., which is used to evaluate the health status of the server. The real-time exchange of heartbeat signals enables the system to continuously monitor the operating status of the two servers. If any abnormal indicators are detected (such as excessive CPU load, insufficient memory, network interruption, etc.), the system will immediately trigger the alarm mechanism.

[0084] When the heartbeat detection software finds an abnormality in PC1 or PC2, it will immediately send an alarm to the system administrator. At the same time, the system will decide whether to perform a master-slave switch based on the preset policy. If it is determined that a master-slave switch is required, the system will determine which server is more suitable as the new master server based on the information in the heartbeat signal. Usually, a server with better performance and lower resource utilization will be selected as the new master server. Once the decision to switch between the master and the standby is made, the system will automatically perform the switch operation. This includes migrating services on PC1 to PC2, or vice versa, depending on which server is selected as the new master server. After the master-slave switch is completed, the system will send a notification to all relevant personnel to inform them of the results of the switch. At the same time, the system will also record detailed log information, including the time, reason, and servers involved in the switch, for subsequent analysis and auditing.

[0085] Once PC1 is cleared and resumes normal operation, it will rejoin the redundant cluster. Before rejoining, PC1 needs to perform some necessary initialization operations to ensure that its status is consistent with other servers in the cluster. PC2, as the current primary server, will synchronize the latest data in its database to PC1. After the data synchronization is completed, the data between PC1 and PC2 will reach a consistent state. In this way, no matter which server becomes the primary server in the future, the integrity and accuracy of the data can be guaranteed.

[0086] like Figure 3d As shown in the figure, when PLC1 detects that PC1 can no longer provide data support or response, it will automatically trigger the switching mechanism. At this time, PLC2 will take over the control task and become the new main controller. After PLC2 takes over, it will continue to obtain the latest optimization data from PC2 and control the cutting machine based on this data. In extreme cases, if both PC1 and PC2 fail, PLC will enter stand-alone mode. In stand-alone mode, PLC will continue to perform cutting tasks based on the last optimized cutting plan received. This ensures the most basic operating capacity of the production line and avoids long-term downtime.

[0087] Once PC1 is cleared and resumes normal operation, it will rejoin the redundant cluster as a slave server. PC2 will synchronize the latest data in its master database to PC1 to ensure data consistency between the two servers. In this way, no matter which server becomes the master server in the future, the integrity and accuracy of the data can be guaranteed.

[0088] Furthermore, each PLC device is equipped with dual power modules and connected to different power supply lines. This dual power design ensures that when one power module or power supply line fails, the system can quickly switch to another power module for power supply, ensuring the continuity of power supply on the production line. A monitoring chip is integrated in the power module to detect the power status in real time. Once an abnormality is detected in a power supply, the system will automatically issue an alarm and switch to the backup power module.

[0089] like Figure 3e As shown, the switch module 34 significantly improves the network communication reliability of the flat glass production line cutting control system by providing multiple communication paths and fast fault recovery capabilities, and reduces production downtime caused by network failures.

[0090] Network topology refers to the layout and connection method of network devices. In the ring network redundancy design, industrial switches are configured into a closed ring structure, and each switch is connected to two adjacent switches to form a continuous ring. This ring network structure provides path redundancy, and data can be transmitted in either direction within the ring. If a switch or connection path in the ring network fails, the data packet can automatically bypass the fault point in the opposite direction and continue to transmit. The ring network redundancy design can detect the fault in a very short time (such as 2 seconds) and automatically switch to the backup path. This fast recovery capability ensures the continuity of data transmission, which is crucial to the real-time requirements of the production line control system.

[0091] Furthermore, industrial switches have fault detection mechanisms that can monitor the communication status in the network in real time. This is usually achieved through protocols such as STP (Spanning Tree Protocol) or its enhanced version RSTP (Rapid Spanning Tree Protocol), which can detect loops in the network and provide fault recovery functions. When the switch detects a network interruption or abnormality, such as a cable disconnection or switch failure, it immediately starts the failover process. This process involves recalculating the network topology and finding a new, fault-free path to transmit data. The process of automatically switching to the backup path is transparent to the user, that is, the user and the upper-layer application will not feel the interruption of the network, and the cutting control data flow maintains consistency and reliability, thereby ensuring the stable operation of the production line.

[0092] like Figure 4 As shown, start the main server (PC1) and the backup server (PC2), and ensure that all hardware devices (including UPS system, PLC controller, industrial switch, etc.) are operating normally. Configure network settings, including virtual IP binding and heartbeat detection module settings. Confirm that the UPS system provides uninterruptible power supply for all key devices.

[0093] Receives flat glass production data, such as glass size, shape, cutting requirements, etc. The main server (PC1) processes this data using optimized cutting calculation software to generate a cutting plan. The cutting plan is synchronously transmitted to the backup server (PC2) as a backup. Based on the cutting plan, control instructions are generated. The control instructions are transmitted to the main PLC controller and the backup PLC controller through redundant network channels.

[0094] The main PLC controller receives the control instruction and drives the flat glass production line cutting equipment to perform the cutting operation. At the same time, the standby PLC controller also receives the same control instruction and is in standby state.

[0095] The heartbeat detection module continuously monitors the status of the primary server (PC1). If the primary server (PC1) fails, the heartbeat detection module detects the loss of the heartbeat signal in a short period of time and triggers the automatic switching mechanism. The virtual IP (VIP) automatically switches from the primary server (PC1) to the backup server (PC2). The backup server (PC2) seamlessly takes over the cutting control task and continues to interact with external devices.

[0096] The ring network structure composed of industrial switches monitors the network status in real time. If a network interruption or abnormality is detected, the ring network structure automatically switches to the backup path to ensure uninterrupted data transmission. When the factory power grid loses power, the UPS system immediately switches to battery power to ensure that the system completes seamless power switching within milliseconds. The UPS system provides enough power to maintain system operation until the power grid is restored or the backup power supply intervenes.

[0097] Through the above-mentioned working process, the present invention ensures the high reliability, data security and real-time monitoring capability of the flat glass production line cutting control system.

[0098] In the several embodiments provided by the present invention, it should be understood that the disclosed system, device or method can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of modules / units is only a logical function division, and there may be other division methods in actual implementation, such as multiple modules or units can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some interfaces, indirect coupling or communication connection of devices or modules or units, which can be electrical, mechanical or other forms.

[0099] The modules / units described as separate components may or may not be physically separated, and the components displayed as modules / units may or may not be physical modules, that is, they may be located in one place, or they may be distributed on multiple network units. Some or all of the modules / units may be selected according to actual needs to achieve the purpose of the embodiments of the present invention. For example, the functional modules / units in the various embodiments of the present invention may be integrated into one processing module, or each module / unit may exist physically separately, or two or more modules / units may be integrated into one module / unit.

[0100] Those of ordinary skill in the art should further appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in terms of function in the above description. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

Claims

1. A cutting redundancy control method for a flat glass production line, characterized in that: The method comprises the following steps: Receive flat glass production data, and perform optimized cutting calculations through the main server to obtain the production line cutting plan, and synchronize the backup to the backup server; Generate control instructions based on the production line cutting plan, transmit them to the main production line cutting control device through a preset communication path, and synchronously back up to the standby production line cutting control device; The flat glass production line cutting equipment is driven to complete the cutting operation based on the control instruction, and when the main server and the main production line cutting control equipment fail, it automatically switches to the backup server and the backup production line cutting control equipment to maintain the continuity of the cutting operation.

2. The flat glass production line cutting redundancy control method according to claim 1, characterized in that: Generating control instructions based on the production line cutting plan and transmitting them to the main production line cutting control device through a preset communication path includes the following steps: Setting a primary connection attribute parameter corresponding to the primary server and a backup connection attribute parameter corresponding to the primary connection attribute parameter; Convert the production line cutting plan into control instructions, and use the main connection parameters to establish a communication connection with the main production line cutting control device; The main connection attribute parameters include virtual IP address, port number, priority, and interface information.

3. The flat glass production line cutting redundancy control method according to claim 2, characterized in that: The step of setting the primary connection attribute parameters corresponding to the primary server and the backup connection attribute parameters corresponding to the primary connection attribute parameters further includes the following steps: An application program for server data monitoring is set up; when the application program detects abnormal data of the main server during execution, it automatically switches to the backup server.

4. The cutting redundancy control method for a flat glass production line according to claim 3, characterized in that: Setting up the application for server data monitoring consists of the following steps: The operating status of the main server and the standby server is monitored in real time through a heartbeat detection signal, wherein the heartbeat detection signal includes the load, memory usage, and network status of the main server and the standby server; The operating states of the main server and the backup server as well as the main production line cutting control device and the backup production line cutting control device are monitored in real time by configuring the industrial switch into a ring network topology structure.

5. The flat glass production line cutting redundancy control method according to claim 1, characterized in that: When both the main server and the backup server are in an abnormal state, the corresponding main production line cutting control device and the backup production line cutting control device enter a stand-alone mode and generate control instructions based on the last obtained production line cutting plan.

6. A redundant control system for cutting of a flat glass production line, characterized in that: The system comprises: A power supply module, comprising a UPS main power supply and a UPS backup power supply, wherein the UPS main power supply is used to supply power to the main power supply, and the UPS backup power supply is used to supply power to the backup power supply; A server module, connected to the power supply module, including a main server and a backup server, wherein the main server is used to receive flat glass production data and perform optimized cutting calculation processing through the main server to obtain a production line cutting plan, and the backup server is used to synchronously receive and back up the flat glass production data; A controller module, connected to the server module and the power supply module, including a main production line cutting control device and a backup production line cutting control device, wherein the main production line cutting control device is used to generate a control instruction based on the production line cutting scheme and transmit the control instruction to the main production line cutting control device through a preset communication path, and the backup production line cutting control device is used to receive the same control instruction as a redundant backup; A switch module, connected to the server module and the controller module, includes a main switch and a standby switch, wherein a ring network structure is formed between the main switch and the standby switch, and the main and standby switching of the flat glass production line cutting redundant control system is realized by real-time monitoring of the operating status of each module; The execution module is connected to the controller module and is used to drive the flat glass production line cutting equipment to complete the cutting operation based on the control instruction.

7. The cutting redundancy control method for a flat glass production line according to claim 5, characterized in that: A heartbeat detection module is configured between the main server and the standby server; The heartbeat detection module is used to detect the running status of the server module in real time by exchanging heartbeat signals through the TCP / IP protocol.

8. The flat glass production line cutting redundant control system according to claim 5, characterized in that: The server module is also configured with mirrored redundancy and striped storage hard disk array; The mirrored redundant and striped storage hard disk array is used to perform mirrored backup of the flat glass production data, and when an abnormal situation is detected, an automatic read backup operation is triggered.

9. The flat glass production line cutting redundant control system according to claim 5, characterized in that: The server module also configures a master database and a slave database; The main server is configured with a main database for real-time updating of the flat panel production data and the production line cutting plan; The standby server is configured with a standby database for synchronizing changes in the primary database.

10. The flat glass production line cutting redundant control system according to claim 5, characterized in that: The system also includes a monitoring and alarm module; The monitoring and alarm module is connected to the server module and the controller module, and is used to monitor the operating status of the system in real time. When a system failure or abnormality is detected, it prompts the operator through an audible and visual alarm, and records the failure information and operation log to facilitate troubleshooting and system maintenance.

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