Method for eliminating network interference of dry quenching control system

Abstract

The invention discloses a method for eliminating network interference of a dry quenching control system, which comprises the following steps of: installing an Ethernet module on a PLC (Programmable Logic Controller) rack of the dry quenching control system, and accessing all external data exchange nodes into the Ethernet module; internal data of the control system are communicated through a Profinet network; a circulating fan sudden stop signal program segment is modified, network abnormity filtering logic is added, and when substation communication is interrupted, sudden stop signals are forbidden to be automatically conducted; remaking a Profinet network cable, and adjusting a network topology structure, so that a data reading path of an operation station is independent of a substation communication link; after hardware configuration, network communication programs and IP address allocation are updated, network pressure testing and interlocking logic verification are carried out, the Ethernet module is installed on the PLC rack, physical isolation of an internal network and an external network of the dry quenching control system is achieved, the influence of external disturbance on Profinet substation communication is effectively blocked, the substation loss rate is reduced to 0 from the original level, and the system reliability is improved. And the stability of network operation is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of network communication control devices, and in particular to a method for eliminating network interference in a dry coke quenching control system. Background Art

[0002] In the production process of modern coking plants, the CDQ control system is the core to ensure the stable operation of the 125t / h CDQ, gas purification system, and coke oven transport system. Its network stability is crucial. However, the original design of the current CDQ control system has inherent network defects. The engineer station, operation station, and substation equipment are located on the same local area network. This network architecture makes the system extremely vulnerable to external disturbances. Once an abnormal situation such as a network storm occurs, it is very easy to cause substation communication loss. For example, in October and December 2024, due to the aforementioned network problems, the emergency stop signal of the circulating fan was mistakenly triggered after the substation was lost, which in turn caused the fan to shut down and the system interlock to shut down, causing serious losses and safety hazards to production.

[0003] Currently, existing technologies for addressing this issue mostly rely on single approaches, such as hardware redundancy or network shielding. While hardware redundancy can enhance system reliability to a certain extent, it cannot fundamentally prevent data conflicts between internal and external networks. Network shielding also provides limited protection and is unable to cope with complex and variable network interference. Therefore, existing technical approaches are unable to effectively resolve the issue of data conflicts between internal and external networks in CDQ control systems. A comprehensive solution, encompassing multiple dimensions, such as hardware isolation and signal logic optimization, is urgently needed to ensure the stable operation of the CDQ control system network. Summary of the Invention

[0004] (1) Technical issues

[0005] The present invention provides a method for eliminating network interference in a dry coke quenching control system. By means of hardware isolation and signal logic optimization, the method solves the problems of the existing system network being susceptible to interference, prone to accidental shutdown, and complex maintenance, thereby ensuring the stable and safe operation of the dry coke quenching control system.

[0006] (2) Technical content

[0007] To solve the above technical problems, the technical solution of the present invention is: a method for eliminating network interference in a dry coke quenching control system, comprising the following steps:

[0008] S1. Hardware transformation: Install an Ethernet module on the PLC rack of the CDQ control system and connect all external data exchange nodes to the Ethernet module;

[0009] S2. Network isolation: The internal data of the control system is communicated through the Profinet network; the external operation station, engineer station and data terminal exchange data with the control system through the Ethernet module;

[0010] S3, signal optimization: modify the circulating fan emergency stop signal program segment, add network abnormality filtering logic, and prohibit the emergency stop signal from automatically turning on when the substation communication is interrupted;

[0011] S4, topology reconstruction: Remake the Profinet network cable and adjust the network topology so that the data reading path of the operation station is independent of the communication link of the substation;

[0012] S5. System debugging: After updating the hardware configuration, network communication program and IP address allocation, perform network stress testing and interlocking logic verification.

[0013] Furthermore, the installation location of the Ethernet module in step S1 must meet the following requirements: the module must be in the same rack as the PLC master station module; the external data terminal must be connected to the Ethernet module through an independent switch, and must not share a physical link with the substation.

[0014] Furthermore, the network isolation implementation method of step S2 includes: the internal Profinet network is only connected to the substation module and the circulating fan controller; the external Ethernet network is connected to the operation station, engineer station, L2 system and big data platform.

[0015] Furthermore, the signal optimization of step S3 is specifically as follows: adding the "substation communication status" judgment condition in the emergency stop signal program segment; when the substation is lost, the emergency stop signal remains disconnected and triggers an audible and visual alarm instead of directly shutting down.

[0016] Furthermore, the system debugging of step S5 includes: simulating network disturbances to test the communication stability of the substation; and verifying that the circulating fan maintains operation when the substation is lost and the power generation system interlocking logic is not triggered.

[0017] Furthermore, the method is applicable to the control network transformation of a 125t / h dry coke quenching system, a gas purification system, and a coke oven coke transportation system in a coking plant.

[0018] (3) Technical effects

[0019] Compared with existing technologies, this invention offers the following advantages: By installing an Ethernet module on the PLC rack, it physically isolates the internal and external networks of the CDQ control system, effectively blocking the impact of external disturbances on Profinet substation communications and reducing the substation loss rate from the original level to zero, significantly improving network operational stability. By adding a "substation communication status" determination condition to the circulating fan emergency stop signal program segment, it eliminates the problem of false triggering of the emergency stop signal due to substation loss, reducing the number of unplanned system downtimes per year and ensuring continuous and stable production processes. This method is applicable to hybrid Profibus / Profinet networks. The retrofit process does not require replacing existing controller hardware, reducing retrofit difficulty and cost, and is widely applicable to various CDQ control system scenarios. By rewiring Profinet network cables and adjusting the network topology, the network architecture is simplified, fault location time is shortened by 80%, maintenance efficiency is significantly improved, and labor and equipment maintenance costs are reduced. During the system retrofit construction period, by formulating and implementing operational plans such as manual valve adjustment and nitrogen protection, the CDQ system maintained minimum safe operation, achieving a zero-accident retrofit process and ensuring personnel safety and production continuity. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 The present invention is a flow chart of a method for eliminating network interference in a dry coke quenching control system. DETAILED DESCRIPTION

[0021] The present invention will be described in further detail below with reference to the accompanying drawings.

[0022] Combined with attachment Figure 1 A method for eliminating network interference in a dry coke quenching control system is disclosed. The method is applicable to the control network reconstruction of a 125t / h dry coke quenching, gas purification system, and coke oven transport system in a coking plant, and comprises the following steps:

[0023] S1. Hardware transformation: Install an Ethernet module on the PLC rack of the CDQ control system and connect all external data exchange nodes to the Ethernet module;

[0024] S2. Network isolation: The internal data of the control system is communicated through the Profinet network; the external operation station, engineer station and data terminal exchange data with the control system through the Ethernet module;

[0025] S3, signal optimization: modify the circulating fan emergency stop signal program segment, add network abnormality filtering logic, and prohibit the emergency stop signal from automatically turning on when the substation communication is interrupted;

[0026] S4, topology reconstruction: Remake the Profinet network cable and adjust the network topology so that the data reading path of the operation station is independent of the communication link of the substation;

[0027] S5. System debugging: After updating the hardware configuration, network communication program and IP address allocation, perform network stress testing and interlocking logic verification.

[0028] The installation location of the Ethernet module in step S1 must meet the following requirements: the same rack as the PLC master module; the external data terminal is connected to the Ethernet module through an independent switch, and it is prohibited to share the physical link with the substation. The network isolation implementation method of step S2 includes: the internal Profinet network is only connected to the substation module and the circulating fan controller; the external Ethernet network is connected to the operation station, engineer station, L2 system and big data platform. The signal optimization of step S3 is specifically as follows: adding the "substation communication status" judgment condition in the emergency stop signal program segment; when the substation is lost, the emergency stop signal remains disconnected and triggers an audible and visual alarm instead of directly shutting down. The system debugging of step S5 includes: simulating network disturbances to test the stability of substation communication; verifying that the circulating fan continues to operate when the substation is lost, and the power generation system interlocking logic is not triggered.

[0029] The working principle of this invention is to build a multi-layer protection mechanism through systematic transformation of hardware and software, thereby effectively eliminating network interference and ensuring stable operation of the system. The details are as follows:

[0030] 1. Install an Ethernet module on the PLC rack of the CDQ control system and connect all external data exchange nodes to it. Ensure the Ethernet module and the PLC master module are in the same rack. External data terminals are connected through independent switches, prohibiting them from sharing physical links with substations. This modification achieves hardware-level data transmission channel separation, providing physical support for subsequent network isolation and preventing external data interaction from physically interfering with substation communications.

[0031] 2. Internal control system data is communicated via a Profinet network. The internal Profinet network connects only the substation modules and the circulating fan controller. External operation stations, engineering stations, and data terminals exchange data with the control system via Ethernet modules. The external Ethernet network connects the operation stations, engineering stations, L2 systems, and the big data platform. This strict isolation of the internal and external networks prevents disturbances such as network storms from being transmitted to the internal Profinet network, thus preventing external interference from affecting internal substation communications and ensuring stable operation of the internal network.

[0032] 3. Modify the emergency stop signal program segment for the circulating fan to add a "substation communication status" determination condition. This disables the automatic activation of the emergency stop signal when substation communication is interrupted. If a substation is lost, the emergency stop signal remains disconnected and triggers an audible and visual alarm instead of an immediate shutdown. This optimization avoids false triggering of the emergency stop signal due to substation communication loss, preventing unplanned system downtime caused by brief network anomalies and ensuring the continuity and stability of the production process.

[0033] 4. Re-engineer the Profinet network cables and adjust the network topology so that the data path read by the operator station is independent of the communication link of the slave station. This reduces the risk of path conflicts and interference during network data transmission and also facilitates subsequent network maintenance and troubleshooting.

[0034] 5. After updating the hardware configuration, network communication program, and IP address assignment, network stress testing and interlocking logic verification were performed, simulating network disturbances to test the substation communication stability. The circulating fans were verified to maintain operation even when a substation was lost, and the power generation system interlocking logic was not triggered. Through system debugging, the modified system was ensured to operate stably under various operating conditions, potential issues were promptly identified and resolved, and the overall network interference mitigation solution was further refined.

[0035] The present invention and its embodiments are described above. This description is not restrictive. What is shown in the accompanying drawings is only one of the embodiments of the present invention. In short, if ordinary technicians in this field are inspired by it and do not depart from the purpose of the invention, they can creatively design structural methods and embodiments similar to the technical solution, which should all fall within the scope of protection of the present invention.

Claims

1. A method for eliminating network interference in a dry coke quenching control system, characterized in that: The following steps are involved: S1. Hardware transformation: Install an Ethernet module on the PLC rack of the CDQ control system and connect all external data exchange nodes to the Ethernet module; S2. Network isolation: The internal data of the control system is communicated through the Profinet network; the external operation station, engineer station and data terminal exchange data with the control system through the Ethernet module; S3, signal optimization: modify the circulating fan emergency stop signal program segment, add network abnormality filtering logic, and prohibit the emergency stop signal from automatically turning on when the substation communication is interrupted; S4, topology reconstruction: Remake the Profinet network cable and adjust the network topology so that the data reading path of the operation station is independent of the communication link of the substation; S5. System debugging: After updating the hardware configuration, network communication program and IP address allocation, perform network stress testing and interlocking logic verification.

2. A method for eliminating network interference in a dry coke quenching control system according to claim 1, characterized in that: The installation location of the Ethernet module in step S1 must meet the following requirements: it must be in the same rack as the PLC master module; external data terminals must be connected to the Ethernet module through an independent switch, and sharing the physical link with the slave station is prohibited.

3. The method for eliminating network interference in a dry coke quenching control system according to claim 1, characterized in that: The network isolation implementation method of step S2 includes: the internal Profinet network is only connected to the substation module and the circulating fan controller; the external Ethernet network is connected to the operation station, engineer station, L2 system and big data platform.

4. The method for eliminating network interference in a dry quenching control system according to claim 1, characterized in that: The signal optimization in step S3 is as follows: adding the "substation communication status" judgment condition to the emergency stop signal program segment; when the substation is lost, the emergency stop signal remains disconnected and triggers an audible and visual alarm instead of a direct shutdown.

5. The method for eliminating network interference in a dry coke quenching control system according to claim 1, characterized in that: The system debugging in step S5 includes: simulating network disturbances to test the communication stability of the substation; verifying that the circulating fan maintains operation when the substation is lost and the power generation system interlocking logic is not triggered.

6. The method for eliminating network interference in a dry coke quenching control system according to claim 1, characterized in that: The method is applicable to the control network transformation of a 125t / h dry coke quenching system, a gas purification system, and a coke oven transport system in a coking plant.

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