Millisecond-level power failure data protection system for industrial control panel

Abstract

The invention belongs to the field of industrial control and computer data security, and particularly relates to a millisecond-level power failure data protection system for an industrial control panel. The invention discloses a millisecond power failure data protection system for an industrial control panel. The millisecond power failure data protection system comprises a core processing component, a real-time synchronous shadow memory component, a bus voltage monitoring component, a pre-entropy reduction logic control component, a nonvolatile storage component and a flight control bus arbitration component. The bus voltage monitoring assembly monitors a voltage drop trend and performs early warning, the pre-entropy reduction logic control assembly calculates a minimum data survival set according to energy entropy, the real-time synchronous shadow memory assembly constructs a synchronous shadow control domain and atomizes data, and the flight control bus arbitration assembly compulsively takes over a bus and freezes processor access at the moment of power failure. Atomized writing of data into the nonvolatile storage component is guaranteed. According to the invention, zero-delay data protection and millisecond-level hot start recovery at the moment of power failure are realized, and the data security and reliability of the industrial control equipment in a severe environment are enhanced.

Description

Technical Field

[0001] This invention belongs to the field of industrial control and computer data security, specifically relating to a millisecond-level power-loss data protection system for industrial control tablets. Background Technology

[0002] With the deep integration of industrial automation and intelligent manufacturing technologies, industrial control panels, as the core hub for industrial field control and human-machine interaction, play a crucial role in ensuring the safety and efficiency of production lines through their operational stability and data integrity. Industrial environments are complex and ever-changing; instantaneous fluctuations or sudden failures in the power supply system can easily lead to millisecond-level abnormal power outages. If the system fails to capture and store critical production states before power is cut off, it can result in the loss of control parameters, logical instability, and even hardware damage. In the field of industrial control, establishing an efficient power-off data protection mechanism has become a fundamental support for ensuring system robustness and business continuity.

[0003] Real-time data protection technology with millisecond-level ultra-short time windows is a key research direction in industrial control systems. This technology aims to utilize the residual energy after a power outage to securely transfer critical operational data from memory to non-volatile storage media within an extremely short time window through coordinated hardware and software methods. Its basic principle emphasizes highly sensitive voltage drop monitoring and rapid data write response, ensuring accurate restoration of the field status after system power is restored and reducing downtime losses caused by power failures.

[0004] Existing technologies generally employ passive protection logic that triggers data transfer only after detection. Limited by operating system scheduling overhead and memory physical write speed, this leads to a physical timing conflict between the data protection process and the real-time nature of power outages, easily causing file system logic errors or irreparable data fragmentation. There is a widespread industry bias towards extending power outage sustainment time through hardware redundancy such as increasing capacitor capacity. This not only increases the size and cost of industrial equipment, but the short lifespan of large-capacity capacitors in harsh industrial environments also limits the overall reliability of the equipment. Traditional systems lack deep coupling analysis of control flow and energy flow, making it impossible to implement adaptive data filtering strategies based on the urgency of industrial tasks. This results in limited energy being wasted on processing low-value data, failing to meet the requirements of zero-latency protection and millisecond-level warm-start in highly dynamic industrial control scenarios. Summary of the Invention

[0005] The purpose of this invention is to provide a millisecond-level power-loss data protection system for industrial control tablets, which can solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A millisecond-level power-loss data protection system for an industrial control tablet includes a core processing component, a real-time synchronous shadow memory component, a bus voltage monitoring component, a pre-entropy reduction logic control component, a non-volatile storage component, and a flight control bus arbitration component, as follows: The core processing component is used to run the industrial control operating system and carry the main control loop to execute adaptive control tasks in the industrial field, generating key dynamic data in real time, including control parameters, actuator feedback status, and communication handshake protocols. The real-time synchronization shadow memory component is physically connected to the core processing component. Based on the dual-port random access memory architecture, a shadow control domain that is synchronized with the main control loop in real time is constructed in physical memory. The real-time synchronization shadow memory component is configured as a reduced instruction set state machine, which is used to extract and compress key state variables in the main control loop in real time and convert them into high-density atomic data blocks with self-verification function. The bus voltage monitoring component is connected to the external power input terminal and is used to monitor the voltage ripple characteristics and drop trend of the power supply bus in real time. It determines whether there is a risk of power failure based on the slope of the voltage fluctuation. When the voltage drops to the preset voltage warning threshold, it immediately sends a warning trigger signal to the pre-entropy reduction logic control component. The pre-entropy reduction logic control component is signal-connected to the bus voltage monitoring component and the real-time synchronous shadow memory component. It is used to adaptively calculate the minimum data survival set that can be supported before the energy is exhausted, based on the urgency level of the current industrial control task and the remaining energy entropy of the bus, and generate a dump priority instruction for the atomized data block. The non-volatile storage component includes a ferroelectric random access memory or a flash memory-specific reserved area, which is used to receive and encapsulate atomic data blocks from the real-time synchronous shadow memory component through a direct memory access channel after receiving a write instruction. The flight control bus arbitration component is connected to the core processing component, the real-time synchronization shadow memory component, and the non-volatile storage component, respectively. When the bus voltage drops below a preset action threshold, it forcibly takes over the control of the system bus and freezes the central processing unit's access to the bus, giving priority to ensuring the atomic writing of data in the shadow control domain to the non-volatile storage component.

[0007] Preferably, when constructing the shadow control domain, the real-time synchronous shadow memory component adopts a shadow copy mapping mechanism to logically reorganize the core parameters of proportional-integral-derivative control involved in the main control loop, the position feedback information of the actuator, and the real-time communication breakpoints of the fieldbus. The simplified instruction set state machine performs real-time processing of the above information, eliminating the instruction parsing overhead at the moment of power failure, and ensuring that the data is in a ready-to-seal state at all times.

[0008] Furthermore, while performing normal logical operations, the core processing component mirrors key variables to the real-time synchronous shadow memory component through a transparent transmission channel. The shadow control domain has an independent data verification matrix, which is used to perform real-time calculation of cyclic redundancy check codes for each atomic data block, ensuring that the data stored in the shadow control domain has logical consistency at any time before the power failure is triggered.

[0009] Furthermore, the bus voltage monitoring component employs a high-sensitivity hardware comparator array. By performing differential operations on the input voltage signal, it obtains the transient rate of voltage change. When the voltage drop rate exceeds a preset rate of change threshold and the absolute value of the voltage is lower than a preset alarm value, the bus voltage monitoring component generates a hardware-level interrupt signal within microseconds.

[0010] Furthermore, the pre-entropy reduction logic control component has a built-in energy entropy estimation model. The energy entropy estimation model dynamically calculates the maintenance time window of the remaining power based on the current bus capacitor's stored energy, the system's real-time power consumption, and the rated write current of the non-volatile storage component, and compares the maintenance time window with the estimated duration required for data sealing.

[0011] Preferably, the pre-entropy reduction logic control component implements a differentiated protection strategy based on the control urgency of the industrial site. When the system determines that it is currently in standby mode, the pre-entropy reduction logic control component instructs the system to prioritize saving environmental configuration parameters and log records. When the system determines that it is currently in process execution mode, the pre-entropy reduction logic control component instructs the system to use the remaining millisecond-level power to bypass the operating system kernel scheduling through the direct memory access channel and prioritize writing the proportional-integral-derivative control parameters and actuator status information into the non-volatile storage component.

[0012] Furthermore, the flight control bus arbitration component is composed of a field-programmable gate array or a complex programmable logic device, and its logic priority is higher than the kernel interrupt scheduling of the operating system. When the flight control bus arbitration component receives a forced trigger signal from the bus voltage monitoring component, its internal hardware state machine immediately flips, cutting off the electrical connection between the central processing unit and the physical bus, preventing the central processing unit from malfunctioning under unstable voltage conditions and causing damage to the file system logic.

[0013] Furthermore, the flight control bus arbitration component is equipped with a high-speed direct memory access controller. The high-speed direct memory access controller preloads an address mapping table from the shadow control domain to the non-volatile memory area. At the moment the bus takeover occurs, the high-speed direct memory access controller starts a burst transfer mode and pushes the atomic data blocks in the shadow control domain into the physical sectors of the non-volatile memory component in a linear sequence.

[0014] As one embodiment of the present invention, the non-volatile storage component adopts a page-level atomic write protocol to ensure that the write operation of each atomic data block on the physical storage medium is atomic, that is, either it is written completely or it is not written at all, avoiding the generation of data fragments or data dead blocks. The non-volatile storage component automatically generates a hardware-level closure flag after the write is completed.

[0015] Furthermore, the industrial control tablet's millisecond-level power-loss data protection system also includes an adaptive hot-start component. During the boot phase after the system is powered on again, the adaptive hot-start component prioritizes detecting the closed flag bit in the non-volatile storage component. If the flag bit is valid, it extracts the atomic data block from the previous power-loss cycle from the non-volatile storage component and maps it back to the operating environment of the core processing component, skipping the lengthy self-test process of the operating system and achieving millisecond-level recovery of the production site status.

[0016] Furthermore, the real-time synchronous shadow memory component also includes a dynamic compression engine. The dynamic compression engine uses a variable-length coding algorithm to perform real-time redundancy removal processing on repetitive state descriptions in the control loop, reducing the physical space required for the shadow control domain and the amount of data transmitted during power failure, thereby improving the coverage of data protection within a limited bus residual energy window.

[0017] Preferably, the bus voltage monitoring component has a noise self-filtering function, which distinguishes between normal power grid fluctuations in the industrial environment and real power outage faults by performing integral smoothing processing on the bus voltage, thereby preventing frequent false triggering of the protection mechanism.

[0018] Furthermore, when calculating the minimum data survival set, the pre-entropy reduction logic control component introduces a task weight coefficient. This task weight coefficient is updated in real time based on the contribution of different variables in the current industrial control algorithm to the system stability, ensuring that energy is precisely allocated to the highest-value data storage task within an extremely short energy sustaining time.

[0019] Furthermore, an emergency handshake interface is provided between the flight control bus arbitration component and the core processing component. Within a specific tiny time offset before forcibly taking over the bus, a freeze command is issued to the central processing unit, inducing the central processing unit to enter a low-power standby mode and releasing the residual power of the bus for the write operation of the non-volatile memory component.

[0020] Compared with the prior art, the present invention has the following beneficial effects: 1. Achieved zero-latency data protection exceeding conventional expectations. By constructing a real-time synchronized shadow memory component that is synchronized in real time with the main control loop, the passive data transfer process after power failure in traditional solutions is transformed into a real-time data preparation process before power failure. The reduced instruction set state machine in the shadow control domain eliminates the physical time delay caused by operating system interrupt response and instruction parsing by consuming and compressing critical variables in real time. This ensures that critical data is already in an atomically encapsulated state at the moment of power failure within milliseconds, resolving the conflict between protection logic and power failure timing.

[0021] 2. Improved system robustness and reliability. This invention abandons the traditional approach of providing hardware redundancy by increasing capacitor capacity. Instead, it utilizes a flight control bus arbitration component to forcibly freeze the central processing unit's access to and take over the bus at the hardware level, preventing file system crashes caused by system logic disorder during periods of voltage fluctuation uncertainty. Since large-capacity electrolytic capacitors are unnecessary, the system not only has a smaller size but also eliminates the constraint of capacitor lifespan on the overall reliability of the device, enhancing the industrial control tablet's adaptability to harsh industrial environments such as high temperatures and high vibrations.

[0022] 3. Possesses extremely high adaptive protection efficiency and energy utilization. The introduction of pre-entropy reduction logic control components enables the system to dynamically adjust protection strategies based on the actual control urgency in the industrial environment. Through real-time estimation of energy entropy, the system can intelligently identify standby and process execution states and adaptively calculate the minimum data survival set, ensuring that limited residual power is accurately used for the preservation of core control states. This avoids energy waste from invalid data and maximizes data integrity within a very short time window.

[0023] 4. Millisecond-level hot-start recovery capability is achieved. Thanks to the atomic data sealing mechanism in the non-volatile storage component, the system does not require complex file system scans and data consistency checks after power-on recovery. The adaptive hot-start component can restore the control state before power failure through reverse mapping, ensuring the continuity of industrial production lines and shortening downtime recovery time. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall technical solution architecture of the present invention; Figure 2 This is a schematic diagram of the core principle framework of data protection based on shadow copy mapping and atomic encapsulation in this invention; Figure 3 This is a logical flowchart of the coordinated triggering of bus voltage monitoring and flight control bus arbitration in this invention; Figure 4 This is a schematic diagram of the multi-level interaction relationship and data flow of the pre-entropy reduction logic control component in this invention for energy entropy estimation and task priority calculation; Figure 5 This is a logical flow diagram of the non-volatile storage component executing the page-level atomic write protocol in this invention. Detailed Implementation

[0025] Example 1: Please refer to the appendix Figure 1 To be continued Figure 5 A millisecond-level power-loss data protection system for an industrial control tablet includes a core processing component, a real-time synchronous shadow memory component, a bus voltage monitoring component, a pre-entropy reduction logic control component, a non-volatile storage component, a flight control bus arbitration component, and an adaptive hot start component. The core processing component is used to carry and run the industrial control operating system, and it contains the main control loop logic. When performing adaptive control tasks in the industrial field, the core processing component is configured to generate key dynamic data in real time, including control parameters, actuator feedback status, and communication handshake protocols.

[0026] The core processing components include a central processing unit (CPU) and a cache array. The CPU executes a preset set of control algorithm instructions to perform real-time calculations on raw signals from industrial field sensors, generating control parameters that include at least the proportional coefficient, integral time constant, and derivative time constant of the proportional-integral-derivative (PID) control algorithm. The actuator feedback status includes the real-time position coordinates, speed vector, and current torque load of the servo motor. The communication handshake protocol includes the fieldbus serial number, communication heartbeat status, and data frame parsing offset.

[0027] The real-time synchronized shadow memory component is physically connected to the core processing component, and its core structure is based on a dual-port random access memory architecture. The real-time synchronized shadow memory component is configured to construct a shadow control domain in physical memory space that is synchronized in real-time with the main control loop. This component integrates a reduced instruction set machine (RISC) state machine, which is configured to continuously absorb and compress the main control loop state variables generated by the core processing component. The RISC state machine utilizes hardware logic circuits to achieve real-time data extraction, transforming discontinuous memory variables into high-density atomic data blocks with self-verification capabilities. The shadow control domain contains an independent data verification matrix for real-time calculation of cyclic redundancy check (CRC) codes for each atomic data block, ensuring logical consistency of the data at any given microsecond.

[0028] The bus voltage monitoring component is electrically connected to the external power input terminal of the industrial control tablet and is used to sense the physical characteristics of the power supply bus in real time. The bus voltage monitoring component includes a hardware comparator array, a differential operation unit, and a noise self-filtering circuit. The hardware comparator array is used to perform high-speed comparison of the real-time monitored bus voltage with a preset reference voltage. The differential operation unit is configured to perform time-dimension derivative operations on the voltage signal to obtain the transient rate of voltage change, i.e., the voltage drop rate. The noise self-filtering circuit filters out high-frequency harmonic interference in the industrial environment by performing integral smoothing processing on the voltage waveform. When the bus voltage monitoring component determines that the voltage drop slope exceeds a preset rate of change threshold and the absolute voltage value is lower than a preset voltage warning threshold, the component is configured to generate a hardware-level interrupt signal within microseconds and transmit this signal to the pre-entropy reduction logic control component.

[0029] In one specific embodiment, the differential operation unit of the bus voltage monitoring component processes the discrete voltage sampling sequence obtained after analog-to-digital conversion (ADC). (in This is the index for the sampling time, and the sampling period is... The sliding window differentiation algorithm is executed. Specifically, in order to accurately capture the voltage drop trend while suppressing high-frequency noise, a multi-point moving average derivative calculation formula based on the center difference is adopted: ; in, Indicates the current sampling time The calculated voltage transient rate; The half-width parameter of the sliding window, taken as a positive integer, for example... ; The coefficients are symmetric weighting coefficients and satisfy the following conditions: It is designed to smooth the difference results within the window, for example, by using the Hanning window coefficient.

[0030] The noise self-filtering circuit is implemented in the analog front end, and its cutoff frequency is... The settings need to be consistent with the differential algorithm window parameters. The design is collaborative, satisfying the following relationship to avoid aliasing and ensure the accuracy of signal feature extraction: ; in, is the voltage sampling frequency. If and only if (for the preset rate of change threshold) and The bus voltage monitoring component generates a hardware-level interrupt signal only when both the preset voltage warning threshold and the condition are met simultaneously. This dual-condition determination effectively filters out transient power grid interference caused by high-power load switching, which has a large slope but whose absolute voltage value has not dropped to the danger range.

[0031] The pre-entropy reduction logic control component is signal-connected to both the bus voltage monitoring component and the real-time synchronization shadow memory component, and integrates an energy entropy estimation model. The pre-entropy reduction logic control component is configured to dynamically calculate the minimum data survival set that can be supported before energy depletion, based on the urgency level of the current industrial control task and the remaining energy entropy of the bus. The energy entropy estimation model executes the following logic: obtaining the stored charge of the current bus capacitor, which is calculated by verbally representing half of the product of the square of the bus voltage and the capacitance; obtaining the real-time power consumption of the system, which is equal to the product of the bus voltage and the real-time current. The pre-entropy reduction logic control component estimates the energy sustainment time window by dividing the stored charge by the real-time power consumption, and compares this window with the estimated duration required to store a specific amount of data, generating a dump priority instruction for the atomized data block.

[0032] Specifically, the energy entropy estimation model built into the pre-entropy reduction logic control component does not employ an idealized simple division method, but rather constructs a time-varying system energy consumption model that incorporates key non-ideal factors. (System remaining available energy) The estimation correction formula is: ; in, This is the nominal value of the bus capacitance; The bus voltage value is monitored in real time; The efficiency factor, which accounts for losses due to the equivalent series resistance (ESR) of the capacitor, is determined experimentally or based on the capacitor datasheet. to Preset between.

[0033] System instantaneous power consumption The estimation uses a piecewise model: ; in, The baseline power consumption before the system power-down process begins; Additional power consumption is added for pre-entropy reduction logic operations and arbitration control; Peak instantaneous power consumption during writing of non-volatile memory components (such as Flash); and These are Boolean state functions, representing whether the logic operation phase and the Flash write phase are active, respectively. The energy sustainment time window... The estimated value is a solution to the following integral equation: ; To meet real-time requirements, this integral equation can be solved rapidly within milliseconds using a discretization summation and iterative prediction method. The system will then calculate the... Estimated time required to complete data sealing under the current priority If a comparison is made, ( (To allow for a safe time margin), a dump instruction is generated.

[0034] The non-volatile storage component is configured as a memory terminal, and its hardware form includes specific reserved sectors in ferroelectric random access memory or flash memory. The non-volatile storage component is equipped with a dedicated direct memory access channel (DMI) for receiving and sealing atomic data blocks from the real-time synchronous shadow memory component, bypassing the CPU scheduling of the core processing component, upon receiving a write instruction. This component employs a page-level atomic write protocol to ensure the atomicity of data write operations; that is, the write operation of each physical storage page must be fully executed. If a write interruption occurs due to energy depletion, the page is deemed invalid through a hardware-level closure flag, preventing logically corrupted data fragmentation.

[0035] The flight control bus arbitration component, acting as the system's underlying hardware security gate, is physically connected to the core processing component, the real-time synchronous shadow memory component, and the non-volatile memory component. The flight control bus arbitration component is composed of a field-programmable gate array (FPGA), and its logical priority is set to the highest level in the system, exceeding the kernel interrupts of the industrial control operating system. When the flight control bus arbitration component receives a forced trigger signal from the bus voltage monitoring component and determines that the bus voltage has fallen below a preset action threshold, its internal hardware state machine immediately flips, forcibly cutting off the core processing component's access to the system's physical bus. Simultaneously with freezing the central processing unit (CPU), the flight control bus arbitration component takes over bus control and activates its internal high-speed direct memory access controller, instantly pushing data from the shadow control domain into the non-volatile memory component according to a pre-loaded address mapping table.

[0036] The adaptive warm-start component, configured in the system's bootloader logic, is used to perform state backtracking during the recovery phase after the industrial control tablet is powered on again. The adaptive warm-start component is configured to prioritize scanning the hardware-level closed flags in the non-volatile memory components. If the flag verification passes, the component initiates reverse mapping logic to decompress the atomic data blocks sealed in the previous power-down cycle and map them back to the core processing component's execution register, enabling the main control loop to skip the operating system's full self-test process and restore to the process execution breakpoint before the power outage.

[0037] In the aforementioned system, the real-time synchronous shadow memory component further includes a dynamic compression engine. This dynamic compression engine is configured to employ a variable-length encoding algorithm to perform real-time redundancy removal on highly repetitive state descriptors in the main control loop. When the actuator is in a constant-speed motion state or steady-state control, the high-order bytes in its feedback data typically remain unchanged. The dynamic compression engine compresses large-capacity original variables into low-entropy atomic data blocks by recording the difference changes in the byte stream, enabling the preservation of more control field details within the same energy sustainment time window.

[0038] Specifically, the dynamic compression engine executes a hybrid algorithm combining improved run-length encoding (RLE) and incremental encoding. For the byte stream mirrored from the main control loop, it first uses a fixed data block length. The test is performed on a unit basis. If the variance of the data values ​​within a block... Below the preset threshold If it is determined to be a highly repetitive state, run-length encoding is used: record the baseline value. and number of repetitions Otherwise, incremental encoding is used: record the first value within the block. Then, record the difference between each value and the previous value in sequence. The compressed data packet format is: [Identifier][Compressed Metadata][Data Payload]. The identifier is used to distinguish the compression strategy. This algorithm is implemented in a pipelined manner within the reduced instruction set state machine of the real-time synchronous shadow memory component, enabling efficient compression of low-entropy data such as PID parameters and constant-velocity motion feedback during steady-state control. It significantly increases the number of data dimensions that can be protected.

[0039] The pre-entropy reduction logic control component introduces a task weighting coefficient mechanism when assessing the urgency of a task. This task weighting coefficient is updated in real-time based on the contribution of different variables in the current industrial control algorithm to system stability. For example, in motion control scenarios, the position loop feedback parameters are set to the highest priority, while the environmental temperature monitoring data is set to a secondary priority. When the energy entropy estimation model determines that the remaining energy can only support a very short time step, the pre-entropy reduction logic control component instructs the system to discard low-weight environmental data and prioritize the atomic storage of high-weight position loop parameters and communication breakpoint data. As a preferred implementation, the task weighting coefficient... The dynamic updates are not based on fixed values, but rather incorporate online sensitivity analysis. This defines the overall control performance indicators of the system. For example, it can be taken as a weighted quadratic integral of the system state error. Task weight coefficients. With variables For performance indicators The sensitivity is related, and its update formula is: ; in, For the first Variables The basic weights are determined offline by the control strategy; This is the adjustment coefficient; The position loop error can be approximated by the adjoint equations of a real-time running control algorithm (such as Model Predictive Control, MPC) or by numerical perturbation methods. For example, for a motion control system, the position loop error of a servo motor... For performance indicators Its sensitivity is extremely high, and its weighting coefficient is... These will be dynamically prioritized. In situations of extreme energy shortage, the system will prioritize protecting high-weight variables. The corresponding atomic data blocks are sealed.

[0040] An emergency handshake interface is also provided between the core processing component and the flight control bus arbitration component. Within a small time offset before the flight control bus arbitration component performs a bus takeover operation, this interface sends a pseudo-hardware interrupt to the core processing component. This interrupt is configured to induce the central processing unit to execute an emergency low-power suspend instruction, shutting down power to unnecessary peripheral device interfaces, reducing the system's instantaneous power consumption, and providing additional energy sustainment time for the physical write process of non-volatile memory components.

[0041] The non-volatile storage component is physically divided into multiple independently controlled storage area arrays. During execution, the page-level atomic write protocol calculates an independent header checksum and tail terminator for each data page to be written. After the data is written, the storage controller performs a readback check to confirm that the tail terminator has been successfully written to the medium. Only when the tail terminator is successfully written and the checksum matches is the hardware-level closure flag corresponding to the data page set to a valid state. This mechanism eliminates the risk of incomplete writes due to power failure at the physical level, ensuring absolute reliability of data recovery.

[0042] The differential calculation unit of the bus voltage monitoring component employs a multi-level time window moving average algorithm when calculating the voltage drop rate. This algorithm calculates the difference between the current voltage value and the voltage value at the previous microsecond, and then weights and accumulates these differences to accurately identify normal voltage fluctuations caused by the start-up and shutdown of high-power inductive loads and power outage symptoms caused by external power supply failures. This noise self-filtering function improves trigger accuracy and prevents unnecessary data storage malfunctions in harsh electromagnetic environments, ensuring the continuity of normal production processes.

[0043] The high-speed direct memory access controller inside the flight control bus arbitration component pre-stores a set of linear address mapping tables. These tables meticulously record the correspondence between each atomic data block in the shadow control domain and the physical sectors of the non-volatile memory component. At the moment of bus takeover, the controller does not need to perform complex logical operations or address lookups. Instead, it uses a burst transfer mode to push the continuous stream of bytes from the shadow memory to the storage medium through a hardware pipeline. This design eliminates software-level addressing overhead, compressing the physical execution time of data protection to the microsecond level.

[0044] In one specific embodiment, the address mapping table inside the flight control bus arbitration component is updated using a double-buffering mechanism. When the non-volatile memory component executes the sector balancing algorithm, it selects a new physical sector. When a device is selected as the next write target, its controller sends a message containing a logical sector number to the flight control bus arbitration component. With the new physical sector number The update notification is received. The hardware state machine inside the flight control bus arbitration component immediately writes the mapping relationship into the shadow mapping table and atomically moves it to the working mapping table in the next idle clock cycle. This update process is performed asynchronously during normal system operation, ensuring that in the event of a power failure, the working mapping table read by the high-speed direct memory access controller (DMA) always points to a valid, erased memory area. The DMA burst transfer parameters (such as Burst Size) are pre-configured according to the page write timing characteristics of the non-volatile memory component, and are typically set to the page size. Integer frequency division is used to achieve seamless push of continuous data streams and maximize the use of the residual energy window.

[0045] Example 2: Based on the millisecond-level power-loss data protection system for industrial control tablets described in Example 1, in this example, the system architecture is further evolved into an enhanced protection architecture based on the coupling of heterogeneous multi-core processing units and distributed shadow memory, which aims to meet the high-bandwidth data protection requirements such as multi-axis synchronous control.

[0046] An enhanced industrial control tablet millisecond-level power-loss data protection system includes a multi-core processing array, a distributed real-time synchronous shadow memory component, a multi-channel voltage feature sensing component, a collaborative pre-entropy reduction logic engine, a redundant non-volatile storage array, a hardware-level bus arbitration controller, and a fast state recovery component.

[0047] The multi-core processing array consists of multiple homogeneous or heterogeneous processor cores. The master core runs a real-time operating system and executes main control logic, while the slave cores are configured as dedicated data processing units responsible for pre-screening massive amounts of industrial field data. The multi-core processing array has a dedicated internal communication bus for high-speed data exchange between different cores.

[0048] The distributed real-time synchronous shadow memory component establishes an independent mirror channel with each core of the multi-core processing array. This component employs a multi-body parallel storage architecture, dividing the physical shadow space into multiple independent shadow units, each corresponding to a control subsystem. This distributed design allows the system to simultaneously synchronize control parameters for multiple motion axes in real time, resolving access conflicts inherent in single-point storage in large-scale systems. Each shadow unit integrates an independent reduced instruction set state machine for locally atomically encapsulating variables of its respective subsystem.

[0049] The multi-channel voltage characteristic sensing component, in addition to monitoring the main power supply bus, also extends real-time monitoring of the voltages of various branches within the system (such as processor core voltage, memory power supply voltage, and peripheral interface voltage). The component acquires the voltage waveforms of each branch through a multi-channel analog-to-digital converter and uses a correlation analysis algorithm to determine the fault source. If the fault occurs only in a specific branch, the component is configured to issue a local protection command instead of triggering global power-down protection, thus improving the system's fault tolerance.

[0050] The collaborative pre-entropy reduction logic engine is configured as a hierarchical decision-making system. At the first level, the engine performs a global energy entropy assessment, calculating the ratio of total remaining energy to total data load. At the second level, the engine performs dynamic resource allocation based on the data urgency of each unit in the distributed shadow memory. The collaborative pre-entropy reduction logic engine contains a dynamic energy flow model that can monitor the charge flow of energy storage components (such as supercapacitor arrays) in real time and adjust the write rate and concurrency based on the instantaneous write power consumption of the non-volatile memory array to ensure that the highest priority tasks are sealed before energy depletion.

[0051] The redundant non-volatile storage array consists of multiple storage chips with different physical media, including a ferroelectric random access memory array with extremely high write endurance and a magnetoresistive random access memory array with large capacity. The collaborative pre-entropy reduction logic engine selects different physical media for dumping based on the criticality of the data. For example, core configuration data related to system recovery is written to the ferroelectric array, while historical logs and trend data are written to the larger magnetoresistive array.

[0052] In this embodiment, the hardware-level bus arbitration controller is configured as a crossbar switch array with multi-path switching capability. When a trigger signal is generated, the controller can sequentially or simultaneously disconnect the bus connection of each processor core according to a preset protection priority, and establish a multi-point to multi-point transmission path between the shadow memory and the storage array. The hardware-level bus arbitration controller integrates a hardware-level flow control mechanism, which dynamically adjusts the data flow throughput by monitoring the busy / idle status of the storage array to prevent data write timeouts caused by bus congestion.

[0053] The rapid state recovery component is configured to perform multi-threaded parallel recovery during the boot process. This component reads multiple atomic data blocks distributed across the storage array and utilizes the parallel processing capabilities of the multi-core processing array to simultaneously perform reverse mapping and logical consistency checks on the data. This parallel recovery mechanism shortens the restart time of large industrial control systems, enabling the system to return to its previous multi-axis synchronous operating state within milliseconds after power restoration.

[0054] In the enhanced system described above, the distributed real-time synchronous shadow memory component also introduces a timestamp alignment mechanism. When encapsulating atomic data blocks, the reduced instruction set state machine automatically embeds a nanosecond-level global system timestamp. This timestamp is used to ensure data synchronization between different subsystems during the recovery phase. If the recovery phase detects that the data timestamp deviation between subsystems exceeds a preset tolerance threshold, the fast state recovery component will execute a logical rollback based on the most recent consistent timestamp to ensure coordinated operation of each workstation on the industrial production line.

[0055] The collaborative pre-entropy reduction logic engine also considers the impact of the physical temperature rise of the storage medium on the write speed when calculating the minimum data survival set. In high-temperature industrial environments, the write latency of the storage medium will increase. The logic engine dynamically reduces the estimated write bandwidth by obtaining feedback from the ambient temperature sensor, leaving more energy margin and ensuring the success rate of data protection actions.

[0056] The hardware-level bus arbitration controller further includes a state machine deadlock detection unit. This unit is configured to monitor the status of the transmission link in real time during bus takeover. If a storage channel experiences a timeout due to a hardware physical fault, the unit will immediately instruct the system to skip the faulty channel and concentrate the remaining energy on data sealing of other normal channels, thus saving critical control information.

[0057] Example 3: Building upon Examples 1 and 2, this example provides a ruggedized industrial control tablet system with millisecond-level power-loss data protection for extremely harsh industrial environments. This system ensures reliable data protection even under severe vibration, electromagnetic pulse interference, and extreme temperature fluctuations by introducing physical-level hardware redundancy and advanced software-level error correction logic.

[0058] A ruggedized industrial control tablet millisecond-level power-loss data protection system includes a ruggedized core processing component, a tri-modal redundant real-time synchronous shadow memory component, an anti-interference bus monitoring unit, an intelligent energy consumption sensing scheduler, an industrial-grade reliable storage matrix, a high-reliability bus arbitrator, and an integrity verification and recovery unit.

[0059] The hardened core processing component employs an industrial-grade chip with ceramic packaging, and its internal circuitry has undergone radiation and vibration resistance enhancement treatment. The core processing component is configured to run a hard real-time embedded kernel, which ensures deterministic execution time of the control flow through static memory allocation. During the data generation phase, the hardened core processing component generates duplicate copies of each set of key variables and stores them in different internal register sets to prevent data errors caused by single-event upsets.

[0060] The triple-modal-redundant real-time synchronous shadow memory component consists of three identical physical memory banks. The reduced instruction set machine simultaneously writes atomic data blocks to these three memory banks. During data extraction and compression, this component introduces majority voting logic. When a power-down protection is triggered, the triple-modal-redundant structure can automatically shield memory banks that may contain erroneous data due to hardware aging or interference, and select two other consistent data blocks for sealing through a voting mechanism. This design improves the system's tolerance to random hardware failures in harsh environments.

[0061] The anti-interference bus monitoring unit employs optocoupler isolation technology in its physical circuit structure to electrically isolate the monitoring circuit from the main power supply circuit, preventing high current surges from damaging the monitoring chip. Internally, the unit incorporates a multi-dimensional discrimination matrix that combines voltage sag depth, sag duration, and the spectral characteristics of voltage ripple. Through Fast Fourier Transform logic, the unit can identify specific power supply fault signatures and eliminate false power-down signals caused by inverter noise or motor back EMF within a very short time.

[0062] The intelligent energy consumption sensing scheduler is configured to perform fine-grained management of all energy-consuming units within the industrial control panel. In normal operating mode, the scheduler records the average power consumption of each functional module in real time. When a power failure is detected, the scheduler, based on a preset energy consumption gradient table, sequentially shuts down the display backlight module, wireless communication module, audio output module, and unnecessary external sensor interfaces with a nanosecond-level response speed. Through this proactive energy management, the system can concentrate the valuable energy provided by the reserve capacitors to supply the non-volatile memory components and the bus arbitration controller.

[0063] The industrial-grade reliable storage matrix employs storage units with error-correcting code (ECC) functionality. During data sealing, the hardware encoder within the storage matrix automatically generates redundant check bits for each data block. Even if strong electromagnetic pulse interference causes some bits to jump during the write process, the system can automatically correct errors using ECC logic in the subsequent recovery phase. This storage matrix supports a wide operating temperature range, ensuring stable physical write characteristics even in extreme environments.

[0064] The high-reliability bus arbiter employs a dual-machine hot-standby architecture. The primary arbiter handles routine bus takeover, while the backup arbiter monitors the primary arbiter's health status in real time. If the primary arbiter experiences a logic failure during a power outage, the backup arbiter can seamlessly take over control. The bus arbiter also integrates a physical layer emergency circuit breaker to physically disconnect electrical connections to external, potentially disruptive peripherals after taking over the bus, creating a clean electromagnetic environment for internal data transmission.

[0065] The integrity verification and recovery unit is configured to perform deep data auditing after the system is powered on again. This unit not only checks the closure flags of atomic data blocks but also performs physical validity checks on the sealed control parameters. For example, if the recovered servo position parameters exceed the limits of the physical travel, or if the sequence number corresponding to the communication breakpoint undergoes a logical jump, the unit will automatically determine the data is invalid and trigger a preset safety protection mode, resetting all actuators to a safe position to prevent production accidents caused by erroneous recovery.

[0066] In the aforementioned ruggedized system, the real-time synchronous shadow memory component further employs spatial diversity storage technology. Three redundant memory banks are physically deployed at different locations on the industrial control tablet motherboard to reduce the risk of localized mechanical shocks or thermal failures causing catastrophic damage to the entire protection system. The reduced instruction set state machine adopts a redundant logic gate design, introducing triple modular redundancy (TMR) logic at the hardware description language (HDL) level to ensure that the state machine itself can still output the correct control sequence even under power-down transient voltage instability.

[0067] The anti-interference bus monitoring unit also has a predictive lifespan assessment function. By analyzing the voltage rise curve of the energy storage capacitor during multiple charge and discharge processes, the unit can describe and calculate the effective capacity decay rate of the capacitor in words. When the capacitor capacity is determined to be below the safety limit, the system will automatically issue a maintenance warning and dynamically increase the energy reserve margin in the pre-entropy reduction logic to compensate for the performance degradation caused by hardware aging.

[0068] The intelligent energy consumption sensing scheduler follows a strict priority chain when performing shutdown operations. This chain is defined as follows: shutting down non-critical peripherals related to the human-machine interface, shutting down non-real-time communication links, then shutting down auxiliary sensing and acquisition circuits, and only retaining power to the central processing unit core operating environment, shadow memory, bus arbitrator, and non-volatile storage components. This hierarchical shutdown strategy not only extends the storage time of core data but also ensures that the shutdown process itself does not generate system inrush currents sufficient to interfere with data integrity.

[0069] The industrial-grade reliable storage matrix supports multi-level sector balancing algorithms. During frequent power-down sealing operations, to prevent specific storage sectors from prematurely failing due to excessive erasure and rewriting, the storage matrix controller automatically distributes atomic data blocks across different physical address spaces. The address mapping table inside the flight control bus arbitrator is updated in real-time with the sector balancing logic, ensuring that write operations at the moment of power failure always point to the storage unit with the optimal physical characteristics.

[0070] This embodiment, through the above-mentioned multi-level physical hardening and logical redundancy design, enables the industrial control tablet millisecond-level power failure data protection system to have extremely high reliability, which can meet the extreme requirements of the aerospace, rail transportation, petrochemical and power industries for the stability of industrial control equipment.

[0071] In all the above embodiments, the system embodies a deep integration of the shadow control domain and the pre-entropy reduction mechanism. This architecture, based on the deep coupling of control flow and energy flow, overcomes the logical shortcomings of traditional passive protection. By pre-emptively preparing data, intelligently allocating energy, and mandating hardware takeover, this invention achieves zero-latency data capture and millisecond-level hot-start recovery within an extremely short time window. The simplified instruction set state machine within the shadow control domain ensures that data is in an immediately usable state through real-time extraction, compression, and verification, reducing the physical response time during power outages. The pre-entropy reduction logic control component endows the system with an intelligent judgment capability similar to human stress response, enabling it to accurately select the most valuable memories for storage in the final moments when energy is scarce. This deep hardware and software collaboration not only improves the continuity of industrial production but also provides solid technical support for the design of future more dynamic and intelligent industrial control systems.

[0072] The millisecond-level power-loss data protection system for industrial control tablets described in this invention is based entirely on hardware-level deterministic latency design for the interaction logic between its core components. Whether it's the interrupt generation of the bus voltage monitoring component or the bus switching of the flight control bus arbitration component, the physical latency is controlled within the nanosecond to microsecond range. This deterministic latency is the key guarantee for achieving millisecond-level power-loss protection. In the selection of non-volatile storage components, this invention fully utilizes the physical characteristics of ferroelectric random access memory (FRAM), which requires no charge pump boosting and has a write speed close to that of static random access memory (SRAM), further reducing energy consumption and time overhead. At the software level, through the precise patching of the operating system by the adaptive warm-start component, the industrial control tablet can quickly resume previous production tasks as if no fault had occurred after a power outage, which has immeasurable application value in highly automated flexible manufacturing lines.

[0073] In practical engineering applications, this system can also be customized according to different industry standards. For example, for power automation equipment, the threshold of the bus voltage monitoring component can be set to be more sensitive to cope with complex power grid transient processes; while for mining machinery control, the triggering logic of the flight control bus arbitration component can be linked with the mechanical emergency braking logic to ensure that in the instant of power loss, not only is the data preserved, but the mechanical structure can also be safely reset. This combination of flexibility and versatility makes the system architecture proposed in this invention widely adaptable to various industries, providing a systematic and efficient engineering solution to the persistent problem of power failure data protection in industrial fields.

[0074] The system described in this invention fully considers maintainability and diagnosability during its design. After each recovery from a failed operation, the adaptive hot-start component generates a detailed protection log, recording the time of the power outage, the waveform characteristics of the bus voltage drop, the amount of data archived, and the recovery time. This data can be retrieved in real-time by a remote monitoring center through a backend management interface for analyzing the power supply quality at the production site and performing predictive maintenance on the equipment. This extension from passive defense to proactive diagnosis further enhances the overall operation and maintenance level and intelligence of the industrial control system.

[0075] In summary, the millisecond-level power-loss data protection system for industrial control tablets proposed in this invention successfully resolves multiple contradictions in real-time performance, reliability, and energy utilization of traditional technical solutions through interdisciplinary architectural integration, adaptive logic control, and highly reliable hardware collaboration. It achieves technical results that exceed conventional expectations and sets a new technical benchmark for data security and business continuity assurance in the field of industrial control.

[0076] Those skilled in the art should understand that the above embodiments are merely illustrative of the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A millisecond-level power failure data protection system for industrial control tablets, characterized in that, The application relates to a power supply system for industrial control, which comprises the following components: a core processing component for running an industrial control operating system, carrying a main control loop to perform adaptive control tasks of an industrial field and generating key dynamic data including control parameters, feedback states of an execution mechanism and a communication handshake protocol in real time; a real-time synchronous shadow memory component, which is physically connected with the core processing component, is used for constructing a shadow control domain in real time with the main control loop in a physical memory based on a dual-port random access memory architecture and extracting and compressing the key dynamic data by using a reduced instruction set state machine to convert the key dynamic data into atomized data blocks with a self-checking function; a bus voltage monitoring component, which is connected with an external power input end, is used for monitoring voltage waveform features of a power supply bus and sending a pre-warning trigger signal when it is determined that there is a power-off risk according to a voltage fluctuation slope; a pre-entropy reduction logic control component, which is connected with the bus voltage monitoring component and the real-time synchronous shadow memory component, is used for calculating a minimum data survival set that can be supported before energy is exhausted according to a task urgency level and a bus residual energy entropy and generating a dump priority instruction; a non-volatile storage component, which is used for receiving and storing the atomized data blocks through a direct memory access channel; a flight control bus arbitration component, which is connected with the core processing component, the real-time synchronous shadow memory component and the non-volatile storage component, is used for forcibly taking over the control right of a system bus after receiving the pre-warning trigger signal and preferentially guaranteeing the writing of the atomized data blocks into the non-volatile storage component.

2. The industrial control tablet millisecond-level power failure data protection system according to claim 1, characterized in that, The real-time synchronous shadow memory component is internally integrated with a data check matrix; The shadow control domain recombines core parameters related to proportional integral derivative control in the main control loop, position feedback information of an execution mechanism and real-time communication breakpoints of a field bus through a shadow copy mapping mechanism and performs real-time swallowing processing by using the reduced instruction set state machine to eliminate instruction analysis overheads in a power-off occurrence moment; The data check matrix is used for performing real-time calculation of a cyclic redundancy check code on each atomized data block to ensure that data in the shadow control domain is logically consistent at any moment before a power-off trigger; The reduced instruction set state machine realizes real-time extraction of data through a hardware logic circuit, converts non-continuous memory variables into high-density atomized packaging formats and makes the data in a ready-to-store state at any moment.

3. The industrial control tablet millisecond-level power failure data protection system according to claim 2, characterized in that, The bus voltage monitoring component comprises a hardware comparator array, a differential operation unit and a noise self-filtering circuit; The hardware comparator array is used for high-speed comparison of a real-time monitored bus voltage with a preset reference voltage reference; The differential operation unit is used for derivation operation in a time dimension of a voltage signal to obtain a voltage change transient rate reflecting a voltage descending rate; The noise self-filtering circuit is used for filtering high-frequency harmonic interference in an industrial environment through integral smoothing processing of multi-stage time window sliding average of a voltage waveform to distinguish normal fluctuation of a power grid from a real power-off fault. When the bus voltage monitoring component determines that the transient rate of voltage change exceeds a preset rate of change threshold and the absolute value of voltage is lower than a preset voltage warning threshold, the bus voltage monitoring component generates a hardware-level interrupt signal within microseconds as the warning trigger signal.

4. The industrial control tablet millisecond-level power failure data protection system according to claim 3, characterized in that, The pre-entropy reduction logic control component has a built-in energy entropy estimation model. The energy entropy estimation model is configured to obtain the stored charge of the current bus capacitor. The stored charge is calculated by expressing the value in words as half of the product of the square of the bus voltage and the capacitance. Simultaneously, the real-time power consumption of the system is obtained, which is expressed as the product of the bus voltage and the real-time current. The pre-entropy reduction logic control component estimates the energy maintenance time window by dividing the stored charge by the real-time power consumption, and compares the energy maintenance time window with the estimated time required to complete the sealing of the atomized data block, thereby determining the dump priority instruction. The pre-entropy reduction logic control component further introduces a task weight coefficient, which is updated in real time according to the contribution of different variables in the industrial control algorithm to the system stability. This coefficient is used to prioritize the preservation of high-weight position loop parameters and communication breakpoint data when the energy maintenance time window is reduced.

5. The industrial control tablet millisecond-level power failure data protection system according to claim 4, characterized in that, The flight control bus arbitration component is composed of a field-programmable gate array or a complex programmable logic device. It integrates a hardware state machine and a high-speed direct memory access controller, and its logic priority is set to be higher than the kernel interrupt scheduling of the industrial control operating system. When the flight control bus arbitration component receives the warning trigger signal and determines that the bus voltage has fallen below the preset action threshold, the hardware state machine immediately flips and forcibly disconnects the electrical connection between the core processing component and the system physical bus to prevent the central processing unit from making erroneous operations under unstable voltage conditions. The high-speed direct memory access controller is preloaded with an address mapping table from the shadow control domain to the non-volatile memory area. At the moment of bus takeover, the high-speed direct memory access controller starts a burst transfer mode and pushes the data in the shadow control domain into the physical sector of the non-volatile memory component in a linear sequence.

6. The industrial control tablet millisecond-level power failure data protection system according to claim 5, characterized in that, The non-volatile storage component adopts a page-level atomic write protocol. During the execution of the page-level atomic write protocol, an independent header checksum and tail terminator are calculated for each data page to be written. After the data is written, the non-volatile storage component performs a readback check. When it confirms that the end marker has been successfully written and the checksum matches, it sets the hardware-level closure flag of the corresponding data page to a valid state, thereby ensuring that the write operation of each atomic data block on the physical storage medium is atomic. The non-volatile storage component is physically divided into multiple independent and controlled storage area arrays and supports multi-level sector balancing algorithms. The sector balancing algorithm monitors the number of erases and writes of each physical sector and distributes the atomic data blocks to different physical address spaces. The address mapping table inside the flight control bus arbitration component is updated in real time as the sector balancing algorithm is executed.

7. The industrial control tablet millisecond-level power failure data protection system according to claim 6, characterized in that, It also includes an adaptive hot start component, which is configured in the system's bootloader logic and is used to perform state backtracking during the recovery phase after the system is powered on again. The adaptive hot-start component is used to preferentially scan the hardware-level closed flag bit in the non-volatile memory component; If the hardware-level closure flag verification passes, the adaptive hot-start component initiates the reverse mapping logic, extracts the atomic data block from the previous power-down cycle from the non-volatile storage component, decompresses it, and directly maps it back to the runtime register environment of the core processing component, thereby skipping the full self-test process of the operating system and achieving millisecond-level production site status recovery. After each execution state recovery, the adaptive hot start component generates a protection log containing the power failure time, voltage drop waveform characteristics, and recovery time, and provides remote diagnostic data through the background management interface.

8. The industrial control tablet millisecond-level power failure data protection system according to claim 7, characterized in that, The real-time synchronous shadow memory component also includes a dynamic compression engine, which is configured to use a variable-length coding algorithm to perform real-time redundancy removal processing on highly repetitive state descriptors in the main control loop. When the actuator is in a constant speed motion state or steady state control, the dynamic compression engine compresses large-capacity original variables into low-entropy atomic data blocks by recording the difference changes in the byte stream, thereby improving the coverage of data protection within the same energy maintenance time window. A transparent transmission channel is also provided between the real-time synchronization shadow memory component and the core processing component. While performing normal logical operations, the core processing component mirrors the key dynamic data to the shadow control domain through the transparent transmission channel. The shadow control domain performs nanosecond-level global system timestamp embedding through the reduced instruction set state machine to ensure data synchronization between different subsystems during the recovery phase.

9. The industrial control tablet millisecond-level power failure data protection system according to claim 8, characterized in that, An emergency handshake interface is provided between the core processing component and the flight control bus arbitration component; Within a tiny time offset before performing the bus takeover operation, the flight control bus arbitration component sends a pseudo-hardware interrupt to the core processing component through the emergency handshake interface. Upon receiving the pseudo-hardware interrupt, the core processing component immediately executes an emergency low-power suspension instruction to shut down the power supply of unnecessary peripheral device interfaces, so as to maximize the release of the residual power of the bus for the write operation of the non-volatile memory component. The system also includes an intelligent energy consumption sensing scheduler. According to a preset energy consumption gradient table, the intelligent energy consumption sensing scheduler sequentially shuts down the display backlight module, the wireless communication module, and the audio output module with a response speed of nanoseconds, thereby gaining additional energy to sustain the data transmission process after the flight control bus arbitration component takes over the bus.

10. The industrial tablet millisecond-level power failure data protection system of claim 9, wherein, The real-time synchronous shadow memory component adopts a triple-modular redundancy physical architecture, consisting of three identical physical storage units; The reduced instruction set state machine simultaneously writes the atomic data blocks to the three identical physical memory banks, and introduces majority voting logic during the data extraction process. The majority voting logic automatically filters out memory banks containing erroneous data, thereby improving the system's hardware failure tolerance in harsh industrial environments. The flight control bus arbitration component also integrates a state machine deadlock detection unit. The state machine deadlock detection unit is used to monitor the status of the transmission link in real time during bus takeover. If a response timeout is detected in the storage channel, the instruction system will skip the storage channel and concentrate the remaining energy on data sealing of other normal channels. The bus voltage monitoring component also has a predictive life assessment function. By analyzing the voltage rise curve of the energy storage capacitor during the charging and discharging process, it calculates the effective capacity decay rate of the capacitor and issues a maintenance warning when the capacity is lower than the safety red line.

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