PLC control system and control method

Abstract

Provided in the present application is a PLC control system, comprising: a CPU module for executing application logic; a plurality of backplane modules connected in series and configured to connect the CPU module to functional modules, wherein each backplane module can be correspondingly connected to one functional module; and an artificial intelligence module, which is one of the functional modules, receives various data, performs data analysis processing on a data processing task of which the data volume exceeds a preset data volume threshold or the logic complexity exceeds a preset logic complexity threshold, and forwards obtained analysis data to the CPU module by means of the corresponding backplane module. The present application applies the edge computing concept to the field of PLCs, and migrates large-scale complex computing from the CPU module to the artificial intelligence module, thereby reducing the resource consumption of the CPU module, and improving the overall processing performance of the PLC control system. Large-scale complex computing is also usually prone to failure, such that individually performing large-scale complex computing by means of the artificial intelligence module also improves the reliability and availability of the CPU module.

Description

PLC Control System and Control Method Technical Field

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

[0002] With the rapid development and increasing popularity of artificial intelligence, the Internet of Things and industrial automation control technologies, in the field of industrial control systems, traditional programmable logic controllers (PLCs) not only face the demand for large-scale development with access to multiple types and large-scale terminal devices, but also the development demand for shifting from programmable logic control to supporting intelligent control based on artificial intelligence and large-scale complex control.

[0003] The implementation of high-speed backplane buses is a technical challenge in the development of controllers towards larger scales. PLC systems typically use traditional serial communication technology to implement backplane buses. Serial buses can improve the reliability of automated equipment in harsh factory and industrial environments. Traditional serial communication technologies include CAN, I2C, UART, SPI, USB, and PCIe. Many processors that serve as the main chips in PLC systems integrate peripherals such as CAN, I2C, UART, SPI, and USB. However, due to the slow speed caused by the integration of peripherals within the processor, they cannot meet the high communication speed requirements of high-speed backplane buses. While PCIe can achieve speeds of up to Gbit / s, it is more expensive, has higher wiring requirements, and requires dedicated interface chips that support PCIe.

[0004] Summary of the Invention

[0005] To address at least one deficiency or improvement need in the prior art, this application provides a PLC control system and control method that enables the current high-speed backplane bus to meet the requirements of large-scale data transmission and high communication rate in specific technical fields such as metallurgy at a lower cost. At the same time, it can improve the availability, reliability and intelligence of industrial controllers.

[0006] To achieve the above objectives, in a first aspect, this application provides a PLC control system, comprising:

[0007] The CPU module is used to include sending domain data packets and executing application logic based on received analysis data;

[0008] A plurality of backplane modules connected in series are configured to receive and forward the domain data packets, and to send the received analysis data to the CPU module via the domain data packets; each backplane module can be connected to a corresponding functional module; the backplane modules are configured to connect the CPU module and the functional modules.

[0009] The artificial intelligence module, which is one of the functional modules, is used to receive relevant data in the domain data packet or receive terminal data sent by the connected terminal device, analyze and process data for data processing tasks where the data volume exceeds a preset data volume threshold or the logical complexity exceeds a preset logical complexity threshold, and forward the obtained analysis data to the CPU module through the corresponding backplane module.

[0010] Furthermore, the CPU module and the backplane module, as well as the backplane modules themselves, exchange data using the EBUS bus based on the EtherCAT communication mechanism.

[0011] The backplane module and the functional module exchange data via TCP communication.

[0012] Furthermore, the artificial intelligence module includes:

[0013] The artificial intelligence module is a business module used to analyze and process the received data to realize corresponding artificial intelligence business.

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

[0015] The artificial intelligence module CPU processor is adapted to the embedded operating system of the artificial intelligence module and is bidirectionally connected to the embedded operating system of the artificial intelligence module.

[0016] The AI ​​module GPU processor is adapted to the embedded operating system of the AI ​​module and is bidirectionally connected to the embedded operating system of the AI ​​module.

[0017] The artificial intelligence module business module also includes:

[0018] An artificial intelligence module TCP client module, through which the artificial intelligence module communicates with the backplane module via TCP;

[0019] The artificial intelligence module access processing module is used to preprocess the received data; the artificial intelligence module access processing module supports the processing of different input data by downloading new access processing models on the embedded operating system of the artificial intelligence module.

[0020] The data module is used to store the data that has been preprocessed by the processing module after being accessed by the artificial intelligence module;

[0021] The analysis module is used to analyze and process the data preprocessed by the artificial intelligence module and the processing module to obtain the analysis data; the analysis module adds new analysis support functions by downloading new edge analysis models on the embedded operating system of the artificial intelligence module.

[0022] The post-processing module is used to send the analyzed data through the artificial intelligence module's TCP client module according to the data mapping rules.

[0023] Furthermore, the CPU module includes:

[0024] The CPU module is an EtherCAT master module used to implement EtherCAT master functions.

[0025] The CPU module has a real-time embedded operating system, which is adapted to the CPU module and is bidirectionally connected to the CPU module's EtherCAT master module.

[0026] CPU module CPU processor, adapted to the CPU module CPU processor, and bidirectionally connected to the CPU module real-time embedded operating system;

[0027] The CPU module's EtherCAT communication chip is bidirectionally connected to the CPU module's CPU processor via the EtherCAT protocol, and also bidirectionally connected to the backplane module via the EBUS bus.

[0028] Furthermore, the backplane module is the EtherCAT slave module corresponding to the EtherCAT master module of the CPU module, used to implement the EtherCAT slave function; the backplane module includes:

[0029] The backplane module's EtherCAT communication chip is bidirectionally connected to the CPU module or other backplane modules via the EBUS bus.

[0030] The backplane module MCU processor is adapted to the CPU processor of the backplane module and is bidirectionally connected to the EtherCAT communication chip of the backplane module through FSMC.

[0031] The backplane module is a TCP server module, through which the backplane module communicates with the functional module via TCP.

[0032] Furthermore, the functional module also includes an I / O module, which is configured to process digital and analog input / output information.

[0033] Furthermore, the functional module also includes a communication module, which is configured to support access by terminal devices containing preset communication protocols.

[0034] Secondly, this application provides a PLC control method based on the PLC control system described in any of the foregoing claims, comprising:

[0035] The CPU module's EtherCAT master module sets different scan cycles for backplane modules according to the EtherCAT domain data scanning mechanism, and groups backplane modules with the same scan cycle into a unified domain; the CPU module's EtherCAT master module generates corresponding domain data packets according to different scan cycles, and sends them to the CPU module's EtherCAT communication chip via the EtherCAT protocol; the CPU module's EtherCAT communication chip transmits the received domain data packets through the EBUS bus according to the network topology.

[0036] In the network topology, the EtherCAT communication chip of each backplane module checks the domain data packets to see if there is any message data to be sent to its own backplane module. If so, it retrieves the data to be received from the domain data packet, then buffers the received data in the memory of the backplane module's EtherCAT communication chip. At the same time, it retrieves the data to be sent from the memory and writes the data to be sent into the domain data packet. Finally, it forwards the new domain data packet to the next backplane module according to the network topology. After processing in this way, the domain data packet is finally returned to the CPU module's EtherCAT master module. The CPU module's EtherCAT master module processes the data in the domain data packet, thus completing a cycle of communication between the CPU module and several backplane modules.

[0037] The backplane module's TCP server module retrieves the buffered data from the corresponding backplane module's EtherCAT communication chip via FSMC, and then sends it to the functional module connected to it via TCP.

[0038] The functional module sends the collected and processed data to the connected backplane module through its TCP client module. The backplane module's TCP server module then caches the received data in the memory of the backplane module's EtherCAT communication chip via FSMC.

[0039] Furthermore, including:

[0040] The artificial intelligence module connects to external terminal devices through a network bridging device. The artificial intelligence module accesses the processing module to preprocess the connected terminal data, and then sends the preprocessed data to the analysis module for analysis and processing to obtain analysis data. Finally, the analysis data is sent to the CPU module.

[0041] The CPU module performs logical operations based on the analyzed data, generates control commands, and sends them to the corresponding functional modules to achieve coordinated control of the terminal devices.

[0042] The analysis module can use different machine learning models to analyze the same preprocessed output data from the AI ​​module's input processing module. It can also be configured to apply different machine learning models to analyze and process input data from different terminal devices.

[0043] and / or

[0044] The artificial intelligence module receives real-time process data sent by the CPU module through the backplane module, accesses the processing module through the artificial intelligence module to preprocess the received real-time process data, and then sends the preprocessed data to the data module for storage.

[0045] The analysis module analyzes and processes the preprocessed data, and sends the analyzed data to the CPU module via the post-processing module, the artificial intelligence module, the TCP client module, and the backplane module.

[0046] The CPU module performs logical operations based on the analyzed data.

[0047] Furthermore, including:

[0048] The artificial intelligence module obtains local data within a preset time window from the data module through the artificial intelligence module access processing module;

[0049] The AI ​​module access processing module sends the acquired local data to the analysis module for analysis and processing, and then sends the analyzed data to the CPU module via the post-processing module, the AI ​​module TCP client module, and the backplane module.

[0050] The CPU module performs logical operations based on the analyzed data.

[0051] In summary, compared with the prior art, the above-described technical solutions conceived in this application can achieve the following beneficial effects:

[0052] (1) This application applies the concept of edge computing to the PLC field, migrating large and complex calculations in specific technical fields such as metallurgy from the CPU module to the artificial intelligence module, reducing the resource consumption of the CPU module and improving the overall processing performance of the PLC control system. Large and complex calculations are also prone to failure. By having the artificial intelligence module perform large and complex calculations independently, the reliability and availability of the CPU module are also improved.

[0053] (2) In the main data link (CPU module -> various backplane modules -> CPU module), data processing is mainly completed by the low-cost EtherCAT communication chip. In the branch data link (backplane module <--> various functional modules), the MCU processor of the backplane module realizes data pass-through between the CPU module and related functional modules through the TCP server module of the backplane module. With the above settings, the maximum speed of the PLC control system can reach 100Mbit / s, and the communication cycle can be as fast as 100μs. At the same time, based on the EtherCAT distributed clock synchronization mechanism, DC can be configured to achieve high-precision synchronization with a synchronization accuracy of <<1μs. In this way, the current high-speed backplane bus cannot meet the requirements of large-scale data transmission and high communication rate in specific technical fields such as metallurgy at a lower cost. At the same time, it can improve the availability, reliability and intelligence of industrial controllers. Attached Figure Description

[0054] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0055] Figure 1 is a schematic block diagram of the core structure of the PLC control system provided in the embodiment of this application;

[0056] Figure 2 is a detailed structural schematic block diagram of the PLC control system provided in the embodiment of this application;

[0057] Figure 3 is a schematic block diagram of the CPU module provided in an embodiment of this application;

[0058] Figure 4 is a schematic block diagram of the backplane module provided in an embodiment of this application;

[0059] Figure 5 is a schematic block diagram of the IO module provided in an embodiment of this application;

[0060] Figure 6 is a schematic block diagram of the artificial intelligence module provided in an embodiment of this application;

[0061] Figure 7 is a schematic block diagram of the communication module provided in an embodiment of this application. Detailed Implementation

[0062] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application. Furthermore, the technical features involved in the various embodiments described below can be combined with each other as long as they do not conflict with each other.

[0063] The terms "comprising" or "having," and any variations thereof, in the specification, claims, or drawings of this application are intended to cover a non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such processes, methods, products, or apparatus.

[0064] As described in the background section of this specification, the implementation of a high-speed backplane bus is a key technical challenge in the development of large-scale controllers. Existing PLC processors, due to the slow speed caused by integrated peripheral communication, cannot meet the high communication rate requirements of specific technical fields such as metallurgy. While PCIe speeds can reach GBit / s, they are expensive, require complex wiring, and necessitate dedicated PCIe interface chips. Therefore, this application proposes a PLC control system and method that enables a lower-cost solution to the current limitations of high-speed backplane buses in meeting the requirements of large-scale data transmission and high communication rates in specific technical fields such as metallurgy. Simultaneously, it improves the availability, reliability, and intelligence capabilities of industrial controllers.

[0065] Referring to Figures 1-7, one embodiment of this application proposes a PLC control system, which may include at least: a CPU module, several backplane modules connected in series, an artificial intelligence module, and a power supply module.

[0066] The power module is configured to convert AC power to DC power to supply power to the PLC control system.

[0067] The CPU module is used to send domain data packets and execute application logic based on the received analysis data.

[0068] Several backplane modules are connected in series. The backplane modules are used to receive and forward domain data packets, and also to send the received analysis data to the CPU module via domain data packets. Each backplane module can be connected to a corresponding functional module. The backplane modules are configured to connect the CPU module and the functional modules.

[0069] The artificial intelligence module, a type of functional module, is used to receive relevant data from domain data packets or terminal data sent by connected terminal devices. It analyzes and processes data for tasks where the data volume exceeds a preset threshold or the logical complexity exceeds a preset threshold, and forwards the resulting analyzed data to the CPU module through the corresponding backplane module. The artificial intelligence module is configured to perform edge computing and artificial intelligence processing.

[0070] The CPU module and the backplane module are bidirectionally connected via EBUS; the backplane modules are bidirectionally connected to each other via EBUS; the backplane module and its corresponding functional module are bidirectionally connected via TCP; the power output terminal of the power module is connected to the power input terminal of the CPU module, and the power input terminal of the power module receives external AC power and outputs DC power to supply power to the PLC control system.

[0071] This application applies edge computing concepts to the PLC field, migrating large and complex calculations in specific technical fields such as metallurgy from the CPU module to the artificial intelligence module. This reduces the resource consumption of the CPU module and improves the overall processing performance of the PLC control system. Large and complex calculations are also prone to failure; by having the artificial intelligence module perform these calculations independently, the reliability and availability of the CPU module are also improved.

[0072] Furthermore, communication between the CPU module and the backplane module, as well as between the backplane modules, is based on EtherCAT (Ethernet Control Automation Technology, an open architecture, Ethernet-based fieldbus system; CAT stands for Control Automation Technology. EtherCAT is a deterministic industrial Ethernet, originally developed by Beckhoff in Germany. Automation typically requires short data update times (or cycle times), low communication jitter during data synchronization, and low hardware costs; EtherCAT was developed to enable the use of Ethernet in automation applications.) communication, using the EBUS bus for data exchange. Data exchange between the backplane module and functional modules is via TCP communication.

[0073] In this application, data processing in the main data link (CPU module -> various backplane modules -> CPU module) is primarily handled by a low-cost EtherCAT communication chip. In the branch data links (backplane module <--> various functional modules), the backplane module MCU processor achieves data pass-through between the CPU module and related functional modules through the backplane module TCP server module. With this setup, the PLC control system can reach a maximum speed of 100 Mbit / s, with a communication cycle as fast as 100 μs. Simultaneously, based on the EtherCAT distributed clock synchronization mechanism, a DC clock can be configured to achieve high-precision synchronization with an accuracy of << 1 μs. This approach addresses the limitations of current high-speed backplane buses in meeting the requirements for large-scale data transmission and high communication rates in specific technical fields such as metallurgy, while simultaneously improving the availability, reliability, and intelligence of industrial controllers.

[0074] In some embodiments, more specifically, referring to FIG3, the CPU module may include an EtherCAT master module, a real-time embedded operating system, a CPU processor, and an EtherCAT communication chip.

[0075] This EtherCAT master module is used to implement EtherCAT master functions.

[0076] This real-time embedded operating system is a real-time embedded operating system adapted to the CPU module.

[0077] The CPU can be either a domestic or imported brand, but it must be compatible with its real-time embedded operating system, such as the LS2K1000LA processor and the SylixOS V3.6.3 real-time embedded operating system.

[0078] The EtherCAT communication chip can be either Beckhoff ET1100 or an FPGA chip that supports EtherCAT communication.

[0079] Its EtherCAT master module and real-time embedded operating system achieve bidirectional connection; its real-time embedded operating system and CPU processor achieve bidirectional connection; its CPU processor and EtherCAT communication chip achieve bidirectional connection through the EtherCAT protocol.

[0080] In some embodiments, more specifically, referring to FIG4, the backplane module may include an EtherCAT communication chip, an MCU processor, and a TCP Server module.

[0081] The EtherCAT communication chip and the MCU processor are bidirectionally connected via FSMC; the MCU processor and the TCP Server module are bidirectionally connected; and the EtherCAT communication chips are bidirectionally connected to each other via EBUS.

[0082] The EtherCAT communication chip can be Beckhoff ET1100 or ET1200, or an FPGA chip that supports EBUS communication; the MCU processor can be any processor that supports FSMC, such as the relevant series of STM32.

[0083] The MCU processor of the backplane module and the MCU or CPU processor of various functional modules are connected bidirectionally via TCP.

[0084] In some embodiments, more specifically referring to Figure 6, the artificial intelligence module may include a business module, an embedded operating system, a CPU processor, and a GPU processor. Its business module is bidirectionally connected to the embedded operating system, its embedded operating system is bidirectionally connected to the CPU processor, and its embedded operating system is bidirectionally connected to the GPU processor.

[0085] The business module of the artificial intelligence module is used to analyze and process the received data to realize the corresponding artificial intelligence business. This business module may include a TCP Client module, an access processing module, an analysis module, a post-processing module, and a data module.

[0086] The artificial intelligence module communicates with the backplane module via TCP through its TCP Client module.

[0087] The access processing module of the artificial intelligence module is used to preprocess the received data; the access processing module of the artificial intelligence module supports the processing of different input data by downloading new access processing models on the embedded operating system of the artificial intelligence module.

[0088] The data module is used to store data that has been preprocessed by the access processing module of the artificial intelligence module.

[0089] The analysis module is used to analyze and process the data preprocessed by the access processing module via the artificial intelligence module to obtain analytical data.

[0090] The post-processing module is used to send the analysis data to the CPU module through the TCP Client module of the artificial intelligence module according to the data mapping rules, and also to send the video analysis data to the HMI (Human Machine Interface) through the network port.

[0091] The embedded operating system is an embedded operating system adapted to the business module of the artificial intelligence module, and it has a bidirectional connection with the business module of the artificial intelligence module.

[0092] Its GPU processor can be an NPU, TPU, etc., and its embedded operating system can be a series of embedded operating systems including Linux; its GPU processor and CPU processor need to be compatible with its embedded operating system; its analysis module adds new analysis support by downloading new edge analysis models on its embedded operating system, and its access processing module supports the processing of different input data by downloading new access processing models on its embedded operating system.

[0093] In some embodiments, more specifically, referring to Figures 2, 5 and 7, the functional module may also include an I / O module and a communication module.

[0094] The I / O module includes a service module and an MCU processor. The service module comprises a TCP Client module and an access processing module; it is bidirectionally connected to the MCU processor. The I / O module is configured to process digital and analog input / output information.

[0095] The communication module includes a TCP Client module and a protocol module, with the TCP Client module and protocol module establishing a bidirectional connection. The communication module can support Profinet networking, or it can support EtherCAT, Profibus, and Modbus networking, each type of communication module supporting a specific communication protocol. The communication module is configured to support access from terminal devices using specific communication protocols.

[0096] Through bidirectional connections between backplane modules and between backplane modules and functional modules such as IO modules, AI modules, and communication modules, it is theoretically possible to load no fewer than 100 IO / AI / communication functional modules. However, based on comprehensive considerations such as performance and deployment, the embodiments of this application limit the load to no more than 64 IO / AI / communication functional modules. IO modules, AI modules, and communication modules can be flexibly selected and deployed according to specific application scenarios.

[0097] The modular structure design based on the backplane module, I / O module, artificial intelligence module, and communication module effectively enables the reuse of functional modules. Based on the low coupling and hot-swappable design of the I / O module, artificial intelligence module, communication module, and backplane module, in the event of failure of the I / O module, artificial intelligence module, or communication module, the functionality of other functional modules is not affected, and they can be quickly replaced while powered on, thereby improving the reliability, availability, and maintainability of the PLC control system.

[0098] An embodiment of this application also provides a PLC control method based on the aforementioned PLC control system. Referring to Figures 1-4, the PLC control method includes: the EtherCAT master module of the CPU module implements the EtherCAT master function (the main function of the EtherCAT master is to control and manage the communication and data exchange of the entire EtherCAT network).

[0099] The EtherCAT master station is responsible for sending control commands to each EtherCAT slave device and receiving feedback data from the EtherCAT slave devices, ensuring the efficient operation of the entire network. The CPU module's EtherCAT master station module generates corresponding domain data packets according to different scan cycles and sends them to the CPU module's EtherCAT communication chip via the EtherCAT protocol. The CPU module's EtherCAT communication chip transmits the received domain data packets through the EBUS bus according to the network topology. Each backplane module's EtherCAT communication chip in the network topology checks the domain data packets to see if there is any message data to be sent to its corresponding backplane module. If so, it retrieves the data to be received (data1) from the domain data packet, caches data1 in its EtherCAT communication chip's memory, retrieves the data to be sent (data2) from that memory, writes data2 into the domain data packet, and finally forwards the domain data packet to the next backplane module according to the network topology. Following this forwarding logic, the domain data packets are processed sequentially, and finally returned to the EtherCAT master module of the CPU module. The EtherCAT master module of the CPU module processes the relevant data2 series data in the domain data packets. In this way, one cycle of communication based on the CPU module and a series of backplane modules is completed.

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

[0101] The above describes the high-performance data processing flow. As can be seen, in the main data link (CPU module -> backplane module -> CPU module), data processing is primarily handled by the hardware EtherCAT communication chip. In the branch data links (backplane module <--> IO module / AI module / communication module), the MCU processor of the backplane module uses the TCP Server module to achieve data pass-through between the CPU module and related functional modules. Based on this method, the PLC control system can achieve a maximum speed of 100 Mbit / s, with a communication cycle as fast as within 100 μs. Simultaneously, based on the EtherCAT distributed clock synchronization mechanism, a configurable DC clock can achieve high-precision synchronization with a synchronization accuracy of << 1 μs.

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

[0103] The analysis module can utilize different machine learning models to analyze the same preprocessed output data from the access processing module. For example, in a smart construction site scenario, it can perform machine learning-based detection of safety helmets and reflective vests on the same video input stream. Simultaneously, the analysis module can also be configured to apply different machine learning models to analyze input data from different terminal devices. For instance, it can apply a strip steel defect detection model to detect strip steel defects based on input data from terminal devices, or apply a belt misalignment recognition model to detect belt misalignment in a belt conveyor system based on input data from terminal devices. One analysis module can connect to multiple terminal devices, and each terminal device's input data can be configured with multiple machine learning models for analysis. Furthermore, the output data processed by the analysis module can be sent to the HMI via the network interface by the post-processing module. This allows for direct observation of the intelligent analysis results and provides foundational data for the self-optimization of cloud-edge machine learning models, thereby further improving the performance of the machine learning models in the artificial intelligence module.

[0104] In some embodiments, referring to FIG6, the PLC control method may further include: an artificial intelligence module receiving real-time process data sent by a CPU module through a backplane module, preprocessing the received real-time process data through an access processing module, and then sending the preprocessed data to a data module for storage; and an analysis module performing analysis based on a complex rule model, and sending the analysis results to a CPU module via a post-processing module, a TCP Client module, and a backplane module, and the CPU module performing logical operations based on the analysis results.

[0105] This method utilizes an independent artificial intelligence (AI) module to perform complex rule-based model analysis. On one hand, it enhances the PLC control system's ability to handle large and complex rule models. On the other hand, migrating large and complex calculations from the CPU module to the AI ​​module reduces CPU resource consumption, increases its processing power, and improves the overall processing performance of the PLC control system. Furthermore, large and complex calculations are often prone to failure; by having the AI ​​module perform these calculations independently, the reliability and availability of the CPU module are also improved. The computational capabilities of the independent AI module also provide a foundation for edge distributed computing within the PLC control system. In summary, this method improves the distributed edge computing capabilities, reliability, and availability of the PLC control system as a whole.

[0106] In some embodiments, referring to Figure 6, the PLC control method may further include: an artificial intelligence module acquiring local data within a preset time window from a data module via an access processing module; the access processing module sending the acquired local data to an analysis module for complex rule-based model analysis; and sending the analysis results to a CPU module via a post-processing module, a TCP Client module, and a backplane module. The CPU module then performs logical operations based on the analysis results. This method enables rule-based analysis of historical data, further improving the edge computing capabilities of the PLC control system.

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

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

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

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

Claims

1. A PLC control system, characterized by, include: The CPU module is used to include sending domain data packets and executing application logic based on received analysis data; A plurality of backplane modules connected in series are configured to receive and forward the domain data packets, and to send the received analysis data to the CPU module via the domain data packets; each backplane module can be connected to a corresponding functional module; the backplane modules are configured to connect the CPU module and the functional modules. The artificial intelligence module, which is one of the functional modules, is used to receive relevant data in the domain data packet or receive terminal data sent by the connected terminal device, analyze and process data for data processing tasks where the data volume exceeds a preset data volume threshold or the logical complexity exceeds a preset logical complexity threshold, and forward the obtained analysis data to the CPU module through the corresponding backplane module.

2. The PLC control system as described in claim 1, characterized in that, The CPU module and the backplane module, as well as the backplane modules themselves, exchange data using the EBUS bus based on the EtherCAT communication mechanism. The backplane module and the functional module exchange data via TCP communication.

3. The PLC control system of claim 2, wherein, The artificial intelligence module includes: The artificial intelligence module is a business module used to analyze and process the received data to realize corresponding artificial intelligence business. An embedded operating system for the artificial intelligence module, adapted to the embedded operating system of the business module of the artificial intelligence module, and bidirectionally connected to the business module of the artificial intelligence module; The CPU processor of the artificial intelligence module is adapted to the CPU processor of the embedded operating system of the artificial intelligence module and is bidirectionally connected to the embedded operating system of the artificial intelligence module. catch; The AI ​​module GPU processor is adapted to the embedded operating system of the AI ​​module and is bidirectionally connected to the embedded operating system of the AI ​​module. The artificial intelligence module business module also includes: An artificial intelligence module TCP client module, through which the artificial intelligence module communicates with the backplane module via TCP; The artificial intelligence module access processing module is used to preprocess the received data; the artificial intelligence module access processing module supports the processing of different input data by downloading new access processing models on the embedded operating system of the artificial intelligence module. The data module is used to store the data that has been preprocessed by the processing module after being accessed by the artificial intelligence module; The analysis module is used to analyze and process the data preprocessed by the artificial intelligence module and the processing module to obtain the analysis data; the analysis module adds new analysis support functions by downloading a new edge analysis model on the embedded operating system of the artificial intelligence module. The post-processing module is used to send the analyzed data through the artificial intelligence module's TCP client module according to the data mapping rules.

4. The PLC control system of claim 3, wherein, The CPU module includes: The CPU module is an EtherCAT master module used to implement EtherCAT master functions. The CPU module has a real-time embedded operating system, which is adapted to the CPU module and is bidirectionally connected to the CPU module's EtherCAT master module. CPU module CPU processor, adapted to the CPU module CPU processor, and bidirectionally connected to the CPU module real-time embedded operating system; The CPU module's EtherCAT communication chip is bidirectionally connected to the CPU module's CPU processor via the EtherCAT protocol, and also bidirectionally connected to the backplane module via the EBUS bus.

5. The PLC control system of claim 4, wherein, The backplane module is the EtherCAT slave module corresponding to the EtherCAT master module of the CPU module, used to implement the EtherCAT slave function; the backplane module includes: The backplane module's EtherCAT communication chip is bidirectionally connected to the CPU module or other backplane modules via the EBUS bus. The backplane module MCU processor is adapted to the CPU processor of the backplane module and is bidirectionally connected to the EtherCAT communication chip of the backplane module through FSMC. The backplane module is a TCP server module, through which the backplane module communicates with the functional module via TCP.

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

7. The PLC control system of any one of claims 1-5, wherein, The functional module also includes a communication module, which is configured to support access from terminal devices containing preset communication protocols.

8. A PLC control method based on the PLC control system according to any one of claims 5 to 7, characterized by, include: The CPU module's EtherCAT master module sets different scan cycles for backplane modules according to the EtherCAT domain data scanning mechanism, grouping backplane modules with the same scan cycle into a unified domain. The CPU module's EtherCAT master module generates corresponding domain data packets based on different scan cycles and sends them to the CPU module's EtherCAT communication chip via the EtherCAT protocol. The CPU module's EtherCAT communication chip then processes the received domain data packets through... The EBUS bus transmits data according to the network topology; In the network topology, the EtherCAT communication chip of each backplane module checks the domain data packets to see if there is any message data to be sent to its own backplane module. If so, it retrieves the data to be received from the domain data packet, then buffers the received data in the memory of the backplane module's EtherCAT communication chip. At the same time, it retrieves the data to be sent from the memory and writes the data to be sent into the domain data packet. Finally, it forwards the new domain data packet to the next backplane module according to the network topology. After processing in this way, the domain data packet is finally returned to the CPU module's EtherCAT master module. The CPU module's EtherCAT master module processes the data in the domain data packet, thus completing a cycle of communication between the CPU module and several backplane modules. The backplane module's TCP server module retrieves the buffered data from the corresponding backplane module's EtherCAT communication chip via FSMC, and then sends it to the functional module connected to it via TCP. The functional module sends the collected and processed data to the connected backplane module through its TCP client module. The backplane module's TCP server module then caches the received data in the memory of the backplane module's EtherCAT communication chip via FSMC.

9. The PLC control method of claim 8, wherein, include: The artificial intelligence module connects to external terminal devices through a network bridging device. The artificial intelligence module accesses the processing module to preprocess the connected terminal data, and then sends the preprocessed data to the analysis module for analysis and processing to obtain analysis data. Finally, the analysis data is sent to the CPU module. The CPU module performs logical operations based on the analyzed data, generates control commands, and sends them to the corresponding functional modules to achieve coordinated control of the terminal devices. The analysis module can use different machine learning models to analyze the same preprocessed output data from the AI ​​module's input processing module, and it can also be configured to analyze different... The input data from terminal devices is analyzed and processed using different machine learning models. and / or The artificial intelligence module receives real-time process data sent by the CPU module through the backplane module, accesses the processing module through the artificial intelligence module to preprocess the received real-time process data, and then sends the preprocessed data to the data module for storage. The analysis module analyzes and processes the preprocessed data, and sends the analyzed data to the CPU module via the post-processing module, the artificial intelligence module, the TCP client module, and the backplane module. The CPU module performs logical operations based on the analyzed data.

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

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