A design method for automatic diagnosis and alarm system of circuit board life in DCS system

Abstract

The present invention belongs to the technical field of instrumentation and analysis and measurement control in a DCS system, and specifically relates to a design method for automatic diagnosis and alarm of the life of a circuit board card in a DCS system. The method comprises the following steps: step 1, establishing a circuit board life model; step 2, determining a hardware architecture; step 3, determining a software architecture; step 4, determining an automatic diagnosis process for the life of a circuit board card in a DCS system. The beneficial effect of the technical solution of the present invention is to establish a component-level life model, thereby predicting the life of the component, which is more accurate than the previous board-level life calculation.

Description

Technical Field

[0001] The invention belongs to the technical field of instrumentation and analysis and measurement control in a DCS system, and in particular relates to a design method for an automatic diagnosis and alarm system for the life of a circuit board card in a DCS system. Background Art

[0002] With the rapid development of my country's nuclear power construction, the safety and reliability of the digital control system (DCS), known as the "nervous system" of nuclear power plants, has attracted more and more attention.

[0003] In order to improve its safety and reliability, DCS systems are generally designed as multiple redundant systems, including dozens or even thousands of circuit boards. The lifespans of each board are different, which brings great difficulties to on-site maintenance.

[0004] Previous circuit board designs did not have a life diagnostic function and were mostly based on MTBF analysis, which could not truly reflect the actual life of the boards on site.

[0005] A method is needed to improve the authenticity and accuracy of circuit board life diagnosis. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a design method for a DCS system circuit board card life automatic diagnosis alarm system, thereby simplifying the hardware structure, not affecting the normal function of the board card, and reducing the workload of on-site equipment maintenance personnel.

[0007] In order to achieve this purpose, the technical solution adopted by the present invention is:

[0008] A design method for a DCS system circuit board card life automatic diagnosis and alarm system comprises the following steps:

[0009] Step 1: Establishment of board life model

[0010] Statistical data in the board life model;

[0011] According to different types of boards, corresponding calculation algorithms are used to establish board storage life model and working life model to generate life-stress data of boards;

[0012] Step 2: Determine the hardware architecture

[0013] The hardware architecture of automatic diagnosis of the life of the circuit board card of the DCS system includes the diagnosis MCU circuit, EEPROM storage circuit, RTC circuit, power supply circuit and diagnosis circuit;

[0014] Step 3: Determine the software architecture

[0015] The DCS system circuit board life automatic diagnosis software architecture includes the board life-stress database module, actual stress diagnosis module, life statistics module, life judgment module, communication module, alarm module, and low power design module;

[0016] Step 4: Determine the automatic diagnosis process of the DCS system circuit board card life:

[0017] (1) Data download: Download the board model life-stress database determined in step 1 to the EEPROM storage circuit determined in step 2, establish a retrieval index, and the corresponding software module is the life-stress database module;

[0018] (2) Communication function: Through the DCS control network, the actual environmental stress, life statistics, remaining life and alarm information are sent to the upper control system during idle time as data backup;

[0019] Get DCS system time and calibrate local time;

[0020] Obtain upper-level control data of DCS system;

[0021] The corresponding software module is the communication module;

[0022] (3) Low power design function: The low power design module is used to control the periodic sleep of the automatic diagnosis hardware of the circuit board card life of the DCS system, thereby extending the working life of the automatic diagnosis hardware of the circuit board card life of the DCS system; the corresponding software module is the low power design module.

[0023] (4) Collecting actual working condition stress: Through the diagnostic circuit of the DCS system circuit board card life automatic diagnosis hardware determined in step 2, obtain the ambient temperature, CPU load rate, bus load, and drive load information, and set the life threshold; the corresponding software module is the actual stress diagnosis module;

[0024] (5) Establishing a board card working life log: Counting the working condition information including power-on time, fuse power-on times, FLASH erase times, connector plug-in times, relay action times, and electrolytic capacitor duration, and establishing a board card working life log; the corresponding software module is the life statistics module;

[0025] (6) Life judgment: Periodically detect the actual stress data, and determine whether the remaining life is lower than the set reminder threshold by searching the board model life-stress database obtained in step 4 (1). If the life is not lower than the set reminder threshold, modify the remaining life and update the work log; if the life is lower than the set reminder threshold, execute step 4 (7); the corresponding software module is the life judgment module;

[0026] (7) Alarm: When the remaining life obtained in step 4 (6) is lower than the set reminder threshold, the alarm function is activated to remind the maintenance personnel to prepare;

[0027] When the remaining life obtained in step 4 (6) is lower than the set replacement threshold, the alarm function is activated to warn the maintenance personnel to replace the board;

[0028] The alarm information is sent to the upper control system through the DCS control bus;

[0029] The corresponding software modules are the alarm module and the communication module.

[0030] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a DCS system circuit board card as described above, in step one, the statistical data includes: original factory failure rate data, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis, and failure rate prediction conventional reliability analysis data.

[0031] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a circuit board card of a DCS system as described above, in step 2, the diagnostic MCU circuit is responsible for independently running the diagnostic algorithm without affecting the normal function of the original system.

[0032] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a circuit board card in a DCS system as described above, in step 2, the EEPROM storage circuit is responsible for storing data in the life-stress database.

[0033] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a circuit board card of a DCS system as described above, in step 2, the RTC circuit is responsible for providing a real-time clock and recording the work log of the board card.

[0034] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a DCS system circuit board card as described above, in step 2, the power supply circuit is responsible for providing power for other hardware in the automatic diagnosis hardware for the life of a DCS system circuit board card.

[0035] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a circuit board card of a DCS system as described above, in step 2, the diagnosis circuit is responsible for obtaining actual operating condition information and performing diagnosis.

[0036] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a DCS system circuit board card as described above, in step 2, the diagnostic circuit includes a temperature detection circuit, an input power detection circuit, a communication bus load detection, a CPU load detection, a memory read and write times detection, and an IO load.

[0037] Furthermore, in the design method of the automatic diagnosis and alarm system for the life of a DCS system circuit board card as described above, in step four (7), the reminder threshold is set to 10%, and the replacement threshold is set to 2%.

[0038] The beneficial effects of the technical solution of the present invention are:

[0039] 1. Establish component-level life models to predict component life, which is more accurate than previous board-level life calculations.

[0040] 2. Real-time acquisition of actual working condition information of the board is more reliable than purely theoretical reliability estimates.

[0041] 3. Can be combined with DCS functional circuit to save costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is a schematic diagram of the diagnostic process of this method. DETAILED DESCRIPTION

[0043] The technical solution of the present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0044] like Figure 1 As shown, the design method of a DCS system circuit board card life automatic diagnosis alarm system of the present invention comprises the following steps:

[0045] Step 1: Establishment of board life model

[0046] Statistical data in the board life model;

[0047] Statistical data include: original factory failure rate data, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis, and failure rate prediction conventional reliability analysis data;

[0048] According to different types of boards, corresponding calculation algorithms are used to establish board storage life model and working life model to generate life-stress data of boards;

[0049] Step 2: Determine the hardware architecture

[0050] The hardware architecture of automatic diagnosis of the life of the circuit board card of the DCS system includes the diagnosis MCU circuit, EEPROM storage circuit, RTC circuit, power supply circuit and diagnosis circuit;

[0051] The diagnostic MCU circuit is responsible for independently running the diagnostic algorithm without affecting the normal function of the original system; the EEPROM storage circuit is responsible for storing data in the life-stress database; the RTC circuit is responsible for providing a real-time clock and recording the work log of the board; the power supply circuit is responsible for providing power for other hardware in the DCS system circuit board life automatic diagnosis hardware; the diagnostic circuit is responsible for obtaining actual working condition information and performing diagnosis; the diagnostic circuit includes temperature detection circuit, input power detection circuit, communication bus load detection, CPU load detection, memory read and write times detection, and IO load;

[0052] Step 3: Determine the software architecture

[0053] The DCS system circuit board life automatic diagnosis software architecture includes the board life-stress database module, actual stress diagnosis module, life statistics module, life judgment module, communication module, alarm module, and low power design module;

[0054] Step 4: Determine the automatic diagnosis process of the DCS system circuit board card life:

[0055] (1) Data download: Download the board model life-stress database determined in step 1 to the EEPROM storage circuit determined in step 2, establish a retrieval index, and the corresponding software module is the life-stress database module;

[0056] (2) Communication function: Through the DCS control network, the actual environmental stress, life statistics, remaining life and alarm information are sent to the upper control system during idle time as data backup;

[0057] Get DCS system time and calibrate local time;

[0058] Obtain upper-level control data of DCS system;

[0059] The corresponding software module is the communication module;

[0060] (3) Low power design function: The low power design module is used to control the periodic sleep of the automatic diagnosis hardware of the circuit board card life of the DCS system, thereby extending the working life of the automatic diagnosis hardware of the circuit board card life of the DCS system; the corresponding software module is the low power design module.

[0061] (4) Collecting actual working condition stress: Through the diagnostic circuit of the DCS system circuit board card life automatic diagnosis hardware determined in step 2, obtain the ambient temperature, CPU load rate, bus load, and drive load information, and set the life threshold; the corresponding software module is the actual stress diagnosis module;

[0062] (5) Establishing a board card working life log: Counting the working condition information including power-on time, fuse power-on times, FLASH erase times, connector plug-in times, relay action times, and electrolytic capacitor duration, and establishing a board card working life log; the corresponding software module is the life statistics module;

[0063] (6) Life judgment: Periodically detect the actual stress data, and determine whether the remaining life is lower than the set reminder threshold by searching the board model life-stress database obtained in step 4 (1). If the life is not lower than the set reminder threshold, modify the remaining life and update the work log; if the life is lower than the set reminder threshold, execute step 4 (7); the corresponding software module is the life judgment module;

[0064] (7) Alarm: When the remaining life obtained in step 4 (6) is lower than the set reminder threshold, the alarm function is activated to remind the maintenance personnel to prepare;

[0065] When the remaining life obtained in step 4 (6) is lower than the set replacement threshold, the alarm function is activated to warn the maintenance personnel to replace the board;

[0066] In this specific embodiment, the reminder threshold is set to 10%, and the replacement threshold is set to 2%.

[0067] The alarm information is sent to the upper control system through the DCS control bus;

[0068] The corresponding software modules are the alarm module and the communication module.

Claims

1. A design method for automatic diagnosis and alarm of circuit board life of a DCS system, characterized in that: The following steps are involved: Step 1: Establishment of board life model Statistical data in the board life model; According to different types of boards, corresponding calculation algorithms are used to establish board storage life model and working life model to generate life-stress data of boards; Step 2: Determine the hardware architecture The hardware architecture of automatic diagnosis of the life of the circuit board card of the DCS system includes the diagnosis MCU circuit, EEPROM storage circuit, RTC circuit, power supply circuit, and diagnosis circuit; Step 3: Determine the software architecture The DCS system circuit board life automatic diagnosis software architecture includes the board life-stress database module, actual stress diagnosis module, life statistics module, life judgment module, communication module, alarm module, and low power design module; Step 4: Determine the automatic diagnosis process of the DCS system circuit board card life: (1) Data download: Download the board model life-stress database determined in step 1 to the EEPROM storage circuit determined in step 2, establish a retrieval index, and the corresponding software module is the life-stress database module; (2) Communication function: Through the DCS control network, the actual environmental stress, life statistics, remaining life and alarm information are sent to the upper control system during idle time as data backup; Get DCS system time and calibrate local time; Obtain upper-level control data of DCS system; The corresponding software module is the communication module; (3) Low power design function: The low power design module is used to control the periodic dormancy of the automatic diagnosis hardware of the circuit board card life of the DCS system, thereby extending the working life of the automatic diagnosis hardware of the circuit board card life of the DCS system; the corresponding software module is the low power design module; (4) Collecting actual working condition stress: Through the diagnostic circuit of the DCS system circuit board card life automatic diagnosis hardware determined in step 2, obtain the ambient temperature, CPU load rate, bus load, and drive load information, and set the life threshold; the corresponding software module is the actual stress diagnosis module; (5) Establishing a board card working life log: Statistics include power-on time, fuse power-on times, FLASH erase times, connector plug-in times, relay action times, and electrolytic capacitor duration, and establish a board card working life log; the corresponding software module is the life statistics module; (6) Life judgment: Periodically detect the actual stress data, and determine whether the remaining life is lower than the set reminder threshold by searching the board model life-stress database obtained in step 4 (1). If the life is not lower than the set reminder threshold, modify the remaining life and update the work log; if the life is lower than the set reminder threshold, execute step 4 (7); the corresponding software module is the life judgment module; (7) Alarm: When the remaining life obtained in step 4 (6) is lower than the set reminder threshold, the alarm function is activated to remind the maintenance personnel to prepare; When the remaining life obtained in step 4 (6) is lower than the set replacement threshold, the alarm function is activated to warn the maintenance personnel to replace the board; The alarm information is sent to the upper control system through the DCS control bus; The corresponding software modules are the alarm module and the communication module.

2. A design method for automatic diagnosis and alarm of the life of a DCS system circuit board as claimed in claim 1, characterized in that: In step one, the statistical data includes: original factory original failure rate data, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis, and failure rate prediction conventional reliability analysis data.

3. The design method of the automatic diagnosis and alarm of the life of the circuit board card of the DCS system as claimed in claim 1 is characterized by: In step 2, the diagnostic MCU circuit is responsible for independently running the diagnostic algorithm without affecting the normal function of the original system.

4. The design method of the automatic diagnosis and alarm of the life of the circuit board card of a DCS system as claimed in claim 1 is characterized by: In step 2, the EEPROM storage circuit is responsible for storing the data in the life-stress database.

5. The design method of automatic diagnosis and alarm of the life of a DCS system circuit board card as claimed in claim 1, characterized in that: In step 2, the RTC circuit is responsible for providing a real-time clock and recording the work log of the board.

6. The design method of the automatic diagnosis and alarm of the life of the circuit board card of the DCS system as claimed in claim 1 is characterized by: In step 2, the power supply circuit is responsible for providing power to other hardware in the DCS system circuit board card life automatic diagnosis hardware.

7. The design method of automatic diagnosis and alarm of the life of a DCS system circuit board card as claimed in claim 1, characterized in that: In step 2, the diagnostic circuit is responsible for obtaining actual operating condition information and performing diagnosis.

8. A design method for automatic diagnosis and alarm of the life of a DCS system circuit board as claimed in claim 7, characterized in that: In step 2, the diagnostic circuit includes a temperature detection circuit, an input power detection circuit, a communication bus load detection circuit, a CPU load detection circuit, a memory read and write times detection circuit, and an IO load circuit.

9. The design method of the automatic diagnosis and alarm of the life of the circuit board card of a DCS system as claimed in claim 1 is characterized by: In step 4 (7), the reminder threshold is set to 10% and the replacement threshold is set to 2%.

10. The design method of automatic diagnosis and alarm of the life of a DCS system circuit board card as claimed in claim 1, characterized in that: In step 1, the statistical data includes: original factory failure rate data, board production date, board storage conditions, board production process, circuit board production date, circuit board production process, circuit board storage conditions, derating analysis, and failure rate prediction conventional reliability analysis data; In step 2, the diagnostic MCU circuit is responsible for independently running the diagnostic algorithm without affecting the normal function of the original system; the EEPROM storage circuit is responsible for storing the data in the life-stress database; the RTC circuit is responsible for providing a real-time clock and recording the work log of the board; the power supply circuit is responsible for providing power for other hardware in the DCS system circuit board life automatic diagnosis hardware; the diagnostic circuit is responsible for obtaining actual working condition information and performing diagnosis; the diagnostic circuit includes a temperature detection circuit, an input power detection circuit, a communication bus load detection, a CPU load detection, a memory read and write times detection, and an IO load; In step 4 (7), the reminder threshold is set to 10% and the replacement threshold is set to 2%.

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