A distributed control system and an industrial control system

Abstract

This invention provides a distributed control system and an industrial control system. The distributed control system includes: a CPU chassis and a plurality of I / O chassis. Each CPU chassis includes a CPU-A module and a first CM-A module. Each I / O chassis includes a second CM-A module and a plurality of I / O modules. The CPU-A module is connected to the first CM-A module via an A-channel AUTBUS bus. The first CM-A module is connected to the second CM-A module via an A-channel AUTBUS bus, thus connecting the CPU chassis and the I / O chassis. The second CM-A module is connected to each I / O module via an A1-channel AUTBUS bus. The I / O modules are used to connect to controlled devices, thereby enabling the CPU-A module to control the controlled devices via the A-channel and A1-channel AUTBUS buses. The technical solution of this invention increases the number of DCS control I / Os and simplifies the DCS cabinet.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of industrial automation, and particularly relates to a distributed control system and an industrial control system. BACKGROUND

[0002] DCS is the abbreviation of Distributed Control System, and is also called distributed control system in the domestic self-row industry. The DCS generally consists of the following four parts: 1) data acquisition device, mainly for data acquisition and preprocessing of process non-controlled variables; 2) field control unit or basic controller, which is the core part of the DCS system; 3) process management level, the human-computer interface device of the DCS, generally equipped with high-resolution, large-screen color CRT, operator keyboard, printer, large-capacity storage, etc.; 4) management level, which is the highest layer of the whole plant automation system, and comprehensively monitors each unit of the system and manages all information of the system.

[0003] The existing DCS, the field control unit and the data acquisition device generally adopt bus communication, and generally adopt serial bus such as RS422 / 485, CAN, etc. to connect the CPU module of the control unit and each IO module of the data acquisition device. The serial bus communication mode has the following problems: including RS422 / 485 and CAN, the biggest disadvantage of the serial bus is low bandwidth, usually only up to 10Mbps, which means that one control unit cannot carry too many IO modules, and the DCS using serial bus can connect at most 64 IO module nodes.

[0004] For more and more common servo drive, encoder, intelligent instrument and other I / O, the data of one node is often 32 bytes, and the DCS using serial bus often needs to configure additional acquisition devices to connect these large data I / O, which leads to that all I / O cannot be configured equally and processed similarly during program development, increasing the development difficulty. And during installation, these additional acquisition devices need to be installed separately due to independent design, also increasing the installation difficulty.

[0005] Figure 1 A large factory control system using the prior art is shown, in addition to these intelligent sensor I / O, servo driver I / O, there are tens of thousands of ordinary I / O points, so the traditional DCS using 485 low-speed I / O backplane bus often needs to be first divided into several control domains according to the process, and then each control domain is further divided into several control stations, each control station undertakes part of I / O, and cannot be uniformly accessed and managed. SUMMARY

[0006] Therefore, the embodiment of the present application provides a distributed control system and an industrial control system, the distributed control system comprising: one CPU cabinet and a plurality of IO cabinets, the CPU cabinet comprising a CPU-A module and a first CM-A module, each IO cabinet comprising a second CM-A module and a plurality of IO modules; the CPU-A module is connected with the first CM-A module through an A route AUTBUS bus, the first CM-A module is connected with the second CM-A module through the A route AUTBUS bus, thereby realizing the connection between the CPU cabinet and the IO cabinet; the second CM-A module is connected with each IO module through an A1 route AUTBUS bus, and the IO module is used for connecting a controlled device, so that the CPU-A module realizes the control over the controlled device through the A route AUTBUS bus and the A1 route AUTBUS bus. The embodiment of the present application improves the number of DCS control I / O and simplifies the DCS cabinet. The fusion of strong real-time and weak real-time control tasks is realized by defining different real-time level logical channels in the AUTBUS bus, and the IO configuration and IO module wiring are simplified by uniformly numbering the control signals of the IO module, thereby improving the development and integration efficiency.

[0007] In the first aspect, the embodiment of the present application provides a distributed control system, comprising: one CPU cabinet and a plurality of IO cabinets, the CPU cabinet comprising a CPU-A module and a first CM-A module, each IO cabinet comprising a second CM-A module and a plurality of IO modules; the CPU-A module is used for running a control program of a controlled device, the first CM-A module is used for forwarding control instructions of the control program to the corresponding second CM-A module and / or acquiring state data of the corresponding controlled device from each second CM-A module for the control program, the CPU-A module, the first CM-A module and each second CM-A module are connected through an A route AUTBUS bus; the second CM-A module is used for forwarding the received control instructions to the corresponding IO module in the IO cabinet and / or acquiring the state data of the corresponding controlled device from the corresponding IO module, the second CM-A module and each IO module in the IO cabinet are connected through an A1 route AUTBUS bus; the IO module is connected with the controlled device and is used for controlling the connected controlled device through the received control instructions and / or acquiring the state data of the connected controlled device.

[0008] According to the above, the bandwidth of the AUTBUS is used to improve the number of DCS control I / O and simplify the DCS cabinet through the A route AUTBUS bus and the A1 route AUTBUS bus.

[0009] In a possible implementation of the first aspect, the CPU-A module is a master node of an A-path AUTBUS bus, and the first CM-A module and each second CM-A module are slave nodes of the A-path AUTBUS bus; and the second CM-A module of an IO chassis is a master node of an A1-path AUTBUS bus of the IO chassis, and each IO module of the IO chassis is a slave node of the A1-path AUTBUS bus.

[0010] According to the above, the CPU-A module is a master node of an A-path AUTBUS bus, and manages each second CM-A module on the A-path AUTBUS bus; and the second CM-A module is a master node of an A1-path AUTBUS bus, and manages each IO module, thereby enhancing the management of the CPU-A module on the IO module.

[0011] In a possible implementation of the first aspect, the deployment positions of each IO chassis include: local or remote, where the local is a cabinet where the CPU chassis is located.

[0012] According to the above, the AUTBUS bus has a transmission distance of 500 m at a bandwidth of 100 bps, and some IO chassis are deployed remotely, thereby realizing remote and local fusion control in the industrial control field of a domain.

[0013] In a possible implementation of the first aspect, the control program includes a plurality of real-time control tasks, and each real-time control task controls at least one IO module on an IO chassis, where the higher the real-time level of a control signal of an IO module of an IO chassis is, the shorter the task period of a corresponding real-time control task of the IO chassis is.

[0014] According to the above, by including a plurality of real-time control tasks in the control program, at least one IO module on an IO chassis is controlled by corresponding tasks, thereby realizing the fusion of control tasks of different real-time levels.

[0015] In a possible implementation of the first aspect, the CPU-A module is further configured to configure a first logical channel for each second CM-A module on the A-path AUTBUS bus, where the bus period of the first logical channel of the second CM-A module of an IO chassis and the task period of a corresponding real-time control task of the IO chassis are positively changed; and the second CM-A module of the IO chassis is further configured to configure a second logical channel with the same bus period for each IO module of the IO chassis on the A1-path AUTBUS, and the bus period of the second logical channel is the same as that of the first logical channel of the second CM-A module of the IO chassis.

[0016] According to the above, the logic channels with different bus periods are set on the A AUTBUS bus and the A1 AUTBUS bus, different real-time control tasks are corresponded, and the control signals of the IO modules with different real-time levels are controlled through the A AUTBUS and the A1 AUTBUS.

[0017] In a possible implementation of the first aspect, the CPU-A module further runs a plurality of real-time systems, and each real-time system runs a real-time control task, wherein the real-time systems exchange data through a virtual bus.

[0018] According to the above, different real-time control tasks are run by different real-time systems, resource isolation of different real-time control tasks is realized, and the timeliness of different real-time control tasks is further improved.

[0019] In a possible implementation of the first aspect, the CPU-A module is further configured to uniformly number the control signals of the IO modules, the number of one control signal comprises a chassis number, a slot number and a name corresponding to the control signal, and the number of one control signal corresponds to a control algorithm generating the control signal.

[0020] According to the above, the control signals of the IO modules are uniformly numbered, and the development process is simplified by uniformly mapping and calling during algorithm programming.

[0021] In a possible implementation of the first aspect, during the integration stage, the CPU-A module is further configured to generate a wiring table between the controlled devices and the IO chassis according to the numbers of the IO modules.

[0022] According to the above, during the integration stage, the IO module wiring tables of the IO chassis are derived based on the uniform numbers of the control signals, I / O wiring is facilitated for assembly engineers, and the system integration period is shortened.

[0023] In a possible implementation of the first aspect, the CPU chassis further comprises a CPU-B module and a first CM-B module, and the IO chassis further comprises a second CM-B module; the CPU-B module and the first CM-B module are redundant backup modules of the CPU-A module and the first CM-A module respectively, the CPU-B module, the first CM-B module and the second CM-B module are connected through a B AUTBUS bus, the B AUTBUS bus is a redundant bus of the A AUTBUS bus; the second CM-B module is a redundant backup module of the second CM-A module of the IO chassis, and is connected with the IO modules of the IO chassis through a corresponding B1 AUTBUS bus, and each B1 AUTBUS bus is a redundant bus of the A1 AUTBUS bus of the IO chassis.

[0024] From the above, by providing redundancy structure for the CPU-A module, the first CM-A module, the second CM-A module, the A route AUTBUS bus and the A1 route AUTBUS bus, the fault tolerance of the distributed control system is improved.

[0025] In the second aspect, the embodiment of the present application provides an industrial control system, comprising: a master control system and a plurality of distributed control systems according to any one of the embodiments of the first aspect; each of the distributed control systems implements a domain control of an industrial control, and the master control system is connected with the plurality of distributed control systems.

[0026] From the above, by combining the plurality of control domain distributed control systems, the global industrial control is realized. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 For a large-scale factory control system using prior art;

[0028] Figure 2 FIG. 1 is a structural schematic diagram of a distributed control system according to an embodiment of the present application;

[0029] Figure 3 FIG. 2 is a structural schematic diagram of an A route AUTBUS bus in the distributed control system according to the embodiment of the present application;

[0030] Figure 4 FIG. 3 is a structural schematic diagram of a remote deployment of an IO case in the distributed control system according to the embodiment of the present application;

[0031] Figure 5 FIG. 4 is a schematic diagram of a multi-task control structure of a distributed control system according to an embodiment of the present application;

[0032] Figure 6 FIG. 5 is a unified numbering diagram of a control signal of the distributed control system according to the embodiment of the present application;

[0033] Figure 7 FIG. 6 is a structural schematic diagram of a distributed control system according to an embodiment of the present application;

[0034] Figure 8 FIG. 7 is a schematic diagram of a redundancy structure of an IO case in the distributed control system according to the embodiment of the present application;

[0035] Figure 9 FIG. 8 is a structural schematic diagram of an industrial control system according to an embodiment of the present application. DETAILED DESCRIPTION

[0036] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" can be the same subset or different subsets as each other and can be combined with each other as long as there is no conflict.

[0037] In the following description, the terms "first\second\third" or module A, module B, module C, etc. are used only to distinguish similar objects or different embodiments, and do not represent a specific order of the objects. It is understood that the specific order or sequence can be interchanged as long as it is allowed, so that the embodiments of the application described herein can be implemented in an order other than that illustrated or described herein.

[0038] In the following description, the labels indicating steps such as S110, S120, etc. do not necessarily mean that the steps are executed in this order. The order of the steps can be interchanged or executed simultaneously as long as it is allowed.

[0039] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the application belongs. The terms used herein are only for the purpose of describing the embodiments of the application and are not intended to limit the application.

[0040] The embodiments of the application provide a distributed control system (DCS) which connects IO modules through an AUTBUS bus, improves the number of DCS connection and management control IO modules, simplifies the DCS cabinet, and realizes the fusion of strong real-time and weak real-time control tasks through defining different real-time level logical channels in the AUTBUS bus. In addition, the I / O configuration and IO module wiring are simplified by uniformly numbering the control signals of the IO modules, and the development and integration efficiency is improved.

[0041] The embodiments of the application will be described below with reference to the accompanying drawings.

[0042] First, the embodiments of the distributed control system are introduced Figures 2 to 4 An embodiment of a distributed control system is introduced.

[0043] An embodiment of a distributed control system comprises a CPU cabinet and a plurality of IO cabinets, the CPU cabinet comprises a CPU-A module and a first CM-A module, each IO cabinet comprises a second CM-A module and a plurality of IO modules; the CPU-A module is connected with the first CM-A module through an A route AUTBUS bus, the first CM-A module is connected with the second CM-A module through the A route AUTBUS bus, thereby realizing the connection between the CPU cabinet and the IO cabinet; the second CM-A module is connected with each IO module through an A1 route AUTBUS bus, and the IO module is used for connecting a controlled device, so that the CPU-A module realizes the control over the controlled device through the A route AUTBUS bus and the A1 route AUTBUS bus.

[0044] Figure 2 An embodiment of a distributed control system is shown, which comprises a CPU cabinet 100 and a plurality of IO cabinets.

[0045] For example, the plurality of IO cabinets comprises an IO cabinet 110, an IO cabinet 120 and an IO cabinet 130. Figure 2 In an actual scenario, the specific number of IO cabinets is determined according to the number of control signals of the DCS system.

[0046] The CPU cabinet 100 comprises a CPU-A module 101 and a first CM-A module 102, and the IO cabinet comprises a second CM-A module and a plurality of IO modules.

[0047] For example, taking the IO cabinet 110 as an example, it comprises a second CM-A module 111, an IO module 113, an IO module 114, an IO module 115, an IO module 116, an IO module 117 and an IO module 118.

[0048] For example, when the IO module is used for digital quantity input or output, it is a DI module and a DO module, each DI module or DO module can correspond to 1 to 8 digital quantities; when it is used for analog quantity input or output, it is an AI module and an AO module; the IO module can also be a thermistor module, a HART module, an encoder module, a shaft control module, a pulse counting module, a PWM module, etc., and the functions thereof are not introduced one by one.

[0049] The CPU-A module 101 is configured to run a control program of the controlled devices, generate control instructions of the controlled devices, and collect state data of the controlled devices. The CPU-A module 101 is connected to the first CM-A module 102 through a bus 100A, which is an A AUTBUS bus of the DCS system A. The CPU-A module 101, the first CM-A module 102, and the second CM-A modules are connected through the bus 100A.

[0050] The CPU-A module 101 forwards the control instructions of the control program to the corresponding second CM-A modules through the first CM-A module 102 and / or acquires the state data of the corresponding controlled devices from the second CM-A modules.

[0051] In some embodiments, the CPU-A module 101 is further configured to manage the entire DCS system, including the configuration and numbering of the first CM-A module 102, the second CM-A modules, and the IO modules.

[0052] In some embodiments, the CPU-A module 102 runs a PLC master station, which runs the control program. In some embodiments, the control program directly controls the IO modules of the IO chassis to control the controlled devices. In other embodiments, the control program includes multiple control tasks, each of which controls the controlled devices to complete an independent process through an IO module of a corresponding IO chassis.

[0053] In some embodiments, the CPU-A module 101 is further configured to manage the entire DCS system, including the configuration and numbering of the first CM-A module 102, the second CM-A modules, and the IO modules.

[0054] The first CM-A module 102 is configured to connect the second CM-A modules through the bus 100A, so that the CPU chassis 100 connects the IO chassis through the A AUTBUS bus. The first CM-A module 102 forwards the control instructions of the control program to the corresponding second CM-A modules and / or acquires the state data of the corresponding controlled devices from the second CM-A modules.

[0055] In some embodiments, the CPU chassis 100 and some IO chassis are in one cabinet, and the bus of the cabinet backboard includes the A AUTBUS bus.

[0056] In some embodiments, each second CM-A module is connected to the A-path AUTBUS bus through a T-head, on one hand, it realizes the expansion of the IO chassis by adding the T-head, on the other hand, when the second CM-A module of an IO chassis has a problem, it does not affect the work of the second CM-A module of the IO chassis connected behind, thereby solving the expansion of the IO chassis and improving the fault tolerance of the DCS system.

[0057] Among them, one AUTBUS bus can connect 256 nodes, the first CM-A module 102 can connect 256-2 = 254 second CM-A modules, that is, 254 IO chassis.

[0058] Figure 3 The structure of the A-path AUTBUS bus in the first embodiment of the distributed control system is shown, inside the CPU chassis 100, the CPU-A module 101 connects the first CM-A module 102 through the A-path AUTBUS bus, that is, the bus 100A; between the CPU chassis 100 and the IO chassis, the first CM-A module 102 connects the second CM-A module 111 in the IO chassis 110, the second CM-A module 121 in the IO chassis 120 and the second CM-A module 131 in the IO chassis 130 through the bus 100A in turn, in the actual scene, the first CM-A module 102 connects any IO chassis less than or equal to 254 through the bus 100A.

[0059] In some embodiments, some IO chassis are deployed remotely relative to the CPU chassis 100, the AUTBUS bus transmission distance between some IO chassis and the CPU chassis 100 reaches 500 meters under the 100Mbps bandwidth, that is, the AUTBUS bus transmission distance between some IO chassis and the CPU chassis 100 reaches 500 meters under the 100Mbps bandwidth.

[0060] Figure 4 The structure of the remote deployment of the IO chassis in the first embodiment of the distributed control system is shown, the DCS cabinet 10 realizes the control of one domain in an industry, which includes: the CPU chassis 100, the IO chassis 110, the IO chassis 120, the IO chassis 130 and the IO chassis 140, in the actual scene, it can include 1 to 254 IO chassis, among them, the IO chassis 140 is deployed remotely, and the IO chassis 110, the IO chassis 120 and the IO chassis 130 are deployed in the DCS cabinet 10. In the actual scene, 1 to 254 IO chassis can be included in the DCS cabinet 10, the number of remote IO chassis is 1 to 254, and the total number of local chassis and remote IO chassis is 254.

[0061] The second CM-A module of each IO chassis connects each IO module through an A1 route AUTBUS bus, and is used for data forwarding between the A route AUTBUS and the A1 route AUTBUS bus, and forwards the received control instruction to the corresponding IO module of the IO chassis and / or obtains state data of the corresponding controlled device from the corresponding IO module.

[0062] The IO module is connected to the controlled device, controls the controlled device, and is used for forwarding the received control instruction to the corresponding IO module of the IO chassis and / or obtaining state data of the corresponding controlled device from the corresponding IO module.

[0063] Among them, the second CM-A module can be connected with 256-1=255 IO modules, that is, one IO chassis can be connected with 255 IO modules.

[0064] For example, the IO chassis 110 is taken as an example, the second CM-A module 111 connects the IO module 113 to the IO module 117 through the bus 110A, and in an actual scene, 1 to 255 IO modules can be connected, and the bus 110A is an A1 route AUTBUS bus of the IO chassis 110. Figure 2

[0065] Among them, the AUTBUS has a high bandwidth of 100Mbps, and each IO chassis can support a large amount of IO modules through the A1 route AUTBUS bus, such as intelligent sensor IO and servo driver I / O access.

[0066] The AUTBUS bus has a bandwidth of 100Mbps, and the traditional 485 bus has a bandwidth of 4Mbps. The AUTBUS bus can support higher bandwidth control data and control more IO. The following compares the number of IO controlled by the AUTBUS and the 485 bus.

[0067] 1) For IO of strong real-time control data, such as a servo driver with a 1ms cycle of 32 bytes, the bandwidth requirement is 0.256Mbps. The AUTBUS bus can support 400 servo drivers with higher bandwidth control data, and the 485 bus can only support 16 servo drivers.

[0068] ​2) For weak real-time control IO, such as 16 bytes of smart meter per 20 ms cycle, its bandwidth requirement is 0.0064 Mbps. The AUTBUS bus supports 160000 smart meters from the bandwidth, and from the structural restriction, the first CM-A module 101 can connect 254 IO chassis, and one IO chassis can connect 255 IO modules, so the AUTBUS bus can connect 254*255=64770 smart meters, and therefore one embodiment of the distributed control system supports weak O of smart meters. The traditional 485 bus can theoretically connect up to 625 smart meters.

[0069] Therefore, the number of IOs supported by one embodiment of the distributed control system is much larger than that of the traditional 485 bus. The number of IOs supported by one embodiment of the distributed control system is also much larger than that of other traditional industrial buses, and the calculation is not listed here.

[0070] In summary, one embodiment of the distributed control system includes one CPU chassis and a plurality of IO chassis, the CPU-A module of the CPU chassis is connected to the first CM-A module through the A route AUTBUS bus, the first CM-A module is connected to the second CM-A module through the A route AUTBUS bus, and the connection and control of the CPU chassis and the IO chassis are realized. The second CM-A module is connected to each IO module through the A1 route AUTBUS bus, and the IO module is used to connect the controlled equipment and control the controlled equipment. One embodiment of the distributed control system can not only access a large amount of IO through the AUTBUS bus, but also improve the number of DCS control I / O and simplify the DCS cabinet.

[0071] Next, an embodiment of a distributed control system is introduced. Figure 2 , Figure 5 and Figure 6 An embodiment of a distributed control system is introduced.

[0072] An embodiment of a distributed control system inherits the structure of one embodiment of a distributed control system, has all the advantages of one embodiment of a distributed control system, and the CPU-A module runs a plurality of real-time control tasks through a plurality of virtualized real-time systems. Each real-time control task controls at least one IO module on the IO chassis according to the bus cycle of the corresponding real-time level, realizes process control of different real-time levels, and realizes comprehensive industrial control in a complex scene where strong real-time and weak real-time coexist.

[0073] Figure 2 The structure shown is also the structure of one embodiment of a distributed control system, and the enhanced parts are introduced below.

[0074] First, the enhancement of one embodiment of a distributed control system in the bus structure of AUTBUS is introduced.

[0075] In the second embodiment of the distributed control system, the CPU-A module 101 is the master node of the A AUTBUS bus, the first CM-A module 102 and each second CM-A module are slave nodes of the A AUTBUS bus, the CPU-A module 101 manages the first CM-A module 102 and each second CM-A module and allocates communication resources of the AUTBUS bus to the first CM-A module 102 and each second CM-A module for transmitting data, and the communication resources form corresponding logical channels on the A AUTBUS bus. For the convenience of description, the logical channels on the A AUTBUS bus are referred to as first logical channels.

[0076] In the second embodiment of the distributed control system, the second CM-A module of each IO chassis is the master node of the A1 AUTBUS bus of the IO chassis, and each IO module is a slave node, the second CM-A module of each IO chassis manages the IO modules in the chassis and allocates communication resources of the AUTBUS bus to the IO modules for transmitting data, and the communication resources form corresponding logical channels on the A1 AUTBUS bus. For the convenience of description, the logical channels on the A1 AUTBUS bus are referred to as second logical channels.

[0077] From the above, the CPU-A module serves as the master node of the A AUTBUS bus, manages each second CM-A module on the A AUTBUS bus, the second CM-A module serves as the master node of the A1 AUTBUS bus, and manages each IO module, thereby enhancing the management of the IO module by the CPU-A module.

[0078] Next, the control enhancement of the second embodiment of the distributed control system for tasks of different real-time levels is introduced.

[0079] In the second embodiment of the distributed control system, the control program of the CPU-A module 101 includes a plurality of real-time control tasks, each real-time control task controls at least one IO module on an IO chassis, and the higher the real-time level of the IO control of an IO chassis, the shorter the task period of the corresponding real-time control task of the IO chassis.

[0080] For example, the second embodiment of the distributed control system is used for automatic control of steel metallurgy, and the control scenario includes weak real-time control tasks and strong real-time control tasks. The task period of the weak real-time control task is 20 ms, the IO object connected by the corresponding IO chassis of the weak real-time control task is a valve, a relay, a temperature, a pressure, and the like, and is connected through DI, DO, AI, AO, RTD, and the like. The task period of the strong real-time control task is 1 ms, the IO object connected by the corresponding IO chassis of the strong real-time control task is a servo driver, and is connected through a servo drive module and an encoder module.

[0081] In the second embodiment of the distributed control system, the CPU-A module is the master node of the A bus, and configures a first logical channel for each second CM-A module on the A bus, wherein the bus cycle of the first logical channel of the second CM-A module of an IO chassis corresponds to the task cycle of the real-time control task corresponding to the IO chassis.

[0082] For example, continuing to take the automatic control of the steel smelting in the second embodiment of the distributed control system as an example, the bus cycle of the first logical channel of the second CM-A module in the IO chassis for weak real-time control tasks and the first logical channel of each IO module of the IO chassis are both 20 ms, which is the same as the task cycle of the weak real-time control task, and the bus cycle of the first logical channel of the second CM-A module in the IO chassis for strong and weak real-time control tasks and the first logical channel of each IO module of the IO chassis are both 1 ms, which is the same as the task cycle of the strong real-time control task.

[0083] In the second embodiment of the distributed control system, a plurality of real-time systems are also running on the CPU-A module, and one real-time control task is running on each real-time system, wherein the real-time systems exchange data through a virtual bus, and one implementation of the virtual bus is a shared memory, and the data exchange of the virtual bus has high real-time performance.

[0084] In the second embodiment of the distributed control system, a plurality of real-time systems are also running on the CPU-A module, and one real-time control task is running on each real-time system, wherein the real-time systems exchange data through a virtual bus, and one implementation of the virtual bus is a shared memory, and the data exchange of the virtual bus has high real-time performance.

[0085] Figure 5 A multi-task control structure diagram of the second embodiment of the distributed control system is shown, which runs two real-time systems (RTOS) on the CPU-A module 101, one of which runs weak real-time control tasks and controls the IO chassis 110 and the IO chassis 120, and the other of which runs strong real-time control tasks and controls the IO chassis 130, so as to realize the simultaneous control of weak real-time control tasks and strong real-time control tasks on the CPU-A module 101. It should be emphasized that in actual scenarios, the control tasks can be divided into multiple levels according to the real-time level, and each real-time control task of each real-time level controls at least one chassis, Figure 5 The number in the above is an example.

[0086] Next, the development and integration enhancement of the IO module in the second embodiment of the distributed control system are introduced.

[0087] The CPU-A module 101 also includes an I / O variable management interface for uniformly numbering the control signals of the IO modules, and the number of a control signal includes the chassis number, slot number and control signal name corresponding to the control signal.

[0088] In the control algorithm development stage, the number of the control signal of an IO module corresponds to the control algorithm for generating the IO module. In the integration stage, the CPU-A module is further configured to generate a wiring table between the controlled device and the IO chassis according to the number of the control signal.

[0089] In the engineering development stage, whether the I / O is weak real-time control task or strong real-time motion control, it can be configured and managed uniformly under the unified I / O variable management interface, as shown in the following figure. Then it is uniformly mapped and called in the algorithm programming, simplifying the development process.

[0090] In the integration stage, based on the unified control signal number in the unified I / O variable management interface, the IO module wiring table of each IO chassis is derived, which is convenient for assembly engineers to perform I / O wiring and shortens the system integration period.

[0091] Figure 6 A method for numbering control signals of a distributed control system embodiment two is shown, which is represented by IO_cabX_SlotX_name, IO represents the control signal of the IO module, cabX represents the number of the IO chassis, SlotX represents the slot of the IO module in the IO chassis, and name represents the name of the control signal.

[0092] For example, cab1, cab2 and cab3 represent IO chassis 110, IO chassis 120 and IO chassis 130, Slot1, Slot2, Slot3 and Slot4 represent the corresponding internal slots 1 / 2 / 3 / 4 of the IO chassis, and the names of the control signals include DI, DO, AI, AO, RTD, HART, SS, AXIS, Count and PWM, etc., which are digital input, digital output, analog input, analog output, thermistor signal, HART signal, encoder signal, axis control signal, pulse counting signal and PWM signal, etc.

[0093] In summary, a distributed control system embodiment two is based on a distributed control system embodiment one, the CPU-A module runs multiple real-time control tasks through virtualized multiple real-time systems, each real-time control task controls at least one IO module on the IO chassis through the bus cycle of the corresponding real-time level of the AUTBUS, realizes process control of different real-time levels, and realizes industrial control in a complex scene where strong real-time and weak real-time coexist. It also uniformly numbers the control signals to improve the efficiency of DCS development and integration.

[0094] Based on Figure 7 and Figure 8The third embodiment of the distributed control system inherits the structure of the first embodiment of the distributed control system or the second embodiment of the distributed control system, has all the advantages of the first embodiment of the distributed control system or the second embodiment of the distributed control system, and has a redundant structure for the CPU-A, the first CM-A module, the A route AUTBUS bus and the A1 route AUTBUS bus, thereby improving the fault tolerance of the distributed control system.

[0095] Figure 7 The structure of the third embodiment of the distributed control system is shown. Figure 2 Based on the shown DCS structure, the third embodiment of the distributed control system has the CPU-B module 103 and the first CM-B module 104 in the CPU chassis 110, the second CM-B module 112 in the IO chassis 110, the second CM-B module 122 in the IO chassis 120 and the second CM-B module 132 in the IO chassis 130.

[0096] The CPU-B module 103 is connected to the first CM-B module 104 through the bus 100B, i.e. the B route AUTBUS bus, and the first CM-B module 104 is connected to each second CM-B module through the B route AUTBUS bus. Each second CM-B module of each IO chassis is connected to each IO module through the B1 route AUTBUS bus.

[0097] For example, the second CM-B module 112 of the IO chassis 110 is connected to each IO module of the IO chassis 110 through the bus 110B, the second CM-B module 122 of the IO chassis 120 is connected to each IO module of the IO chassis 120 through the bus 120B, and the second CM-B module 132 of the IO chassis 130 is connected to each IO module of the IO chassis 130 through the bus 130A. The bus 110B, the bus 120B and the bus 130A are respectively the B route AUTBUS bus in the IO chassis 110, the IO chassis 120 and the IO chassis 130.

[0098] The CPU-B module 103 and the first CM-B module 104 are respectively the redundant structure of the CPU-A module 101, the first CM-A module 102 and the bus 100A. Each second CM-B module of each IO chassis and the B1 route AUTBUS bus are respectively the redundant structure of the second CM-A module in each chassis and the A1 route AUTBUS bus.

[0099] Figure 8 The redundant structure of one IO chassis in the third embodiment of the distributed control system is shown. Figure 7Taking the connection of the IO module 113 in the IO chassis 110 as an example, the second CM-A module 111 connects the IO module 113 through the bus 110A in the chassis, the second CM-B module 112 connects the IO module 113 through the bus 110B in the chassis, and the redundant connection of the IO module 113 is realized. For example, the IO module 113 is an analog acquisition and output module, which outputs analog control signals through DA and acquires analog field signals through AD. The IO module 113 can also be an IO module with other functions.

[0100] The embodiment of the present application also provides an industrial control system, which comprises a master control system and a plurality of DCS systems, and realizes a complete industrial control system, wherein each DCS system is any one of the distributed control system in the embodiment one or the embodiment two or the embodiment three.

[0101] Figure 9 The structure of an industrial control system is shown, wherein the industrial control system 1 connects a plurality of DCS system cabinets in the plant cabinet, the industrial control system 1 is the master control system of the industrial system, each DCS system cabinet completes the independent control of an industrial domain, and has the function of any one of the distributed control system in the embodiment one or the embodiment two or the embodiment three. For example, the industrial control system 1 connects the DCS system cabinet 10, the DCS system cabinet 20 and the DCS system cabinet 30, and the actual scene can determine the connected DCS system cabinet according to the number of the controlled industrial domains.

[0102] For example, the DCS system cabinet 10 comprises a CPU chassis 100, an IO chassis 110, an IO chassis 120, an IO chassis 130 and an IO chassis 140, wherein the IO chassis 140 is remotely deployed, and the actual scene can determine the number of the local IO chassis and the number of the remote IO chassis according to the number of the domain control signals and the distribution of the control signals.

[0103] It should be noted that the above only describes the preferred embodiments of the present application and the technical principles applied. Those skilled in the art will understand that the present application is not limited to the specific embodiments described herein, and those skilled in the art can make various obvious changes, readjustments and substitutions without departing from the protection scope of the present application. Therefore, although the present application has been described in detail through the above embodiments, the present application is not limited to the above embodiments, and can include more other equivalent embodiments without departing from the concept of the present application, and all belong to the protection scope of the present application.

Claims

1. A distributed control system, characterized by, The application relates to a CPU cabinet and multiple IO cabinets, the CPU cabinet comprises a CPU-A module and a first CM-A module, each IO cabinet comprises a second CM-A module and multiple IO modules, wherein the deployment positions of the IO cabinets comprise local or remote positions, the local position is a cabinet where the CPU cabinet is located; the CPU-A module is used for running a control program of a controlled device, the first CM-A module is used for forwarding control instructions of the control program to corresponding second CM-A modules and / or acquiring state data of corresponding controlled devices of the second CM-A modules by the control program, the CPU-A module, the first CM-A module and the second CM-A modules are connected through an A route AUTBUS bus; the control program comprises multiple real-time control tasks, each real-time control task controls at least one IO module on an IO cabinet, wherein the higher the real-time level of a control signal of an IO module on an IO cabinet is, the shorter the task cycle of a real-time control task corresponding to the IO cabinet is; the CPU-A module is further used for configuring a first logical channel on the A route AUTBUS bus for each second CM-A module, wherein the bus cycle of the first logical channel of the second CM-A module of an IO cabinet is positively changed with the task cycle of the real-time control task corresponding to the IO cabinet; the second CM-A module is used for forwarding the received control instructions to corresponding IO modules of the IO cabinet and / or acquiring state data of corresponding controlled devices from the corresponding IO modules, the second CM-A module and the IO modules in the IO cabinet are connected through an A1 route AUTBUS bus; the second CM-A module is further used for configuring a bus cycle second logical channel on the A1 route AUTBUS for the IO modules of the IO cabinet, the bus cycle of the second logical channel is the same as that of the first logical channel of the second CM-A module of the IO cabinet; the IO module is connected to a controlled device and is used for controlling the connected controlled device through the received control instructions and / or acquiring state data of the connected controlled device. The CPU-A module is a master node of the A route AUTBUS bus, the first CM-A module and the second CM-A modules are slave nodes of the A route AUTBUS bus; the second CM-A module of an IO cabinet is a master node of the A1 route AUTBUS bus of the IO cabinet, and the IO modules of the IO cabinet are slave nodes of the A1 route AUTBUS bus. The CPU-A module further runs multiple real-time systems, one real-time control task is run on each real-time system, wherein the real-time systems exchange data through a virtual bus. The CPU-A module is further used for uniformly numbering control signals of the IO modules, the number of one control signal comprises cabinet number, slot position number and name corresponding to the control signal; the number of one control signal corresponds to a control algorithm for generating the control signal. In the integration stage, the CPU-A module is further used for generating a wiring table between the controlled device and the IO cabinet according to the number of the IO module. ​ ​ 2. The distributed control system of claim 1, wherein, ​ ​ 3. The distributed control system of claim 1, wherein, ​ 4. The distributed control system of claim 1, wherein, ​ ​ 5. The distributed control system of claim 4, wherein, ​ 6. The distributed control system according to any one of claims 1 to 5, characterized by, The CPU cabinet further comprises a CPU-B module and a first CM-B module, and the IO cabinet further comprises a second CM-B module; The CPU-B module and the first CM-B module are redundant backup modules of the CPU-A module and the first CM-A module respectively, the CPU-B module, the first CM-B module and the second CM-B module are connected through a B-AUTBUS bus, and the B-AUTBUS bus is a redundant bus of the A-AUTBUS bus; The second CM-B module is a redundant backup module of the second CM-A module of the IO cabinet, connects each IO module of the IO cabinet through a corresponding B1-AUTBUS bus, and each B1-AUTBUS bus is a redundant bus of an A1-AUTBUS bus of the IO cabinet.

7. An industrial control system, characterized by Comprise: A main control system and a plurality of distributed control systems according to any one of claims 1 to 6; Each of the distributed control systems realizes a domain control of industrial control, and the main control system is connected with the plurality of distributed control systems to realize global industrial control.

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