Plc control system, method and io collection merging device

Abstract

The application provides a PLC control system, method and IO collection and combination device, the system comprises a plurality of PLC controllers, an IO collection and combination device and controlled equipment; the IO collection and combination device is connected with the controlled equipment and each PLC controller respectively; the IO collection and combination device is used for collecting operation information data of the controlled equipment and sending the operation information data to each PLC controller; the PLC controller is used for generating control information based on the operation information data and sending respective control information to the IO collection and combination device; the IO collection and combination device is also used for fault-tolerant combination of each control information and sending the fault-tolerant combined control information to the controlled equipment. The application can avoid PLC control interruption caused by link communication failure, and each PLC controller can participate in control work, without switching to a redundant PLC controller after a main PLC controller fails, and has higher system operation reliability compared with a traditional redundant PLC backup mode.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automation control, and in particular to a PLC control system, method and IO collection and merging device. BACKGROUND

[0002] At present, in order to improve the operation reliability of a PLC control system (Programmable Logic Controller), a redundant backup of a PLC is usually performed. According to the set position of a redundant PLC controller, the PLC redundant backup scheme can be divided into two implementation manners of local backup and cloud backup. The local redundant backup scheme is to directly deploy the redundant PLC in an industrial field, and when a fault occurs in the field PLC, the main PLC controller is switched to the redundant PLC to ensure system reliability. The cloud redundant backup scheme is to deploy the redundant PLC in the cloud, and the field PLC transmits real-time operation feedback information of field devices to the redundant PLC in a link communication manner, and when a fault occurs in the field PLC, the redundant PLC is switched to perform remote control of the field devices to ensure reliable operation of the system.

[0003] The above two PLC redundant backup manners have the following problems: on the one hand, when a fault occurs in the field PLC, a controller switching action needs to be performed, and there is a certain time delay; on the other hand, the technology of deploying the redundant PLC in the cloud relies on link communication for data transmission, and introduces a system operation reliability problem caused by link faults, so there is still a great risk in the operation reliability of the current PLC control system. SUMMARY

[0004] Embodiments of the present application provide a PLC control system, method and IO collection and merging device to solve the problem of great risk in the operation reliability of a PLC control system.

[0005] In a first aspect, embodiments of the present application provide a PLC control system, comprising a plurality of PLC controllers, an IO collection and merging device and controlled devices; the IO collection and merging device is connected with the controlled devices and each PLC controller respectively;

[0006] The IO collection and merging device is used for collecting operation information data of the controlled devices and sending the operation information data to each PLC controller;

[0007] The PLC controller is used for generating control information based on the operation information data and sending the respective control information to the IO collection and merging device;

[0008] The IO collection and merging device is further used for fault-tolerant merging of each control information and sending the fault-tolerant merged control information to the controlled devices.

[0009] In a possible implementation, the IO sub-set merging device is specifically configured to perform fault-tolerant merging of the control information by majority voting.

[0010] In a possible implementation, the IO sub-set merging device is specifically configured to copy the operation information data into N copies and send each copy of the operation information data to a respective PLC controller; the number of PLC controllers is N; the operation information data corresponds to the PLC controllers in one-to-one correspondence.

[0011] In a possible implementation, the IO sub-set merging device and the respective PLC controllers are connected in wireless communication;

[0012] The IO sub-set merging device is specifically configured to collect operation information data of the controlled devices and send the operation information data to the respective PLC controllers through the wireless communication link;

[0013] The respective PLC controllers are specifically configured to generate control information based on the operation information data and send the respective control information to the IO sub-set merging device through the wireless communication link.

[0014] In a possible implementation, the number of controlled devices is a plurality, and each controlled device is connected to the IO sub-set merging device;

[0015] The IO sub-set merging device is specifically configured to collect operation information data of the respective controlled devices, package the respective operation information data into an operation information data file, and send the operation information data file to the respective PLC controllers;

[0016] The PLC controllers are specifically configured to extract the operation information data of the respective controlled devices from the operation information data file, generate control information of the operation information data of each controlled device based on the operation information data corresponding to the controlled device, and send the control information of the controlled device to the IO sub-set merging device;

[0017] The IO sub-set merging device is further configured to perform fault-tolerant merging of all control information of each controlled device and send the fault-tolerant merged control information to the controlled device.

[0018] In a possible implementation, the IO sub-set merging device is a plurality, each IO sub-set merging device is connected to at least one controlled device, and each IO sub-set merging device is connected to the respective PLC controllers;

[0019] Each IO sub-set merging device is specifically configured to collect operation information data of the respective controlled devices connected to the IO sub-set merging device, package the respective operation information data into an operation information data file, and send the operation information data file to the respective PLC controllers;

[0020] Each PLC controller is specifically configured to extract operation information data of each controlled device in each operation information data file, generate control information of the controlled device based on the operation information data of each controlled device, pack operation information data of all controlled devices connected to each IO set combining device as control information files corresponding to the IO set combining device according to the corresponding connection relationship between the IO set combining device and the controlled devices, and send the control information files to the corresponding IO set combining device.

[0021] Each IO set combining device is further configured to extract control information of each controlled device in the control information file, combine all control information of the controlled device for fault tolerance, and send the control information combined for fault tolerance to the controlled device.

[0022] In a possible implementation manner, the IO set combining device is connected to the controlled device in wired communication through a bus.

[0023] In a second aspect, an embodiment of the present application provides a PLC control method applied to the system of the first aspect or any possible implementation manner of the first aspect.

[0024] The method comprises the following steps.

[0025] The IO set combining device collects operation information data of the controlled device and sends the operation information data to each PLC controller.

[0026] The PLC controller generates control information based on the operation information data and sends the respective control information to the IO set combining device.

[0027] The IO set combining device combines each control information for fault tolerance and sends the control information combined for fault tolerance to the controlled device.

[0028] In a third aspect, an embodiment of the present application provides an IO set combining device, which comprises a memory, a processor, and a computer program stored in the memory and executable on the processor, and the processor implements the steps of the method of the second aspect or any possible implementation manner of the second aspect when executing the computer program.

[0029] The PLC control system, method and IO set combining device provided by the embodiment of the present application have the following advantages.

[0030] The PLC control system provided by the application is connected with IO integration devices independently by each PLC controller, when a single PLC controller fails or the connection between a single PLC controller and the IO integration device is invalid, other PLC controllers can still work and send control information to the IO integration device, so that the PLC control interruption caused by link communication failure is avoided, and each PLC controller can participate in the control work, without switching to a redundant PLC controller after the main PLC controller fails, and the system operation reliability is higher than that of the traditional redundant PLC backup mode. BRIEF DESCRIPTION OF DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the application, the drawings needed to be used in the embodiments or prior art description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative labor.

[0032] Figure 1 is a structural schematic diagram of the PLC control system provided by an embodiment of the application;

[0033] Figure 2 is a signal flow direction schematic diagram of the PLC control system provided by an embodiment of the application;

[0034] Figure 3 is a signal flow direction schematic diagram of the PLC controller provided by an embodiment of the application;

[0035] Figure 4 is a signal flow direction schematic diagram of the multi-IO integration function module provided by an embodiment of the application;

[0036] Figure 5 is an implementation flowchart of the PLC control method provided by an embodiment of the application;

[0037] Figure 6 is a schematic diagram of the IO integration device provided by an embodiment of the application. DETAILED DESCRIPTION

[0038] In the following description, specific details are set forth in order to provide a thorough understanding of embodiments of the application. However, persons of ordinary skill in the art will readily recognize that embodiments of the application can be practiced without some or all of the specific details set forth herein. In other instances, well-known structures, devices, circuits, and processes have not been described in detail in order to avoid obscuring aspects of the application.

[0039] In order to make the objects, technical solutions and advantages of the present application clearer, the following will be described in detail with specific embodiments in conjunction with the drawings.

[0040] Referring to Figure 1 , a structure diagram of a PLC control system provided by an embodiment of the present application is shown, and will be described in detail as follows.

[0041] As Figure 1 shown, the PLC control system 1 comprises a plurality of PLC controllers 11, an IO aggregation and merging device 12 and controlled devices 13; the IO aggregation and merging device 12 is connected with the controlled devices 13 and each PLC controller 11 respectively;

[0042] The IO aggregation and merging device 12 is used for collecting running information data of the controlled devices 13 and sending the running information data to each PLC controller 11;

[0043] The PLC controller 11 is used for generating control information based on the running information data and sending the respective control information to the IO aggregation and merging device 12;

[0044] The IO aggregation and merging device 12 is also used for fault-tolerant merging of each control information and sending the fault-tolerant merged control information to the controlled devices 13.

[0045] In the embodiment, the IO aggregation and merging device 12 distributes the running information data of the controlled devices to the plurality of PLC controllers for processing at the same time, so as to obtain a plurality of control information for the same controlled device, and then fault-tolerant merges the control information, determines the final control information in the plurality of control information and issues the final control information to the controlled device, which has better reliability compared with the control information generated by a single PLC controller.

[0046] In addition, in the embodiment, each PLC controller is independently connected with the IO aggregation and merging device, and when a single PLC controller fails or the connection between a single PLC controller and the IO aggregation and merging device is invalid, the other PLC controllers can still work and send the control information to the IO aggregation and merging device, so as to avoid the PLC control interruption caused by the communication link failure, and the dependence on the communication link is lower compared with the existing cloud redundant PLC mode.

[0047] At present, whether the redundant PLC is deployed in an industrial field or in the cloud, when the main PLC running in the field does not fail, the redundant PLC in the field or the cloud is in an idle state and only receives the field feedback information without processing, which leads to low utilization of the redundant PLC and causes resource waste. In view of such a situation, in the embodiment, the plurality of PLC controllers generate control information for the same controlled device, and each PLC controller can participate in the control work, which has higher PLC utilization.

[0048] In the embodiment, the plurality of PLC controllers work simultaneously, and there is no need to switch to the redundant PLC controller after the main PLC controller fails, compared with the traditional redundant PLC backup mode, the switching process of the PLC controller is omitted, and the system operation reliability is high.

[0049] In a possible implementation, the IO diversity combining device 12 is specifically configured to perform fault-tolerant combination on each control information by majority voting.

[0050] In the embodiment, the control information generated by the normal PLC controller for the same controlled device should be the same, if a PLC controller fails, the control information generated by the PLC controller may be different from other PLC controllers. However, in all control information, the correct control information should account for a large proportion, and the majority voting is to select the control information with the largest proportion from all control information as the final control information, and the control information generated by the faulty PLC controller is excluded, so as to achieve the purpose of fault-tolerant combination.

[0051] In a possible implementation, the IO diversity combining device 12 is specifically configured to copy the running information data into N parts, and send each part of the running information data to each PLC controller 11; wherein the number of PLC controllers 11 is N; the running information data corresponds to the PLC controller 11 one by one.

[0052] In the embodiment, the IO diversity combining device 12 copies the running information data collected from the controlled device into the number of parts corresponding to the PLC controller (i.e. N parts), and uploads each part of the running information data to each PLC controller respectively, so that each PLC controller can obtain the same running information data, and the diversity of the running information data is realized.

[0053] In a possible implementation, the IO diversity combining device 12 and each PLC controller 11 are connected in wireless communication;

[0054] The IO diversity combining device 12 is specifically configured to collect the running information data of the controlled device 13, and send the running information data to each PLC controller 11 through a wireless communication link;

[0055] Each PLC controller 11 is specifically configured to generate control information based on the running information data, and send the respective control information to the IO diversity combining device 12 through a wireless communication link.

[0056] In the embodiment, each PLC controller 11 can be set in the cloud, in the form of distributed deployment in different locations, and transmit data with the IO collection and combination device 12 through wireless communication, for example, through 5G communication. Even if a certain PLC controller 11 fails or the location cannot realize wireless communication, other PLC controllers 11 can still work normally to ensure normal operation of the system.

[0057] In a possible implementation, the number of controlled devices 13 is multiple, and each controlled device 13 is connected with the IO collection and combination device 12.

[0058] The IO collection and combination device 12 is specifically configured to collect the running information data of each controlled device 13, pack each running information data into a running information data file, and send the running information data file to each PLC controller 11.

[0059] The PLC controller 11 is specifically configured to extract the running information data of each controlled device 13 from the running information data file, generate control information of the running information data of the controlled device 13 based on the corresponding running information data of each controlled device 13, and send the control information of the controlled device 13 to the IO collection and combination device 12.

[0060] The IO collection and combination device 12 is further configured to perform fault-tolerant combination on all control information of each controlled device 13, and send the fault-tolerant combined control information to the controlled device 13.

[0061] In the embodiment, the IO collection and combination device 12 can be connected with multiple controlled devices 13 at the same time. During system operation, the IO collection and combination device 12 collects the running data information of each controlled device and packs it into a running data information file, and then uploads it to each PLC controller 11, that is, each PLC controller 11 receives the running data information of all controlled devices 13.

[0062] Each PLC controller 11 generates control information of all controlled devices 13 and sends it to the IO collection and combination device 12. The IO collection and combination device 12 performs fault-tolerant combination on all control information corresponding to each controlled device 13, and finally obtains the control information of each controlled device 13 to control each controlled device 13.

[0063] In a possible implementation, the IO collection and combination device 12 is multiple, each IO collection and combination device 12 is connected with at least one controlled device 13, and each IO collection and combination device 12 is connected with each PLC controller 11.

[0064] Each IO set combining device 12 is specifically used to collect the running information data of each controlled device 13 connected to the IO set combining device 12, pack each running information data into a running information data file, and send the running information data file to each PLC controller 11.

[0065] Each PLC controller 11 is specifically used to extract the running information data of each controlled device 13 from each running information data file, generate the control information of each controlled device 13 based on the running information data of each controlled device 13, pack the running information data of all controlled devices 13 connected to each IO set combining device 12 as the control information file corresponding to each IO set combining device 12 according to the corresponding connection relationship between the IO set combining device 12 and the controlled device 13, and send each control information file to the corresponding IO set combining device 12.

[0066] Each IO set combining device 12 is also used to extract the control information of each controlled device 13 from the control information file, combine all the control information of each controlled device 13 for fault tolerance, and send the control information after fault tolerance to the controlled device 13.

[0067] In the embodiment, the PLC control system can further include a plurality of IO set combining devices 12, each of which is connected to each PLC controller 11. In operation, any IO set combining device 12 collects the running information data of all controlled devices 13 connected thereto, packs the running data information into one running data information file, copies N copies and sends to each PLC controller 11.

[0068] Any PLC controller 11 can receive the running data information file from a plurality of IO set combining devices 12, process each file respectively, pack the processing results according to the connection relationship between the IO set combining device 12 and the controlled device 13, obtain a plurality of control information files, and the control information file corresponds to the IO set combining device 12 one by one, and the control information file corresponding to each IO set combining device 12 contains the control information of all controlled devices 13 connected to the IO set combining device 12.

[0069] After any IO set combining device 12 receives the control information file from a plurality of PLC controllers 11, it extracts a plurality of control information of a certain controlled device 13 from each control information file, combines the control information for fault tolerance, obtains the control information for controlling the controlled device, and performs the above operation on the control information of other controlled devices 13, so as to obtain the control information of all controlled devices 13.

[0070] In a possible implementation, the IO sub-set merging device 12 is connected to the controlled device 13 through a bus in wired communication.

[0071] In the embodiment, there are usually multiple controlled devices 13 in the same field, and one IO sub-set merging device 12 can be arranged in each field and connected to the controlled devices 13 through a bus, so that the PLC controller 11 in the cloud can perform batch control on the controlled devices 13 in multiple fields.

[0072] In a specific embodiment, as shown in Figure 2 The cloud control layer refers to a clouded PLC pool composed of a plurality of distributed clouded PLC nodes, which is the control core of the clouded PLC control system, is responsible for processing the running information of the field devices uploaded by the multi-IO sub-set merging function modules, and outputs the device control information processed by the clouded PLC pool to the multi-IO sub-set merging function modules. The clouded PLC node is the PLC controller 11 in the above embodiment, and the multi-IO sub-set merging function module is the IO sub-set merging device 12 in the above embodiment. The industrial field layer includes field IO devices and multi-IO sub-set merging function modules deployed on the device side. The device running information generated by the field devices during the production is collected by the multi-IO sub-set merging function modules through the field bus, and the multi-IO sub-set merging function modules need to pack and upload the collected device running information to each clouded PLC node, and then the received IO device control information is fault-tolerant and merged and then respectively sent to each IO device.

[0073] The cloud control layer refers to the part of the clouded PLC pool, which contains n clouded PLC nodes. These clouded PLC nodes have no limit on the deployment location in the spatial layer, that is, each clouded PLC node in the clouded PLC pool is distributed, and each clouded PLC node has the same level of data processing capability and network communication capability. As shown in Figure 3 In the running process of the clouded PLC control system with the clouded PLC pool as the core controller, each clouded PLC node in the pool receives the running information data of m field IO devices uploaded by the multi-IO sub-set merging function module through the 5G communication link, each node independently processes the running information data of the m devices, and makes PLC control decisions to give the control information of the m devices, that is, each clouded PLC node participates in the control of the field devices in parallel, and each clouded PLC node also sends the control information corresponding to the m IO devices to the multi-IO sub-set merging function module through the 5G communication link. The above process is the process of the clouded PLC pool completing the control of the field IO devices.

[0074] AsFigure 4 As shown, the multi-IO sub-set combining function module is the key to realize the clouded PLC redundancy backup, which is mainly responsible for completing the uploading of device running information and the issuing of device control information. The module is an intermediate node for uploading the running information of field devices to the clouded PLC pool, and divides the uploading process into two steps: uploading the running information of IO devices to the function module and uploading the processed running information of the function module to the clouded PLC pool. Each IO device in the industrial field uploads its own running information data to the multi-IO sub-set combining function module through the communication mode of the field bus, and the function module packages all the received device running information data into a data file and sends it to each clouded PLC node deployed in a distributed manner through multiple 5G communication links at the same time. The above operation ensures that each clouded PLC node in the clouded PLC pool can receive the running information data of all the controlled IO devices in the industrial field. The module is also an intermediate node for issuing control information from the clouded PLC pool to field devices, and divides the issuing process into two steps: issuing control information from the clouded PLC pool to the function module and issuing the fault-tolerant combined control information from the function module to each IO device. Each clouded PLC node in the clouded PLC pool issues the control information of each IO device to the function module through its own 5G communication link, and the function module needs to perform fault-tolerant combination processing on the control information of each IO device from several clouded PLC nodes. The fault-tolerant combination processing method used by the application is a majority voting decision method, and the function module uses the majority voting mechanism to elect the final control information of each IO device, and then issues each control information to the corresponding IO device through the field bus.

[0075] The running process of the clouded PLC industrial control system includes the following parts: industrial control field information collection, field information transmission, information processing and control information generation, control information transmission and field device operation.

[0076] Running process 1: industrial control field information collection

[0077] The information of the industrial control field device during operation is an important basis for the control end to master the field operation status, and the field information can be collected by using the field bus. The information of each field device is uploaded to the multi-IO sub-set combining function module for processing.

[0078] Running process 2: field information transmission

[0079] The field information processed by the multi-IO sub-set combining function module includes the running state of each field device, and is transmitted to the clouded PLC node deployed in a distributed manner through the 5G communication link for processing.

[0080] Running process 3: information processing and control information generation

[0081] The task of information processing and control information generation is responsible for the cloud setting cloud PLC pool, which is composed of multiple cloud PLCs. The previous hard PLC redundancy backup is to set redundant PLCs in parallel with working PLCs. When the working PLC does not fail, the redundant PLC only plays a role in synchronizing information with the working PLC. The disadvantage of this processing method is mainly reflected in the waste of hardware resources. Each cloud PLC in the cloud PLC pool adopted by the patent participates in the operation control of the industrial field device, thereby fully reducing resource waste and forming a cloud PLC redundancy backup. After the distributed cloud PLC nodes form their control information set for each field device, the control information set is respectively sent to the multi-IO set combining function module.

[0082] Operation process 4: control information transmission

[0083] The distributed cloud PLC nodes send control information to the industrial field device, which is also achieved through the 5G communication link. Similar to uploading field information, each cloud PLC node sends control information to the multi-IO set combining function module and further processes it.

[0084] Operation process 5: field device operation

[0085] The multi-IO set combining function module will perform fault-tolerant combination on the control information of each device, and send the processed control information to the corresponding field device through the field bus. According to the received control information, the field device is controlled to operate normally and collect field information, thereby completing the closed-loop control.

[0086] It should be understood that the size of the serial number of each step in the above embodiment does not mean the order of execution, and the execution order of each process should be determined according to its function and internal logic, and should not constitute any limitation on the implementation process of the embodiment of the present application.

[0087] The following is a device embodiment of the present application. For details not described in detail, please refer to the corresponding method embodiments described above.

[0088] Figure 5 The implementation flowchart of the PLC control method provided by the embodiment of the present application is shown. In order to facilitate the description, only the part related to the embodiment of the present application is shown. The method is used in the PLC control system as described in the above embodiment, and is described in detail as follows:

[0089] Step 501, the IO set combining device collects the operation information data of the controlled device, and sends the operation information data to each PLC controller.

[0090] In step 502, the PLC controller generates control information based on the operation information data, and sends the respective control information to the IO set-merge device.

[0091] In step 503, the IO set-merge device fault-tolerantly merges the respective control information, and sends the fault-tolerantly merged control information to the controlled device.

[0092] In a possible implementation, the IO set-merge device fault-tolerantly merges the respective control information by majority voting.

[0093] In a possible implementation, the IO set-merge device duplicates the operation information data into N copies, and sends each copy of the operation information data to a respective PLC controller; the number of PLC controllers is N; and the operation information data and the PLC controller are in one-to-one correspondence.

[0094] In a possible implementation, the IO set-merge device and the respective PLC controller are wirelessly connected;

[0095] The IO set-merge device collects operation information data of the controlled device, and sends the operation information data to the respective PLC controller through a wireless communication link;

[0096] The respective PLC controller generates control information based on the operation information data, and sends the respective control information to the IO set-merge device through the wireless communication link.

[0097] In a possible implementation, the number of controlled devices is a plurality, and each controlled device is connected to the IO set-merge device;

[0098] The IO set-merge device collects operation information data of each controlled device, packs each operation information data into an operation information data file, and sends the operation information data file to the respective PLC controller;

[0099] The PLC controller extracts operation information data of each controlled device from the operation information data file, generates control information of the operation information data of the controlled device based on the operation information data corresponding to the controlled device, and sends the control information of the controlled device to the IO set-merge device;

[0100] The IO set-merge device fault-tolerantly merges all control information of each controlled device, and sends the fault-tolerantly merged control information to the controlled device.

[0101] In a possible implementation, the IO set-merge device is a plurality, each IO set-merge device is connected to at least one controlled device, and each IO set-merge device is connected to the respective PLC controller;

[0102] Each IO set combining device collects running information data of each controlled device connected to the IO set combining device, packs each running information data into a running information data file, and sends the running information data file to each PLC controller;

[0103] Each PLC controller extracts running information data of each controlled device from each running information data file, generates control information of each controlled device based on the running information data of the controlled device, packs running information data of all controlled devices connected to each IO set combining device as control information files corresponding to the IO set combining device according to the corresponding connection relationship between the IO set combining device and the controlled devices, and sends each control information file to the corresponding IO set combining device.

[0104] Each IO set combining device extracts control information of each controlled device from the control information file, combines all control information of each controlled device for fault tolerance, and sends the control information after fault tolerance to the controlled device.

[0105] In a possible implementation, the IO set combining device is connected to the controlled device through a bus in wired communication.

[0106] In the PLC control system provided by the embodiments, each PLC controller is independently connected to an IO set combining device, and when a single PLC controller fails or the connection between a single PLC controller and an IO set combining device is invalid, other PLC controllers can still work and send control information to the IO set combining device, thereby avoiding PLC control interruption caused by link communication failure, and each PLC controller can participate in control work without switching to a redundant PLC controller after a main PLC controller fails, which has higher system operation reliability compared with a traditional redundant PLC backup mode.

[0107] Figure 6 is a schematic diagram of an IO set combining device provided by the embodiments. As shown in Figure 6 The IO set combining device 6 of this embodiment includes a processor 60, a memory 61, and a computer program 62 stored in the memory 61 and executable on the processor 60. The processor 60 implements the steps in each of the above PLC control method embodiments when executing the computer program 62, for example Figure 5 Steps 501 to 503 shown in

[0108] By way of example, the computer program 62 can be segmented into one or more modules / units stored in the memory 61 and executed by the processor 60 to accomplish the present application. The one or more modules / units can be a series of computer program instruction segments capable of accomplishing a specific function, which are used to describe the execution process of the computer program 62 in the IO assembly device 6.

[0109] The IO assembly device 6 can include, but is not limited to, the processor 60 and the memory 61. Those skilled in the art can understand that the IO assembly device 6 can include more or fewer components than those shown, or combine certain components, or include different components, for example, the IO assembly device can also include an input / output device, a network access device, a bus, etc. Figure 6 The IO assembly device 6 is only an example and does not constitute a limitation on the IO assembly device 6, and can include more or fewer components than those shown, or combine certain components, or include different components, for example, the IO assembly device can also include an input / output device, a network access device, a bus, etc.

[0110] The processor 60 can be a central processing unit (CPU), and can also be other general-purpose processors, digital signal processors (DSP), application specific integrated circuits (ASIC), field-programmable gate arrays (FPGA) or other programmable logic devices, discrete gates or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or the processor can also be any conventional processor.

[0111] The memory 61 can be an internal storage unit of the IO assembly device 6, such as a hard disk or a memory of the IO assembly device 6. The memory 61 can also be an external storage device of the IO assembly device 6, such as a plug-in hard disk, a smart media card (SMC), a secure digital (SD) card, a flash card, etc. Further, the memory 61 can include both an internal storage unit and an external storage device of the IO assembly device 6. The memory 61 is used to store the computer program and other programs and data required by the IO assembly device. The memory 61 can also be used to temporarily store data that has been output or will be output.

[0112] Those skilled in the art can clearly understand that, for the convenience and brevity of description, only the above-mentioned division of each functional unit and module is exemplified, and in actual application, the above-mentioned functions can be completed by different functional units and modules according to needs, that is, the internal structure of the device is divided into different functional units or modules to complete all or part of the functions described above. Each functional unit and module in the embodiment can be integrated in one processing unit, or each unit can be physically present separately, or two or more units can be integrated in one unit. The above-mentioned integrated unit can be realized in the form of hardware or software. In addition, the specific names of each functional unit and module are only for easy distinction, and do not limit the protection scope of the present application. The specific working process of the units and modules in the above system can refer to the corresponding process in the foregoing method embodiments, which will not be repeated here.

[0113] In the above embodiments, the description of each embodiment has its own emphasis, and the parts not described or recorded in detail in a certain embodiment can be referred to the related description of other embodiments.

[0114] Those of ordinary skill in the art can realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be realized in electronic hardware or a combination of computer software and electronic hardware. Whether the functions are executed in hardware or software depends on the specific application and design constraints of the technical solution. A person skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0115] In the embodiments provided by the present application, it should be understood that the disclosed apparatus / terminal and method can be implemented by other ways. For example, the above-mentioned apparatus / terminal embodiments are only schematic, and the division of the modules or units is only a logical function division, and there can be another division way in actual implementation, for example, a plurality of units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the displayed or discussed mutual coupling or direct coupling or communication connection can be indirect coupling or communication connection through some interface, device or unit, and can be electrical, mechanical or other forms.

[0116] The units described as separate components can or can not be physically separated, and the components shown as units can or can not be physical units, that is, they can be located in one place, or can be distributed on multiple network units. Part or all of the units can be selected according to actual needs to achieve the purpose of the embodiment.

[0117] In addition, each function unit in each embodiment of the present application can be integrated in one processing unit, or each unit can be physically present separately, or two or more units can be integrated in one unit. The integrated unit can be realized in the form of hardware or in the form of a software function unit.

[0118] The integrated module / unit, if realized in the form of a software function unit and sold or used as an independent product, can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the above-mentioned embodiment methods can also be completed by a computer program instructing related hardware, and the computer program can be stored in a computer-readable storage medium. When the processor executes the computer program, the steps of each PLC control method embodiment can be implemented. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or some intermediate forms, etc. The computer-readable medium can include any entity or device capable of carrying the computer program code, recording medium, U disk, mobile hard disk, magnetic disk, optical disk, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signal, telecommunication signal, and software distribution medium, etc. It should be noted that the content included in the computer-readable medium can be appropriately increased or decreased according to the requirements of legislation and patent practice in the jurisdiction, for example, in some jurisdictions, according to legislation and patent practice, the computer-readable medium does not include electrical carrier signals and telecommunication signals.

[0119] The above-described embodiments are only used to illustrate the technical solutions of the present application, rather than limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacements for some technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be included in the protection scope of the present application.

Claims

1. A PLC control system, characterized by, The IO integration and combination device is connected with the controlled devices and the PLC controllers respectively. The IO integration and combination device is used for collecting the running information data of the controlled devices and sending the running information data to the PLC controllers. The PLC controllers are used for generating control information based on the running information data and sending the control information to the IO integration and combination device. The IO integration and combination device is also used for fault-tolerant combination of the control information and sending the fault-tolerant combined control information to the controlled devices. The IO integration and combination device is specifically used for fault-tolerant combination of the control information by majority voting and taking the control information with the largest proportion in all control information as the fault-tolerant combined control information.

2. The PLC control system of claim 1, wherein, The IO integration and combination device is specifically used for copying the running information data into N parts and sending each part of the running information data to the PLC controllers; wherein the number of the PLC controllers is N; the running information data corresponds to the PLC controllers one by one.

3. The PLC control system of claim 1, wherein, The IO integration and combination device and the PLC controllers are connected by wireless communication. The IO integration and combination device is specifically used for collecting the running information data of the controlled devices and sending the running information data to the PLC controllers by the wireless communication link. The PLC controllers are specifically used for generating control information based on the running information data and sending the control information to the IO integration and combination device by the wireless communication link.

4. The PLC control system of claim 1, wherein, The number of the controlled devices is multiple, and each controlled device is connected with the IO integration and combination device. The IO integration and combination device is specifically used for collecting the running information data of the controlled devices, packing each running information data into a running information data file, and sending the running information data file to the PLC controllers. The PLC controllers are specifically used for extracting the running information data of each controlled device from the running information data file, generating control information of the running information data of each controlled device based on the running information data corresponding to each controlled device, and sending the control information of each controlled device to the IO integration and combination device. The IO integration and combination device is also used for fault-tolerant combination of all control information of each controlled device and sending the fault-tolerant combined control information to the controlled device.

5. The PLC control system of claim 4, wherein, The IO integration and combination device is multiple, each IO integration and combination device is connected with at least one controlled device, and each IO integration and combination device is connected with the PLC controllers. Each IO integration and combination device is specifically used for collecting the running information data of each controlled device connected with the IO integration and combination device, packing each running information data into a running information data file, and sending the running information data file to the PLC controllers. Each PLC controller is specifically configured to extract operation information data of each controlled device in each operation information data file, generate control information of each controlled device based on the operation information data of each controlled device, pack operation information data of all controlled devices connected to each IO set combining device as control information files corresponding to each IO set combining device according to the corresponding connection relationship between the IO set combining device and the controlled devices, and send each control information file to the corresponding IO set combining device. Each IO set combining device is further configured to extract control information of each controlled device in the control information file, combine all control information of each controlled device in a fault-tolerant manner, and send the fault-tolerant combined control information to the controlled device.

6. The PLC control system of claim 1, wherein, The IO set combining device is connected to the controlled device in a wired communication manner through a bus.

7. A PLC control method characterized by, The application is applied to the PLC control system as claimed in any one of claims 1 to 6. The method comprises: The IO set combining device collects operation information data of the controlled device and sends the operation information data to each PLC controller. The PLC controller generates control information based on the operation information data and sends the respective control information to the IO set combining device. The IO set combining device combines each control information in a fault-tolerant manner and sends the fault-tolerant combined control information to the controlled device. The IO set combining device combines each control information in a majority voting manner, and takes control information with the largest proportion in all control information as the fault-tolerant combined control information.

8. An IO aggregation and consolidation apparatus comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein, The processor implements the steps of the method as claimed in claim 7 when executing the computer program.

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