Signal simulation debugging method for multi-level ship lock industrial control system

Abstract

A signal simulation debugging method for a multi-level ship lock industrial control system, comprising the following steps: step S1, building a ship lock industrial control signal simulation platform; step S2, connecting the ship lock industrial control signal simulation platform with the multi-level ship lock industrial control system; step S3, simulating and modeling the gate operation speed, and simulating and modeling the valve operation speed; step S4, using a cyclic scanning operation mode to simulate the ship lock process of the multi-level ship lock industrial control system; the cyclic scanning period of the ship lock process simulation matches the cyclic scanning period of the multi-level ship lock industrial control system operation; the ship lock process simulation includes process simulation and abnormal working condition simulation. The present invention simulates various signals required for the operation of the ship lock industrial control system in real time according to the operation process, meeting the debugging and testing requirements of various control functions under the normal process state of the ship lock; through the simulation of fault or abnormal signals, meeting the various alarm and emergency protection functions and system fault tolerance test of the ship lock in fault and accident mode.

Description

Technical Field

[0001] The invention belongs to the technical field of simulation and emulation of a multi-level ship lock industrial control system, and in particular relates to a signal simulation and debugging method for a multi-level ship lock industrial control system. Background Art

[0002] The multi-stage ship lock is generally a continuous multi-stage ship lock with the characteristics of large operating head, complex process and high safety requirements. At present, the world's largest and most multi-stage ship lock is the Three Gorges Five-stage Ship Lock. Taking the Three Gorges Five-stage Ship Lock as an example, the characteristics of the existing multi-stage ship lock are:

[0003] 1. The scale of the ship lock industrial control system is large: the multi-level ship lock industrial control system consists of multiple local control units at 1 to 6 locks, centralized communication workstations, centralized monitoring host and operator workstations, database servers and other equipment. The control process of multi-level ship locks is very complex, and there is a strict process interlocking relationship between the locks at each level. The centralized control system and the local control units need to work together to ensure the safety and reliability of the system. The network topology of the multi-level ship lock industrial control system is as follows: Figure 1 shown.

[0004] 2. Large head and complex process: For example, the upstream water level of the Three Gorges Five-Level Ship Lock has a large fluctuation, there are many ship lock operation modes, and the water transfer process is complex. Normally, the upstream water level is between 145 and 155, and the fourth-level operation is adopted; between 155 and 165, the fifth-level water replenishment operation is adopted; and between 165 and 175, the fifth-level operation is adopted.

[0005] 3. The system debugging cycle is long and consumes a lot of manpower and material resources;

[0006] 4. There are many restrictions on on-site debugging and testing conditions;

[0007] Based on the introduction of the above background technology, the technical problem to be solved by the present invention is: due to the large operating head, complex process and high safety requirements of the multi-stage ship lock, the on-site debugging and testing cycle of the multi-stage ship lock industrial control system is long and consumes a lot of manpower and material resources. During the 30-40-day overhaul period, the conventional debugging and testing methods cannot complete the upgrading and transformation of the ship lock industrial control system. Due to the limitations of on-site debugging and testing conditions, the safe and reliable operation of the multi-stage ship lock cannot be guaranteed only through on-site debugging and testing. Summary of the invention

[0008] In view of the technical problems existing in the background technology, the signal simulation and debugging method of the multi-level lock industrial control system provided by the present invention simulates various signals required for the operation of the lock industrial control system in real time according to the operating process, so as to meet the debugging and testing requirements of various control functions under the normal process state of the lock; through the simulation of fault or abnormal signals, it meets the various alarm and emergency protection functions and system fault tolerance testing of the lock in fault and accident modes.

[0009] In order to solve the above technical problems, the present invention adopts the following technical solutions to achieve:

[0010] A signal simulation debugging method for a multi-level ship lock industrial control system, step S1, building a ship lock industrial control signal simulation platform;

[0011] Step S2, connecting the ship lock industrial control signal simulation platform with the multi-level ship lock industrial control system;

[0012] Step S3, performing simulation modeling on the gate operation speed and the valve operation speed;

[0013] Step S4, adopting a cyclic scanning operation mode to perform a ship lock process simulation on the multi-level ship lock industrial control system; the cyclic scanning period of the ship lock process simulation matches the cyclic scanning period of the multi-level ship lock industrial control system; the ship lock process simulation includes process simulation and abnormal working condition simulation;

[0014] The loop sequence of the lock process simulation is as follows: system initialization, reading the control output signal of the multi-level lock industrial control system, simulating the operating status of each lock equipment, simulating the operation detection signal of the lock equipment, simulating abnormal working conditions, generating the lock industrial control operation simulation signal and outputting the simulation signal.

[0015] Preferably, in step S1, the ship lock industrial control signal simulation platform includes a signal simulation server, a simulation graphics workstation, a simulation signal workstation, a simulation control PLC and a signal isolation relay cabinet.

[0016] Preferably, in step S2, the connection between the ship lock industrial control signal simulation platform and the multi-level ship lock industrial control system includes a software interface connection and a hardware interface connection; the software interface connection means that the simulation output data of the ship lock industrial control signal simulation platform is directly written into the input data mapping area of ​​the multi-level ship lock industrial control system in the format of data acquisition of the multi-level ship lock industrial control system through a network connection; the hardware interface connection means that the I / O port of the simulation control PLC is isolated through a relay cabinet and then transmitted to the I / O port of the multi-level ship lock industrial control system by hard wire;

[0017] The signal simulation server, the simulation graphic workstation, the simulation signal workstation and the simulation control PLC are connected to the multi-level ship lock industrial control system through a software interface connection method; the simulation control PLC is connected to the multi-level ship lock industrial control system through a hardware interface connection method.

[0018] Preferably, in step S3, the process simulation means: simulating the operating state of the multi-stage ship lock equipment according to the operating process, operating parameters of each equipment of the multi-stage ship lock and the output signal of the multi-stage ship lock industrial control system, and simulating and outputting various signals required for detection by the industrial control system;

[0019] The objects of process simulation include:

[0020] 1) Simulation of gate valve and hoist operation process and stroke detection signal;

[0021] 2) Hydraulic pump station operation process and operation feedback signal simulation;

[0022] 3) Simulation of single and double-sided water delivery technology and water level signal of multi-stage ship locks;

[0023] 4) Anti-collision device operation process and height detection signal simulation;

[0024] 5) Simulation of lock auxiliary equipment and operation feedback signals;

[0025] 6) Power distribution circuit detection signal simulation;

[0026] 7) Secondary loop control detection signal simulation.

[0027] Preferably, the abnormal working condition simulation is to simulate the diagnosis, alarm and emergency treatment process of the multi-stage ship lock industrial control system under fault conditions and accident conditions; the requirements for abnormal working condition simulation are: to use manual / automatic methods to lag, delay, cut off, invert and jump the process signal, trigger the response of the multi-stage ship lock industrial control system to abnormal conditions, and debug and test the comprehensiveness, correctness and safety of the diagnosis, alarm and emergency treatment functions of the ship lock industrial control system. " / " means or.

[0028] Preferably, the abnormal condition injection of abnormal condition simulation is divided into two types: digital abnormal condition injection and analog abnormal condition injection;

[0029] 1) The digital quantity abnormal injection method is: using methods including signal disconnection, signal short circuit, signal inversion, jitter according to a set period, delayed connection, and delayed disconnection to perform abnormal injection processing on the digital quantity simulation signal, and defining the digital quantity abnormal injection information in the form of a structure variable to facilitate retrieval, processing and storage;

[0030] 2) The method of analog quantity abnormality injection is: use methods including signal disconnection, signal drift, sensor slope drift, signal jump, and no change with the collected quantity (constant value) to inject faults into the analog quantity, and fully simulate the zero drift, temperature drift, time drift caused by the decrease in analog sensor acquisition accuracy, the jump caused by sensor interference, and sensor failures caused by disconnection, short circuit, etc.

[0031] Preferably, in step S3, the gate operation speed simulation modeling process is:

[0032] 1) The gate opening and closing adopts variable speed and double-side synchronous control. The gate hydraulic opening and closing machine system adopts 1 to 2 proportional pumps to drive and realize gate speed adjustment;

[0033] 2) Based on the linear relationship between the output flow of the proportional pump and the control given voltage, and considering the differences in the hydraulic pump station, a linear correction is made by taking into account the actual operating speed of the gate at 30% and 70% given values;

[0034] 3) Calculate the real-time operating speed of the gate hoist according to the given control voltage, rated flow of the proportional pump, inner and outer diameters of the gate cylinder, and working efficiency of the proportional pump;

[0035] 4) Set the gate opening speed calculation formula (m / min):

[0036]

[0037] 5) Set the gate closing speed calculation formula (m / min):

[0038]

[0039] In the above formula, the definitions of each parameter are as follows:

[0040] Rated flow rate of proportional pump: Q (unit: L / min);

[0041] Proportional pump 1 given voltage value: U1 (0-10V);

[0042] Proportional pump 2 given voltage value: U2 (0-10V);

[0043] Proportional pump 1 operation coefficient: K1 (K1 = 1 when put into operation, K1 = 0 when cut off);

[0044] Proportional pump 1 operation coefficient: K2 (K2 = 1 when put into operation, K2 = 0 when cut off);

[0045] Proportional pump working efficiency coefficient: η (obtained by looking up the table based on the proportional pump working pressure);

[0046] Proportional pump 1 flow correction coefficient: ξ1 (the value is 1 when not linearly calibrated);

[0047] Proportional pump 2 flow correction coefficient: ξ2 (the value is 1 when not linearly calibrated);

[0048] Inner diameter of gate cylinder: D (unit: m);

[0049] Gate piston rod outer diameter: d (unit: m);

[0050] The valve operation speed simulation modeling process is as follows:

[0051] In order to reduce the vibration generated during the valve opening process, the multi-stage ship locks use fast opening and slow closing of the valves (for example, the Three Gorges ship lock generally has an opening time of 2 minutes and a closing time of 4 minutes); in order to meet the hydraulic flow required for fast valve opening, multi-pump operation is generally adopted (for example, the Three Gorges ship lock uses a combination of 1 constant pressure variable pump + 2 proportional pumps); since the valve closing oil pump has low pressure and slow speed, a constant pressure variable pump is used for valve closing. When the constant pressure variable pump fails, it can also be replaced by a proportional pump.

[0052] 1) Set the valve opening speed calculation formula (m / min):

[0053]

[0054] 2) Set the valve closing speed calculation formula (m / min):

[0055]

[0056] In the above formula, the definitions of each parameter are as follows:

[0057] Rated flow rate of proportional pump: Q1 (unit: L / min);

[0058] Constant pressure variable pump flow rate: Q2 (unit: L / min);

[0059] Proportional pump 1 given voltage value: U1 (0-10V);

[0060] Proportional pump 2 given voltage value: U2 (0-10V);

[0061] Proportional pump 1 operation coefficient: K1 (K1 = 1 when put into operation, K1 = 0 when cut off);

[0062] Proportional pump 2 operation coefficient: K2 (K2 = 1 when put into operation, K2 = 0 when cut off);

[0063] Constant pressure variable pump operation coefficient: K3 (K3 = 1 when put into operation, K3 = 0 when cut off);

[0064] Proportional pump 1 flow correction coefficient: ξ1 (the value is 1 when not linearly calibrated);

[0065] Proportional pump 2 flow correction coefficient: ξ2 (the value is 1 when not linearly calibrated);

[0066] Flow correction coefficient of constant pressure variable pump: ξ3 (the value is 1 when not linearly calibrated);

[0067] Proportional pump efficiency coefficient: η1 (obtained from the table based on the proportional pump working pressure);

[0068] Constant pressure variable pump efficiency coefficient: η2 (obtained by looking up the table based on the constant pressure variable working pressure);

[0069] Inner diameter of valve cylinder: D (unit: m);

[0070] Valve piston rod outer diameter: d (unit: m).

[0071] The present invention can achieve the following beneficial effects:

[0072] The present invention adopts a method of combining software simulation with hardware simulation to construct a simulation system, simulates and models the key processes of multi-stage ship locks, and simulates various signals required for the operation of the ship lock industrial control system in real time according to the operating process, so as to meet the debugging and testing requirements of various control functions under the normal process state of the ship lock; through the simulation of fault or abnormal signals, it meets the various alarm and emergency protection functions and system fault tolerance testing of the ship lock in fault and accident modes. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] The present invention will be further described below in conjunction with the accompanying drawings and embodiments:

[0074] Figure 1 The network topology of the multi-level ship lock industrial control system in this embodiment;

[0075] Figure 2 This is a block diagram of the simulation operation principle of the multi-stage ship lock industrial control system of the present invention;

[0076] Figure 3 This is a network topology diagram of the multi-level ship lock industrial control signal simulation platform of the present invention;

[0077] Figure 4 A schematic diagram of the data flow and input and output interfaces of the simulation platform of the present invention;

[0078] Figure 5 This is a flow chart of the ship lock process simulation cycle scanning of the present invention. DETAILED DESCRIPTION

[0079] Embodiment 1:

[0080] Before the opening of the Three Gorges Five-Level Ship Lock, the on-site single-machine debugging, waterless debugging, and water debugging of the ship lock industrial control system took 18 months, consuming a lot of manpower and material resources. In the 20 years since the Three Gorges ship lock was opened to navigation, the cargo volume passing through the lock has increased year by year, far exceeding the design indicators, and the pressure on navigation is very huge. During the maintenance period, the single-line timed reversal operation of the ship lock has restricted the efficiency of ship passage. Therefore, the maintenance time of the ship lock is often controlled at about 30 to 40 days. Due to the short maintenance time, under normal conditions, it is impossible to meet the time required for the transformation of the ship lock industrial control system. The ship lock industrial control system will select different operating modes for the different water level coordination relationships between the upstream and downstream of the multi-level ship lock. However, in the actual on-site debugging and testing, the coordination relationship between the upper and lower water levels cannot be changed at any time according to the needs. It is difficult to achieve comprehensive process debugging and test verification, and destructive working conditions cannot be debugged and tested on site.

[0081] The process control of the multi-level ship lock industrial control system is a repeated cycle of signal acquisition, process processing, and control output. The present invention proposes a signal simulation debugging method for the multi-level ship lock industrial control system. Figure 2 As shown, the present invention takes the multi-stage ship lock industrial control system as the simulation object, models the key processes of the ship lock according to the multi-stage ship lock operation process, and uses a method combining software simulation and hardware simulation to simulate various signals required for input detection of the ship lock industrial control system, and sends them to the signal acquisition port of the ship lock industrial control system. The simulation process includes two steps: ship lock operation process simulation and abnormal working condition simulation, which are combined with the control cycle process of the simulation object (multi-stage ship lock industrial control system) to form a closed-loop simulation system. The specific technical scheme is as follows:

[0082] The preferred solution is Figure 1 to Figure 2 As shown, a signal simulation debugging method for a multi-level ship lock industrial control system comprises the following steps:

[0083] Step S1, building a ship lock industrial control signal simulation platform;

[0084] Step S2, connecting the ship lock industrial control signal simulation platform with the multi-level ship lock industrial control system;

[0085] Step S3, performing simulation modeling on the gate operation speed and the valve operation speed;

[0086] Step S4, using a cyclic scanning operation mode to perform a ship lock process simulation on the multi-level ship lock industrial control system; the cyclic scanning period of the ship lock process simulation matches the cyclic scanning period of the multi-level ship lock industrial control system; the ship lock process simulation includes process simulation and abnormal working condition simulation;

[0087] The loop sequence of the lock process simulation is as follows: system initialization, reading the control output signal of the multi-level lock industrial control system, simulating the operating status of each lock equipment, simulating the operation detection signal of the lock equipment, simulating abnormal working conditions, generating the lock industrial control operation simulation signal and outputting the simulation signal.

[0088] Preferably, in step S1, Figure 3 As shown in the figure, the ship lock industrial control signal simulation platform includes a signal simulation server, a simulation graphics workstation, a simulation signal workstation, a simulation control PLC and a signal isolation relay cabinet. The ship lock industrial control signal simulation platform is used to realize the collection of operation information of multi-level ship lock control systems, multi-level ship lock operation process simulation, abnormal working condition simulation and ship lock industrial control signal simulation output.

[0089] Preferably, in step S2, the connection method between the ship lock industrial control signal simulation platform and the multi-level ship lock industrial control system includes a software interface connection and a hardware interface connection; the software interface connection means that the simulation output data of the ship lock industrial control signal simulation platform is directly written into the input data mapping area of ​​the multi-level ship lock industrial control system in the format of data acquisition of the multi-level ship lock industrial control system through a network connection; the advantages of the software interface are simple interface, large amount of interactive data, low system cost and good economy, and the disadvantage is that it is impossible to verify and test the adaptability of the hardware I / O interface of the industrial control system.

[0090] The hardware interface connection means that the I / O port of the simulation control PLC is isolated through a relay cabinet and then transmitted to the I / O port of the multi-level ship lock industrial control system by hard wire; comprehensive simulation and testing of the hardware I / O port of the industrial control system can be achieved. The disadvantage is that the system cost is high and the workload of connecting the interfaces is large.

[0091] Simulation platform data flow and input and output interfaces such as Figure 4 As shown, the signal simulation server, the simulation graphic workstation, the simulation signal workstation and the simulation control PLC are connected to the multi-level ship lock industrial control system through a software interface connection method; the simulation control PLC is connected to the multi-level ship lock industrial control system through a hardware interface connection method.

[0092] Preferably, in step S3, the process simulation means: simulating the operating state of the multi-stage ship lock equipment according to the operating process, operating parameters of each equipment of the multi-stage ship lock and the output signal of the multi-stage ship lock industrial control system, and simulating and outputting various signals required for detection by the industrial control system;

[0093] The objects of process simulation include:

[0094] 1) Simulation of gate valve and hoist operation process and stroke detection signal;

[0095] 2) Hydraulic pump station operation process and operation feedback signal simulation;

[0096] 3) Simulation of single and double-sided water delivery technology and water level signal of multi-stage ship locks;

[0097] 4) Anti-collision device operation process and height detection signal simulation;

[0098] 5) Simulation of lock auxiliary equipment and operation feedback signals;

[0099] 6) Power distribution circuit detection signal simulation;

[0100] 7) Secondary loop control detection signal simulation.

[0101] Preferably, the abnormal working condition simulation is to simulate the diagnosis, alarm and emergency treatment process of the multi-stage ship lock industrial control system under fault conditions and accident conditions; the requirements for abnormal working condition simulation are: to use manual / automatic methods to lag, delay, cut off, invert and jump the process signal, trigger the response of the multi-stage ship lock industrial control system to abnormal conditions, and debug and test the comprehensiveness, correctness and safety of the diagnosis, alarm and emergency treatment functions of the ship lock industrial control system. " / " means or.

[0102] The ship lock process simulation adopts a cyclic scanning operation mode, and the process simulation cyclic scanning period matches the cyclic scanning period of the ship lock industrial control system. The ship lock process simulation cycle includes system initialization, reading the control output signal of the ship lock industrial control system, simulating the operation status of each ship lock equipment, simulating the operation detection signal of the ship lock equipment, simulating abnormal working conditions, generating the ship lock industrial control operation simulation signal, and simulating the signal output process, and it is carried out in sequence. The process simulation cyclic scanning process is as follows: Figure 5 shown.

[0103] The simulation of the ship lock operation process must solve the problem of the similarity of the simulation operation. Except for the operation process of the gate and valve and the water delivery process, the operation control of other equipment is controlled by the switch quantity and runs in a constant state. The similarity of the simulation operation is basically close to 100%. The speed of the gate and valve operation is variable and is related to the control setting of the hydraulic oil pump. The simulation of the water delivery process is more complicated, and the real-time water delivery flow is related to the initial water head and the valve opening and closing mode. In order to improve the similarity of the simulation, the present invention solves the similarity problem of the gate, valve operation and water delivery process simulation by modeling the gate, valve operation and water delivery process.

[0104] Preferably, the debugging and testing of the lock industrial control system is divided into normal working condition testing and abnormal working condition testing. Under normal working conditions, the correctness of various control functions of the ship lock industrial control system is debugged and tested; under abnormal working conditions, the correctness of various functions such as the system fault tolerance, diagnosis, alarm, and emergency processing under abnormal working conditions (including fault working conditions and accident working conditions) is tested. The present invention provides a ship lock operation simulation signal for the debugging and testing of the ship lock industrial control system under normal working conditions through the simulation of the ship lock operation process signal; and on this basis, abnormal working condition simulation is carried out to simulate various abnormal working conditions (including fault working conditions and accident working conditions) that may occur during the operation of multi-stage ship locks, so as to meet the requirements of abnormal working condition testing of multi-stage ship locks. In order to achieve comprehensive testing of abnormal working conditions, an innovative abnormal working condition injection function was invented in the multi-level ship lock operation signal simulation. Based on the ship lock operation process signal simulation, according to the requirements of abnormal working condition simulation, the process signal is manually / automatically delayed, delayed, cut off, inverted, jumped, etc., triggering the industrial control system's response to abnormal working conditions, debugging and testing the comprehensiveness, correctness, and safety of the ship lock industrial control system's diagnosis, alarm, emergency handling and other functions. Abnormal working condition injection is divided into digital abnormal injection and analog abnormal injection.

[0105] The abnormal condition injection of abnormal condition simulation is divided into two types: digital abnormal condition injection and analog abnormal condition injection;

[0106] 1) The digital quantity abnormal injection method is: using methods including signal disconnection, signal short circuit, signal inversion, jitter according to a set period, delayed connection, and delayed disconnection to perform abnormal injection processing on the digital quantity simulation signal, and defining the digital quantity abnormal injection information in the form of a structure variable to facilitate retrieval, processing and storage;

[0107] Digital quantity abnormal injection structure variable definition:

[0108] ① Abnormal injection control word (WORD);

[0109] ② Delayed connection time (INT, unit: milliseconds, minimum value: 100ms);

[0110] ③ Delayed connection time (INT, unit: milliseconds, minimum value: 100ms);

[0111] ④Signal jitter period (INT, unit: milliseconds, minimum jitter period: 200ms);

[0112] The analysis of the abnormal injection control word of digital quantity is as follows:

[0113]

[0114] 2) The method of analog quantity abnormality injection is: use methods including signal disconnection, signal drift, sensor slope drift, signal jump, and no change with the collected quantity (constant value) to inject faults into the analog quantity, and fully simulate the zero drift, temperature drift, time drift caused by the decrease in analog sensor acquisition accuracy, the jump caused by sensor interference, and sensor failures caused by disconnection, short circuit, etc.

[0115] Analog abnormal injection structure variable definition:

[0116] ①Fault injection control word (WORD);

[0117] ② Output constant value (INT, 0-20000);

[0118] ③Simulation signal value (REAL);

[0119] ④Range (REAL);

[0120] ⑤Zero point (REAL);

[0121] ⑥Slope adjustment (REAL);

[0122] ⑦ Random error range (REAL, 0-100%);

[0123] ⑧Random number (INT, 0-100, generated by the host computer);

[0124] ⑨Output value (INT, 0-20000).

[0125] The analog abnormal injection control word is parsed as:

[0126]

[0127] The simulation workstation uses graphical methods to dynamically display the lock operation simulation status, realize the initialization control of the lock operation simulation, and adjust the simulation operation parameters. According to the operation process and test items, normal operation process simulation and manual / automatic abnormal condition injection simulation are carried out. Statistics and print test data and test reports.

[0128] The simulation database adopts an open source database, which can record the input signal, simulation signal, simulation output signal, test items, test results and other data of the simulation platform.

[0129] The multi-stage ship lock simulation device is suitable for the software development and testing of the multi-stage ship lock industrial control system, the factory debugging and testing of the system software and hardware, the on-site construction debugging and testing, the function upgrade debugging and testing after the system is put into operation, and the system debugging and testing before the system is put into operation after maintenance and repair. It can serve the whole life cycle of the system.

[0130] Preferably, in step S3, the gate operation speed simulation modeling process is:

[0131] 1) The gate opening and closing adopts variable speed and double-side synchronous control. The gate hydraulic opening and closing machine system adopts 1 to 2 proportional pumps to drive and realize gate speed adjustment;

[0132] 2) Based on the linear relationship between the output flow of the proportional pump and the control given voltage, and considering the differences in the hydraulic pump station, a linear correction is made by taking into account the actual operating speed of the gate at 30% and 70% given values;

[0133] 3) Calculate the real-time operating speed of the gate hoist according to the given control voltage, rated flow of the proportional pump, inner and outer diameters of the gate cylinder, and working efficiency of the proportional pump;

[0134] 4) Set the gate opening speed calculation formula (m / min):

[0135]

[0136] 5) Set the gate closing speed calculation formula (m / min):

[0137]

[0138] In the above formula, the definitions of each parameter are as follows:

[0139] Rated flow rate of proportional pump: Q (unit: L / min);

[0140] Proportional pump 1 given voltage value: U1 (0-10V);

[0141] Proportional pump 2 given voltage value: U2 (0-10V);

[0142] Proportional pump 1 operation coefficient: K1 (K1 = 1 when put into operation, K1 = 0 when cut off);

[0143] Proportional pump 1 operation coefficient: K2 (K2 = 1 when put into operation, K2 = 0 when cut off);

[0144] Proportional pump working efficiency coefficient: η (obtained by looking up the table based on the proportional pump working pressure);

[0145] Proportional pump 1 flow correction coefficient: ξ1 (the value is 1 when not linearly calibrated);

[0146] Proportional pump 2 flow correction coefficient: ξ2 (the value is 1 when not linearly calibrated);

[0147] Inner diameter of gate cylinder: D (unit: m);

[0148] Gate piston rod outer diameter: d (unit: m);

[0149] The valve operation speed simulation modeling process is as follows:

[0150] In order to reduce the vibration generated during the valve opening process, the multi-stage ship locks use fast opening and slow closing of the valves (for example, the Three Gorges ship lock generally has an opening time of 2 minutes and a closing time of 4 minutes); in order to meet the hydraulic flow required for fast valve opening, multi-pump operation is generally adopted (for example, the Three Gorges ship lock uses a combination of 1 constant pressure variable pump + 2 proportional pumps); since the valve closing oil pump has low pressure and slow speed, a constant pressure variable pump is used for valve closing. When the constant pressure variable pump fails, it can also be replaced by a proportional pump.

[0151] 1) Set the valve opening speed calculation formula (m / min):

[0152]

[0153] 2) Set the valve closing speed calculation formula (m / min):

[0154]

[0155] In the above formula, the definitions of each parameter are as follows:

[0156] Rated flow rate of proportional pump: Q1 (unit: L / min);

[0157] Constant pressure variable pump flow rate: Q2 (unit: L / min);

[0158] Proportional pump 1 given voltage value: U1 (0-10V);

[0159] Proportional pump 2 given voltage value: U2 (0-10V);

[0160] Proportional pump 1 operation coefficient: K1 (K1 = 1 when put into operation, K1 = 0 when cut off);

[0161] Proportional pump 2 operation coefficient: K2 (K2 = 1 when put into operation, K2 = 0 when cut off);

[0162] Constant pressure variable pump operation coefficient: K3 (K3 = 1 when put into operation, K3 = 0 when cut off);

[0163] Proportional pump 1 flow correction coefficient: ξ1 (the value is 1 when not linearly calibrated);

[0164] Proportional pump 2 flow correction coefficient: ξ2 (the value is 1 when not linearly calibrated);

[0165] Flow correction coefficient of constant pressure variable pump: ξ3 (the value is 1 when not linearly calibrated);

[0166] Proportional pump efficiency coefficient: η1 (obtained from the table based on the proportional pump working pressure);

[0167] Constant pressure variable pump efficiency coefficient: η2 (obtained by looking up the table based on the constant pressure variable working pressure);

[0168] Inner diameter of valve cylinder: D (unit: m);

[0169] Valve piston rod outer diameter: d (unit: m).

[0170] After the technical solution of the present invention was applied in the Three Gorges multi-stage ship lock, the following results were achieved:

[0171] 1) In order to ensure that the control system of the Three Gorges ship lock is successfully updated and replaced during the maintenance in 2024 (planned construction period of 42 days), the simulation method of the present invention is used to build an industrial control signal simulation platform for the Three Gorges ship lock. The simulation platform adopts a combination of software interface output and hardware interface output to achieve full hardware simulation of the industrial control detection signal of any local control station of the ship lock, which not only realizes the comprehensive adaptation and verification of the hardware signal, but also achieves economic rationality.

[0172] 2) The similarity between the output signal of the simulation system and the detection signal of the lock industrial control prototype is improved to the greatest extent.

[0173] ① The simulation operation scanning cycle is consistent with the scanning cycle of the lock control system PLC (100ms) to ensure the consistency and synchronization of the simulation output signal and the signal acquisition of the lock control system.

[0174] ② The output signals of the simulated hardware interface (digital quantity, analog quantity, high-speed counting, etc.) are completely consistent with the real signals;

[0175] ③ Through the simulation modeling and calibration of the gate and valve opening and closing operation, the similarity between the gate and valve simulation output of the opening, speed, limit and other signals and the actual operation status of the gate and valve reaches more than 95%;

[0176] ④ Through the simulation modeling and calibration of the multi-stage ship lock water delivery process, the similarity between the ship lock water delivery simulation, the lock chamber water level change process simulation and the actual water delivery state of the prototype reached more than 90%.

[0177] 3) Through the simulation of the ship lock operation process, the comprehensive debugging and testing of the control functions and protection functions of the Three Gorges ship lock industrial control system under various ship lock operation and control modes with reservoir water levels ranging from ▽145m to ▽175m were realized. This solved the problem that during the maintenance period in 2024, due to the limitation of reservoir water level conditions, only a single ship lock operation mode could be debugged and tested.

[0178] 4) Through abnormal working condition simulation, nearly 4,000 fault simulation tests of the Three Gorges Ship Lock Industrial Control System and combined tests of multiple faults occurring simultaneously were carried out to improve the system's fault tolerance and provide a guarantee for the long-term safe and stable operation of the ship lock industrial control.

[0179] 5) Using the simulation platform, comprehensive debugging work was carried out on the new ship lock industrial control system after the Three Gorges ship lock renovation. According to the test outline, the new system hardware adaptability test, on-site unit control and protection function test, centralized control system control and protection function test, and system joint test were completed in just 20 days, providing safety guarantees for the installation, debugging and commissioning of the new control system during the maintenance period in 2024, solving the problems of short maintenance time and inability to fully carry out on-site debugging and testing of the new system, and creating huge social benefits.

[0180] The above embodiments are only preferred technical solutions of the present invention and should not be regarded as limiting the present invention. The protection scope of the present invention shall be the technical solutions recorded in the claims, including equivalent replacement solutions of the technical features in the technical solutions recorded in the claims. That is, equivalent replacement improvements within this scope are also within the protection scope of the present invention.

Claims

1. A signal simulation debugging method for a multi-level ship lock industrial control system, characterized in that: Step S1, building a ship lock industrial control signal simulation platform; Step S2, connecting the ship lock industrial control signal simulation platform with the multi-level ship lock industrial control system; Step S3, performing simulation modeling on the gate operation speed and the valve operation speed; Step S4, using a cyclic scanning operation mode to perform ship lock process simulation on the multi-stage ship lock industrial control system; The cyclic scanning period of the ship lock process simulation matches the cyclic scanning period of the multi-level ship lock industrial control system; The ship lock process simulation includes process simulation and abnormal working condition simulation; The cycle sequence of the ship lock process simulation is as follows: system initialization, reading the control output signal of the multi-level ship lock industrial control system, simulating the operating status of each ship lock device, simulating the ship lock device operation detection signal, simulating abnormal working conditions, generating the ship lock industrial control operation simulation signal and outputting the simulation signal; In step S1, the ship lock industrial control signal simulation platform includes a signal simulation server, a simulation graphics workstation, a simulation signal workstation, a simulation control PLC and a signal isolation relay cabinet; In step S2, the connection between the ship lock industrial control signal simulation platform and the multi-level ship lock industrial control system includes software interface connection and hardware interface connection; the software interface connection means that the simulation output data of the ship lock industrial control signal simulation platform is directly written into the input data mapping area of ​​the multi-level ship lock industrial control system in the format of data acquisition of the multi-level ship lock industrial control system through a network connection; the hardware interface connection means that the I / O port of the simulation control PLC is isolated through a relay cabinet and then transmitted to the I / O port of the multi-level ship lock industrial control system by hard wire; The signal simulation server, simulation graphic workstation, simulation signal workstation and simulation control PLC are connected to the multi-level ship lock industrial control system through a software interface connection method; the simulation control PLC is connected to the multi-level ship lock industrial control system through a hardware interface connection method; In step S3, the process simulation means: according to the operation process, operation parameters of each equipment of the multi-stage ship lock and the output signal of the multi-stage ship lock industrial control system, the operation state of the multi-stage ship lock equipment is simulated, and various signals required for the industrial control system to detect are simulated and output; The objects of process simulation include: 1) Simulation of gate valve and hoist operation process and stroke detection signal; 2) Simulation of hydraulic pump station operation process and operation feedback signal; 3) Simulation of single and double-sided water delivery technology and water level signal of multi-stage ship locks; 4) Anti-collision device operation process and height detection signal simulation; 5) Simulation of lock auxiliary equipment and operation feedback signals; 6) Power distribution circuit detection signal simulation; 7) Secondary loop control detection signal simulation; The abnormal working condition simulation is to simulate the diagnosis, alarm and emergency treatment process of the multi-stage ship lock industrial control system under fault conditions and accident conditions; the requirements of abnormal working condition simulation: the process signal is delayed, delayed, cut off, inverted and jumped in a manual / automatic manner to trigger the response of the multi-stage ship lock industrial control system to abnormal conditions, which is used to debug and test the comprehensiveness, correctness and safety of the diagnosis, alarm and emergency treatment functions of the ship lock industrial control system; The abnormal condition injection of abnormal condition simulation is divided into two types: digital abnormal condition injection and analog abnormal condition injection; 1) The digital quantity abnormal injection method is: using methods including signal disconnection, signal short circuit, signal inversion, jitter according to a set period, delayed connection, and delayed disconnection to perform abnormal injection processing on the digital quantity simulation signal, and defining the digital quantity abnormal injection information in the form of a structure variable to facilitate retrieval, processing and storage; 2) The method of analog quantity abnormality injection is: use methods including signal disconnection, signal drift, sensor slope drift, signal jump, and non-change with the collected quantity to inject faults into the analog quantity, and fully simulate the zero drift, temperature drift, time drift caused by the decrease in analog sensor acquisition accuracy, the jump caused by sensor interference, and sensor failures caused by disconnection, short circuit, etc.

2. The signal simulation debugging method for the multi-level ship lock industrial control system according to claim 1 is characterized in that: In step S3, the gate operation speed simulation modeling process is: 1) The gate opening and closing adopts variable speed and double-side synchronous control. The gate hydraulic opening and closing machine system adopts 1~2 proportional pumps to drive and realize gate speed adjustment; 2) Based on the linear relationship between the output flow of the proportional pump and the control given voltage, and considering the differences in the hydraulic pump station, a linear correction is made by taking into account the actual operating speed of the gate at 30% and 70% given values; 3) Calculate the real-time operating speed of the gate hoist according to the given control voltage, rated flow of the proportional pump, inner and outer diameters of the gate cylinder, and working efficiency of the proportional pump; 4) Set the gate opening speed calculation formula: ； 5) Set the gate closing speed calculation formula: ； In the above formula, the definitions of each parameter are as follows: Rated flow of proportional pump: Q; Proportional pump 1 given voltage value: U1; Proportional pump 2 given voltage value: U2; Proportional pump 1 operation coefficient: K1; Proportional pump 1 operation coefficient: K2; Proportional pump working efficiency coefficient: η; Proportional pump 1 flow correction coefficient: ξ1; Proportional pump 2 flow correction coefficient: ξ2; Inner diameter of gate cylinder: D; Gate piston rod outer diameter: d; The valve operation speed simulation modeling process is as follows: 1) Set the valve opening speed calculation formula (m / min): ； 2) Set the valve closing speed calculation formula (m / min): ； In the above formula, the definitions of each parameter are as follows: Rated flow of proportional pump: Q1; Constant pressure variable pump flow: Q2; Proportional pump 1 given voltage value: U1; Proportional pump 2 given voltage value: U2; Proportional pump 1 operation coefficient: K1; Proportional pump 2 operation coefficient: K2; Constant pressure variable pump operation coefficient: K3; Proportional pump 1 flow correction coefficient: ξ1; Proportional pump 2 flow correction coefficient: ξ2; Flow correction coefficient of constant pressure variable pump: ξ3; Proportional pump efficiency coefficient: η1; Constant pressure variable pump efficiency coefficient: η2; Inner diameter of valve cylinder: D; Valve piston rod outer diameter: d.

Images