PLC controller function module with hot plug function

Abstract

The application provides a PLC controller function module with a hot plug function, and belongs to the technical field of PLC controllers.The PLC controller function module comprises a main controller, a function module body, a hot plug interface and a quick-release connecting structure, wherein the main controller and the function module body are connected and separated through the quick-release connecting structure, and the hot plug interface is used for signal and data transmission when the function module and the main controller are connected and separated.The hot plug function allows the function module to be replaced or upgraded without interrupting the system operation, greatly shortens the maintenance time, reduces the downtime cost caused by maintenance, and improves the continuous operation ability and reliability of the industrial automation system.

Description

TECHNICAL FIELD

[0001] The application provides a PLC controller function module with hot plug function, and belongs to the technical field of PLC controllers. BACKGROUND

[0002] With the continuous improvement of industrial automation level, programmable logic controller (PLC) plays a crucial role in industrial automation control system. PLC controller realizes control, monitoring and data acquisition of field devices by connecting various function modules. However, in complex industrial environment, function modules may fail or need to be upgraded and maintained, and the replacement or upgrade operation of function modules often needs to shut down the whole system, causing production interruption and efficiency loss.

[0003] In order to solve the above problems, in recent years, PLC controller function modules with hot plug function have appeared. Hot plug technology allows function modules to be pulled out or inserted from the system without shutting down the system power, so as to realize online replacement and upgrade, greatly improving the availability and maintenance efficiency of the system.

[0004] In the existing hot plug PLC controller function module technology, mechanical locking or electronic locking is usually used to realize the fixation and unlocking of function modules. However, these locking methods may have problems such as complex structure, cumbersome operation, unstable locking effect, etc. At the same time, there is a lack of efficient and reliable solutions for the identification and signal, data transmission of function modules. SUMMARY

[0005] The application provides a PLC controller function module with hot plug function to solve the problems mentioned in the background.

[0006] The application provides a PLC controller function module with hot plug function, which comprises a main controller, a function module body, a hot plug interface and a quick release connection structure. The main controller and the function module body are connected and separated through the quick release connection structure. The hot plug interface is used for signal and data transmission when the function module is connected and separated with the main controller.

[0007] Further, the function module body comprises an intelligent identification unit, a communication interface unit, a data processing unit, an I / O interface unit, a quick release connection structure interface, a fault diagnosis unit and a storage unit.

[0008] Further, the data storage unit comprises:

[0009] When the function module main controller is connected, the data storage unit performs initialization operation, establishes a storage area according to a preset data structure and format, allocates a storage space for each storage area, and sets corresponding access permission and security mechanism;

[0010] The data storage unit collects running data of the function module in real time through the I / O interface unit, pre-processes the collected data, and organizes the pre-processed data according to a time stamp;

[0011] The organized data is compressed through a compression algorithm, and the storage and retrieval performance of the data is optimized through indexing and data structure;

[0012] Based on distributed storage and redundant backup mechanism, the storage space is further set; the sensitive data stored is encrypted, the access control strategy is set, and the encryption algorithm and access control strategy are regularly updated.

[0013] Further, the fault diagnosis step of the fault diagnosis unit comprises:

[0014] The fault diagnosis unit collects running data of the PLC controller and the function module through the communication interface unit, and pre-processes the collected data;

[0015] Based on the built-in fault diagnosis model, the processed data is analyzed to detect whether there is an abnormality or fault;

[0016] If an abnormality or fault is detected, the fault diagnosis report is generated according to the fault type and severity, and the fault diagnosis report is further analyzed and verified in combination with historical data and expert knowledge base;

[0017] Through the input / output signal detection function of the PLC controller, the location of the fault is located in combination with the fault diagnosis report;

[0018] If the fault location is successful, the isolation mechanism is started to isolate the fault part from the normal part;

[0019] If the fault location fails, the analog signal fault diagnosis method is used to perform secondary positioning by simulating a fault scene, and the previous step is executed after successful positioning;

[0020] According to the results of fault diagnosis and positioning, a corresponding fault handling scheme is developed for fault handling, and after the fault handling is completed, the system is tested and verified;

[0021] Based on the results of testing and verification, the causes and laws of the fault are analyzed, and corresponding preventive measures and optimization schemes are developed;

[0022] The process and results of each fault diagnosis and treatment are recorded in detail, and a fault report is generated. The fault reports are periodically summarized and analyzed to find common and regular problems, and improvement measures and optimization schemes are developed.

[0023] Further, the fault handling scheme includes replacing faulty components, repairing damaged equipment, and adjusting parameter settings.

[0024] Further, if the fault location fails, a secondary location is performed through an analog signal fault diagnosis method by simulating a fault scenario. After successful location, the previous step is executed, including:

[0025] Based on the working principle and fault characteristics of known PLC controllers and functional modules, a fault scenario model is constructed. Through simulation software, the fault occurrence conditions similar to the real environment are simulated, and different parameters and variables are set to simulate various possible fault modes.

[0026] In the simulated fault scenario, the analog signals are collected in real time through sensors, and the collected analog signals are processed and key information is extracted. Through data analysis tools, the analog signals are subjected to frequency spectrum analysis, time domain analysis, and correlation analysis.

[0027] Combined with expert knowledge and historical data, a fault feature library is established to store the signal features corresponding to various faults. Through pattern recognition algorithms, the extracted analog signal features are matched and identified.

[0028] If the signal features matching the known fault characteristics are identified, the corresponding fault is determined.

[0029] If the initial location fails, a secondary location strategy is developed based on the results of analog signal analysis.

[0030] Using the redundancy design and backup function of the PLC controller, the fault range is narrowed by switching the backup channel or standby equipment. Combined with the topology of the system and the dependency relationship between the functional modules, the fault propagation path is speculated.

[0031] According to the developed secondary location strategy, the fault point is investigated and verified by step-by-step approximation method and elimination method.

[0032] The results of secondary location are fed back to the fault diagnosis model to update and optimize the model.

[0033] Further, the quick release connection structure includes a guide structure, a locking mechanism, and an unlocking mechanism.

[0034] Further, the quick release connection structure uses magnetic locking.

[0035] Further, the implementation step of the hot plug function comprises:

[0036] When the functional module body approaches the PLC controller, the main controller detects whether a new functional module is ready to be connected through the communication interface unit;

[0037] If a new functional module is detected to be connected, the main controller starts the intelligent identification unit to identify the information of the functional module about to be connected;

[0038] If the identification is passed, the main controller guides the functional module body to be aligned through the guide structure of the quick-release connection structure, and at the same time, the main controller starts the fault diagnosis unit to pre-check the electrical environment of the PLC controller and the functional module body;

[0039] Before the functional module body contacts the hot plug interface, the main controller pre-adjusts the resistance value of the PTC through the control circuit to make it enter the preheating state;

[0040] When the functional module body contacts the hot plug interface, the main controller accurately controls the conduction time of the MOS tube through the timing circuit, and when the functional module body is fully contacted with the interface, the main controller gradually increases the conduction time of the MOS tube according to the signal of the timing circuit;

[0041] During the connection of the functional module body and the main controller, the main controller monitors the current change in real time through the MOS tube current detection resistor; if an abnormal current is found, the conduction state of the main controller MOS tube is adjusted;

[0042] After the functional module body is stably connected with the main controller, the locking mechanism of the quick-release connection structure fixes the functional module body on the PLC controller, the main controller activates the functional module, and transmits signals and data through the I / O interface unit;

[0043] When the functional module needs to be separated, the main controller stops the signal and data transmission with the functional module, and starts the unlocking mechanism to release the locking state of the functional module body;

[0044] At the same time of unlocking, the main controller controls the MOS tube to be turned off, disconnects the electrical connection between the functional module and the main controller, and pulls out the functional module body from the main controller through the quick-release connection structure.

[0045] Further, the main controller monitors the current change in real time through the MOS tube current detection resistor during the connection of the functional module body and the main controller; if an abnormal current is found, the conduction state of the main controller MOS tube is adjusted, comprising:

[0046] The main controller starts the monitoring function of the MOS tube current detection resistor when the functional module body and the hot plug interface start to contact, and obtains the current value in the MOS tube in real time through the high-precision current detection circuit, and converts it into a digital signal;

[0047] After the main controller receives the current data, data analysis is performed to determine whether the current is within the preset safe range, and the current change trend is compared with historical data to predict abnormal conditions;

[0048] If it is found that the current value exceeds the preset safety threshold or the current change trend is abnormal, a warning signal is sent through the main controller;

[0049] The main controller selects an adjustment strategy according to the specific situation of the current anomaly and the system state;

[0050] If the adjustment strategy cannot control the current anomaly, or the abnormal condition continues to worsen, the main controller starts a safety protection mechanism.

[0051] The application has the following advantages: the hot plug function allows replacement or upgrade of the functional module without interrupting system operation, greatly shortening maintenance time and reducing downtime costs caused by maintenance, improving the continuous operation capability and reliability of the industrial automation system; users can quickly add or replace modules with different functions according to actual needs, such as adding I / O interfaces, communication protocol conversion modules, etc., which provides convenience for flexible configuration and future upgrade of the system; through the integrated intelligent identification and fault diagnosis unit, the system can automatically identify the type and version of the newly connected module, configure itself, and implement strict electrical environment monitoring and fault prediction during connection and operation, effectively avoiding system failures caused by misoperation or hardware problems, and enhancing the stability and safety of the system; the fine current control strategy and dynamic adjustment of MOS tube conduction time, combined with the fast current anomaly response mechanism, can effectively prevent large current impact and overload, protect the module and system from electrical damage, and prolong the service life; the data storage unit not only provides efficient real-time data collection and processing capability, but also realizes efficient compression, indexing and encrypted storage of data, combined with distributed storage and redundant backup, to ensure the safety and integrity of the data, providing a reliable data foundation for subsequent analysis and decision-making and fault tracing; through the integrated fault diagnosis unit, combined with the analog signal fault diagnosis method, it can accurately locate and quickly respond to various faults, reduce fault troubleshooting time, and based on deep analysis of fault history, continuously optimize preventive measures and system performance, and improve the overall fault recovery speed and system robustness. BRIEF DESCRIPTION OF DRAWINGS

[0052] Figure 1 A PLC controller functional module with a hot plug function is shown in the figure.

[0053] Figure 2 The schematic view of the functional module body of the present application. DETAILED DESCRIPTION

[0054] In order to more clearly understand the above-mentioned purposes, features and advantages of the present application, the present application will be described in detail below in combination with the drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0055] In the following description, a large number of specific details are set forth in order to facilitate a thorough understanding of the present application. The described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of protection of the present application.

[0056] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. The terms used in the specification of the present application are only for the purpose of describing the specific embodiments and are not intended to limit the present application.

[0057] One embodiment of the present application, as shown in Figure 1 A PLC controller functional module with hot plug function, comprising a main controller, a functional module body, a hot plug interface and a quick release connection structure, the main controller and the functional module body are connected and separated through the quick release connection structure, and the hot plug interface is used for signal and data transmission when the functional module and the main controller are connected and separated.

[0058] The working principle of the above technical solution is as follows: the quick-release connection structure is a key component that connects the main controller and the functional module body. This design makes the connection and separation between the two rapid and simple. When it is necessary to add or remove a functional module, the user can quickly achieve this goal by operating the quick-release connection structure, without the need to shut down or restart the entire PLC system. The hot plug interface is another key component, which is responsible for signal and data transmission when the functional module is connected or separated from the main controller. This means that when the functional module is inserted or removed, the system can still maintain the running state and perform real-time data transmission. When the functional module is inserted, the hot plug interface quickly identifies and establishes a communication connection with the main controller. During this process, the module's status information, configuration data, and possibly required control signals are transmitted through the interface. If it is necessary to remove the functional module, the hot plug interface ensures that all data transmission has been completed before disconnection, and the system state has been correctly updated. This can avoid data loss or system crash. The main controller is the core component of the PLC system, responsible for processing input signals, executing control logic, and outputting control signals. The functional module provides specific functions or interfaces to expand the capabilities of the main controller. When the functional module is connected to the main controller through the quick-release connection structure, the main controller will identify the module and perform corresponding configuration according to its type and function. Subsequently, the main controller can communicate with the functional module through the hot plug interface to exchange data and execute control commands. Due to the use of hot plug design, users can easily add, remove, or replace functional modules without interrupting system operation. This makes system maintenance and upgrading more simple and efficient. For example, if a functional module fails, the user can quickly remove it and insert a new or backup module to replace it. This minimizes system downtime and reduces production losses.

[0059] The above technical solution has the following effects: due to the hot plug design, users can dynamically add, remove or replace functional modules while the system is running, without the need to shut down or restart the entire system. This greatly improves the flexibility of the system, making it better adapt to changing production needs and control requirements. When a functional module fails or needs to be upgraded, users can directly pull it out through the quick-release connection structure and replace it with a new or backup module. This plug-and-play design greatly simplifies the maintenance process of the system, reduces downtime and improves production efficiency. In traditional PLC systems, if a functional module needs to be replaced or upgraded, the entire system usually needs to be shut down, which will cause production interruption. The hot plug function allows module replacement without interrupting system operation, significantly reducing system downtime and reducing production losses. The hot plug design allows the system to isolate and replace faulty modules without interrupting operation, reducing the risk of system crashes due to a single module failure. In addition, by dynamically adding backup modules, the system's redundancy and fault tolerance can be improved. When a new functional module is inserted, the main controller can automatically identify its type and function and make corresponding configurations. This makes the system configuration process simpler and more automated, reducing human error and configuration complexity. By adding modules with different functions, users can easily expand the capabilities of the PLC system. This scalability allows the system to better adapt to future technological developments and changes in business needs. The quick-release connection structure and hot plug interface make the module replacement and upgrade process more convenient and intuitive, improving user experience. At the same time, by reducing system downtime and maintenance complexity, it also reduces user operating costs and pressure.

[0060] One embodiment of the present application, as shown in Figure 2 The functional module body includes an intelligent identification unit, a communication interface unit, a data processing unit, an I / O interface unit, a quick-release connection structure interface, a fault diagnosis unit, and a storage unit.

[0061] The working principle and effect of the above technical solution are: the intelligent identification unit is usually activated first when the functional module is inserted into the PLC controller, and exchanges information with the main controller through the communication interface unit to identify the type, version and functional characteristics of the module. The communication interface unit serves as a bridge for data exchange between the module and the main controller and other devices, supports multiple communication protocols (such as Ethernet / IP, PROFINET, Modbus, etc.), ensures the efficiency and compatibility of data transmission. It is responsible for receiving control instructions, uploading state information and data, and is the basis for realizing the collaborative work of modules. The data processing unit receives instructions and data from the main controller or external sensors, performs necessary calculations, logical processing and decision making. It generates control instructions for the I / O interface unit according to the preset control algorithm or user program, or processes the collected data and prepares to upload to the main controller or higher-level management system. The I / O interface unit is directly connected with the field device, responsible for receiving input signals (such as temperature, pressure, position, etc.) from the sensor and sending output instructions (such as starting the motor, valve control, etc.) to the actuator. The flexibility and diversity of this unit are the key to the wide applicability of the PLC system. The quick-release connection structure interface provides quick connection and disconnection functions at the physical level, ensuring that functional modules can be quickly replaced or upgraded without interrupting system operation. Through the ingenious design of the guide structure, locking mechanism and unlocking mechanism, the simplicity of the plugging process and the stability of the electrical connection are ensured. The fault diagnosis unit monitors the working state of the module and the system in real time, and identifies potential fault signs by analyzing running data (such as current, voltage, temperature, etc.). Once an anomaly is detected, the unit can take prompt action, such as cutting off power, issuing a warning or adjusting working parameters, to prevent the fault from expanding and protect the safe operation of the entire system. The storage unit is used to save configuration information, running parameters, historical data and fault records, etc. When the module is first connected, the storage unit will initialize and create necessary data structures. During operation, real-time data is collected and preprocessed before being stored, providing data support for fault diagnosis, performance evaluation and system optimization. In addition, data encryption and access control mechanisms ensure data security.

[0062] In an embodiment of the present application, the data storage step of the data storage unit includes:

[0063] When the functional module main controller is connected, the data storage unit performs initialization operation, establishes storage areas according to the preset data structure and format; the storage areas include configuration information area, running state area, historical data area, etc. And allocate storage space for each storage area, and set the corresponding access permission and security mechanism;

[0064] The data storage unit collects real-time operational data of the functional modules, such as sensor readings and actuator states, through the I / O interface unit. The collected data is pre-processed, including data cleaning, format conversion, and standardization. The pre-processed data is organized by timestamp.

[0065] The organized data is compressed by compression algorithms to reduce storage space and improve transmission efficiency. Indexing and data structures, such as hash tables and B-trees, are used to optimize data storage and retrieval performance.

[0066] Based on distributed storage and redundant backup mechanisms, the storage space is further configured. Sensitive data is encrypted, access control policies are set, and encryption algorithms and access control policies are regularly updated.

[0067] The working principle of the above technical solution is as follows: when the functional module is connected to the main controller, the data storage unit first performs initialization operation. This process involves planning storage space according to predefined data structure and format, creating different storage areas such as configuration information area, running state area and historical data area. Each area is assigned a specific storage space size, and access permissions and security measures are configured to ensure data isolation and protection at different levels; the data storage unit is connected to the sensors and actuators of the functional module through the I / O interface, and real-time operational data is captured. These raw data are pre-processed, including removing invalid or erroneous data (data cleaning), converting data format to match storage requirements (format conversion), and standardizing data for comparison and analysis. The processed data is sorted by timestamp, enhancing the time series characteristics of the data and query efficiency; to improve storage efficiency and data transmission speed, the pre-processed data is processed by compression algorithms to reduce its size. At the same time, through efficient index structure (such as hash table or B-tree), the data is organized, making data retrieval fast and accurate, even in massive data; to improve data reliability and system scalability, data is stored in different physical locations, forming a distributed storage architecture. Combined with the redundant backup mechanism, i.e. the same data has a copy in multiple nodes, ensuring that even if some storage units fail, data is still accessible, enhancing the fault tolerance of the system; sensitive data is encrypted before storage, ensuring that even if the data is accessed illegally, its content cannot be directly read. At the same time, strict access control policies limit data access permissions, only authorized users and applications can perform read and write operations. Regularly update encryption algorithms and access control policies to respond to changing security threats and maintain the forefront of data security.

[0068] The effects of the above technical solutions are as follows: by collecting and preprocessing the running data in real time, including data cleaning, format conversion and standardization, the quality of the stored data is ensured, and the complexity of subsequent analysis and processing is reduced. At the same time, the data is organized using timestamps, which facilitates quick information retrieval at specific time points and improves data retrieval speed; the application of data compression technology significantly reduces the storage space requirement, so that limited storage resources can accommodate more data. This is particularly important for industrial control systems that need to store a large amount of historical data for a long time, reducing storage costs and improving the overall economy of the system; through distributed storage and redundant backup mechanism, even if a part of the storage system fails, data can still be obtained from other backup nodes, ensuring the continuity and integrity of the data. Encryption of sensitive data and strict access control policy further strengthen the security protection of data, effectively preventing unauthorized access and data leakage risks; the preset data structure and format and the ability to dynamically allocate storage space enable the system to flexibly adapt to different types and sizes of data requirements. As the system develops and the amount of data grows, the storage area can be easily expanded to support continuous optimization and upgrading of the system; regular updates of encryption algorithms and access control policies ensure that data protection measures are always synchronized with the latest security standards, reducing the risks caused by technology aging. Clear access permission settings simplify operation and maintenance management, making it easy to track data operation records, which is extremely beneficial for troubleshooting and responsibility definition.

[0069] In an embodiment of the present application, the fault diagnosis step of the fault diagnosis unit comprises:

[0070] The fault diagnosis unit collects the running data of the PLC controller and the functional modules through the communication interface unit, and the running parameters include input / output signals, communication status, power status, etc. The collected data is preprocessed, and the preprocessing includes removing noise, filling missing values, and data standardization.

[0071] Based on the built-in fault diagnosis model, the processed data is analyzed to detect whether there is an anomaly or fault.

[0072] If an anomaly or fault is detected, the fault diagnosis report is classified according to the fault type and severity, and further analyzed and verified in combination with historical data and expert knowledge base.

[0073] Through the input / output signal detection function of the PLC controller, the location of the fault is located in combination with the fault diagnosis report.

[0074] If the fault location is successful, the isolation mechanism is started to isolate the fault part from the normal part.

[0075] If the fault location fails, the analog signal fault diagnosis method is used to perform secondary positioning through the simulation of fault scenarios. After successful positioning, the previous step is executed.

[0076] According to the results of fault diagnosis and positioning, a corresponding fault handling scheme is developed for fault handling, which includes replacing faulty components, repairing damaged equipment, and adjusting parameter settings. After fault handling is completed, the system is tested and verified;

[0077] Based on the results of testing and verification, the causes and regularities of faults are analyzed, and corresponding preventive measures and optimization schemes are developed;

[0078] The process and results of each fault diagnosis and handling are recorded in detail, and a fault report is generated. The fault reports are regularly summarized and analyzed to identify common and regular problems, and improvement measures and optimization schemes are developed.

[0079] The working principle of the above technical solution is as follows: real-time running data is collected from PLC controllers and various functional modules through a communication interface. These data cover key parameters such as input / output signal status, communication status, and power status. In the preprocessing stage, noise in the data is filtered out, missing values are filled in, and data standardization is implemented to eliminate data bias and provide an accurate and reliable basis for subsequent analysis. The built-in fault diagnosis model (which may include machine learning algorithms, rule engines, etc.) is used to analyze the preprocessed data in depth, identify any patterns or indicators that deviate from normal operating conditions, i.e., abnormal or fault signals. This process involves complex algorithm analysis aimed at accurately determining the existence and characteristics of faults. Once an anomaly is detected, the system further classifies the fault type and assesses its severity, generating a diagnostic report. The preliminary diagnosis results are cross-verified in combination with historical fault data and expert system knowledge to ensure the accuracy of the diagnosis. The input / output monitoring function of the PLC and the diagnostic report are used to accurately locate the fault position. Once successful positioning is achieved, an isolation mechanism is immediately activated to prevent the spread of the fault. If the initial positioning is unsuccessful, advanced diagnostic means are used to perform secondary positioning by simulating fault scenarios. Based on the positioning results, specific fault handling measures such as replacing parts, repairing equipment, or adjusting parameters are developed and executed. After handling, comprehensive system testing and verification are performed to ensure that all faults have been completely resolved and the system has returned to normal operation. The causes of the faults are analyzed in depth, and the regularities of fault occurrence are summarized to develop preventive measures and system optimization schemes to reduce the probability of future faults. The entire process and results of each fault handling are recorded in detail to form a fault report, which is regularly summarized and analyzed to identify common problems and trends, guiding future system improvement and maintenance strategy optimization.

[0080] The effect of the above technical scheme is that: through real-time monitoring and intelligent analysis, abnormalities can be quickly identified at the early stage of failure, the production interruption time caused by failure not being discovered in time is reduced, the high accuracy of the diagnosis result is ensured, false positives and false negatives are avoided, the failure positioning and isolation mechanism can quickly lock and isolate the problem area, effectively prevent the spread of failure, ensure the normal operation of other system components, and reduce the risk of the entire system being paralyzed due to a single point failure; based on the detailed report and regular analysis of the fault diagnosis, the enterprise can more scientifically plan the maintenance activities, shift from passive maintenance to predictive maintenance, reduce unnecessary maintenance operations, save maintenance costs, and prolong the service life of the equipment; through rapid failure response and processing, downtime is minimized, the continuous operation of the production line is maintained, and the production efficiency and capacity are directly improved, creating more value for the enterprise; periodic aggregation and analysis of fault reports help enterprises discover and solve common problems, and promote continuous improvement in technology and management; based on fault data analysis, potential optimization space can be found to guide technological innovation and system upgrade; the historical data and expert knowledge base accumulated during the fault diagnosis process provide rich decision-making basis for the management layer, which helps to make more intelligent choices when facing complex problems, and improves decision-making efficiency and quality.

[0081] In an embodiment of the present application, if the failure positioning fails, a secondary positioning is performed through the analog signal fault diagnosis method by simulating a fault scene, and after the positioning is successful, the previous step is executed, comprising:

[0082] Based on the working principle and fault characteristics of the known PLC controller and functional modules, a fault scene model is constructed, a simulation software is used to simulate the fault occurrence conditions similar to the real environment, and different parameters and variables are set to simulate various possible fault modes;

[0083] In the simulated fault scene, the analog signals are collected in real time through sensors, the collected analog signals are processed, the processing includes filtering, amplification and digitization, and key information is extracted; through a data analysis tool, the analog signals are subjected to frequency spectrum analysis, time domain analysis and correlation analysis;

[0084] In combination with expert knowledge and historical data, a fault feature library is established to store the signal features corresponding to various faults, and through a pattern recognition algorithm, the extracted analog signal features are matched and identified;

[0085] If the signal features consistent with the known fault features are identified, the corresponding fault is determined;

[0086] If the initial positioning fails, a secondary positioning strategy is developed according to the results of the analog signal analysis;

[0087] The redundancy design and backup function of the PLC controller are used to narrow down the fault range by switching the backup channel or standby equipment; and the fault propagation path is inferred in combination with the topology of the system and the dependency relationship between the functional modules.

[0088] According to the formulated secondary positioning strategy, the fault point is investigated and verified by the step-by-step approximation method and the elimination method;

[0089] The results of the secondary positioning are fed back to the fault diagnosis model for updating and optimizing the model.

[0090] The working principle of the above technical solution is as follows: first, based on the actual working principle of the PLC controller and the functional modules and the known fault characteristics, a virtual fault scenario model is constructed. Various fault conditions that may be encountered in the real environment are simulated using simulation software, including but not limited to electrical faults, communication interruptions, hardware damage, etc. By adjusting different parameters and variables, a wide range of fault mode library is generated, laying a foundation for subsequent simulation analysis; in the simulation environment, sensors are used to monitor the changes of analog signals in real time. These signals are preprocessed through filtering, amplification, digitization, etc. to eliminate interference and convert them into a form convenient for analysis. Then, advanced data analysis methods such as frequency spectrum analysis, time domain analysis, and correlation analysis are used to extract key feature information from the signals; a database containing typical fault characteristics is constructed using expert systems and historical fault cases. By matching the processed analog signal features with the fault feature database, the fault type can be preliminarily identified if a match is found. This process incorporates machine learning algorithms to improve the accuracy and efficiency of identification; if the initial simulation positioning fails, the system will adjust the strategy based on the results of the simulation signal analysis. By utilizing the redundancy design of the PLC system, the system switches to the backup channel or activates the standby equipment to narrow down the fault impact range, and analyzes the possible propagation path of the fault in combination with the system structure. Then, the step-by-step approximation and elimination method is used to systematically investigate each potential fault point until the fault is accurately located; finally, the results of the secondary positioning are fed back to the fault diagnosis model for continuous updating and optimization of the model. This means that each diagnosis process not only handles the current fault, but also trains and improves the fault diagnosis capability, ensuring that the model can adapt to a wider range of more complex fault conditions, forming a closed-loop system that continuously learns and evolves.

[0091] The technical scheme has the effects that: through simulating a fault scene and deeply analyzing an analog signal, a fault source can be quickly located without interrupting actual production or system operation, and time delay and resource waste caused by blind disassembly and inspection are reduced; meanwhile, in combination with advanced signal processing technology and pattern recognition algorithm, the accuracy of diagnosis is improved, and the possibility of misjudgment is reduced; through the redundant design and backup function of the PLC controller, the system running continuity can be ensured and downtime loss can be reduced when a fault occurs; in addition, accurate fault location can replace or repair the fault part in a targeted manner, unnecessary replacement of parts is avoided, and maintenance cost is greatly saved; through the establishment and continuous optimization of the fault feature library, potential faults can be warned in advance, preventive maintenance reduces the risk of sudden failure, and the stability and safety of the system are enhanced; in combination with system topology analysis of the fault propagation path, a more robust system architecture can be designed to prevent fault chain reactions; after each fault diagnosis, experience is fed back to the model for updating and optimization, forming a self-learning and continuous improvement mechanism, which not only improves the efficiency of future fault diagnosis, but also promotes the entire maintenance system to a higher level of intelligence and automation; in combination with expert knowledge and historical data, the valuable experience is converted into an operable fault feature library and diagnostic rules, which is helpful for knowledge inheritance and new employee training; meanwhile, with the accumulation and analysis of more cases, the capacity of the expert system can be continuously expanded and deepened.

[0092] In one embodiment of the present application, the quick-release connection structure includes a guide structure, a locking mechanism, and an unlocking mechanism. The guide structure is used for alignment during insertion of the functional module body; the locking mechanism is used to fix the inserted functional module body on the PLC controller; and the unlocking mechanism is used to unlock and pull out the fixed functional module body.

[0093] The quick-release connection structure adopts magnetic locking.

[0094] The working principle of the above technical solution is that the guide structure is designed with precise geometric shape or guide groove, which matches the corresponding features on the functional module, ensuring that the module can be smoothly slid into place along the correct path. This not only simplifies the installation process, but also avoids damage caused by incorrect docking, ensuring the correct alignment of the electrical interface. Once the functional module is correctly aligned and contacts the quick-release connection structure, the magnetic locking mechanism comes into play. This mechanism usually includes magnetic elements on the functional module and the controller, which automatically complete the locking when they are close due to magnetic attraction. The size of the magnetic force is carefully designed to be strong enough to firmly fix the module, ensuring that it will not loosen under vibration or slight external force, while allowing it to be easily unlocked by a specific operation when needed. When it is necessary to remove the functional module, the unlocking mechanism intervenes. The unlocking mechanism neutralizes the locking magnetic force through an electromagnet controlled by an electronic signal. In the case of electromagnetic locking, an electrical signal is sent to the unlocking electromagnet to generate a magnetic field of opposite polarity, thereby canceling the attractive force of the fixed magnet and allowing the module to be safely removed.

[0095] The effect of the above technical solution is that the quick-release connection structure allows the functional module to be quickly and easily replaced or upgraded without the need for complex tools or professional skills, significantly reducing the time required for maintenance and upgrading, improving production efficiency and system usability; the guide structure ensures that the functional module can be accurately aligned with the interface, making it easy for non-professionals to complete the insertion and removal operation, reducing the difficulty and error rate of operation; the magnetic locking mechanism ensures stable connection while avoiding the wear and failure problems that may exist in traditional mechanical locks, enhancing the reliability of the connection and reducing the risk of accidents caused by loose connections; the quick-release design simplifies the maintenance process, reducing the labor and time costs required for maintenance, and also reducing additional repair costs caused by improper maintenance, which is beneficial to reducing overall operating costs in the long run; the quick-release structure allows the system to flexibly adapt to different functional module configurations, facilitating quick adjustment or upgrade according to production needs, increasing the adaptability of the system and the compatibility of future technological development; the ability to quickly replace faulty modules can significantly reduce system downtime when a fault occurs, ensuring production continuity, which is particularly important for continuous production processes, and helps maintain production efficiency and economic benefits.

[0096] In an embodiment of the present application, the implementation steps of the hot plug function include:

[0097] When the functional module body approaches the PLC controller, the main controller detects whether there is a new functional module ready to access through the communication interface unit;

[0098] If a new functional module is detected, the main controller starts the intelligent identification unit to identify the information of the functional module about to be accessed; the information includes type and version;

[0099] If the identification is passed, the main controller guides the functional module body through the guide structure of the quick-release connection structure, and at the same time, the main controller starts the fault diagnosis unit to pre-check the electrical environment of the PLC controller and the functional module body.

[0100] Before the functional module body contacts the hot plug interface, the main controller adjusts the resistance value of the PTC (positive temperature coefficient thermistor) through the control circuit in advance, so that the PTC enters a preheating state; the preheating of the PTC helps to reduce the temperature impact in the insertion moment, thereby indirectly reducing the current impact.

[0101] When the functional module body contacts the hot plug interface, the main controller accurately controls the conduction time of the MOS tube through the timing circuit, and in the initial contact stage, the MOS tube is in an off state to prevent the generation of a large current in an instant. When the functional module body is fully contacted with the interface, the main controller gradually increases the conduction time of the MOS tube according to the signal of the timing circuit; so that the current rises smoothly;

[0102] During the connection of the functional module body and the main controller, the main controller monitors the current change in real time through the MOS tube current detection resistor; if an abnormal current is found, the main controller adjusts the conduction state of the MOS tube;

[0103] After the functional module body is stably connected with the main controller, the locking mechanism of the quick-release connection structure fixes the functional module body on the PLC controller, the main controller activates the functional module, and transmits signals and data through the I / O interface unit;

[0104] When the functional module needs to be separated, the main controller stops the signal and data transmission with the functional module, and starts the unlocking mechanism to release the locking state of the functional module body;

[0105] At the same time of unlocking, the main controller controls the MOS tube to be turned off, disconnects the electrical connection between the functional module and the main controller, and pulls out the functional module body from the main controller through the quick-release connection structure.

[0106] The working principle of the technical solution is as follows: when the functional module approaches the PLC controller, the main controller first senses this event through the communication interface unit and starts the intelligent identification unit. This unit is responsible for identifying the type and version information of the module and confirming whether it is compatible with the current system, preparing for subsequent operations; after successful identification, the main controller uses the guiding mechanism of the quick-release connection structure to guide the module to accurately align. At the same time, the fault diagnosis unit starts to pre-check the electrical environment to ensure the safety of the connection. To reduce the temperature and current impact of hot plug, the main controller adjusts the resistance value of the PTC thermistor by controlling its preheating, thereby smoothly transitioning; at the moment when the functional module contacts the hot plug interface, the main controller precisely controls the conduction time of the MOS tube by using a timing circuit, initially keeping the MOS tube closed to avoid large current instantaneous impact. As the contact gradually completes, the main controller gradually increases the conduction time of the MOS tube, allowing the current to rise smoothly and ensuring the stability of the electrical connection; during the connection process, the main controller monitors the current change in real time through the MOS tube current detection resistor. Once an abnormality is detected, the MOS tube conduction state is immediately adjusted or the connection is disconnected to prevent system damage, embodying a high degree of self-protection mechanism; after the functional module is stably connected to the main controller, the locking mechanism of the quick-release connection structure fixes it, and the main controller activates the functional module to start bidirectional transmission of signals and data through the I / O interface, realizing the normal operation of the module; when the module needs to be separated, the main controller first stops data transmission, activates the unlocking mechanism to release the module, and controls the MOS tube to disconnect the electrical connection to ensure safe separation. Through the quick-release connection structure, the functional module can be quickly and non-destructively pulled out of the main controller.

[0107] Effects of the above technical solutions are as follows: through the fast, uninterrupted hot plug operation, the functional module can be replaced or upgraded in the system running state, greatly shortening the maintenance time, reducing the unplanned downtime, and improving the maintainability and flexibility of the system; through intelligent identification, electrical environment pre-checking, PTC preheating, MOS tube control and other measures before and after the module access, the risks of electrical impact, current overload and short circuit are effectively prevented, the system hardware is protected from damage, and the safety of the operator is ensured; accurate MOS tube conduction time control and real-time current monitoring ensure the smooth rise of the current, and once the abnormal current is detected, the connection can be quickly adjusted or disconnected, avoiding the expansion of electrical faults and enhancing the stability and reliability of the system; from module identification to fault diagnosis, electrical environment pre-checking, current control and other full-automatic processing, manual intervention is reduced, the work efficiency is improved, and the operation error rate is reduced by relying on intelligent identification and control logic; the hot plug function enables the system to easily accommodate new or upgraded functional modules, providing convenience for continuous optimization and function expansion of the system, supporting rapid iteration of technology and adaptation to different application scenarios; during the replacement or upgrade of the functional module, the impact on the system running is minimized, ensuring the continuity of production or service, which is crucial for industrial automation, data centers and other applications with high availability requirements; fast maintenance response, reduced downtime, automatic fault prevention and processing mechanism jointly reduce maintenance costs, while improving equipment utilization and enhancing return on investment.

[0108] In one embodiment of the present application, during the connection of the functional module body and the main controller, the main controller monitors the current change in real time through the MOS tube current detection resistor; if an abnormal current is found, the conduction state of the MOS tube of the main controller is adjusted, including:

[0109] When the main controller starts to contact the functional module body and the hot plug interface, the monitoring function of the MOS tube current detection resistor is started, and the current value in the MOS tube is obtained in real time through a high-precision current detection circuit, and converted into a digital signal;

[0110] After the main controller receives the current data, data analysis is performed to determine whether the current is within the preset safety range, and at the same time, the historical data is compared to analyze the trend of the current change and predict abnormal conditions;

[0111] If the current value exceeds the preset safety threshold or the current change trend is abnormal, a warning signal is sent by the main controller;

[0112] The main controller selects an adjustment strategy according to the specific situation of the abnormal current and the system state; for example, the conduction time of the MOS tube can be gradually reduced to reduce the current value; or other related parameters such as voltage, frequency, etc. can be adjusted to optimize the electrical environment.

[0113] If the adjustment strategy cannot control the current anomaly, or the abnormal situation continues to worsen, the safety protection mechanism is started by the main controller. This includes immediately disconnecting the MOS tube connection, completely isolating the functional module from the electrical connection of the main controller; or starting the standby power supply to ensure the safe and stable operation of the system.

[0114] The working principle of the above technical solution is: when the functional module starts to contact with the hot plug interface, the main controller activates the monitoring function of the MOS tube current detection resistor. Through the high-precision current detection circuit, the current value is continuously and real-time obtained from the MOS tube, and it is converted into a digital signal convenient for processing. This step ensures immediate monitoring of current changes; after the main controller receives the current data, it immediately analyzes. First, it is judged whether the current remains within the preset safety threshold to avoid overload. At the same time, the system will compare historical data to analyze the trend of current changes and use algorithms to predict potential abnormal situations, which helps to detect potential problems early; if the analysis result shows that the current exceeds the safety range or the trend is abnormal, the main controller immediately triggers the early warning mechanism. The early warning can be in the form of audible and visual alarms or system log records, quickly notifying the operator or system administrator, providing timely information for manual intervention; according to the specific situation of the current anomaly and the system state, the main controller takes appropriate adjustment strategies. This may include dynamically adjusting the on-time of the MOS tube to reduce the current, or adjusting the voltage, frequency and other electrical parameters to optimize the operating environment and try to solve the problem without affecting system performance; if the above adjustment strategy cannot effectively control the current anomaly, or the anomaly worsens, the main controller will execute the safety protection measures. This includes immediately disconnecting the MOS tube connection, completely isolating the functional module from the electrical connection of the main controller to prevent the spread of faults.

[0115] The effects of the above technical solutions are as follows: the real-time current monitoring and the fast response mechanism can timely discover and handle current abnormalities, effectively prevent safety accidents such as equipment damage, short circuit or fire caused by overcurrent, and greatly enhance the operation safety of the system; the timely sending of the overwarning signal enables the operator to quickly know the problem and intervene in processing, reduces the troubleshooting time, improves the efficiency of the maintenance work, and at the same time, the system log record helps to trace the fault cause, facilitating subsequent analysis and prevention; the main controller can dynamically adjust the conduction state or electrical parameters of the MOS tube according to the current abnormality, and the adaptive adjustment strategy can optimize the electrical environment, ensure the current within the safe range, maintain the stable operation of the system, and reduce the need for human intervention; by effectively managing the current, the impact of overload and current mutation on components is avoided, thereby prolonging the service life of key equipment such as functional modules and the main controller, and reducing the maintenance and replacement costs caused by electrical problems; when the current abnormality cannot be controlled through the adjustment strategy, the system can automatically start the safety protection mechanism, such as disconnecting or enabling the standby power supply, and the fast fault isolation and response strategy maximizes the protection of the core functions of the system, maintaining the business continuity; the automation monitoring and intelligent management of the whole process reduce the complexity and error rate of manual operation, improve the automation and intelligence level of the system, and conform to the development trend of modern industrial automation and intelligent operation and maintenance.

[0116] Obviously, those skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application belong to the scope of the claims of the present application and their equivalent technologies, the present application also intends to include these modifications and variations.

Claims

1. A PLC controller function module with hot plug function, comprising a main controller, a function module body, a hot plug interface and a quick release connection structure, characterized in that, The main controller is connected and separated from the functional module body through the quick release connection structure, and the hot plug interface is used for signal and data transmission when the functional module body is connected and separated from the main controller. The implementation steps of the hot plug function include: When the functional module body approaches the PLC controller, the main controller detects whether there is a new functional module ready to access through the communication interface unit; If a new functional module is detected, the main controller starts the intelligent identification unit to identify the information of the functional module about to be accessed; If the identification is passed, the main controller guides the functional module body to align through the guide structure of the quick release connection structure, and the main controller starts the fault diagnosis unit to pre-check the electrical environment of the PLC controller and the functional module body; Before the functional module body contacts the hot plug interface, the main controller pre-adjusts the resistance value of the PTC through the control circuit to make it enter the preheating state; When the functional module body contacts the hot plug interface, the main controller accurately controls the conduction time of the MOS tube through the timing circuit, and when the functional module body is fully contacted with the interface, the main controller gradually increases the conduction time of the MOS tube according to the signal of the timing circuit; During the connection of the functional module body and the main controller, the main controller monitors the current change in real time through the MOS tube current detection resistor; if an abnormal current is found, the conduction state of the main controller MOS tube is adjusted; After the functional module body is stably connected with the main controller, the locking mechanism of the quick release connection structure fixes the functional module body on the PLC controller, the main controller activates the functional module, and the signal and data transmission is carried out through the I / O interface unit; When the functional module needs to be separated, the main controller stops the signal and data transmission with the functional module, and starts the unlocking mechanism to release the locking state of the functional module body; At the same time of unlocking, the main controller controls the MOS tube to turn off, disconnects the electrical connection between the functional module and the main controller, and pulls out the functional module body from the main controller through the quick release connection structure.

2. The PLC controller function module with hot plug function according to claim 1, characterized in that, The functional module body includes an intelligent identification unit, a communication interface unit, a data processing unit, an I / O interface unit, a quick release connection structure interface, a fault diagnosis unit, and a data storage unit.

3. The PLC controller function module with hot plug function according to claim 2, characterized in that, The data storage step of the data storage unit includes: When the functional module main controller is connected, the data storage unit performs initialization operation, establishes a storage area according to the preset data structure and format, allocates storage space for each storage area, and sets corresponding access permission and security mechanism; The data storage unit collects running data of the functional module in real time through the I / O interface unit, and pre-processes the collected data; and organizes the pre-processed data according to the time stamp; The organized data is compressed through the compression algorithm, and the storage and retrieval performance of the data is optimized through the index and data structure; Based on the distributed storage and redundant backup mechanism, the storage space is further set; the sensitive data stored is encrypted, the access control strategy is set, and the encryption algorithm and access control strategy are updated regularly.

4. The PLC controller function module with hot plug function according to claim 2, characterized in that, The fault diagnosis step of the fault diagnosis unit comprises: The fault diagnosis unit collects the operation data of the PLC controller and the functional modules through the communication interface unit, and pre-processes the collected data; Based on the built-in fault diagnosis model, the processed data is analyzed to detect whether there is an anomaly or fault; If an anomaly or fault is detected, the fault diagnosis report is generated according to the fault type and severity, and the fault diagnosis report is further analyzed and verified in combination with historical data and expert knowledge base; Through the input / output signal detection function of the PLC controller, the fault location is located in combination with the fault diagnosis report; If the fault location is successful, the isolation mechanism is started to isolate the fault part from the normal part; If the fault location fails, the secondary positioning is performed through the analog signal fault diagnosis method by simulating the fault scene, and the previous step is executed after the successful positioning; According to the results of fault diagnosis and positioning, the corresponding fault handling scheme is formulated for fault handling, and after the fault handling is completed, the system is tested and verified; Based on the results of testing and verification, the causes and laws of fault occurrence are analyzed, and corresponding preventive measures and optimization schemes are formulated; The process and results of each fault diagnosis and handling are recorded in detail, and a fault report is generated, and the fault report is summarized and analyzed regularly to find common and regular problems, and improvement measures and optimization schemes are formulated.

5. The PLC controller function module with hot plug function according to claim 4, characterized in that, The fault handling scheme includes replacing faulty components, repairing damaged equipment, and adjusting parameter settings.

6. The PLC controller function module with hot plug function according to claim 4, characterized in that, If the fault location fails, the secondary positioning is performed through the analog signal fault diagnosis method by simulating the fault scene, and the previous step is executed after the successful positioning, comprising: Based on the known working principle and fault characteristics of the PLC controller and the functional modules, a fault scene model is constructed, a simulation software is used to simulate the fault occurrence conditions similar to the real environment, and different parameters and variables are set to simulate various possible fault modes; In the simulated fault scene, the analog signals are collected in real time through the sensors, the collected analog signals are processed, and the key information is extracted; the data analysis tool is used for frequency spectrum analysis, time domain analysis and correlation analysis of the analog signals; In combination with expert knowledge and historical data, a fault feature library is established to store the signal characteristics corresponding to various faults, and a pattern recognition algorithm is used to match and identify the extracted analog signal characteristics; If the signal characteristics consistent with the known fault characteristics are identified, the corresponding fault is determined; If the initial positioning fails, the secondary positioning strategy is formulated according to the results of analog signal analysis; The redundancy design and backup function of the PLC controller are used to narrow down the fault range by switching the backup channel or standby equipment; and in combination with the topology structure of the system and the dependency relationship between the functional modules, the fault propagation path is speculated; According to the formulated secondary positioning strategy, the fault point is investigated and verified by the step-by-step approximation method and the elimination method; The results of secondary positioning are fed back to the fault diagnosis model to update and optimize the model.

7. The PLC controller function module with hot plug-in function according to claim 1, characterized in that, The quick release connection structure comprises a guide structure, a locking mechanism and an unlocking mechanism.

8. The PLC controller function module with hot plug function according to claim 7, characterized in that, The quick release connection structure adopts magnetic locking.

9. The PLC controller function module with hot plug function according to claim 1, characterized in that, In the process of connecting the functional module body and the main controller, the main controller monitors the current change in real time through the MOS tube current detection resistor. If the current is found to be abnormal, the conduction state of the MOS tube of the main controller is adjusted, including: When the functional module body and the hot plug interface start to contact, the main controller starts the monitoring function of the MOS tube current detection resistor, and through the high-precision current detection circuit, the current value in the MOS tube is obtained in real time and converted into a digital signal; After the main controller receives the current data, it analyzes the data, judges whether the current is within the preset safety range, compares it with the historical data, analyzes the trend of the current change, and predicts abnormal conditions; If the current value is found to exceed the preset safety threshold or the current change trend is abnormal, a warning signal is sent through the main controller; The main controller selects an adjustment strategy according to the specific situation of the current abnormality and the system state; If the adjustment strategy cannot control the current abnormality or the abnormality continues to worsen, the main controller starts the safety protection mechanism.

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