Industrial control restart system and method

Abstract

The invention discloses an industrial control restart system and method, and the system comprises a monitoring module which is used for monitoring the operation state of an industrial control system in real time; the fault detection module is in signal connection with the monitoring module and is used for detecting faults or abnormities possibly occurring in the system; the control module is connected with the fault detection module and is used for sending a restart instruction when a fault or abnormity is detected; the backup module is used for storing current system data and setting parameters before restarting so as to ensure data integrity; and the restart management module is in signal connection with the control module and is used for receiving the restart instruction and executing restart operation. According to the industrial control restarting system and method, restarting can be rapidly and efficiently carried out when the system breaks down or is upgraded, the data integrity is ensured through the backup module, and the problem of data loss caused by faults or abnormal restarting is avoided.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial production, and in particular relates to an industrial control restart system and method. Background Art

[0002] Industrial production refers to the process of processing raw materials or semi-finished products into finished products or providing industrial services by using machinery, technology and various resources (such as labor, raw materials and energy). Industrial production involves multiple links and processes, from the procurement, processing and manufacturing of raw materials to the inspection, packaging and distribution of finished products. Its purpose is to mass-produce high-quality products to meet market demand and achieve economic benefits; In industrial production control systems, the control system may need to be restarted for various reasons. For example, when the system detects a fault or upgrades the software, it is usually necessary to restart the system. However, traditional restart methods may cause long system downtime and are prone to data loss, which affects subsequent normal production and production efficiency. Summary of the invention

[0003] The purpose of the present invention is to provide an industrial control restart system and method to solve the problems in the background technology.

[0004] In order to achieve the above object, the present invention adopts the following technical solution: The present invention provides an industrial control restart system, comprising: Monitoring module, used to monitor the operating status of the industrial control system in real time; A fault detection module is connected to the monitoring module signal to detect possible faults or anomalies in the system; A control module, connected to the fault detection module, for issuing a restart instruction when a fault or anomaly is detected; Backup module, used to save current system data and setting parameters before restart to ensure data integrity; The restart management module is connected to the control module signal and is used to receive the restart instruction and execute the restart operation.

[0005] A further improvement of the present invention is that the monitoring module comprises: Sensor interface unit, used to connect and manage various industrial sensors and collect real-time data on system operation status; A data acquisition unit, used to acquire data from the sensor interface unit and perform preliminary filtering, calibration and preprocessing; A communication unit, used to transmit the monitoring data of the sensor interface unit and the pre-processed data of the data acquisition unit to the fault detection module and the control module; A data storage unit for storing real-time monitoring data, historical data collected by the sensor interface, and analysis results; The control unit is used to provide an interface for operators to view real-time monitoring data and system status and perform interactive operations; The alarm unit is used to send out audible and visual alarms to alert operators when the system detects an abnormality or failure.

[0006] A further improvement of the present invention is that the fault detection module comprises: A fault identification unit for identifying faults or abnormal conditions in system operation using threshold-based detection, pattern recognition algorithms, and statistical analysis methods; A data input unit, used to receive real-time monitoring data and pre-processed data from the sensor interface unit and the data acquisition unit in the monitoring module; A fault classification unit, used to classify the detected faults or anomalies and determine their severity and type; A decision-making unit is used to decide whether to issue a restart instruction or take other countermeasures based on the fault classification result; The diagnostic unit is used to provide further diagnostic analysis for the detected fault or abnormality to help determine the cause of the fault.

[0007] A further improvement of the present invention is that the control module comprises: An instruction receiving unit, used for receiving control instructions and status information from the monitoring module and the fault detection module; A processing unit, for parsing and processing received instructions to determine specific control operations to be performed; An execution unit is used to execute control commands issued by the processing unit and control specific execution devices or system components; Feedback unit, used to monitor the response of each component during the execution process and collect feedback information to confirm the effectiveness and correctness of instruction execution; Safety unit, used to ensure the safety of control operations, immediately stop operations if abnormal conditions are detected, or initiate safety measures; The parameter setting unit is used to allow the user to set and adjust control parameters to optimize system performance.

[0008] A further improvement of the present invention is that the restart management module includes: A restart execution unit is used to actually execute the restart operation of the system or device; Restart strategy unit, used to store and manage multiple restart strategies and select the most suitable restart method according to the system status; The recovery management unit is used to manage the recovery operation of the system or device after the restart is completed to ensure that all services and functions can be restored normally.

[0009] A further improvement of the present invention is that the backup module comprises: Storage management unit, used to manage and maintain the storage location of backup data to ensure the reliability and security of data storage; Backup strategy unit, used to define and manage backup strategies; The planning and scheduling unit is used to execute the scheduled backup task scheduling to ensure that the backup is performed at the set time and frequency; Data recovery unit, used to recover data from backup when needed, to ensure that the system or user can normally access and use the recovered data; A verification unit, used to verify the backup data to ensure the integrity and availability of the backup data; The alarm and notification unit is used to send alarms or notifications to relevant personnel when problems occur during the backup process.

[0010] The present invention also provides an industrial control restart method, comprising: Real-time monitoring of the operating status of industrial control systems; Detect faults or anomalies in the system and analyze and diagnose them; When a fault or abnormality is detected, a restart command is issued; Save current system data and setting parameters before restarting; Receive the restart instruction and execute the restart operation.

[0011] A further improvement of the present invention is to monitor the operating status of the industrial control system in real time, including: collecting real-time data of the system operating status; performing preliminary filtering, calibration and preprocessing on the real-time data; storing real-time monitoring data, historical data collected by the sensor interface and analysis results; providing an interface for operators to view real-time monitoring data and system status and perform interactive operations; when the system detects an abnormality or failure, it issues an audible and visual alarm to prompt the operator.

[0012] A further improvement of the present invention is to detect faults or anomalies in the system and analyze and diagnose the faults or anomalies, including: using threshold-based detection, pattern recognition algorithms, and statistical analysis methods to identify faults or anomalies in system operation; classifying the detected faults or anomalies to determine their severity and type; based on the fault classification results, deciding whether to issue a restart instruction or take other countermeasures; providing further diagnostic analysis for the detected faults or anomalies to help determine the cause of the fault.

[0013] The present invention also provides a computer-readable storage medium, wherein the computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of the industrial control restart method are implemented.

[0014] Compared with the prior art, the present invention has at least the following beneficial technical effects: The present invention provides an industrial control restart system and method. By setting a fault detection module, it is possible to detect faults or anomalies that may occur in the system, thereby facilitating personnel to subsequently handle the faults and anomalies and improving the efficiency of personnel in handling faults and anomalies. The present invention can not only quickly and efficiently restart the system when a fault or upgrade occurs, but also ensure the integrity of the data through the backup module, avoiding the problem of data loss caused by faulty or abnormal restarts. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a structural block diagram of an industrial control restart system of the present invention; Figure 2 This is a block diagram of the monitoring module of the present invention; Figure 3 This is a block diagram of a fault detection module of the present invention; Figure 4 This is a control module block diagram of the present invention; Figure 5 This is a block diagram of the restart management module of the present invention; Figure 6 This is a block diagram of the backup module of the present invention; Figure 7 The present invention is a flowchart of an industrial control restart method. DETAILED DESCRIPTION

[0016] In the following, only some exemplary embodiments are briefly described. As those skilled in the art will appreciate, the described embodiments may be modified in various ways without departing from the spirit or scope of the present invention. Therefore, the drawings and descriptions are considered to be exemplary and non-restrictive in nature.

[0017] It should be understood that when used in this specification and the appended claims, the terms "include" and "comprises" indicate the presence of described features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof.

[0018] It should also be understood that the terms used in the present specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention. As used in the present specification and the appended claims, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" are intended to include plural forms.

[0019] It should be further understood that the term "and / or" used in the present description and the appended claims refers to any and all possible combinations of one or more of the associated listed items, and includes these combinations.

[0020] Various structural schematic diagrams of the embodiments disclosed in the present invention are shown in the accompanying drawings. These figures are not drawn to scale, and some details are magnified and some details may be omitted for the purpose of clear expression. The shapes of various regions and layers shown in the figures and the relative sizes and positional relationships therebetween are only exemplary, and may deviate in practice due to manufacturing tolerances or technical limitations, and those skilled in the art may additionally design regions / layers with different shapes, sizes, and relative positions according to actual needs.

[0021] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0022] Example 1 like Figure 1-6 As shown, this embodiment provides an industrial control restart system, including: Monitoring module, used to monitor the operating status of the industrial control system in real time; The monitoring modules include: The sensor interface unit is used to connect and manage various industrial sensors and collect real-time data on the system operation status, including temperature sensor interface, pressure sensor interface, vibration sensor interface, etc. A data acquisition unit, used to obtain data from the sensor interface unit and perform preliminary filtering, calibration and preprocessing, and an analog-to-digital converter may be used; The communication unit is used to transmit the monitoring data of the sensor interface unit and the pre-processed data of the data acquisition unit to the fault detection module and the control module. A wireless communication module such as Wi-Fi, Zigbee module, etc. can be used; Data storage unit, used to store real-time monitoring data, historical data collected by the sensor interface and analysis results, which can use external storage devices such as SD cards; The control unit is used to provide an interface for operators to view real-time monitoring data and system status and perform interactive operations, and a touch screen may be used; An alarm unit is used to send out an audible and visual alarm to alert the operator when the system detects an abnormality or failure. A buzzer may be used; Specifically, the sensor interface unit connects to various industrial sensors to collect real-time data on the system's operating status. The data acquisition unit filters, calibrates and preprocesses the data. The communication unit transmits the analysis results to the fault detection module and the control module. The data storage unit stores the monitoring data and analysis results for subsequent analysis and reporting. The control unit provides an interface for operators to view and interact. The alarm unit issues an alarm when an abnormality or fault is detected.

[0023] A fault detection module is connected to the monitoring module signal to detect possible faults or anomalies in the system; The fault detection module includes: A fault identification unit, which is used to identify faults or abnormal conditions in system operation using various algorithms and rules, including threshold-based detection, pattern recognition algorithms, and statistical analysis methods; A data input unit, used to receive real-time monitoring data and pre-processed data from the sensor interface unit and the data acquisition unit in the monitoring module, and a data bus may be used; Fault classification unit, used to classify detected faults or anomalies and determine their severity and type, which can adopt classification algorithms, fault tree analysis, etc.; A decision-making unit is used to decide whether to issue a restart instruction or take other countermeasures based on the fault classification result; A diagnostic unit, used to provide further diagnostic analysis for detected faults or anomalies to help determine the cause of the fault; Specifically, the data input unit receives real-time data from the monitoring module, the fault identification unit uses predetermined algorithms and rules to detect faults or anomalies, the fault classification unit classifies the identified faults, the decision unit decides whether to issue a restart instruction or take other countermeasures based on the classification results, and the diagnosis unit provides further diagnostic analysis of the detected faults or anomalies to determine the cause of the fault.

[0024] A control module, connected to the fault detection module, for issuing a restart instruction when a fault or anomaly is detected; The control module includes: An instruction receiving unit, used to receive control instructions and status information from the monitoring module and the fault detection module, and may adopt a communication interface; A processing unit, used for parsing and processing received instructions to determine specific control operations to be performed, and a microcontroller may be used; The execution unit is used to execute the control commands issued by the processing unit and control specific execution devices or system components, and a relay may be used; Feedback unit, used to monitor the response of each component during the execution process, collect feedback information to confirm the effectiveness and correctness of instruction execution, and can use a state monitor; Safety unit, used to ensure the safety of control operations, immediately stop the operation if an abnormal situation is detected, or initiate safety measures, which can be achieved by using safety relays; Parameter setting unit, used to allow users to set and adjust control parameters and optimize system performance, and a configuration interface may be used; Specifically, the instruction receiving unit is used to receive control instructions from the monitoring module and the fault detection module. The processing unit parses the instructions and determines the specific control operation. The execution unit executes the control command of the processing unit. The feedback unit monitors the response during the execution process. The safety unit initiates emergency measures when an abnormal situation is detected. The parameter setting unit allows the user to set and adjust the control parameters.

[0025] Backup module, used to save current system data and setting parameters before restart to ensure data integrity; The backup modules include: The storage management unit is used to manage and maintain the storage location of the backup data to ensure the reliability and security of data storage. A hard disk storage device may be used. The backup policy unit is used to define and manage backup policies, which can use policy configuration files; The planning and scheduling unit is used to execute the scheduled backup task scheduling to ensure that the backup is performed at the set time and frequency, and a task scheduler may be used; Data recovery unit, used to recover data from backup when needed, to ensure that the system or user can normally access and use the recovered data; A verification unit is used to verify the backup data to ensure the integrity and availability of the backup data, and a CRC check mechanism may be used; Alarm and notification unit, used to send alarms or notifications to relevant personnel when problems occur during the backup process, and an email notification system can be used; Specifically, the storage management unit is responsible for data storage, the backup strategy unit defines the specific backup strategy, the planning and scheduling unit performs backup operations according to the predetermined time and frequency, the data recovery unit performs data recovery when necessary, the verification unit checks the integrity of the data, and the alarm and notification unit issues an alarm notification when a problem occurs.

[0026] The restart management module is connected to the control module signal, and is used to receive the restart instruction and execute the restart operation; The restart management module includes: A restart execution unit is used to actually execute the restart operation of the system or device, and a reset controller may be used; The restart strategy unit is used to store and manage multiple restart strategies and select the most suitable restart method according to the system status. The strategy database can be used; The recovery management unit is used to manage the recovery operation of the system or device after the restart is completed to ensure that all services and functions can be restored normally. It can be used as the configuration manager; Specifically, the restart execution unit executes the restart operation according to the instruction of the processing unit, the restart strategy unit stores a variety of restart strategies, and the recovery management unit ensures the normal recovery of the system after the restart.

[0027] Example 2 like Figure 7 As shown, this embodiment provides an industrial control restart method, including: S1: Real-time monitoring of the operating status of industrial control systems; S2: Detect faults or anomalies in the system and analyze and diagnose the faults or anomalies; S3: When a fault or anomaly is detected, a restart command is issued; S4: Save current system data and setting parameters before restarting; S5: Receive the restart instruction and execute the restart operation.

[0028] In this embodiment, the operating status of the industrial control system is monitored in real time, including: collecting real-time data on the system operating status; performing preliminary filtering, calibration and preprocessing on the real-time data; storing real-time monitoring data, historical data collected by the sensor interface and analysis results; providing an interface for operators to view real-time monitoring data and system status and perform interactive operations; when the system detects an abnormality or failure, it issues an audible and visual alarm to prompt the operator.

[0029] In this embodiment, faults or anomalies in the system are detected and analyzed and diagnosed, including: using threshold-based detection, pattern recognition algorithms, and statistical analysis methods to identify faults or anomalies in system operation; classifying the detected faults or anomalies to determine their severity and type; based on the fault classification results, deciding whether to issue a restart instruction or take other countermeasures; providing further diagnostic analysis for the detected faults or anomalies to help determine the cause of the fault.

[0030] Example 3 This embodiment provides a computer-readable storage medium, wherein the computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of the industrial control restart method are implemented.

[0031] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present application may adopt the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program codes.

[0032] The present application is described with reference to the flowcharts and / or block diagrams of the methods, systems and computer program products according to the embodiments of the present application. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of the processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A system that specifies the functions of a box or boxes.

[0033] These computer program instructions may also be stored in a computer readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture including an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0034] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0035] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the attached claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims are included in the present invention. Any figure mark in the claims should not be regarded as limiting the claims involved.

[0036] In addition, it should be understood that although this specification is described in accordance with the implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation modes that can be understood by those skilled in the art. The above content is only to illustrate the technical idea of ​​the present invention, and cannot be used to limit the protection scope of the present invention. Any changes made on the basis of the technical solution according to the technical idea proposed by the present invention shall fall within the protection scope of the claims of the present invention.

Claims

1. An industrial control restart system, characterized in that: include: Monitoring module, used to monitor the operating status of the industrial control system in real time; A fault detection module is connected to the monitoring module signal to detect possible faults or anomalies in the system; A control module, connected to the fault detection module, for issuing a restart instruction when a fault or anomaly is detected; Backup module, used to save current system data and setting parameters before restart to ensure data integrity; The restart management module is connected to the control module signal and is used to receive the restart instruction and execute the restart operation.

2. An industrial control restart system according to claim 1, characterized in that: The monitoring modules include: Sensor interface unit, used to connect and manage various industrial sensors and collect real-time data on system operation status; A data acquisition unit, used to acquire data from the sensor interface unit and perform preliminary filtering, calibration and preprocessing; A communication unit, used to transmit the monitoring data of the sensor interface unit and the pre-processed data of the data acquisition unit to the fault detection module and the control module; A data storage unit for storing real-time monitoring data, historical data collected by the sensor interface, and analysis results; The control unit is used to provide an interface for operators to view real-time monitoring data and system status and perform interactive operations; The alarm unit is used to send out audible and visual alarms to alert operators when the system detects an abnormality or failure.

3. An industrial control restart system according to claim 1, characterized in that: The fault detection module includes: A fault identification unit for identifying faults or abnormal conditions in system operation using threshold-based detection, pattern recognition algorithms, and statistical analysis methods; A data input unit, used to receive real-time monitoring data and pre-processed data from the sensor interface unit and the data acquisition unit in the monitoring module; A fault classification unit, used to classify the detected faults or anomalies and determine their severity and type; A decision-making unit is used to decide whether to issue a restart instruction or take other countermeasures based on the fault classification result; The diagnostic unit is used to provide further diagnostic analysis for the detected fault or abnormality to help determine the cause of the fault.

4. The industrial control restart system according to claim 1, characterized in that: The control module includes: An instruction receiving unit, used for receiving control instructions and status information from the monitoring module and the fault detection module; A processing unit, for parsing and processing received instructions to determine specific control operations to be performed; An execution unit is used to execute control commands issued by the processing unit and control specific execution devices or system components; Feedback unit, used to monitor the response of each component during the execution process and collect feedback information to confirm the effectiveness and correctness of instruction execution; Safety unit, used to ensure the safety of control operations, immediately stop operations if abnormal conditions are detected, or initiate safety measures; The parameter setting unit is used to allow the user to set and adjust control parameters to optimize system performance.

5. The industrial control restart system according to claim 1, characterized in that: The restart management module includes: A restart execution unit is used to actually execute the restart operation of the system or device; Restart strategy unit, used to store and manage multiple restart strategies and select the most suitable restart method according to the system status; The recovery management unit is used to manage the recovery operation of the system or device after the restart is completed to ensure that all services and functions can be restored normally.

6. An industrial control restart system according to claim 1, characterized in that: The backup modules include: Storage management unit, used to manage and maintain the storage location of backup data to ensure the reliability and security of data storage; Backup strategy unit, used to define and manage backup strategies; The planning and scheduling unit is used to execute the scheduled backup task scheduling to ensure that the backup is performed at the set time and frequency; Data recovery unit, used to recover data from backup when needed, to ensure that the system or user can normally access and use the recovered data; A verification unit, used to verify the backup data to ensure the integrity and availability of the backup data; The alarm and notification unit is used to send alarms or notifications to relevant personnel when problems occur during the backup process.

7. An industrial control restart method, characterized in that: include: Real-time monitoring of the operating status of industrial control systems; Detect faults or anomalies in the system and analyze and diagnose them; When a fault or abnormality is detected, a restart command is issued; Save current system data and setting parameters before restarting; Receive the restart instruction and execute the restart operation.

8. An industrial control restart method according to claim 7, characterized in that: Real-time monitoring of the operating status of industrial control systems, including: collecting real-time data on the system operating status; performing preliminary filtering, calibration and preprocessing on real-time data; storing real-time monitoring data, historical data collected by sensor interfaces and analysis results; providing an interface for operators to view real-time monitoring data and system status and perform interactive operations; when the system detects an abnormality or failure, it issues an audible and visual alarm to alert the operator.

9. An industrial control restart method according to claim 7, characterized in that: Detect faults or anomalies in the system and analyze and diagnose the faults or anomalies, including: using threshold-based detection, pattern recognition algorithms, and statistical analysis methods to identify faults or anomalies in system operation; classifying detected faults or anomalies to determine their severity and type; based on the fault classification results, deciding whether to issue a restart instruction or take other countermeasures; providing further diagnostic analysis for detected faults or anomalies to help determine the cause of the fault.

10. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, and when the computer program is executed by a processor, the steps of an industrial control restart method according to any one of claims 7 to 9 are implemented.

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