Method and system for improving reliability of DCS (Distributed Control System)

Abstract

The invention discloses a method and a system for improving reliability of a DCS (Distributed Control System). The method comprises the following steps: splitting an original loop structure of a first object, and configuring a loop communication module; and optimizing and upgrading the upper computer communication system and the control system of the first object. And comparing display contents of new and old systems to ensure information synchronization. According to the method and the system for improving the reliability of the DCS, a more humanized layout is adopted by a new interface, so that an operator can more intuitively know the running state and parameter setting of equipment. The operation state and parameter information of the equipment can be presented in a clearer and more visual manner, so that the operation state of the equipment can be conveniently concerned in real time, and problems can be timely found. The communication efficiency and stability are improved, and communication faults are reduced. The loop structure is optimized, the influence of signal interference on communication is reduced, and data transmission is more accurate and faster.

Description

Technical Field

[0001] The present invention relates to the technical field of DCS system architecture update, and in particular to a method and system for improving the reliability of a DCS system. Background Art

[0002] Distributed control system, or DCS system, is the core component of thermal control system of thermal power plant. At present, many power plants adopt dual DCS system architecture, which is responsible for the control tasks of desulfurization side and boiler side respectively. In view of the relatively small number of control devices on the desulfurization side and the consistent control logic, serial port is usually used for data communication. However, with the continuous advancement of control system technology, the stability and timeliness of serial port connection can no longer meet the urgent needs of current system development. Summary of the invention

[0003] In view of the above-mentioned problems, the present invention is proposed.

[0004] Therefore, the technical problem solved by the present invention is: in order to enhance the stability, precise control and timeliness of the DCS system on the desulfurization side, the modules and host computer connected by the serial port are completely replaced, and a more efficient and portable network cable interface is used for connection, and the control network is reconfigured. At the same time, the software and hardware of the host computer are upgraded to ensure that it can meet the stringent requirements of the current desulfurization system control.

[0005] To solve the above technical problems, the present invention provides the following technical solutions: A method for improving the reliability of a DCS system, comprising: splitting the original loop structure of a first object and configuring a loop communication module.

[0006] Optimize and upgrade the upper system of the first object.

[0007] Ensure information is synchronized by comparing displays between old and new systems.

[0008] As a preferred solution of the method for improving the reliability of the DCS system described in the present invention, wherein: the splitting of the original loop structure of the first object includes, when repairing one of the communication loops of the first object, performing a dismantling operation at a specific device intermediate node, and monitoring the operating status of the redundant loop and the running equipment at the same time.

[0009] As a preferred solution of the method for improving the reliability of a DCS system described in the present invention, the host system includes but is not limited to a host computer communication system and a control system.

[0010] As a preferred solution of the method for improving DCS system reliability described in the present invention, the optimization and upgrading of the host computer communication system and control system of the first object includes upgrading the host computer communication system and introducing an intelligent fault transfer mechanism.

[0011] As a preferred solution of the method for improving the reliability of a DCS system described in the present invention, wherein: the first object includes but is not limited to a DCS system, and the DCS system includes control equipment in normal operation, equipment in shutdown state or equipment requiring maintenance.

[0012] Introduce intelligent failover mechanism and configure independent historical data station and OPC communication station.

[0013] As a preferred solution of the method for improving the reliability of the DCS system described in the present invention, wherein: the optimization and upgrading of the host computer communication system and the control system for the first object also includes the following control system upgrading steps:

[0014] Back up all existing project files and copy all data intact to a safe storage medium.

[0015] Start creating new project files in the S+ environment and design and configure them according to the latest system requirements and technical standards.

[0016] Import the new project file into the new industrial computer and perform a stand-alone test before formally connecting to the network.

[0017] After the single-machine test is passed, shut down the original server, cut off the power supply, and install the new industrial computer in place.

[0018] Check the startup process of the new industrial computer to ensure that all hardware components can work properly and the system can start smoothly.

[0019] The new industrial computer is connected to the communication network and communicated with the NIS21 / IET800 module.

[0020] As a preferred solution of the method for improving the reliability of the DCS system described in the present invention, the comparison of the display contents of the new and old systems to ensure information synchronization includes transferring data and updating engineering files, comparing the display contents of the new and old systems, and ensuring that the information on all industrial computers is synchronized.

[0021] A system for improving the reliability of a DCS system, characterized by comprising:

[0022] The configuration module splits the original loop structure of the first object and configures the loop communication module.

[0023] An upgrade module is used to optimize and upgrade the host computer communication system and control system of the first object.

[0024] The synchronization module compares the display contents of the new and old systems to ensure information synchronization.

[0025] A computer device comprises a memory and a processor, wherein the memory stores a computer program, and the processor implements the steps of the above method when executing the computer program.

[0026] A computer-readable storage medium stores a computer program, which implements the steps of the method described above when executed by a processor.

[0027] Beneficial effects of the present invention: The new interface adopts a more user-friendly layout, allowing operators to more intuitively understand the operating status and parameter settings of the equipment. The operating status and parameter information of the equipment can be presented in a clearer and more intuitive manner, which is convenient for the monitor to pay attention to the operating status of the equipment in real time and find problems in time. The communication efficiency and stability are improved, and the occurrence of communication failures is reduced. The loop structure is optimized, the impact of signal interference on communication is reduced, and data transmission is more accurate and fast. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. Among them:

[0029] Figure 1 A method for improving the reliability of a DCS system and an overall flow chart of the system are provided in the first embodiment of the present invention. DETAILED DESCRIPTION

[0030] In order to make the above-mentioned purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the drawings of the specification. Obviously, the described embodiments are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary persons in the art without creative work should fall within the scope of protection of the present invention.

[0031] Example 1, reference Figure 1 , is an embodiment of the present invention, and provides a method for improving the reliability of a DCS system, comprising:

[0032] S1: split the original loop structure of the first object and configure the loop communication module.

[0033] Furthermore, in the present invention, the first object is a DCS system, including control equipment in normal operation, equipment in shutdown state or equipment requiring maintenance.

[0034] In the embodiment of the present invention, the first object mainly refers to a DCS system, i.e., a distributed control system. The first object includes but is not limited to a DCS system, and may also be a PLC system (programmable logic controller), a SCADA system (supervisory control and data acquisition), and an EMS system (energy management system).

[0035] Specifically, the DCS system includes control equipment that is in normal operation, equipment that is in shutdown state or needs maintenance. Control equipment that is in normal operation refers to equipment that participates in process control in real time during the production process. Including but not limited to field controllers, process monitors, and data acquisition equipment. Equipment in shutdown state refers to equipment that suspends operation during a specific period of time due to planned maintenance, equipment upgrades or process requirements. Including but not limited to backup controllers, redundant network modules, and backup power supply equipment. Equipment that needs maintenance refers to equipment that needs maintenance due to failure, aging or regular maintenance. Including but not limited to failed sensors and damaged control modules.

[0036] In an optional embodiment, the equipment classification in the PLC system also includes control equipment in normal operation, equipment in shutdown state or equipment that needs to be repaired. Control equipment in normal operation includes but is not limited to PLC host, input and output modules (I / O modules), and communication interfaces. Equipment in shutdown state includes but is not limited to standby PLC control units and redundant communication modules. Equipment that needs to be repaired includes but is not limited to aging I / O modules and failed communication modules.

[0037] In an optional embodiment, the equipment classification in the SCADA system also includes control equipment in normal operation, equipment in shutdown state or equipment that needs to be repaired. Control equipment in normal operation includes but is not limited to remote terminal units (RTUs), HMI systems, and servers. Equipment in shutdown state includes but is not limited to standby RTUs and redundant servers. Equipment that needs to be repaired includes but is not limited to failed RTU communication modules and data storage devices.

[0038] In an optional embodiment, the equipment classification in the EMS system also includes control equipment in normal operation, equipment in shutdown state or equipment that needs to be repaired. Control equipment in normal operation includes but is not limited to energy consumption monitoring equipment, energy management terminals, and communication gateways. Equipment in shutdown state includes but is not limited to backup energy consumption monitoring equipment and backup gateways. Equipment that needs to be repaired includes but is not limited to outdated energy consumption monitoring equipment and communication modules.

[0039] It should be noted that the method for improving system reliability proposed in the present invention has wide applicability. It is not limited to DCS systems. In PLC, SCADA, EMS and other systems, the stability and reliability of the system can also be improved by splitting the original loop structure and configuring the communication module. In addition, although the equipment status in different systems is different, it can basically be classified and managed by the operating status of the equipment, the configuration of the spare equipment, and the equipment that needs to be repaired, thereby further improving the robustness and flexibility of various automation systems.

[0040] In the traditional communication mode between the host computer and the loop, a variety of different communication protocols are usually used, such as Modbus, OPC (OLE for Process Control), Profibus, etc. However, the present invention adopts a communication protocol called Ethernet / IP, which is an industrial communication protocol for data transmission on Ethernet. The Ethernet / IP protocol has the following significant advantages:

[0041] Openness and standardization: Ethernet / IP protocol is based on standard Ethernet technology. This openness and standardization feature gives it obvious advantages in system integration and interoperability. Due to the widespread popularity and standardization of Ethernet technology, Ethernet / IP protocol can be easily integrated with other Ethernet-based systems and devices, thus simplifying the deployment and maintenance process of the entire system.

[0042] High bandwidth and speed: Compared with traditional industrial communication networks, Ethernet / IP protocol can provide higher data transmission rate. This high bandwidth and high speed feature enables it to meet the high requirements of data transmission speed and real-time performance in the field of modern industrial control.

[0043] Easy to deploy and maintain: Ethernet / IP protocol utilizes the existing Ethernet infrastructure, which not only simplifies the network installation process, but also reduces maintenance costs. Due to the popularity of Ethernet technology, Ethernet infrastructure has been deployed in most industrial environments. Therefore, the use of Ethernet / IP protocol can make full use of existing resources and reduce additional investment.

[0044] In terms of communication modules, the present invention adopts the NIS21 / IET800 model, which has the following advantages compared to the NIS21 / ICT12 model used before the upgrade:

[0045] High performance: NIS21 / IET800 model uses advanced communication technology to ensure high speed and high reliability of data transmission. This high performance feature enables it to meet the high requirements of data transmission speed and accuracy in the field of modern industrial control.

[0046] Easy to integrate: The NIS21 / IET800 model offers a variety of interface options for easy integration with different systems and devices. This flexibility enables it to be easily connected to other devices and systems, thus simplifying the integration process of the entire system.

[0047] Security: The NIS21 / IET800 model has built-in security mechanisms to protect the security and privacy of data during transmission. This security feature is essential to protect industrial control systems from external threats and attacks.

[0048] S2: Optimize and upgrade the upper system of the first object.

[0049] In the embodiment of the present invention, the host system includes not only the host computer communication system and control system, but also the data analysis and decision support system, user interface and visualization system, remote monitoring and control system, and maintenance management system.

[0050] In an optional embodiment, the optimization and upgrading method of the data analysis and decision support system is as follows:

[0051] Introduce advanced machine learning algorithms (such as random forests, support vector machines, etc.) to achieve automatic data analysis and prediction. Use streaming data processing frameworks (such as Apache Kafka, Apache Flink) to analyze sensor data from production lines in real time, respond quickly to abnormal situations, and achieve dynamic decision support. Develop explainable AI models so that operators can understand the reasons behind the analysis results and enhance trust. Establish an adaptive decision-making mechanism to continuously optimize decision rules based on historical data and real-time feedback to improve the accuracy and flexibility of decision-making.

[0052] In an optional embodiment, the optimization and upgrading method of the user interface and visualization system is as follows: provide customized dashboards according to different user roles (such as operators, maintenance personnel, and management), display relevant key performance indicators (KPIs) and real-time data, introduce AR technology, and provide users with real-time guidance and visualization information during equipment maintenance and operation to help users understand complex data and equipment status more intuitively. Design an adaptive user interface that can automatically adjust the layout according to different devices (PC, tablet, mobile phone) to ensure that information can be well displayed on various screens. Develop interactive charts and data visualization tools to allow users to interact with data by clicking, dragging, etc., and conduct in-depth analysis of specific data points or trends.

[0053] In an optional embodiment, the optimization and upgrading method of the remote monitoring and control system is as follows: Introduce multiple authentication and encryption technologies to ensure the security of remote access and prevent unauthorized access. Add edge computing functions to field devices to handle some data analysis tasks, reduce data transmission delays, and improve real-time response capabilities. Develop a dedicated mobile application to support operators to perform remote monitoring and control in an external environment, providing convenient operation and information acquisition methods. Implement an intelligent alarm system to automatically push notifications to users based on data changes and set thresholds to help them respond quickly to emergencies.

[0054] In an optional embodiment, the optimization and upgrading method of the maintenance management system is as follows: Use historical data and real-time sensor data to build a predictive maintenance model, automatically generate maintenance recommendations and schedules, and reduce equipment failure rates. Develop a mobile platform that allows maintenance personnel to directly access maintenance records, equipment status, and technical documents on site to improve work efficiency. Integrate with the supply chain management system to achieve real-time monitoring and demand forecasting of spare parts, optimize spare parts procurement and inventory management, and reduce downtime. Introduce a scheduling optimization algorithm to automatically generate the optimal maintenance task scheduling plan based on equipment status, maintenance history, and personnel availability to improve resource utilization.

[0055] It should be noted that in the existing design, only the loop redundancy structure is implemented, and the importance of the host computer redundancy structure is not taken into account. This means that in the system architecture, if an extreme situation is encountered, such as multiple servers failing at the same time, not only will the system be unable to display and operate normally, but the system's historical data records, alarm records, and other key functions will also be completely ineffective. Such a design defect may lead to serious consequences at a critical moment, because the system cannot provide the necessary information support, making it impossible for maintenance personnel to understand the system's operating status in a timely manner, and unable to analyze and process historical events.

[0056] The present invention has carried out innovative redundant structure optimization and upgrading for the host computer communication system. Specifically, each server is equipped with multiple network ports, which can not only exchange real-time data with the NIS21 / IET800 system, but also establish a stable connection with the data switch. Through such a design, the server can maintain communication with the operator station through the switch to ensure the timely transmission and processing of information. In addition, in order to further improve the reliability and stability of the system, the present invention also introduces an intelligent fault transfer mechanism. When a server in the system fails or fails to work properly, other servers can quickly take over its tasks, seamlessly supplement the database of the failed server, and continue to effectively control the operator station.

[0057] Specifically, in the present invention, the design of the intelligent failover mechanism is to effectively solve the problem of insufficient redundant structure of the host computer in the existing system architecture. This mechanism ensures that when a server fails, other servers can quickly take over its tasks, avoid system interruption, and ensure continuous data exchange and stable control of the operator station. Specifically, the intelligent failover mechanism is implemented through the following steps:

[0058] In the architecture of the present invention, each server is equipped with multiple network ports, which are connected to the data switch and the operator station through multiple redundant links. The existence of redundant links ensures that even if a link or a network port of a server fails, the system can continue to transmit data through the backup communication link. For example, if the network port of server A fails, the system will automatically switch to the backup port of server A or continue data exchange through the network port of server B to ensure the continuity of data transmission.

[0059] The intelligent failover mechanism in the present invention includes a dynamic load balancing system and a fault detection module. The dynamic load balancing system monitors the load of each server in real time and automatically allocates data processing tasks according to the system operation status. When the load of a server is too high or a failure is about to occur, the load balancing system will transfer some tasks to other servers in advance, thereby avoiding overloading of a single server.

[0060] At the same time, the fault detection module continuously monitors the operating status of each server, especially key parameters such as network connection status, CPU load, memory usage, etc. When it is detected that a server cannot work properly (such as server downtime, network anomaly, etc.), the system will immediately trigger the failover mechanism.

[0061] When a server fails, the system automatically assigns all tasks of the server to other normal servers through the introduced failover protocol. For example, when server A fails, server B will take over A's tasks. The takeover process includes:

[0062] Receiving and processing real-time data: Server B receives the unfinished real-time data processing tasks of Server A through redundant links to ensure the stable operation of the control system and operator station.

[0063] Database synchronization: Server B will quickly obtain and synchronize the database information of Server A to ensure that key data such as historical data and alarm records will not be lost. Through the database synchronization mechanism, all servers in the system can have consistent data copies in a short period of time, thereby ensuring data integrity and consistency.

[0064] During this process, the operator does not need to intervene manually. The entire failover process is carried out seamlessly, the system remains stable and does not affect the operator's monitoring and control of the system.

[0065] In addition, the intelligent failover mechanism in the present invention also has a self-healing function. When it is detected that the failure of server A has been repaired or restored to normal, the system will automatically reallocate the previously transferred tasks back to server A to balance the load and improve the overall system performance.

[0066] It should be noted that the intelligent failover mechanism of the present invention ensures that in the event of a server failure, the system can seamlessly transfer tasks and maintain stable operation of the control system and operator station through redundant communication links, dynamic load balancing, database synchronization and self-healing functions. This mechanism greatly improves the reliability and redundancy of the system and avoids the impact of single point failures on the normal operation of the system.

[0067] At the same time, the present invention is specially configured with an independent historical data station and an OPC communication station. The main function of the historical data station is to separately save and back up key information such as system data and alarm records. This can significantly reduce the operating pressure of the system and reduce energy consumption, thereby improving the operating efficiency and stability of the entire system. On the other hand, the design of the OPC communication station focuses on realizing the one-way communication function with the external network. This one-way data transmission mechanism ensures that data can be safely transmitted from the internal network to the external network without being affected by any external network, thereby protecting the health of the communication structure. This design effectively prevents potential viruses or malware from invading the system through two-way communication channels, enhancing the security of the entire system.

[0068] It should be noted that based on the upgrade of communication network and hardware, the control system needs to adapt to the new working environment. The ABB S+ system fully inherits the advantages of the early PGP system operation and use, and simultaneously integrates ABB PGIM historical data and historical event management technology, and fully supports the latest human-machine interface monitoring software of Windows 7, Windows Server 2008 or Windows 10, Windows Server 2016 operating platforms.

[0069] Control system upgrade steps:

[0070] When upgrading the control system, the first thing to do is to ensure the security of the entire process and the integrity of the data. Therefore, the first step is to back up all existing project files, including but not limited to key data such as databases, tag libraries, alarm libraries, picture libraries, and historical records. The backup work needs to be done carefully to ensure that all data is copied to a safe storage medium completely and accurately, so that it can be quickly restored to the original state if problems occur during or after the upgrade.

[0071] Next, we start to create new engineering files in the S+ environment. This process needs to be designed and configured according to the latest system requirements and technical standards to ensure that the new system can meet the current and future operating requirements. During the production process, engineers need to carefully check every detail to ensure the accuracy and stability of the new engineering files.

[0072] After the new project files are created, they need to be imported into the new industrial computer, but before they are officially connected to the network, a stand-alone test should be performed. This testing phase is to ensure that the new system can work properly when running independently without any software or hardware problems. During the test, engineers need to simulate various operating conditions to ensure that the system's response and performance meet expectations.

[0073] Once the stand-alone test is passed, the original server can be shut down, the power can be cut off, and the new industrial computer can be installed in place. During the power-on test phase, engineers need to check the startup process of the new industrial computer to ensure that all hardware components are working properly and the system can start smoothly.

[0074] Subsequently, the new industrial computer needs to be connected to the communication network and communicated with the NIS21 / IET800 module. During this process, engineers need to correctly configure network parameters, including matching IP addresses, to ensure that the new system can seamlessly connect with existing network equipment.

[0075] The newly added operator station also needs to be connected to the communication switch synchronously to transfer data and update engineering files. This step is to ensure that the operator station can obtain the latest system data and can interact with the new system correctly. Similarly, the engineer needs to check the configuration of the operator station to ensure that its IP address and other network parameters are set correctly.

[0076] S3: Compare the display contents of the new and old systems to ensure that the information is synchronized.

[0077] In order to ensure the stability and consistency of the entire system, the operator checks the screen display of each industrial computer in turn to see if it is consistent. This step is to compare the display content of the old and new systems to ensure that the information on all industrial computers is synchronized and there is no data inconsistency. If any differences are found, they need to be adjusted in time until the screen display of all industrial computers is completely consistent.

[0078] The computer device may be a server. The computer device includes a processor, a memory, an input / output interface (I / O for short) and a communication interface. The processor, the memory and the input / output interface are connected via a system bus, and the communication interface is connected to the system bus via the input / output interface. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system, a computer program and a database. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The database of the computer device is used to store data cluster data of a power monitoring system. The input / output interface of the computer device is used to exchange information between the processor and an external device. The communication interface of the computer device is used to communicate with an external terminal via a network connection. When the computer program is executed by the processor, a method for improving the reliability of a DCS system is implemented.

[0079] A person of ordinary skill in the art can understand that all or part of the processes in the above-mentioned embodiment method can be completed by instructing the relevant hardware through a computer program, and the computer program can be stored in a non-volatile computer-readable storage medium. When the computer program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to the memory, database or other medium used in the embodiments provided in the present application can include at least one of non-volatile and volatile memory. Non-volatile memory may include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory may include random access memory (RAM) or external cache memory, etc. As an illustration and not limitation, RAM can be in various forms, such as static random access memory (SRAM) or dynamic random access memory (DRAM). The database involved in each embodiment provided in this application may include at least one of a relational database and a non-relational database. Non-relational databases may include distributed databases based on blockchains, etc., but are not limited to this. The processor involved in each embodiment provided in this application may be a general-purpose processor, a central processing unit, a graphics processor, a digital signal processor, a programmable logic device, a data processing logic device based on quantum computing, etc., but are not limited to this.

[0080] Embodiment 2 is an embodiment of the present invention, which provides a method and system for improving the reliability of a DCS system. In order to verify the beneficial effects of the present invention, a scientific demonstration is carried out through simulation experiments.

[0081] In order to verify a method to improve the reliability of DCS systems, the experiment will optimize the DCS (distributed control system) actually running in an industrial production facility and compare the system performance under existing technologies.

[0082] The existing DCS system uses the traditional RS485 communication protocol, the control system has no redundant structure, the system display has delays and instability, and equipment maintenance requires overall shutdown, affecting production efficiency.

[0083] The comparison object of this experiment is the DCS system based on the traditional communication and control architecture. The test objects include the control equipment in operation and some shutdown equipment that needs maintenance.

[0084] The optimization scheme adopted in the invention is: split the communication loop of some equipment, configure the loop communication module of NIS21 / IET800 model, and adopt Ethernet / IP protocol. Optimize the host computer system, add redundant network ports, realize real-time data exchange with NIS21 / IET800, deploy intelligent fault transfer mechanism, and ensure system stability. The specific steps include:

[0085] Split the original loop structure: In a certain control device, select the device node that needs to be repaired to remove the loop, and monitor the operation of the redundant loop to ensure the normal operation of other devices. In traditional systems, the entire loop needs to be shut down for maintenance.

[0086] Configure loop communication module: introduce NIS21 / IET800 communication module, adopt Ethernet / IP protocol, replace the original RS485 protocol, and improve the data transmission speed and reliability of the system through independent communication path.

[0087] Optimization and upgrade of host computer: multiple network ports are configured for each server. The redundant ports exchange data with NIS21 / IET800 in real time and establish a stable connection with the switch to ensure redundancy and reliability of data transmission. An intelligent failover mechanism is introduced. When a server fails, the system automatically transfers the data flow to the backup server to ensure uninterrupted operation. Independent historical data stations and OPC communication stations are configured to ensure system data backup and information synchronization.

[0088] Compare the displays of the new and old systems: After the system switches to the new architecture, compare the displays of the new and old systems to ensure that all data transmission and display information of the new system is fully synchronized with the old system.

[0089] The steps of the prior art include using RS485 protocol and non-redundant control system, which requires the entire equipment to be shut down for maintenance, and the system response speed is slow; while the present invention improves the reliability and maintainability of the system by optimizing the network protocol, introducing a redundant mechanism, configuring a communication module, etc.

[0090] The experimental results are shown in Table 1.

[0091] Table 1 Experimental results

[0092]

[0093] By comparing the data in the table, it can be clearly seen that our invention is significantly superior to the existing technical system in multiple key technical parameters, which is specifically manifested in the following aspects:

[0094] Data transmission speed: The existing DCS system uses RS485 communication protocol, which has a slow transmission speed of about 50ms. However, our invention, which uses Ethernet / IP protocol, has increased the transmission speed to about 5ms, an increase of 90%. This technical improvement greatly reduces system latency, especially in large control systems where data real-time performance is critical.

[0095] System response time: The system response time of the existing technology is slow, about 150ms, while our invention reduces the response time to about 20ms by optimizing the communication loop and introducing a redundancy mechanism, with an optimization margin of 86.67%. This shows that our invention can respond quickly when dealing with emergencies and ensure the safety and reliability of the production process.

[0096] Downtime for maintenance: Under the existing technology, the system usually needs to be shut down for maintenance, and the maintenance time is as long as 4 hours. However, through the equipment splitting and redundancy mechanism invented by us, the maintenance time is greatly reduced to only 0.5 hours, shortened by 87.5%, and significantly improved the maintainability of the system.

[0097] Display information synchronization delay: In the prior art, the display information synchronization delay is relatively large, about 200ms, but by optimizing the host computer and control system, the invention reduces this delay to 10ms, an improvement of 95%. The improvement of information synchronization is crucial to ensure that system operators can obtain accurate equipment status information in real time.

[0098] Failure switching capability: The existing system has no redundancy mechanism. Once the server fails, the system will face the risk of data loss and downtime. However, our invention introduces an intelligent failover mechanism. When a server fails, the system will switch to the backup server within 1 second to ensure that data is not lost.

[0099] Equipment failure rate: After the optimization of the invention, the equipment failure rate was reduced from 5% to 1%, a reduction of 80%. This shows that our invention has significant advantages in improving system reliability and reducing equipment failures.

[0100] In summary, experimental data show that our invention is significantly superior to existing technologies in terms of system response speed, reliability, maintenance convenience, and fault transfer mechanism. In particular, the reliability and stability of the DCS system have been effectively improved by optimizing communication protocols, configuring redundancy mechanisms, and introducing intelligent fault transfer. This innovative improvement can significantly reduce downtime and improve production efficiency in industrial production, and has significant practical value.

[0101] Embodiment 3 is an embodiment of the present invention, which provides a system for improving the reliability of a DCS system, specifically comprising:

[0102] A configuration module is provided to split the original loop structure of the first object and configure a loop communication module;

[0103] An upgrade module, which optimizes and upgrades the host computer communication system and control system of the first object;

[0104] The synchronization module compares the display contents of the new and old systems to ensure information synchronization.

[0105] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for improving the reliability of a DCS system, characterized in that: include: Splitting the original loop structure of the first object and configuring a loop communication module; Optimizing and upgrading the upper system of the first object; Ensure information is synchronized by comparing displays between old and new systems.

2. The method for improving the reliability of a DCS system according to claim 1, characterized in that: The splitting of the original loop structure of the first object includes, when repairing one of the communication loops of the first object, performing a dismantling operation at a specific device intermediate node, and monitoring the operating status of the redundant loop and the running equipment at the same time.

3. The method for improving the reliability of a DCS system as claimed in claim 2, characterized in that: The host system includes but is not limited to a host computer communication system and a control system.

4. The method for improving the reliability of a DCS system as claimed in claim 3, characterized in that: The optimization and upgrading of the host computer communication system and control system for the first object includes: The host computer communication system is upgraded and an intelligent fault transfer mechanism is introduced.

5. The method for improving the reliability of a DCS system as claimed in claim 4, characterized in that: The first object includes but is not limited to a DCS system, and the DCS system includes control equipment that is in normal operation, equipment that is in shutdown state or needs to be repaired.

6. The method for improving the reliability of a DCS system as claimed in claim 4, characterized in that: The optimization and upgrading of the host computer communication system and control system for the first object also includes the following control system upgrading steps: Back up all existing project files and copy all data completely to a safe storage medium; Start creating new engineering documents in the S+ environment, designing and configuring according to the latest system requirements and technical standards; Import the new project file into the new industrial computer and perform a single-machine test before formal networking; After the single-machine test is passed, shut down the original server, cut off the power supply, and install the new industrial computer in place; Check the startup process of the new industrial computer to ensure that all hardware components can work properly and the system can start smoothly; The new industrial computer is connected to the communication network and communicated with the NIS21 / IET800 module.

7. The method for improving the reliability of a DCS system according to claim 1, characterized in that: The comparing of the display contents of the new and old systems to ensure information synchronization includes transferring data to each other and updating engineering files, comparing the display contents of the new and old systems to ensure that the information on all industrial computers is synchronized.

8. A system for improving the reliability of a DCS system using the method according to any one of claims 1 to 7, characterized in that: A configuration module is provided to split the original loop structure of the first object and configure a loop communication module; An upgrade module, which optimizes and upgrades the host computer communication system and control system of the first object; The synchronization module compares the display contents of the new and old systems to ensure information synchronization.

9. A computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: When the processor executes the computer program, the steps of the method according to any one of claims 1 to 7 are implemented.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that: When the computer program is executed by a processor, the steps of the method according to any one of claims 1 to 7 are implemented.

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