SCADA system applied to blast furnace centralized control center

Abstract

The invention relates to an SCADA (supervisory control and data acquisition) system applied to a blast furnace centralized control center, which comprises a blast furnace bottom layer PLC (programmable logic controller) system, a blast furnace field access layer switch, a blast furnace field convergence layer switch, a centralized control center IDC (internet data center) cluster server, a centralized control center HMI (human machine interface) switch and a centralized control center thin client, the blast furnace bottom layer PLC system is used for reading and exchanging operation data among field equipment of each main system of the blast furnace; the blast furnace field convergence layer switch is used for data communication exchange of the blast furnace bottom layer PLC system; the centralized control center IDC cluster server consists of one management server and more than four operation servers, and is used for virtualizing a plurality of SCADA (Supervisory Control and Data Acquisition) systems, controlling the blast furnace bottom layer PLC system and connecting the centralized control center thin client; wherein the more than four operation servers are redundant backups for each other; and the centralized control center thin client remotely accesses the virtualized SCADA system to realize remote control of each PLC system of the blast furnace.

Description

Technical Field

[0001] The invention relates to a SCADA system, in particular to a SCADA system applied to a blast furnace centralized control center. Background Art

[0002] SCADA (Supervisory Control And Data Acquisition) system, namely data acquisition and monitoring control system, is widely used, especially in the remote monitoring and control, parameter adjustment and measurement, signal alarm and acquisition and other functions of the molten iron production process in the blast furnace centralized control center.

[0003] The blast furnace centralized control center is a remote blast furnace centralized control center based on the SCADA system. It takes independent resource allocation and deep integration of technical management as its concept, breaking the model of traditional blast furnace control room and operation area, realizing full professional centralized control of blast furnace processes, and improving the overall level of ironmaking management.

[0004] At present, for the SCADA system of the blast furnace centralized control center, on the one hand, a relatively traditional communication method is still used, that is, a ring network topology is used for communication construction. However, the ring network structure has topological shortcomings such as poor reliability, poor network security, and poor scalability. It is also difficult to find out in a short time when a failure occurs, and the failure of one node will affect the convergence layer network of the entire SCADA system. On the other hand, the SCADA system is still built based on fixed physical industrial computers and servers. This construction method not only generates high economic costs, poor hardware compatibility, and low utilization of resources such as CPU and memory, but also makes it lack of reliability. Once the physical equipment is damaged, the SCADA system of the blast furnace centralized control center will be directly paralyzed. Therefore, for the SCADA system of the entire blast furnace centralized control center, the traditional system structure will have corresponding problems whether it is the access layer network communication or the system construction foundation, thereby affecting the normal operation of the blast furnace production by the production personnel of the blast furnace centralized control center through the SCADA system. Therefore, for the blast furnace, which cannot be stopped at will and is high temperature and high pressure, these problems obviously have many potential risks. Summary of the invention

[0005] The purpose of the present invention is to provide a SCADA system applied to a blast furnace centralized control center to solve the problems of poor reliability, poor security, poor scalability, poor economy, etc. caused by the access layer ring network topology and the physical equipment-based construction in the prior art.

[0006] In order to solve the above technical problems, the present invention adopts the technical solution shown below.

[0007] A SCADA system applied to a blast furnace centralized control center comprises: a blast furnace bottom PLC system, a blast furnace field access layer switch, a blast furnace field convergence layer switch, a centralized control center IDC cluster server, a centralized control center HMI switch, and a centralized control center thin client.

[0008] The underlying PLC system of the blast furnace realizes the reading and exchange of operating data between the field equipment of each main system of the blast furnace.

[0009] Switches (blast furnace site access layer switches, blast furnace site aggregation layer switches) are used to ensure data communication and exchange between the blast furnace site bottom-level PLC and the centralized control center SCADA system.

[0010] The IDC cluster server of the centralized control center consists of 1 management server and 4 (or more) computing servers. It is used to virtualize several required SCADA systems, control the underlying PLC system of the blast furnace, and connect to the thin client of the centralized control center. Among them, the 4 (or more) computing servers are mutually redundant.

[0011] The thin client of the centralized control center can remotely control each PLC system of the blast furnace by remotely accessing the virtualized SCADA system.

[0012] Link aggregation refers to the logical integration of multiple physical ports after aggregation to achieve load sharing and transmission link redundancy among multiple ports of the switch.

[0013] Switch stacking means that two switches are made to work together through stacking cables and are logically integrated. The main stacking switch and the standby stacking switch can serve as redundant backups for each other.

[0014] Furthermore, the SCADA system of the entire blast furnace control center consists of two parts, namely a SCADA communication network based on a dual-star topology and a SCADA virtual system based on an IDC cluster server.

[0015] Among them, the SCADA communication network based on the dual-star network topology is mainly composed of the blast furnace bottom PLC system, access layer switches, and aggregation layer switches, including: each interface of the 10 blast furnace on-site access layer switches is equipped with VLAN function, and each switch has an adaptive Ethernet interface for connecting the various PLC systems of the blast furnace through a network cable. In addition, there are two pairs of optical interfaces with link aggregation function, which are used to connect to two blast furnace on-site stacked aggregation switches through optical cables.

[0016] Each interface of the two blast furnace on-site aggregation layer switches also has VLAN function, and the two switches are logically formed into one switch through physical stacking lines, and are divided into active and standby stacking switches. The 10G optical ports at the same position of the two switches are set as a group, and link aggregation is set. The multiple groups of optical ports of the active and standby stacking switches are connected to the corresponding blast furnace on-site access layer switches through optical cables. In addition, there is another group of optical ports connected to the switch of the IDC cluster server in the centralized control center through optical cables.

[0017] Furthermore, the two IDC core layer switches and two HMI switches of the centralized control center are logically integrated through physical stacking lines, and the IDC core stacking main switch and the HMI stacking main switch are connected through optical fiber pigtails, and the IDC core stacking standby switch and the HMI stacking standby switch are connected through optical fiber pigtails, and are equipped with VLAN function and optical interfaces with link aggregation function; at the same time, the thin client of the centralized control center is connected to the HMI switch respectively to form redundancy on the link.

[0018] Furthermore, the SCADA virtual system based on the IDC cluster server includes: using the IDC cluster server to virtualize 10 virtual machines required for the SCADA system, of which 8 are used to install the SCADA system operation client and 2 are used to install the SCADA system data acquisition server, and remotely access the virtualized SCADA system through the centralized control center thin client to realize the control of the blast furnace bottom PLC system by the operating production personnel; Among them, for the composition of the SCADA system, each SCADA system virtual data acquisition server and virtual operation client are independent of each other. The data acquisition server reads the data of the blast furnace's underlying PLC through the switch and the communication network, and then runs the operation client to present the data read by the data acquisition server through the screen to realize screen operation.

[0019] Furthermore, a blast furnace SCADA system project was created based on the PLC systems of the blast furnace hot blast stove, main body, top water pumping, ore chute / charging, water slag flushing, ore chute dust removal, bag dust removal, iron-making yard dust removal, TRT and water treatment. Two virtualized SCADA data acquisition servers were used for the project to acquire data from the on-site PLC, and eight operating SCADA clients were used for the project to realize remote control of various areas of the blast furnace site.

[0020] If any of the 10 virtual machines operated by the operator in the centralized control center runs abnormally, the IDC cluster server will quickly make a judgment, reload and run the data of the virtual machine on another running physical machine, thereby ensuring normal production.

[0021] Furthermore, according to the process operation of the blast furnace system, the thin client used to remotely connect to the virtualized SCADA system is also divided into 8 sites, which are used for blast furnace charging process operation station, blast furnace hot blast furnace process operation station, blast furnace body process operation station, blast furnace iron-making yard dust removal process operation station, blast furnace water slag flushing process operation station, blast furnace water treatment process operation station, blast furnace environmental dust removal process operation station and foreman's independent operation station, etc.

[0022] Compared with the existing technology, the design proposed by the present invention can achieve the following effects: (1) The underlying PLC network topology of the traditional SCADA system of the blast furnace centralized control center usually adopts a ring network topology. However, this method is very difficult to maintain after a failure, and it is difficult to find and solve the problem in a short time. The dual-star topology structure is easy to find problems. Once a failure occurs, it is only necessary to check the access switch corresponding to each PLC to quickly find the root cause of the problem without affecting the overall operation of the SCADA system of the blast furnace centralized control center.

[0023] (2) In the ring network topology, once a node fails, it is very easy to cause the entire network to oscillate, thereby affecting the operation of the SCADA system of the entire blast furnace control center. However, if the communication network of the SCADA system of the blast furnace control center based on the dual-star topology is damaged at a certain node, it will not affect the entire network, and thus will not affect the normal operation of the SCADA system of the blast furnace control center as a whole. Moreover, any switch in the entire communication network is equipped with VLAN configuration, which can effectively deal with broadcast storms and direct access from different LANs, which greatly increases the security of SCADA system communication overall.

[0024] (3) Compared with the disadvantage of the traditional ring network that adding a new node will affect the entire network, the dual-star network has strong scalability. Therefore, during the normal production of the blast furnace, there is no need to stop, and the underlying PLC system can be added by configuring the VLAN of the newly added node, and it will not affect the normal operation of the personnel in the centralized control center.

[0025] (4) Using IDC cluster servers, the SCADA system operating client of the blast furnace centralized control center is virtualized, which effectively alleviates the pressure of upgrading and replacing the traditional SCADA system based on physical industrial computer servers, gets rid of the operating system's restrictions on hardware compatibility, reduces the cost of subsequent hardware replacement, and improves maintenance efficiency.

[0026] (5) Compared with traditional industrial computers, thin clients connected to virtualized SCADA systems occupy less space, consume less electricity, and have lower hardware costs.

[0027] (6) By utilizing the virtual resource pool technology of the IDC cluster server, the system can use its own resources according to the configuration required by the SCADA system client and data acquisition server, thereby maximizing resource utilization; (7) The entire SCADA system has excellent reliability. Regardless of the switch failure, communication link failure, thin client failure, or physical machine failure corresponding to the SCADA virtual machine, it can ensure the stable control of the blast furnace site by the production personnel of the centralized control center. Among them, for the SCADA communication network layer based on the dual-star topology structure, the aggregation switch, IDC core switch, HMI switch, etc. all use stacking technology, and the communication link uses link aggregation technology, which enables automatic switching in the event of a failure; for the blast furnace virtualization SCADA system based on the IDC cluster server, once the physical machine where the virtual machine corresponding to the SCADA system is located fails, the IDC will quickly make a judgment and reload and run the data of the virtual machine on another running physical machine; for the thin client used for remote connection, once a failure occurs, other thin clients can be used to remotely access the corresponding virtual machine without affecting the normal operation of the blast furnace. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 The present invention is a schematic diagram of the blast furnace site structure of the SCADA system of the blast furnace centralized control center.

[0029] Figure 2 The schematic diagram of the structure of the centralized control center of the SCADA system of the blast furnace centralized control center applied to the present invention.

[0030] Figure 3 Schematic diagram of the overall working principle of the system of the present invention. DETAILED DESCRIPTION

[0031] The present invention is further described in detail below in conjunction with examples. The examples are exemplary and intended to be used to explain the present invention, but should not be construed as limiting the present invention.

[0032] This embodiment provides a SCADA system for a blast furnace centralized control center, which mainly includes two parts, namely a SCADA communication network based on a dual-star topology structure and a SCADA virtual system based on an IDC cluster server.

[0033] Some of them, such as Figure 1 and Figure 2 As shown in the figure, it reflects the SCADA communication network based on the dual-star topology of the blast furnace centralized control center, including: the blast furnace's underlying PLC system, blast furnace field access layer switch, blast furnace field aggregation layer switch, IDC core switch, centralized control center IDC cluster server, HMI switch and thin client.

[0034] Among them, the blast furnace bottom PLC system provides the blast furnace on-site operation data for the blast furnace centralized control center SCADA system; the switch provides a communication path for the blast furnace centralized control center SCADA system to collect data; the IDC cluster server consists of 1 management server and 4 computing and centralized control center thin clients, of which the 4 computing servers are redundant backups for each other; the centralized control center thin client is composed of servers. It is used to virtualize several required SCADA systems, and control the bottom PLC system and the virtualized SCADA system for remote access to achieve remote control of the PLC system; link aggregation refers to the logical integration of multiple physical ports after aggregation to achieve load sharing and transmission link redundancy between multiple ports of the switch; switch stacking refers to the use of stacking lines to make two switches work together and integrate logically, so that the main stacking switch and the standby stacking switch can serve as redundant backups for each other.

[0035] The 10 switches that form the access layer of the blast furnace site have all interfaces equipped with VLAN functions, and their Ethernet ports are all adaptive and are used to connect the blast furnace system, main system, top water supply system, ore chute / feeding system, water slag flushing system, ore chute dust removal system, bag dust removal system, iron-making yard dust removal system, TRT system, and water treatment system. In addition, each switch is equipped with two pairs of optical interfaces with link aggregation functions, which are connected to the two stacked aggregation layer switches at the blast furnace site through optical cables; The two switches used to build the aggregation layer at the blast furnace site also have VLAN functions on their optical ports, and the two switches are logically integrated into one switch through physical stacking cables. One is set as the stacking master switch, and the other is set as the stacking backup switch. The optical ports at the same position of the two switches are set as a group, and the links are bundled by setting link aggregation. Among them, multiple groups of optical ports of the two stacked switches are connected to two pairs of optical ports of each access switch at the blast furnace site through optical cables. In addition, each group of optical ports is connected to the core switch of the IDC cluster server in the centralized control center through optical cables; Build two IDC core switches in the core layer of the centralized control center and configure two HMI switches in the centralized control center, one of which is set as the stacking master switch and the other as the stacking standby switch. The IDC core stacking master switch and the HMI stacking master switch, the IDC core stacking standby switch and the HMI stacking standby switch are connected to each other through optical ports with link aggregation function, and are equipped with VLAN function. Secondly, the thin clients of the centralized control center are connected to the HMI switches respectively to form link redundancy; For the SCADA communication network based on the dual-star topology structure of the entire blast furnace centralized control center, when the PLC corresponding to any system in the blast furnace fails, it will not affect the entire communication network, and for the blast furnace operator, the blast furnace on-site communication fault point can be quickly determined. Moreover, if the blast furnace needs to add a new PLC system, even during the normal production of the blast furnace, it can be normally accessed by simply setting up a VLAN at the newly added node switch.

[0036] Another part, such as Figure 2 As shown in the figure, it reflects the SCADA virtual system of the blast furnace control center based on the IDC cluster server, including: 1 management server and 4 computing servers and two IDC core switches.

[0037] The entire process of building a SCADA virtual system based on an IDC cluster server is divided into three parts: the construction of an IDC cluster server, the construction of a virtual machine, and the construction of a SCADA system based on a virtual machine.

[0038] The entire IDC cluster server is constructed as follows: the management ports of four computing servers and one management server are configured, and then the ESXI systems of one management server and four computing servers are installed and configured, and then the DNS server is installed on the management server, and vCenter is installed, and finally the virtual machine can be set up and installed on the vCenter platform according to the requirements of the corresponding blast furnace SCADA system; The construction of virtual machines is based on the blast furnace process requirements. The vCenter platform of the IDC cluster server is used to allocate resources according to the requirements of each virtual machine for parameters such as CPU, memory, hard disk, and VLAN, and 10 virtual machines required by the blast furnace SCADA system are virtualized. Finally, the SCADA system was built based on 10 virtual machines. The construction of the SCADA system is divided into the construction of the data acquisition server and the operation client. Among them, the data acquisition server reads and exchanges the data of various systems of the blast furnace through the dual-star network communication method, and the operation client combines the data with the controls and presents them through the screen, allowing the operator to operate.

[0039] Therefore, a blast furnace SCADA system project was created based on the PLC systems of the blast furnace hot blast stove, main body, top water injection, ore chute / loading, water slag flushing, ore chute dust removal, bag dust removal, iron-making yard dust removal, TRT and water treatment. Two virtualized SCADA data acquisition servers were used to acquire data from the on-site PLCs, and eight operating SCADA clients were used to realize the regional control of the major PLC systems on the blast furnace site.

[0040] At the same time, the 8 virtual machines are used to connect to the 8 thin clients of the centralized control center, and according to the production process, form operation stations for the production personnel of the centralized control center, which are divided into loading process operation station, hot blast furnace process operation station, main body process operation station, iron-making yard dust removal process station, water slag flushing process station, water treatment process station and foreman's independent operation station.

[0041] Through IDC cluster servers, SCADA system software resources can be pooled, so that they can be configured according to different requirements such as data acquisition servers and operation clients, making the most of their own resources. In addition, the IDC-based SCADA system gets rid of the need for hardware compatibility, reduces the cost of later hardware replacement, and improves maintenance efficiency.

[0042] The SCADA communication network based on the dual-star topology and the virtualized SCADA system built on the IDC cluster server not only have the advantages of both, but also make the entire SCADA system extremely secure.

[0043] Among them, Figure 3 As shown, for the SCADA system communication network using stacking technology and link aggregation technology, if the aggregation switch 1, IDC core switch 1, and HMI switch 1 fail, the stacking system will perform self-checking through the network, and the stacking standby switch will take over all the services of the stacking master switch. If the links a-1, b-1, c-1, d-1, e-1, and f-1 fail, the corresponding stacking master switch will quickly switch the link to a-2, b-2, c-2, d-2, e-2, and f-2 according to the link aggregation function; secondly, the IDC also uses its own physical machine redundancy, that is, once the physical machine where the virtual machine corresponding to the SCADA system is located fails, the IDC will quickly make a judgment and reload and run the data of the virtual machine on another running physical machine, thereby ensuring the normal operation of the SCADA system by the production operators of the blast furnace centralized control center; in addition, if the thin client fails, other thin clients can also be used to access the virtual machine for production operations.

[0044] Therefore, no matter it is a switch failure, communication link failure, thin client failure or a physical machine failure corresponding to the SCADA virtual machine, the SCADA system can obtain data from each PLC system of the blast furnace in real time, thereby ensuring that the centralized control center can accurately determine the current status of the furnace and perform real-time operations through the SCADA system, reflecting the reliability of the SCADA system of the entire blast furnace centralized control center.

[0045] In addition to the above embodiments, the present invention also includes other implementation modes. Any technical solutions formed by equivalent transformation or equivalent replacement should fall within the protection scope of the claims of the present invention.

Claims

1. A SCADA system applied to a blast furnace centralized control center, characterized in that: include: Blast furnace bottom PLC system, blast furnace field access layer switch, blast furnace field aggregation layer switch, centralized control center IDC cluster server, centralized control center HMI switch, centralized control center thin client, including: The blast furnace bottom PLC system is used to read and exchange operating data between field devices of each main system of the blast furnace; The blast furnace on-site access layer switch and blast furnace on-site aggregation layer switch are used for data communication and exchange between the blast furnace bottom PLC system and the centralized control center SCADA system; The IDC cluster server of the centralized control center consists of 1 management server and 4 or more computing servers, which are used to virtualize several SCADA systems, control the underlying PLC system of the blast furnace and connect to the thin client of the centralized control center; wherein, the 4 or more computing servers are mutually redundant backups; The thin client of the centralized control center remotely accesses the virtualized SCADA system to achieve remote control of each PLC system of the blast furnace.

2. The system according to claim 1, characterized in that: The system uses link aggregation, which means that multiple physical ports are aggregated and logically integrated to achieve load sharing and transmission link redundancy among multiple ports of the switch; the system uses switch stacking, which means that two switches work together through stacking cables and are logically integrated. The main stacking switch and the backup stacking switch can serve as redundant backups for each other.

3. The system according to claim 1, characterized in that: The whole system consists of two parts: the SCADA communication network based on the dual-star topology and the SCADA virtual system based on the IDC cluster server; Among them, the SCADA communication network based on the dual-star network topology is mainly composed of the blast furnace bottom PLC system, blast furnace on-site access layer switches, and blast furnace on-site aggregation layer switches. Each interface of the 10 blast furnace on-site access layer switches is equipped with VLAN function, and each access layer switch has an adaptive Ethernet interface for connecting to each PLC system of the blast furnace through a network cable. In addition, there are two pairs of optical interfaces with link aggregation function, which are used to connect to two blast furnace on-site stacked aggregation layer switches through optical cables. The VLAN function is also set for each interface of the two blast furnace on-site aggregation layer switches, and the two blast furnace on-site aggregation layer switches are logically formed into one switch through physical stacking lines, and are divided into primary and standby stacking switches. The 10G optical ports at the same position of the two blast furnace on-site aggregation layer switches are set as a group, and link aggregation is set up; among them, multiple groups of optical ports of the primary and standby stacking switches are connected to the corresponding blast furnace on-site access layer switches through optical cables. In addition, there is another group of optical ports that connect themselves to the switches of the IDC cluster servers in the centralized control center through optical cables.

4. The system according to claim 1, characterized in that: The two IDC core layer switches and two HMI switches of the centralized control center are logically integrated through physical stacking lines, and the IDC core stacking main switch and the HMI stacking main switch are connected through optical fiber pigtails, and the IDC core stacking standby switch and the HMI stacking standby switch are connected through optical fiber pigtails, and are equipped with VLAN function and optical interface with link aggregation function; at the same time, the thin client of the centralized control center is connected to the HMI switch respectively to form redundancy on the link.

5. The system according to claim 4, characterized in that: The SCADA virtual system based on IDC cluster servers includes: using IDC cluster servers to virtualize 10 virtual machines required for the SCADA system, of which 8 are used to install the SCADA system operation client and 2 are used to install the SCADA system data acquisition server, and remotely access the virtualized SCADA system through the centralized control center thin client to enable the production operators to control the blast furnace's underlying PLC system; Among them, for the composition of the SCADA system, the data acquisition server and operation client of each SCADA system are independent of each other. The data acquisition server reads the data of the blast furnace's underlying PLC through the switch and the communication network, and then the operation client presents the data read by the data acquisition server through the screen to realize screen operation.

6. The system according to claim 5, characterized in that: According to the blast furnace hot blast stove, main body, top water injection, ore chute / charging, water slag flushing, ore chute dust removal, bag dust removal, iron-making yard dust removal, TRT and water treatment, the PLC system produces a blast furnace SCADA system project. Two virtualized SCADA system data acquisition servers are used for the project to acquire data from the on-site PLC, and eight virtualized SCADA system operation clients are used for the project to achieve remote control of various areas of the blast furnace site. If any of the 10 virtual machines operated by the operator of the centralized control center runs abnormally, the IDC cluster server will quickly make a judgment, reload and run the data of the virtual machine on another running physical machine, so as to ensure normal production.

7. The system according to claim 5, characterized in that: According to the process operation of the blast furnace system, the thin client of the centralized control center used to remotely connect to the virtualized SCADA system is also divided into 8 sites, which are used for blast furnace charging process operation station, blast furnace hot blast furnace process operation station, blast furnace main body process operation station, blast furnace iron-making yard dust removal process operation station, blast furnace water slag flushing process operation station, blast furnace water treatment process operation station, blast furnace environmental dust removal process operation station and foreman's independent operation station.

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