IO rack simulation system and simulation method for triple redundancy system

Abstract

The invention discloses an IO rack simulation system for a triple redundancy system, and the system comprises a controller rack which is used for installing a controller; the computer performs configuration parameter synchronization, communication protocol simulation and channel mode setting; the computer is provided with three Ethernet ports, each Ethernet port is provided with a plurality of groups of IP addresses, and the IP addresses are in one-to-one correspondence with the IP addresses of the remote communication modules of the IO racks and are used for simulating the remote communication modules of the IO racks at the same time; and the communication cables are respectively connected with the controllers and the Ethernet ports corresponding to the computer. The IO rack simulation system for the triple redundancy system can simulate a plurality of IO racks at the same time, and has the advantages of being low in cost and convenient to deploy.

Description

Technical Field

[0001] The present invention relates to the field of industrial control system simulation, and in particular to an IO rack simulation system for a triple redundant system. Background Art

[0002] The triple redundant control system has a high degree of reliability and safety to avoid accidents or incidents caused by equipment failure or unstable control system. It is widely used in various scenarios with high reliability requirements, such as petrochemical, nuclear power, aerospace and other fields. The triple redundant control system is usually composed of a controller rack and multiple IO racks, where the controller rack is installed with three redundant controllers, and the remaining IO modules are installed on each IO rack. During the project implementation process, after the project personnel completed the writing of the on-site logic configuration program, they could only perform a simple verification of the correctness of the program through the channel forcing function, and could not simulate the actual load of the system and the changes in the channels. It was necessary to wait until all the on-site equipment was installed before using real scenarios for performance evaluation and optimization, which resulted in a slow debugging process for the project. Summary of the invention

[0003] The purpose of the present invention is to solve the defects in the prior art and provide an IO rack simulation system for a triple redundant system, which can simulate multiple IO racks at the same time.

[0004] In order to achieve the above object, the present invention provides an IO rack simulation system for a triple redundant system, the triple redundant system comprising three mutually redundant controllers, a plurality of IO racks, each IO rack being equipped with a plurality of IO modules and three remote communication modules respectively connected to the corresponding controllers; the IO rack simulation system of the present invention comprises:

[0005] A controller rack, used for installing the above controller;

[0006] Computer, for synchronizing configuration parameters, simulating communication protocols and setting channel modes; the computer is provided with three Ethernet ports, each of which is configured with multiple groups of IP addresses, corresponding one to one with the IP addresses of the remote communication modules of each IO rack, and used to simulate the remote communication modules of each IO rack at the same time;

[0007] Communication cables are used to connect the corresponding Ethernet ports of each controller and the computer.

[0008] The present invention also provides a simulation method for the IO rack simulation system, comprising the following steps:

[0009] Set the IP address of the computer Ethernet port. The IP address set for each Ethernet port includes all the IP addresses of the remote communication modules corresponding to each IO rack;

[0010] Configuration parameter synchronization: establish communication with the controller through the computer's Ethernet port, read and parse the parameter test value, and determine the IO module model and configuration parameters configured in each slot of the IO rack;

[0011] IO rack communication protocol simulation: After the computer receives the detection message, configuration message, and scanning message sent by the controller to the IO rack, it simulates the real IO rack to parse the message data and assemble the response message and send it to the controller;

[0012] Channel simulation mode setting: Set the channel simulation mode of digital input DI and analog input AI through the computer.

[0013] Furthermore, the above-mentioned controllers and corresponding remote communication modules form an internal communication network and use fixed rules to set their own IP addresses: the IP addresses of the three controllers are fixed to 192.168.1.100, 192.168.2.100, and 192.168.3.100, respectively; the IP addresses of the three remote communication modules installed in each IO rack are fixed to 192.168.1.N, 192.168.2.N, and 192.168.3.N, respectively, where N is the rack number, and the value range is a natural number of 1-16.

[0014] Furthermore, the specific steps for configuration parameter synchronization are as follows:

[0015] S100, establish communication with the controller through the Ethernet port of the computer, and read the configuration parameter check value;

[0016] S101, determine whether the configuration parameter check value currently used is consistent with the configuration parameter check value of the controller; if not, proceed to S102; if consistent, proceed to S103;

[0017] S102, reading the latest configuration parameters from the controller;

[0018] S103, parsing and using the current configuration parameters, determining the IO module models configured in each slot of the IO rack, and loading the configuration parameters of each IO module.

[0019] Furthermore, the modes supported by the digital input DI are: constant ON, constant OFF, and set frequency square wave; the modes supported by the analog input AI are: constant current value, step change current value, and sinusoidal wave change current value.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] The present invention adopts three Ethernet ports of a computer to replace three remote communication modules of an IO rack, so that messages sent by a controller to different IO racks can be received and processed by the computer, thereby realizing the function of simulating multiple IO racks at the same time; at the same time, the computer has built-in IO rack simulation software to perform automatic synchronization of configuration parameters, communication protocol simulation and channel simulation mode.

[0022] The present invention is used for an IO rack simulation system of a triple redundant system and has the characteristics of low cost and convenient deployment. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A structural block diagram of a triple redundant system applied to the IO rack simulation system of the present invention;

[0024] Figure 2 It is a structural block diagram of the IO rack simulation system of the present invention;

[0025] Figure 3 The present invention is a flowchart of synchronizing configuration parameters of the IO rack simulation system. DETAILED DESCRIPTION

[0026] The present invention is described in detail below with reference to the accompanying drawings.

[0027] like Figure 1 As shown, the system structure of the triple redundant system is composed of a controller rack 100 and multiple IO racks 400, and network communication is realized through three independent communication cables. The controller rack 100 is only used to install three controllers, namely controller A101, controller B102, and controller C103. The IO rack 400 is composed of three remote communication modules and multiple IO modules 404, and the three remote communication modules are used to realize the protocol conversion between the controller and the IO module, namely remote communication module A401, remote communication module B402, and remote communication module C403. Controller A101 and all remote communication modules A401 are in a local area network, controller B102 and all remote communication modules B402 are in a local area network, and controller C103 and all remote communication modules C403 are in a local area network. The three local area networks are usually formed using switches and are independent of each other. The instrument signal on site is connected to the IO module. The controller realizes the collection of the instrument signal on site and the output of the control signal through the communication cable. The project site configures the rack scale according to the number of channels, usually with one controller rack 100 and multiple IO racks 400.

[0028] like Figure 2As shown, in order to realize the simulation of the IO rack of the triple redundant system, the present invention designs an IO rack simulation system, which specifically includes a controller rack 100, three communication cables, a computer 300, and an IO rack simulation software 304. The slots of the controller rack are installed with three redundant controllers, and the computer 300 has three Ethernet ports, namely Ethernet port A301, Ethernet port B302, and Ethernet port C303. The IO rack simulation software 304 is run in the computer, and the software is used to realize the functions of automatic synchronization of configuration parameters, communication protocol simulation, and channel simulation mode setting. The implementation of each function is detailed in the following system implementation description.

[0029] The implementation steps of this simulation system are as follows:

[0030] Step 1: System networking.

[0031] Each controller is connected to the Ethernet port of the computer using a communication cable, specifically: controller A101 is connected to the Ethernet port A301 of the computer; controller B102 is connected to the Ethernet port B302 of the computer; controller C103 is connected to the Ethernet port C303 of the computer.

[0032] Step 2: Set the IP address of the computer's Ethernet port.

[0033]

[0034] As shown in the above table, the three Ethernet ports of computer 300 are used to replace the three remote communication modules of the IO rack. Therefore, the three Ethernet ports are respectively set with all possible IP addresses of the three remote communication modules of the IO rack, that is, Ethernet port A is set with 192.168.1.1-16, a total of 16 IP addresses; Ethernet port B is set with 192.168.2.1-16, a total of 16 IP addresses; Ethernet port C is set with 192.168.3.1-16, a total of 16 IP addresses, so that the messages sent by the controller to different IO racks can be received and processed by the computer.

[0035] Step 3: Synchronize configuration parameters.

[0036] When the computer 300 runs the IO rack simulation software 304, the software will automatically perform the configuration parameter synchronization process, such as Figure 3 , the specific process is:

[0037] S100, establishing communication with the controller through the Ethernet port of the computer 300, and reading the configuration parameter check value;

[0038] S101, determine whether the configuration parameter verification value currently used is consistent with the configuration parameter verification value of the controller? If not, proceed to S102; if consistent, proceed to S103;

[0039] S102, reading the latest configuration parameters from the controller;

[0040] S103, parsing and using the current configuration parameters, determining the IO module models configured in each slot of the IO rack, and loading the configuration parameters of each IO module.

[0041] Step 4: IO rack communication simulation.

[0042] Since the three Ethernet ports of the computer are respectively set with the IP addresses of the three remote communication modules, when the controller sends a communication message to the remote communication module of each IO rack, the message will be received by the IO rack simulation software. The IO rack simulation software has a communication protocol simulation function. After receiving the detection message, configuration message, and scanning message sent by the controller to the IO rack, it can simulate the real IO rack to parse the message data and form a response message and send it to the controller.

[0043] Step 5: Channel simulation mode setting

[0044] The IO rack simulation software supports the channel mode setting function, which is used to set the channel simulation mode of digital input DI and analog input AI. The modes supported by digital input DI are: constant ON, constant OFF, and set frequency square wave; the modes supported by analog input AI are: constant current value, step change current value, and sine wave change current value.

[0045] The above are only preferred embodiments of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should be regarded as the protection scope of the present invention.

Claims

1. An IO rack simulation system for a triple redundant system, the triple redundant system comprising three mutually redundant controllers, a plurality of IO racks, each IO rack being equipped with a plurality of IO modules and three remote communication modules respectively connected to the corresponding controllers, characterized in that: The IO rack simulation system comprises: A controller rack, used for installing the controller; A computer is used to perform configuration parameter synchronization, communication protocol simulation and channel mode setting; the computer is provided with three Ethernet ports, each of which is respectively configured with multiple groups of IP addresses, which correspond one-to-one with the IP addresses of the remote communication modules of each IO rack, and are used to simulate the remote communication modules of each IO rack at the same time; Communication cables are used to connect the corresponding Ethernet ports of each controller and the computer.

2. A simulation method using the IO rack simulation system of claim 1, characterized in that: The IO rack simulation method comprises the following steps: Set the IP address of the computer Ethernet port. The IP address set for each Ethernet port includes all the IP addresses of the remote communication modules corresponding to each IO rack; Configuration parameter synchronization: establish communication with the controller through the computer's Ethernet port, read and parse the parameter test value, and determine the IO module model and configuration parameters configured in each slot of the IO rack; IO rack communication protocol simulation: After the computer receives the detection message, configuration message, and scanning message sent by the controller to the IO rack, it simulates the real IO rack to parse the message data and assemble the response message and send it to the controller; Channel simulation mode setting: Set the channel simulation mode of digital input DI and analog input AI through the computer.

3. The simulation method according to claim 2, characterized in that: The controller and the corresponding remote communication module form an internal communication network and use fixed rules to set their own IP addresses: the IP addresses of the three controllers are fixed to 192.168.1.100, 192.168.2.100, and 192.168.3.100, respectively; the IP addresses of the three remote communication modules installed in each IO rack are fixed to 192.168.1.N, 192.168.2.N, and 192.168.3.N, respectively, where N is the rack number, and the value range is a natural number of 1-16.

4. The simulation method according to claim 3, characterized in that: The specific steps of synchronizing the configuration parameters are as follows: S100, establish communication with the controller through the Ethernet port of the computer, and read the configuration parameter check value; S101, determining whether the configuration parameter check value currently in use is consistent with the configuration parameter check value of the controller; If they are not consistent, then go to S102; if they are consistent, then go to S103; S102, reading the latest configuration parameters from the controller; S103, parsing and using the current configuration parameters, determining the IO module models configured in each slot of the IO rack, and loading the configuration parameters of each IO module.

5. The simulation method according to claim 4, characterized in that: The modes supported by the digital input DI are: constant ON, constant OFF, and set frequency square wave; the modes supported by the analog input AI are: constant current value, step change current value, and sinusoidal wave change current value.

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