Suspicious signal processing method, device and system and electronic medium

Abstract

The invention provides an industrial field suspicious signal processing method, and aims to solve the problems that current and voltage signals of an industrial field are interfered by a complex environment when being collected, and traditional filtering is easy to distort when the signals jump greatly to cause system misoperation. According to the method, before and after time values are compared during signal collection, whether the collected signals are suspicious or not is judged, a signal holding state is entered, and stable operation of a control system can be maintained during signal fluctuation. And during the period, judging whether to quit a signal holding state according to a signal change trend, if not, resetting time, monitoring by using a fault counter, and setting a forced quit mechanism of signal holding. According to the invention, signal distortion is effectively avoided, system stability is enhanced, operation flexibility and traceability are improved, signal processing efficiency is optimized, a reliable solution is provided for signal processing in the field of industrial control, safety, accuracy and efficiency of industrial production are improved, and the method has a wide application prospect.

Description

Technical Field

[0001] The present application belongs to the technical field of industrial control system signal processing, and specifically relates to a suspicious signal holding method, device, system and electronic medium. Background Art

[0002] In the field of industrial control, accurately collecting current and voltage signals from various sites and accurately transmitting them to the control system is the key to achieving effective control. However, the environment of industrial sites is often extremely complex and harsh, with numerous interference sources, which inevitably causes the collected signals to be mixed with a large amount of clutter or suffer from abnormal interference.

[0003] At present, the commonly used response method in the industry is to sample the signal to be collected multiple times and combine it with filtering processing, hoping to achieve the purpose of smoothing the signal. Although this traditional method can reduce the impact of some interference to a certain extent, it has a significant defect. When the field signal changes greatly, for example, due to the sudden start and stop of large equipment, electromagnetic pulse interference, etc., the signal changes greatly instantly. After multiple sampling and filtering, the overall signal will be distorted to a certain extent. This distortion may cause serious consequences in some industrial control scenarios with high signal accuracy requirements. For example, in an automated production line, signal distortion may cause the control system to misjudge the operating status of the equipment, and then issue erroneous control instructions, causing the equipment to malfunction. This will not only affect the normal production order on site and lead to a significant decrease in production efficiency, but may also cause a large amount of economic losses such as equipment damage and waste of raw materials. Even in some specific industrial environments, such as chemical production and power transmission, it may also cause safety accidents and threaten the safety of personnel.

[0004] In summary, in the field of industrial control, how to effectively identify suspicious fluctuations in signals collected at industrial sites and develop practical solutions has become an important technical problem that technical personnel in this field need to overcome urgently. Summary of the invention

[0005] In view of the above shortcomings and deficiencies of the prior art, the present application provides a suspicious signal holding method, device, system and electronic medium, which compares the previous and next time values ​​when collecting signals, determines whether the collected signals are suspicious, enters the signal holding state, and can maintain the stable operation of the control system during signal fluctuations. During this period, it is determined whether to exit the signal holding state based on the signal change trend. If it is not satisfied, the time is reset, and a fault counter is used for monitoring at the same time, and a forced exit mechanism for signal holding is set to ensure that the signal holding state is exited in time when the signal fluctuates for a long time, collect real field signals, prevent the real signal from being shielded by the suspicious signal holding function, and improve processing efficiency and quality.

[0006] To achieve the above objectives, the present application adopts the following technical solution, a suspicious signal processing method, comprising: Collect signals of the field instrument at the current moment and the previous moment to obtain a first sampling value and a second sampling value; Comparing the first sampling value with the second sampling value to determine whether the first sampling value is a suspicious signal; If the first sampling signal is a suspicious signal, the sampling signal of the controller is maintained at the second sampling value; Determine whether the collected signal has returned to stability during the signal holding period. If so, exit the signal holding and re-collect the field signal. If not, reset the signal holding time at the end of the signal holding time until the number of resets reaches a threshold. After the signal hold time reset times reaches the threshold, if the collected signal still does not return to stability, the signal hold is forced to exit.

[0007] Furthermore, the method for determining a suspicious signal includes: Calculating a suspicious signal change rate of the first sampling value and the second sampling value; If the suspicious signal change rate is greater than a preset suspicious signal change rate, the first sampling value is determined to be a suspicious signal; otherwise, the first sampling value is determined to be a normal signal.

[0008] Furthermore, the preset suspicious signal change rate is 5% of the sampling full scale.

[0009] Furthermore, during the signal retention period, the method for determining whether the collected signal has recovered stability includes: Collect signals of the field instrument at the current moment and the previous moment to obtain a third sampling value and a fourth sampling value; Calculate the recovery signal change rate of the third sampling value and the fourth sampling value; If the recovery signal change rate is greater than the preset recovery signal change rate, it is determined that the current signal is still an abnormal signal and the signal retention continues; otherwise, it is determined that the current signal has recovered and stabilized and the signal retention is exited.

[0010] Furthermore, the preset recovery signal change rate is less than 1% of the sampling full scale for the same trend change or less than 5% of the sampling full scale for the reverse trend change.

[0011] Furthermore, it also includes a fault counter for counting the number of times the signal is held and reset. During the signal holding period, the fault counter counts the number of times the signal holding time is reset. If the number reaches a threshold, the signal holding state is forced to exit.

[0012] Furthermore, after the forced exit signal holding state, the suspicious signal judgment is closed, and the field instrument signals are directly collected and sent to the control system.

[0013] The present invention also provides another embodiment, a suspicious signal processing device, comprising: Acquisition module: used to collect field instrument signals; Comparison module: used to compare the field instrument signals collected by the acquisition module to determine whether they are suspicious signals; Signal holding module: used to output the previous signal to the controller and hold the signal when a suspicious signal is detected; Hold exit module: used to detect signal stability during signal hold process, and exit or force exit from signal hold state; Fault counting module: used to count the number of signal hold resets and force exit from the signal hold state when the number reaches the threshold.

[0014] The present application also discloses a suspicious signal processing system, comprising: one or more processors; A computer readable storage medium for storing one or more programs, When the one or more programs are executed by the one or more processors, the one or more processors implement the steps of the method described in any one of claims 1 to 7.

[0015] The present application also discloses a computer-readable storage medium, on which a computer program is stored. When the computer program is executed by a processor, the steps of the method described in any one of claims 1 to 7 are implemented.

[0016] The beneficial effects of this application are: 1. Accurate signal transmission: After identifying a suspicious signal, the sampled signal is maintained, which can effectively avoid filtering distortion caused by large signal jumps, ensuring that the signal sent to the control system is accurate and reliable, meeting the needs of high-precision industrial scenarios.

[0017] 2. Stable system operation: Reduce the risk of false operation caused by signal interference, and enhance the system's adaptability to complex and harsh environments with flexible parameter adjustment and environmental adaptation functions, maintain stable production order, and reduce accidents and interruptions.

[0018] 3. Efficient signal processing: Reasonable hold and exit mechanism and accurate verification and calibration prevent the real signal from being shielded by the suspicious signal hold function, improve processing efficiency and quality, and promote efficient operation of industrial production. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present application is described with the aid of the following drawings: Figure 1 The flowchart of the suspicious signal processing method of the present application is shown; Figure 2The flowchart of signal holding state exit of this application is shown. DETAILED DESCRIPTION

[0020] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below in conjunction with the accompanying drawings through specific implementation methods. It is understood that the specific embodiments described below are only used to explain the relevant inventions, rather than to limit the invention. It should also be noted that the embodiments and features in the embodiments of this application can be combined with each other in the absence of conflict; for ease of description, only the parts related to the invention are shown in the accompanying drawings.

[0021] As can be seen from the background technology, in the field of industrial control, due to the harsh environment of the industrial site, when the signal of the field instrument changes drastically, the control system cannot accurately identify and formulate a practical and effective processing method, and then issues erroneous control instructions, causing the equipment to malfunction, thereby affecting the production efficiency of the control system and even causing safety accidents.

[0022] In response to the above problems, the present application provides a suspicious signal processing method. When the controller detects that the signal of the field instrument has a large fluctuation, it is judged as a suspicious signal, and the suspicious signal is maintained as the normal signal output at the previous moment. When the system has signal fluctuations, the system is kept running smoothly. At the same time, for the suspicious signal holding method, a suspicious signal exit method is set. When the system signal tends to be stable, the suspicious signal holding state can be exited in time to ensure that the system can accurately collect the real signal of the field instrument, thereby improving the reliability and stability of the industrial control system and reducing production accidents and losses caused by signal abnormalities. Specific methods are as follows: Figure 1 As shown, including: S1: Collect the signals of the field instrument at the current moment and the previous moment, obtain the first sampling value and the second sampling value, compare the first sampling value with the second sampling value, and judge whether the first sampling value is a suspicious signal. The controller accurately collects the signal of the field instrument at the current moment through the data acquisition module connected to the field instrument, defines it as the first sampling value, and simultaneously obtains the signal stored in the cache at the previous moment, that is, the second sampling value, and performs data preprocessing on the two sampling values ​​to ensure the authenticity and validity of the two collected sampling values. Furthermore, the suspicious signal judgment method of the sampling value includes the following steps.

[0023] S101: Calculate suspicious signal change rates of the first sampling value and the second sampling value.

[0024] S102: If the suspicious signal change rate is greater than a preset suspicious signal change rate, determining that the first sampling value is a suspicious signal; otherwise, determining that the first sampling value is a normal signal.

[0025] Preferably, the preset suspicious signal change rate can be configured by configuration software. In this embodiment, the current signal of 4-25mA collected from the field instrument is used as an example for explanation. When the host computer software is configured, the suspicious signal change rate is set to 5% of the full scale, that is, when the data deviation between the first sampling value and the second sampling value is greater than 25mA*5%=1.25mA, the controller believes that the signal collected on site has a large fluctuation and the signal is unavailable, and determines that the first sampling value collected at the current moment is a suspicious signal.

[0026] S2: If the first sampling signal is a suspicious signal, the sampling signal of the controller is maintained at the second sampling value. Since the control system continuously collects field signals, after the signal stabilizes, if the data collection at the previous moment does not find a suspicious signal, the signal at the previous moment is confirmed to be a normal signal. When the first sampling value collected at the current moment is confirmed to be a suspicious signal, in order to avoid the controller sending a suspicious signal, the signal sent by the controller is fixed to the second sampling value. The controller maintains the second sampling value for external output to ensure that the control system will not receive erroneous signal data during the signal abnormality, avoid suspicious signals causing system misjudgment, and thereby ensure that the data collection of the control system remains stable and the normal operation of the system is guaranteed.

[0027] S3: Determine whether the collected signal has stabilized during the signal holding period. If so, exit the signal holding period and re-collect the field signal. If not, reset the signal holding period at the end of the signal holding period until the number of resets reaches the threshold. In order to avoid distortion of the signal collected by the controller due to long-term signal holding, this solution also designs a signal holding exit method during the signal holding period. Figure 2 Shown, incl.

[0028] S301: Collect signals of the field instrument at the current moment and the previous moment to obtain a third sampling value and a fourth sampling value; S302: Calculate the recovery signal change rate of the third sampling value and the fourth sampling value; S303: If the recovery signal change rate is greater than the preset recovery signal change rate, it is determined that the current signal is still an abnormal signal and the signal retention is continued; otherwise, it is determined that the current signal is restored to stability and the signal retention is exited.

[0029] During the signal holding period, the present application can also continuously determine whether the collected signal has recovered stability. The specific method is to collect the signals of the current moment and the previous moment of the field instrument again, obtain the third sampling value and the fourth sampling value, and calculate their recovery signal change rate. If the recovery signal change rate is greater than the preset recovery signal change rate, it is determined that the current signal is still an abnormal signal, and the signal holding continues; otherwise, it is determined that the current signal has recovered stability, exits the signal holding, and re-collects the field signal. Among them, the preset recovery signal change rate is less than 1% of the sampling full scale for the same trend change or less than 5% of the sampling full scale for the reverse trend change. Since there may be repeated fluctuations when the signal fails, the reverse recovery signal change rate detection is added to the signal holding exit condition to prevent the suspicious state from being cleared. Adding the reverse change rate detection can also ensure that occasional signal interference can be filtered out.

[0030] In one implementation, taking a single signal holding time of 50ms as an example, within the 50ms of signal holding, the controller continuously collects field instrument signals. When the collected current moment signal and the previous moment signal return to stability, the signal holding is exited, and the data collected at the current moment is sent to the control system through the controller. If the signal holding time reaches 50ms, and the signal at the current moment still fluctuates greatly, and the fluctuation is still greater than the recovery signal change rate, it is considered that the signal is not yet stable. Preferably, a fault counter is set in the controller. When the signal holding time reaches 50ms, if the signal has not returned to stability, the fault counter is incremented by 1 and the signal holding time is reset to 50ms to start a new round of holding and judgment.

[0031] In another embodiment of the present invention, the signal holding time is 50ms. In order to reduce the load of the controller, the signal acquisition is started only after the 50ms signal holding time expires, and the third sampling value at the moment when the signal holding time reaches 50ms and the fourth sampling value at the previous moment are obtained, and the recovery signal change rate is compared to determine whether the signal holding state can be actively exited. If the signal has not recovered stability after the signal holding time expires, the fault counter is increased by 1 and the signal holding time is reset to 50ms to start a new round of holding and judgment.

[0032] In order to ensure that the real field instrument signal can be collected when the signal fluctuates abnormally for a long time, the present invention also configures a counting threshold for the fault counter, which can be adjusted by the host computer software. Taking 10 times as an example, when the field instrument has a signal fluctuation for a long time, the controller identifies it as a suspicious signal, and then maintains the signal and outputs a valid signal to the control system so that the system can operate stably. If the signal holding time is reset for 10 consecutive times, and the signal fluctuation duration reaches 500ms, it is still unable to actively exit the signal holding, then a forced instruction is sent to the controller through the fault counter to force the exit of the signal holding state, collect the real signal and send it to the control system. Ensure that the real signal will not be permanently shielded by the suspicious function, thereby maintaining the smooth flow of information between the industrial control system and the field signal, and avoiding serious production accidents and economic losses caused by signal blocking.

[0033] S4: After the signal hold time reset times reach the threshold, if the collected signal still does not return to stability, the signal hold is forced to exit. When the signal can return to stability during the signal hold period, the signal hold state can be actively exited. At this time, the signal of the field instrument has been stable. After the controller collects the field instrument signal, it will perform the suspected signal hold judgment again. If the signal does not fluctuate and remains stable, the collected field instrument signal will be sent up. If the signal fluctuates again, the suspected signal hold state will be entered again through the suspected signal judgment and hold mechanism to maintain the signal stability of the control system.

[0034] Furthermore, after the forced exit of the signal holding state, the suspicious signal judgment is closed, and the on-site instrument signals are directly collected and sent to the control system. For the signals collected after the forced exit of the signal holding, since the signals still have large fluctuations, the signal holding cannot be exited normally. At this time, the controller will report the collected fluctuation signal to the control system in real terms, and will no longer perform the signal holding judgment. The control system will diagnose the cause of the signal abnormality based on the real fluctuation signal, which is convenient for technicians to perform on-site maintenance according to the actual situation.

[0035] In summary, the beneficial effects of the method of the present invention are: 1. Accurate signal transmission: After identifying a suspicious signal, the sampled signal is maintained, which can effectively avoid filtering distortion caused by large signal jumps, ensuring that the signal sent to the control system is accurate and reliable, meeting the needs of high-precision industrial scenarios.

[0036] 2. Stable system operation: Reduce the risk of false operation caused by signal interference, and enhance the system's adaptability to complex and harsh environments with flexible parameter adjustment and environmental adaptation functions, maintain stable production order, and reduce accidents and interruptions.

[0037] 3. Efficient signal processing: Reasonable hold and exit mechanism and accurate verification and calibration prevent the real signal from being shielded by the suspicious signal hold function, improve processing efficiency and quality, and promote efficient operation of industrial production.

[0038] Another embodiment of the present invention is a suspicious signal processing device, comprising: Acquisition module: used to collect field instrument signals; Comparison module: used to compare the field instrument signals collected by the acquisition module to determine whether they are suspicious signals; Signal holding module: used to output the previous signal to the controller and hold the signal when a suspicious signal is detected; Hold exit module: used to detect signal stability during signal hold process, and exit or force exit from signal hold state; Fault counting module: used to count the number of signal hold resets and force exit from the signal hold state when the number reaches the threshold.

[0039] Among them, during the signal holding process, the hold exit module continuously collects and compares data of the real signal on site to determine whether the signal on site has recovered and stabilized; if the signal recovers and stabilizes during the signal holding period, the signal holding module is actively exited to collect and upload the real data on site. If it is still confirmed that the signal on site has not recovered and stabilized after the signal holding time expires, the signal holding time is reset through the built-in fault counter, and the count on the fault counter is accumulated by 1 until the fault counter count reaches the threshold. Among them, the technical threshold of the fault counter can be configured by the host computer software, and different maximum signal holding times are determined for different types of signal acquisition.

[0040] When the fault counter reaches the maximum value and still cannot actively exit the fault hold, the hold exit module will force the signal to exit the hold state. At this time, the signal collected by the acquisition module will no longer perform data comparison and hold judgment, and the real signal will be directly sent to the control system. The control system will determine the cause of the abnormality based on the real on-site instrument signal and initiate a corresponding alarm.

[0041] In summary, the present invention prevents the system from falling into the dilemma of infinite waiting or error processing due to continuous abnormal signals by maintaining abnormal signals, and ensures that the system can still maintain basic operating capabilities when encountering extreme situations. At the same time, through the exit mechanism of signal holding, under certain circumstances, the signal holding state can be exited in time, the real data of the field instrument can be obtained and sent up, which is convenient for technicians to accurately discover and identify the cause of the fault, so that the operation and maintenance personnel can quickly intervene to deal with it.

[0042] A third embodiment of the present invention is a suspicious signal processing system, comprising: one or more processors; A computer readable storage medium for storing one or more programs, When the one or more programs are executed by the one or more processors, the one or more processors implement the steps of the method described in any one of claims 1 to 7.

[0043] A fourth embodiment of the present invention is a computer-readable storage medium, wherein a computer program is stored on the computer-readable storage medium, and when the computer program is executed by a processor, the steps of the device address allocation method described in any one of claims 1 to 7 are implemented.

[0044] It should be noted that in the claims, any reference signs placed between brackets shall not be construed as limiting the claims. The word "comprising" does not exclude the presence of components or steps not listed in the claims. The word "a" or "an" preceding a component does not exclude the presence of a plurality of such components. The invention may be implemented by means of hardware comprising several distinct components and by means of a suitably programmed computer. The use of the words first, second, third, etc., is for convenience of expression only and does not imply any order. These words may be understood as part of the component name.

[0045] In addition, it should be noted that, in the description of this specification, the description of the terms "one embodiment", "some embodiments", "embodiment", "example", "specific example" or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, unless they are contradictory.

[0046] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments after knowing the basic creative concept. Therefore, the claims should be interpreted as including the preferred embodiments and all changes and modifications falling within the scope of the present invention.

[0047] Obviously, those skilled in the art can make various modifications and variations to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention should also include these modifications and variations.

Claims

1. A suspicious signal processing method, characterized in that: include: Collect signals of the field instrument at the current moment and the previous moment to obtain a first sampling value and a second sampling value; Comparing the first sampling value with the second sampling value to determine whether the first sampling value is a suspicious signal; If the first sampling signal is a suspicious signal, the sampling signal of the controller is maintained at the second sampling value; Determine whether the collected signal has returned to stability during the signal holding period. If so, exit the signal holding and re-collect the field signal. If not, reset the signal holding time at the end of the signal holding time until the number of resets reaches a threshold. After the signal hold time reset times reaches the threshold, if the collected signal still does not return to stability, the signal hold is forced to exit.

2. The suspicious signal processing method according to claim 1, characterized in that: The method for judging the suspicious signal includes: Calculating a suspicious signal change rate of the first sampling value and the second sampling value; If the suspicious signal change rate is greater than a preset suspicious signal change rate, the first sampling value is determined to be a suspicious signal; otherwise, the first sampling value is determined to be a normal signal.

3. The suspicious signal processing method according to claim 2, characterized in that: The preset suspicious signal change rate is 5% of the sampling full scale.

4. The suspicious signal processing method according to claim 1, characterized in that: During the signal holding period, the method for judging whether the collected signal has recovered stability includes: Collect signals of the field instrument at the current moment and the previous moment to obtain a third sampling value and a fourth sampling value; Calculate the recovery signal change rate of the third sampling value and the fourth sampling value; If the recovery signal change rate is greater than the preset recovery signal change rate, it is determined that the current signal is still an abnormal signal and the signal retention continues; otherwise, it is determined that the current signal has recovered and stabilized and the signal retention is exited.

5. The suspicious signal processing method according to claim 4, characterized in that: The preset recovery signal change rate is less than 1% of the sampling full scale for the same trend change or less than 5% of the sampling full scale for the reverse trend change.

6. The suspicious signal processing method according to claim 1, characterized in that: It also includes a fault counter for counting the number of times the signal is held and reset. During the signal holding period, the fault counter counts the number of times the signal holding time is reset. If the number reaches a threshold, the signal holding state is forced to exit.

7. The suspicious signal processing method according to claim 1, characterized in that: After the forced exit signal holding state, the suspicious signal judgment is turned off, and the field instrument signals are directly collected and sent to the control system.

8. A suspicious signal processing device, characterized in that: include: Acquisition module: used to collect field instrument signals; Comparison module: used to compare the field instrument signals collected by the acquisition module to determine whether they are suspicious signals; Signal holding module: used to output the previous signal to the controller and hold the signal when a suspicious signal is detected; Hold exit module: used to detect signal stability during signal hold process, and exit or force exit from signal hold state; Fault counting module: used to count the number of signal hold resets and force exit from the signal hold state when the number reaches the threshold.

9. A suspicious signal processing system, characterized in that: include: one or more processors; A computer readable storage medium for storing one or more programs, When the one or more programs are executed by the one or more processors, the one or more processors implement the steps of the method described in any one of claims 1 to 7.

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

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