Apparatus and method for comprehensive processing of analog input signals of industrial systems

Abstract

This invention discloses a device for comprehensive processing of analog input signals in industrial systems. Addressing the problem that current AI input processing is relatively simple and cannot meet complex requirements, this invention utilizes a fault bypass module, an interlocking output control module, a MOS bypass module, and a MOS grouping module to achieve MOS bypass, fault bypass, and AI interlocking output control functions for analog input signal points that participate in both SIS interlocking and DCS control. This simplifies operation and improves work efficiency.

Description

Technical Field

[0001] This invention belongs to the technical field of signal processing, and particularly relates to a device and method for comprehensive processing of analog input signals of industrial systems. Background Technology

[0002] Currently, there isn't an integrated function block for practical applications regarding AI (analog input signal) input functions in the TCS900 central control system; it simply judges the AI ​​input value for interlocking purposes. Specifically, there are two scenarios:

[0003] (1) Typical Applications

[0004] It simply compares the real-time values ​​of the input AI, outputs the comparison results, and combines basic logic units to build the implementation of bypass switch + AI interlocking related functions.

[0005] This application has relatively simple functions and is suitable for general project sites. However, it cannot meet the complex and demanding requirements of SIS interlocking in project sites, such as functions like fault bypass, interlocking dead time, and MOS grouping. Therefore, it cannot meet the increasingly complex practical application needs.

[0006] (2) Function block application

[0007] This application simply encapsulates the functions of (1) application into functional blocks, reducing the amount of code work, but does not actually add complex functions, and cannot meet the increasingly complex actual functional applications. Summary of the Invention

[0008] The purpose of this invention is to provide a device and method for comprehensive processing of analog input signals of industrial systems, and to solve the problem of implementing specific functions of AI analog input signals in practical applications of the Supcon TCS900 system.

[0009] To solve the above problems, the technical solution of the present invention is as follows:

[0010] A device for comprehensively processing analog input signals of an industrial system includes: a fault bypass module, an interlocking output control module, a MOS bypass module, and a MOS grouping module;

[0011] The MOS bypass module is configured such that when an analog input signal point participates in both SIS interlocking and DCS control, a MOS switch needs to be set on both the SIS side and the DCS side when setting a MOS bypass for the analog input signal point; when the DCS and SIS communication is normal, the state of the MOS switches on both sides is consistent; when the DCS and SIS communication is interrupted, the MOS switch on the SIS side operates normally.

[0012] The MOS grouping module is configured to allow only one MOS switch to be activated in a SIL loop interlock;

[0013] The fault bypass module is configured to automatically disconnect the bypass when a fault occurs at an analog input signal point, and to continuously disconnect the bypass for a preset time, generating a bypass alarm.

[0014] The interlocking output control module is configured to, after triggering interlocking voting, output a comparison result between the real-time value of the analog input signal and the interlocking value; at the same time, it determines whether the real-time value of the analog input signal exceeds a preset range, and if so, resets the interlocking voting.

[0015] According to one embodiment of the present invention, the MOS bypass module is further configured to, when any MOS switch is triggered, acquire the current bypass output value on the SIS side, XOR the current bypass output value with the MOS switch feedback value to generate a pulse, start timing, and initialize the SIS bypass output value to MOS bypass; when the pulse time is reached, update the current bypass output value and the SIS bypass output value to the MOS switch feedback value.

[0016] According to one embodiment of the present invention, the MOS grouping module is further configured to set a MOS unlock switch and enable the unlock switch. When the unlock switch is enabled, the MOS unlock switch enables arbitrary switching of the MOS switch.

[0017] According to one embodiment of the present invention, the MOS grouping module includes multiple inputs. When the number of input MOS switches exceeds a preset number, a new MOS grouping module is added and connected in a cascaded manner.

[0018] According to one embodiment of the present invention, the fault bypass module is further configured to cancel the fault bypass when the bypass of the faulty analog input signal point reaches a preset time, or when it is activated by the MOS bypass corresponding to the bypassed analog input signal point.

[0019] According to one embodiment of the present invention, the interlocking output control module sets the interlocking value to be between the minimum analog input signal value and the maximum analog input signal value to prevent interlocking output errors.

[0020] A method for comprehensively processing analog input signals of an industrial system includes:

[0021] When an analog input signal point participates in both SIS interlocking and DCS control, a MOS switch needs to be set on both the SIS side and the DCS side when setting a MOS bypass for the analog input signal point. Under normal communication between DCS and SIS, the state of the MOS switches on both sides is kept consistent. When communication between DCS and SIS is interrupted, the MOS switch on the SIS side operates normally.

[0022] MOS bypasses are grouped, and only one MOS switch is allowed to be activated in a SIL loop interlock.

[0023] When a fault occurs at an analog input signal point, its bypass is automatically disconnected, and after the bypass is disconnected for a preset time, a bypass alarm is generated, realizing the fault self-bypass function.

[0024] When the interlock voting is triggered, the comparison result between the real-time value of the analog input signal and the interlock value is output; at the same time, it is determined whether the real-time value of the analog input signal exceeds the preset range. If so, the interlock voting is reset.

[0025] According to an embodiment of the present invention, when the DCS and SIS communication is normal, the consistency processing of the states of the MOS switches on both sides further includes:

[0026] When any MOS switch changes, the MOS switch state is monitored on the SIS side. If a change occurs, a pulse timing is triggered. During the timing period, the output of the MOS switch is synchronized to be consistent with the bypass state. After the timing ends, the output of the MOS switch is synchronized with the bypass state feedback value.

[0027] Meanwhile, on the DCS side, it is determined whether the MOS switch is activated. If so, a timer is started. During the timer, the DCS bypass output is consistent with the MOS switch state. After the timer ends, the DCS bypass output is consistent with the bypass state communicated via SIS. If the MOS switch is not activated, it is checked whether the bypass state communicated via SIS has changed. If so, the DCS bypass output value is updated to be consistent with the bypass state communicated via SIS.

[0028] According to one embodiment of the present invention, when performing MOS grouping, the number of MOS grouping input bypass switches that are ON is counted, and it is determined whether the MOS enable switch is ON. If yes, it is further determined whether the MOS unlock switch is ON. If yes, switching is performed according to the number of input MOS switches. If no, it is further determined whether the number of input MOS switches is greater than 1. If no, switching is performed according to the number of input MOS switches. If yes, MOS switch switching is performed once. At the same time, when the MOS enable switch is OFF, MOS switch switching is also performed once.

[0029] According to one embodiment of the present invention, when interlocking voting is performed, the interlocking value is set between the minimum analog input signal value and the maximum analog input signal value to prevent interlocking output errors.

[0030] Because of the above technical solutions, this invention has the following advantages and positive effects compared with the prior art:

[0031] This invention provides a device for comprehensively processing analog input signals of industrial systems. Addressing the problem that current AI input processing is relatively simple and cannot meet complex requirements, this device utilizes a fault bypass module, an interlocking output control module, a MOS bypass module, and a MOS grouping module. This enables the following: when an analog input signal point participates in both SIS interlocking and DCS control, a MOS switch must be installed on both the SIS and DCS sides to bypass it. Under normal DCS-SIS communication, the states of the MOS switches on both sides are kept consistent. When DCS-SIS communication is interrupted, the MOS switch on the SIS side continues to operate normally. In a SIL loop interlock, only one MOS switch is allowed to be activated. When an analog input signal point malfunctions, its bypass is automatically disconnected for a preset time, generating a bypass alarm. After interlocking voting is triggered, the device outputs a comparison between the real-time value of the analog input signal and the interlocking value. Simultaneously, it determines whether the real-time value of the analog input signal exceeds a preset range; if so, the interlocking voting is reset. Attached Figure Description

[0032] Figure 1 This is a block diagram of a device for comprehensively processing analog input signals of an industrial system according to an embodiment of the present invention;

[0033] Figure 2 This is a logic flowchart of the MOS bypass on the SIS side in one embodiment of the present invention;

[0034] Figure 3 This is a logic flowchart of MOS bypass on the DCS side in one embodiment of the present invention.

[0035] Figure 4 This is a code diagram of MOS bypass processing in one embodiment of the present invention;

[0036] Figure 5 This is a logic flowchart of a MOS group in one embodiment of the present invention;

[0037] Figure 6 This is a schematic diagram of cascaded MOS grouping function blocks in one embodiment of the present invention;

[0038] Figure 7This is a diagram illustrating the combined construction of the MOS bypass and MOS grouping functional blocks in one embodiment of the present invention.

[0039] Figure 8 This is a flowchart of the fault self-bypass logic in one embodiment of the present invention;

[0040] Figure 9 This is a fault self-bypass code diagram according to an embodiment of the present invention;

[0041] Figure 10 This is a schematic diagram of a fault bypass module in one embodiment of the present invention;

[0042] Figure 11 This is a flowchart of the AI ​​interlocking output logic in one embodiment of the present invention. Detailed Implementation

[0043] The following detailed description, in conjunction with the accompanying drawings and specific embodiments, provides an apparatus and method for comprehensively processing analog input signals of industrial systems according to the present invention. The advantages and features of the present invention will become more apparent from the following description and claims.

[0044] Please refer to Figure 1 This embodiment provides a device for comprehensive processing of analog input signals of an industrial system, including: a fault bypass module, an interlocking output control module, a MOS bypass module, and a MOS grouping module;

[0045] The MOS bypass module is configured such that when an analog input signal point participates in both SIS interlocking and DCS control, a MOS switch needs to be set on both the SIS side and the DCS side when setting a MOS bypass for the analog input signal point; when the DCS and SIS communication is normal, the state of the MOS switches on both sides is kept consistent; when the DCS and SIS communication is interrupted, the MOS switch on the SIS side operates normally.

[0046] The MOS grouping module is configured to allow only one MOS switch to be activated in a SIL loop interlock;

[0047] The fault bypass module is configured to automatically disconnect the bypass when a fault occurs at an analog input signal point, and to generate a bypass alarm after the bypass disconnection lasts for a preset time.

[0048] The interlocking output control module is configured to, upon triggering interlocking voting, output a comparison result between the real-time value of the analog input signal and the interlocking value; simultaneously, it determines whether the real-time value of the analog input signal exceeds a preset range, and if so, resets the interlocking voting.

[0049] Furthermore, the MOS bypass module is also configured to, when any MOS switch is triggered, acquire the current bypass output value on the SIS side, XOR the current bypass output value with the MOS switch feedback value to generate a pulse, start timing, and initialize the SIS bypass output value to MOS bypass; when the pulse time is reached, update the current bypass output value and the SIS bypass output value to the MOS switch feedback value.

[0050] The MOS grouping module is also configured to set a MOS unlock switch and enable the unlock switch. When the unlock switch is enabled, the MOS unlock switch enables arbitrary switching of the MOS switch.

[0051] The MOS grouping module includes multiple inputs. When the number of input MOS switches exceeds the preset number, a new MOS grouping module is added and connected in a cascade manner.

[0052] The fault bypass module is also configured to cancel the fault bypass when the bypass of the faulty analog input signal point reaches a preset time, or when it is activated by the MOS bypass corresponding to the bypassed analog input signal point.

[0053] The interlock output control module sets the interlock value between the minimum and maximum analog input signal values ​​to prevent interlock output errors.

[0054] The above-mentioned device realizes functions such as fault self-bypass, interlock dead zone, MOS grouping and MOS bypass, which can meet the increasingly complex practical applications.

[0055] This device is mainly used in the current Supcon TCS900 system to implement fault bypass, interlocking control, and MOS bypass control functions for field analog instrument inputs. The following is a specific example illustrating the device's functionality and processing methods.

[0056] The SIS system of a certain unit has four pressure gauges connected to the field, and related interlocking action schemes need to be developed. The unit also has a DCS control system. In terms of personnel operation, process operators routinely operate from the DCS side, and the relevant SIS field instruments require maintenance and repair.

[0057] An auxiliary control panel for the SIS system needs to be placed on the CCR side. This auxiliary control panel needs to be equipped with a MOS enable switch to manage access permissions for the SIS's MOS switches.

[0058] In addition, to prevent critical field interlocking circuits from being triggered due to SIS instrument failure, and in accordance with the principle of fault-oriented safety, a fault bypass function needs to be set up.

[0059] For the aforementioned field devices, a MOS bypass needs to be configured for the pressure gauges as required. The conventional approach would simply be to install a relevant MOS switch within the SIS system for bypass interlocking. However, this example considers that SIS systems are generally under static monitoring, and no resident SIS operators are typically assigned to any factory. To better adapt MOS operation and management to the on-site operator schedule, this example installs corresponding MOS switches on both the SIS and DCS systems. Considering the system's independence requirements, data exchange between the two MOS switches utilizes communication transmission.

[0060] Meanwhile, to ensure the validity and uniqueness of MOS operation, the MOS switch states of the DCS and SIS should be consistent under normal system operation, requiring consistent functional processing. In the event of an abnormal communication interruption between the DCS and SIS, the MOS switches on the SIS side should still be able to operate normally.

[0061] The aforementioned MOS bypass function is encapsulated using PLC software code to improve usability and work efficiency. The resulting functional block, the MOS bypass module, is configured to, when setting a MOS bypass for an analog input signal point that participates in both SIS interlocking and DCS control, require MOS switches on both the SIS and DCS sides. Under normal DCS-SIS communication, the state of the MOS switches on both sides is kept consistent. When DCS-SIS communication is interrupted, the MOS switch on the SIS side continues to operate normally.

[0062] For details, please refer to Figure 2 When any MOS switch changes, the MOS switch state is monitored on the SIS side. If a change occurs, a pulse timing T01 is triggered. During the timing of T01, the output of the MOS switch is synchronized with that of the bypass switch. After the timing of T01 ends, the output of the MOS switch is synchronized with the MOS bypass state feedback value.

[0063] Also, please see Figure 3 When any MOS switch is triggered, on the DCS side, it is determined whether the MOS switch has activated. If so, timer T01 begins. During the timer, the DCS bypass output is consistent with the bypass switch state (used to synchronize the SIS bypass output with the DCS). After timer T01 ends, the DCS bypass output is consistent with the bypass state communicated by the SIS. If the DCS bypass switch does not activate, it checks whether the bypass state communicated by the SIS has changed (whether the SIS bypass has activated). If so, the DCS bypass output value is updated to be consistent with the bypass state communicated by the SIS.

[0064] Please refer to the custom code implementation of this MOS bypass module. Figure 4 In the diagram, MOS_DCS is the DCS-side MOS bypass identifier, MOS_SIS is the SIS-side MOS bypass identifier, STA_MOS is the MOS switch feedback identifier, O_MOS is the MOS bypass output identifier, O_MOS_SIS is the SIS-side MOS bypass output identifier, MOS_SIS_O is the SIS-side MOS switching identifier, and MOS_DCS_O is the DCS-side MOS switching identifier.

[0065] For interlocking within the same SIL loop, to improve the reliability of normal interlocking operation and reduce arbitrary switching of MOS switches, a MOS grouping function is introduced. This function restricts a SIL loop to only one MOS switch being activated unless there are special requirements. The purpose is to better utilize the interlocking and ensure normal loop monitoring. A SIL loop is a control loop constructed using software simulation. It is mainly used for verifying and testing complex systems to ensure that the system can operate normally under various conditions.

[0066] In addition, to accommodate emergency situations, the restriction has an unlocking function. Once unlocked, the MOS switch can be switched arbitrarily, and this unlocking switch can be included in access control.

[0067] In addition, to prevent unauthorized operation of the MOS switch by process personnel, a MOS enable switch restriction has been added. The switching on or off of the MOS switch will only be effective when this enable switch is enabled.

[0068] The function of MOS grouping is mainly for Figure 3 The STA_MOS parameters shown are the output parameters of this function. This function is implemented using PLC software code encapsulation to improve usability and efficiency. The resulting encapsulated module, the MOS grouping module, can be found in [link to documentation]. Figure 5 The logic implementation of this MOS grouping module includes the following steps:

[0069] The system counts the number of MOS group input bypass switches that are ON. It then checks if the MOS enable switch is ON. If so, it further checks if the MOS unlock switch is ON. If so, it performs switching according to the input number of MOS switches. If not, it checks if the input number of MOS switches is greater than 1. If not, it performs switching according to the input number of MOS switches. If so, it performs one MOS switch switching operation. Simultaneously, when the MOS enable switch is OFF, it also performs one MOS switch switching operation.

[0070] When the number of MOS groups exceeds the 16 inputs shown in the function block, two function blocks need to be cascaded, involving the input parameter MOS_RUN, which is the output O_MOS_RUN of the remaining cascaded MOS group function blocks. In this embodiment, the bypass switches for the four pressure gauges of the device are each configured with two function blocks, and their cascading diagram is shown below. Figure 6 As shown, when multiple function blocks are cascaded, this is achieved through the MOS_RUN and O_MOS_RUN parameters.

[0071] The aforementioned MOS bypass module and MOS grouping module must be used together. Please refer to the documentation for module setup. Figure 7 In the diagram, the red and orange symbols indicate the parameter passing between the two modules, while the blue symbols indicate the MOS_EN enable switch and the MOS_Unlock unlock switch.

[0072] The fault self-bypass function in this embodiment mainly aims to automatically disconnect the bypass when a fault occurs at a certain AI point, maintain the bypass for a pre-set time, and generate a bypass alarm. During this time, if the corresponding MOS switch is triggered or expires, the fault bypass is canceled. If the corresponding pressure gauge is configured with a fault safety value, an interlock will be triggered. The implementation of this fault self-bypass function is encapsulated using PLC software code; its logic implementation can be found in [link to relevant documentation]. Figure 8 In the diagram, AM_EN enables fault bypass, AI_OK indicates the AI ​​channel is normal, AUTO_MOS is the fault bypass flag, AM_T_S is the fault bypass time, and ERR_MOS is the AI ​​fault bypass flag. Please refer to the function code of this fault bypass module. Figure 9 .

[0073] In practical applications, when pressure gauge 01PT_1001 malfunctions, the instrument is automatically bypassed for 15 seconds. Please refer to the documentation for module setup. Figure 10 In the diagram, O_ERR_MOS is the output bit of the fault bypass, which can be connected to relevant variables to provide alarm prompts.

[0074] Regarding AI interlock output control, this function is implemented within the SIS system. A common requirement is to compare the data transmitted from field instruments with a preset interlock value and then output a voting logic result. This embodiment combines the aforementioned MOS bypass module and fault self-bypass module to add an interlock reset dead zone to the AI ​​interlock output control. That is, when the real-time value of the AI ​​input signal fluctuates around the interlock value, frequent interlock voting output actions will occur. To avoid this situation, a comparison dead zone function is introduced. When interlock voting is triggered, the interlock voting will only reset if the real-time value of the AI ​​exceeds the dead zone setting range.

[0075] Meanwhile, error prevention features have been added to the setting of interlock values, requiring that the interlock values ​​be set within the AI ​​range, that is, between the maximum AI value and the minimum AI value.

[0076] In this embodiment, the function of AI interlocking output control is encapsulated in PLC software code to obtain the interlocking output control module. Four types of interlocking outputs are set for this interlocking output control module, namely HH / H / L / LL. Due to their repetitive nature, the logic of this module is explained below using the HH interlocking output as an example.

[0077] Please refer to Figure 11 First, determine if the interlock setting value is within the AI ​​range. If so, further determine if the MOS bypass is activated. If so, the voting output is ON. If the interlock setting value is not within the AI ​​range, reset the interlock value and determine if the MOS bypass is activated. If not, determine if the interlock output is triggered. If so, determine if the AI ​​real-time value exceeds the interlock reset dead zone. If so, the voting output is OFF. If the interlock output is not activated, determine if the AI ​​real-time value is greater than or equal to the interlock value. If so, activate the interlock output and the voting output is OFF.

[0078] In summary, this embodiment provides a solution for simultaneously establishing MOS switches in SIS and DCS, systematically organizing the relevant control of AI analog quantities, and modularizing and standardizing them to facilitate operation and improve work efficiency.

[0079] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the above embodiments. Even if various changes are made to the present invention, if these changes fall within the scope of the claims of the present invention and their equivalents, they shall still fall within the protection scope of the present invention.

Claims

1. A device for comprehensively processing analog input signals of an industrial system, characterized in that, include: Fault bypass module, interlocking output control module, MOS bypass module and MOS grouping module; The MOS bypass module is configured such that when an analog input signal point participates in both SIS interlocking and DCS control, a MOS switch needs to be set on both the SIS side and the DCS side when setting a MOS bypass for the analog input signal point; when the DCS and SIS communication is normal, the state of the MOS switches on both sides is consistent; when the DCS and SIS communication is interrupted, the MOS switch on the SIS side operates normally. The MOS grouping module is configured to allow only one MOS switch to be activated in a SIL loop interlock; The fault bypass module is configured to automatically disconnect the bypass when a fault occurs at an analog input signal point, and to continuously disconnect the bypass for a preset time, generating a bypass alarm. The interlocking output control module is configured to output a comparison result between the real-time value of the analog input signal and the interlocking value after interlocking voting is triggered; at the same time, it determines whether the real-time value of the analog input signal exceeds a preset range, and if so, resets the interlocking voting. The MOS bypass module is further configured to, when any MOS switch is triggered, acquire the current bypass output value on the SIS side, XOR the current bypass output value with the MOS switch feedback value to generate a pulse, start timing, and initialize the SIS bypass output value to MOS bypass; when the pulse time is reached, update the current bypass output value and the SIS bypass output value to the MOS switch feedback value. The MOS grouping module is also configured to set a MOS unlock switch and enable the unlock switch. When the unlock switch is enabled, the MOS unlock switch enables arbitrary switching of the MOS switch. The MOS grouping module includes multiple inputs. When the number of input MOS switches exceeds a preset number, a new MOS grouping module is added and connected in a cascaded manner. The fault bypass module is also configured to cancel the fault bypass when the bypass of the faulty analog input signal point reaches a preset time, or when it is activated by the MOS bypass corresponding to the bypassed analog input signal point. The interlocking output control module sets the interlocking value between the minimum and maximum analog input signal values ​​to prevent interlocking output errors.

2. A method for comprehensively processing analog input signals of an industrial system, characterized in that, include: When an analog input signal point participates in both SIS interlocking and DCS control, a MOS switch needs to be set on both the SIS side and the DCS side when setting a MOS bypass for the analog input signal point. Under normal communication between DCS and SIS, the state of the MOS switches on both sides is kept consistent. When communication between DCS and SIS is interrupted, the MOS switch on the SIS side operates normally. MOS bypasses are grouped, and only one MOS switch is allowed to be activated in a SIL loop interlock. When a fault occurs at an analog input signal point, its bypass is automatically disconnected, and after the bypass is disconnected for a preset time, a bypass alarm is generated, realizing the fault self-bypass function. When the interlock voting is triggered, the comparison result between the real-time value of the analog input signal and the interlock value is output; at the same time, it is determined whether the real-time value of the analog input signal exceeds the preset range. If so, the interlock voting is reset. Among these measures, under the condition that the communication between DCS and SIS is normal, the consistency processing of the states of the MOS switches on both sides further includes: When any MOS switch changes, the MOS switch state is monitored on the SIS side. If a change occurs, a pulse timing is triggered. During the timing period, the output of the MOS switch is synchronized to be consistent with the bypass state. After the timing ends, the output of the MOS switch is synchronized with the bypass state feedback value. Meanwhile, on the DCS side, it is determined whether the MOS switch is activated. If so, a timer is started. During the timer, the DCS bypass output is consistent with the MOS switch state. After the timer ends, the DCS bypass output is consistent with the bypass state communicated by SIS. If the MOS switch is not activated, it is checked whether the bypass state communicated by SIS has changed. If so, the DCS bypass output value is updated to be consistent with the bypass state communicated by SIS. When performing MOS grouping, count the number of MOS grouping input bypass switches that are ON, and determine whether the MOS enable switch is ON. If yes, further determine whether the MOS unlock switch is ON. If yes, perform switching according to the input number of MOS switches. If no, further determine whether the input number of MOS switches is greater than 1. If no, perform switching according to the input number of MOS switches. If yes, perform MOS switch switching once. At the same time, when the MOS enable switch is OFF, perform MOS switch switching once as well. When interlocking is voted on, the interlocking value is set between the minimum and maximum analog input signal values ​​to prevent interlocking output errors.

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