Virtualization control system

Abstract

The invention provides a virtualization control system. Comprising a virtual controller which comprises a plurality of functional modules, defines functions realized by each functional module by using software, and deploys the virtual controller to an embedded hardware device, a virtual machine and / or a cloud platform server; the control network is used for data communication between the virtual controller and the I / O module, the gateway and the control software; the gateway is used for protocol conversion between the virtual controller and the I / O module, communication is carried out by using the Ethernet and a DP protocol, and remote communication between the virtual controller and the gateway is realized; the I / O module is used for being connected with field equipment and transmitting acquired field equipment data to the virtual controller; and the control software is used for executing data monitoring and management tasks and communicating with the virtual controller through a system network. The flexibility, expansibility and reliability of the system can be improved, the control capability of the system is improved, and therefore the resource utilization rate is increased.

Description

Technical Field

[0001] The present application relates to the technical field of distributed control systems, and in particular to a virtualized control system. Background Art

[0002] Distributed Control System (DCS) is widely used in various industrial fields. It adopts the design concept of decentralized control and centralized management, and realizes data sharing and collaborative work through network interconnection between multiple controllers. Traditional DCS systems rely on hardware environment deployment, such as control cabinets, controllers, I / O modules, etc. However, the deployment speed, resource allocation and scalability of these physical controllers are limited, resulting in increased environment, time and cost in actual applications, and more complicated maintenance work.

[0003] With the increasing requirements for refined and efficient production control in the industrial field, as well as the rapid development of emerging information technologies such as artificial intelligence and big data, existing DCS control systems face many challenges. Traditional DCS can only process traditional sensor signals such as temperature, pressure, flow and liquid level. However, with the demand for more complex signals in modern industrial applications, such as visual and voice signals and support for wireless communications such as 5G, traditional control systems are difficult to meet these new demands. In addition, the existing DCS system cannot be deeply integrated with technologies such as artificial intelligence and big data, making it difficult to achieve more efficient processing and intelligent analysis of data. Summary of the invention

[0004] In view of this, an embodiment of the present application provides a virtualized control system to solve the problems existing in the prior art, such as low system flexibility, scalability and reliability, poor system control capability, and low resource utilization.

[0005] The embodiment of the present application provides a virtualized control system, including: a virtual controller, including multiple functional modules, and using software to define the functions implemented by each functional module, the virtual controller is deployed to an embedded hardware device, a virtual machine and / or a cloud platform server, and the virtual controller communicates data with a gateway and an I / O module through a controller network; a control network is used for data communication between the virtual controller and the I / O module, the gateway and the control software; a gateway is used for protocol conversion between the virtual controller and the I / O module, communicating using Ethernet and DP protocols, and realizing remote communication between the virtual controller and the gateway; the I / O module is used to connect to the field device and transmit the collected field device data to the virtual controller; the control software is used to perform data monitoring and management tasks, and communicate with the virtual controller through the system network.

[0006] At least one of the above technical solutions adopted in the embodiments of the present application can achieve the following beneficial effects: Through a virtual controller, including multiple functional modules, and using software to define the functions implemented by each functional module, the virtual controller is deployed to an embedded hardware device, a virtual machine and / or a cloud platform server, and the virtual controller communicates data with the gateway and I / O module through the controller network; the control network is used for data communication between the virtual controller and the I / O module, the gateway and the control software; the gateway is used for protocol conversion between the virtual controller and the I / O module, using Ethernet and DP protocols for communication, and realizing remote communication between the virtual controller and the gateway; the I / O module is used to connect with the field equipment and transmit the collected field equipment data to the virtual controller; the control software is used to perform data monitoring and management tasks, and communicate with the virtual controller through the system network. This application can improve the flexibility, scalability and reliability of the system, improve the system control capability, and thus improve resource utilization. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0008] Figure 1 It is a schematic diagram of the overall architecture of a virtualized control system involved in an actual scenario in an embodiment of the present application; Figure 2 It is a schematic diagram of the overall structure of the virtualized control system provided in the embodiment of the present application; Figure 3 It is a schematic diagram of the overall structure of the virtual controller provided in an embodiment of the present application. DETAILED DESCRIPTION

[0009] In the following description, specific details such as specific system structures, technologies, etc. are provided for the purpose of illustration rather than limitation, so as to provide a thorough understanding of the embodiments of the present application. However, it should be clear to those skilled in the art that the present application may also be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted to prevent unnecessary details from obstructing the description of the present application.

[0010] DCS (Distributed Control System), also known as distributed control system, adopts the basic design concept of decentralized control, centralized management and operation, and is widely used in various industrial fields. Different from traditional centralized control systems, DCS distributes control functions to multiple controllers, which are interconnected through the network to achieve data sharing and collaborative work. In general, the hardware environment requires the deployment of control cabinets, controllers, I / O modules, etc. The deployment speed, resource allocation, and scalability of these physical controllers are all subject to corresponding restrictions, which leads to an increase in the actual environment, time, and cost, and the maintenance is more complicated.

[0011] Traditional DCS control systems have been used in the industrial field for many years and can complete traditional control tasks well. However, with the increasing requirements of process industries for refined and efficient production control, as well as the different requirements of different users, traditional controllers cannot adapt to the needs of different users. All types of controllers have the same functions and cannot be expanded to adapt to new functions. New generation information technologies such as artificial intelligence and big data cannot be further fully integrated. Traditional controllers need to develop new hardware and new firmware to adapt to new functions, and use multiple models to meet the requirements of different industries. Virtual controllers decouple the module functions inside the controller, define the functions of each module through software, and only need to give the module different functions through software to respond to new requirements. With the current industry's exploration of technical systems for industrial Internet, Industry 4.0, etc., virtualization technology has become particularly important.

[0012] Therefore, the current DCS control system still has the following limitations: 1. It is necessary to process visual, speech and other signals that have not been previously available; 2. Need to support wireless communications such as 5G; 3. The tedious manual debugging process needs to be avoided; 4. The control cycle is relatively long and the controller load is high; 5. Incompatible and unscalable with different communication protocols; 6. It is difficult to achieve deep integration with artificial intelligence, big data and other technologies; 7. It is difficult to meet higher requirements for control systems and data.

[0013] Based on the limitations of the prior art, the present application provides a virtualized control system, which adopts DCS controller virtualization technology and can be deployed on a virtual machine of a power plant's private cloud computing platform. It utilizes the computing power resources of the cloud server and loads a real-time operating system through the redundant virtual machine environment provided by the cloud server to realize the operation of the DCS DPU in a virtualized environment, and realizes the virtualized deployment of DCS control logic and monitoring screens, ultimately achieving interactive and comprehensive utilization of data and rational allocation of resources.

[0014] The overall architecture of the virtualized control system provided by the present application in actual scenarios is described below in conjunction with the accompanying drawings. Figure 1 is a schematic diagram of the overall architecture of the virtualized control system involved in the actual scenario of the embodiment of the present application, such as Figure 1 As shown, the overall architecture of the virtualized control system may specifically include the following contents: This virtualized control system consists of a virtual controller, control network, remote gateway and I / O module, and is equipped with an operator station, engineer, history station and related supporting software. The system operation conforms to the conventional DCS operation habits. The virtual controller is a fully virtualized controller. The virtual controller supports deployment in a single virtual machine and can be installed on a cloud platform. The cloud platform allocates virtual machines for installing cloud controllers, network communications and their dependent environments. The logical configuration and data storage of the cloud controller are implemented in the virtual server, and the logical operation relies on the virtual controller. The virtualized control system is based on the company's in-service (K+654) DCS control system, deploys traditional physical controllers on a high-performance cloud computing platform, and realizes the operation of DCS controller control logic functions in a commercial server hardware platform environment; further, with the help of virtualization technology, the logical function (software) is separated from the physical equipment of commercial hardware, and flexible deployment is achieved on demand. A single physical server can deploy multiple virtual controllers to improve flexibility and scalability; in terms of communication expansion, it supports the access of on-site I / O device data to the virtual controller through 5G communication.

[0015] This virtualized control system can virtualize the physical controller under the premise of ensuring the safety, reliability and performance of the control system, providing users with a set of software-based intelligent controllers and efficient redundant industrial Ethernet communication systems that can run on general computer resources, and has convenient 5G access capabilities. It not only has all the functions of the physical DCS control system, but also has the elastic expansion capability of the virtual controller computing power, and can provide an integrated closed-loop control operating environment for the implementation of intelligent application algorithms based on machine learning, big data optimization, intelligent control and other technologies.

[0016] The purpose of this application is to realize controller virtualization, and by reconstructing the controller hardware, realize the next generation of new and intelligent controller devices, thereby replacing traditional hardware controllers. The virtualized controller can be deployed on an X86 general-purpose computing server or a virtual machine on a cloud computing platform, using the computing power resources of the cloud server, loading the real-time operating system through the redundant virtual machine environment provided by the cloud server, realizing the softwareization of the K-CUXX main controller functions, and running on the X86 general-purpose computing server or its virtualized environment, interconnecting with the I / O gateway module through Ethernet to form a virtual control system, realizing all the functions of the physical DCS system. The technical advantages of the virtualized control system provided by this application are reflected in the following aspects: 1. Improve resource utilization: Through virtualization technology, multiple virtual machines can be created on a physical server to achieve higher resource utilization and flexibility; 2. Improve system reliability: Each virtual machine is independent and has its own operating system and application. If a virtual machine fails, other virtual machines can continue to operate normally without any impact; 3. Improve security: Virtualization technology can realize dynamic allocation and adjustment of resources, which can better adapt to different business needs and scenarios; 4. In the power industry, the application of virtualization technology has become an important driving force for industry change. It not only improves operational efficiency and enhances data security, but also optimizes resource allocation, injecting new vitality into the sustainable development of the power industry.

[0017] The structure of the virtualization control system provided in the embodiment of the present application is described below in conjunction with the accompanying drawings and specific embodiments. Figure 2 is a schematic diagram of the overall structure of the virtualized control system provided in the embodiment of the present application, such as Figure 2 As shown, the virtualized control system may specifically include the following contents: The virtual controller 201 includes a plurality of functional modules, and uses software to define the functions implemented by each functional module, and deploys the virtual controller to an embedded hardware device, a virtual machine and / or a cloud platform server. The virtual controller communicates data with the gateway and the I / O module through the controller network; Control network 202, used for data communication between the virtual controller and I / O modules, gateways and control software; The gateway 203 is used for protocol conversion between the virtual controller and the I / O module, uses Ethernet and DP protocols for communication, and realizes remote communication between the virtual controller and the gateway; I / O module 204, used to connect with field devices and transmit collected field device data to the virtual controller; The control software 205 is used to perform data monitoring and management tasks and communicate with the virtual controller through the system network.

[0018] In some embodiments, the virtual controller combines different functional modules according to application requirements, and uses split-core processing technology to separate calculation and communication management during operation.

[0019] Specifically, the hardware resources of the virtual controller mainly include computing servers (such as X86 general computing servers) or virtual machines of cloud computing platforms for running virtual controllers. The computing server provides powerful computing capabilities and supports the parallel operation of multiple virtual controllers. Each virtual controller is deployed on a single hardware resource through virtualization technology, avoiding the deployment limitation of multiple hardware controllers in traditional DCS systems. Figure 3 is a schematic diagram of the overall structure of the virtual controller provided in the embodiment of the present application, such as Figure 3 As shown, the virtual controller may specifically include the following contents: For example, in some examples, the hardware resources deployed by the virtual controller may include the following: Central Processing Unit (CPU): Provides computing power for the virtual controller and supports high-speed data processing and control tasks.

[0020] Memory (RAM): Provides the required operating space for the virtual controller's applications and ensures real-time processing of large amounts of data.

[0021] Storage unit: stores control logic, real-time data and historical data to ensure long-term storage and backup of data.

[0022] Through virtualization technology, virtual controllers can run in an environment with shared hardware resources, improving resource utilization and system flexibility.

[0023] Furthermore, the operation of virtual controllers depends on the support of virtualization platform software and operating system. Virtualization platform software (such as Xen, VMware, etc.) provides infrastructure for virtual machines, ensuring that multiple virtual controllers can run independently on the same hardware without interfering with each other.

[0024] For example, Xen virtualization platform or VMware is responsible for allocating computing resources to virtual controllers and ensuring the independent operation of virtual controllers. Virtualization platform software can dynamically adjust resource allocation and flexibly schedule computing resources according to workload changes.

[0025] The operating system (such as Linux or Windows Server) installed in the virtual controller supports the core functions of the virtual controller, including the execution of control logic, data storage, communication with I / O modules, etc. The choice of operating system is based on the system requirements and compatibility to ensure that the virtual controller can run efficiently.

[0026] In some examples, various functions of the virtual controller are completed by different functional modules, and the functions corresponding to each functional module are defined by software, that is, the virtual controller is composed of functional modules that implement different functions, and the functions implemented by each functional module are defined by software. In actual applications, different combinations of functions can be implemented according to application requirements.

[0027] In some examples, the virtual controller uses split-core processing technology to separate computing, communication management, and functional module tasks, thereby optimizing system performance.

[0028] Operation management (IEC operation): IEC standards (such as IEC 61131-3) specify the program structure and operation logic of industrial control systems. In the virtual controller, IEC operations are processed by independent CPU cores to ensure efficient control logic operation capabilities. Each virtual controller is allocated one or more dedicated CPU cores to execute complex control algorithms, such as PID control, process control, and alarm logic. This separate processing ensures high operation performance and avoids interference between control tasks and communication tasks.

[0029] Communication management: Communication management is mainly responsible for data exchange between the virtual controller and I / O modules, gateways, and other virtual controllers. In this embodiment, the communication management task is processed by another independent CPU core. In this way, the computing core of the virtual controller focuses on executing control tasks, while the communication core handles data transmission, protocol conversion, and data packet processing, avoiding resource contention between computing tasks and communication tasks, and ensuring the stability and low latency of real-time data transmission.

[0030] The split-core processing technology enables the virtual controller to run efficiently while ensuring the stability and response speed of the virtual controller when processing large amounts of real-time data.

[0031] Furthermore, the application software of the virtual controller includes control logic software, data processing module and communication protocol module, etc., to ensure that the virtual controller can complete all the functions of the traditional physical controller, including: Control logic software: According to the set control rules, the operating status of the field equipment is adjusted in real time. These control logics include the adjustment of parameters such as temperature, pressure, flow, and liquid level.

[0032] Data processing module: Receives real-time data from I / O modules or external devices, processes and analyzes them. For example, the control strategy can be optimized through machine learning algorithms, or the health status of the equipment can be analyzed through the fault diagnosis module.

[0033] Communication protocol module: Supports standardized industrial communication protocols (such as Modbus, PROFIBUS, Ethernet / IP, etc.), ensuring that the virtual controller can communicate with field devices from different manufacturers.

[0034] In actual operation, the virtual controller implements control tasks in the following ways: Control logic configuration: Load the control logic into the virtual controller through the configuration interface of the engineer station, and configure the corresponding control parameters and device interfaces.

[0035] Data acquisition and processing: The virtual controller exchanges data with the I / O module through the communication management module to obtain real-time data of the field equipment. The operation management module executes the control algorithm according to the real-time data and outputs control instructions to the field equipment.

[0036] Multi-task parallel processing: The virtual controller achieves multi-task parallel processing through split-core processing technology, and can process multiple control loops at the same time to ensure the real-time and accuracy of each control task.

[0037] According to the system structure of the present embodiment, the virtual controller combines hardware resources, virtualization platform software, operating system and application software, and adopts split-core processing technology to effectively separate computing and communication management, thereby improving the computing power and response speed of the control system. The virtual controller can efficiently run on a cloud computing platform or a general computing server, fully utilize computing resources, provide powerful industrial control capabilities, and replace traditional DCS controllers to meet the needs of modern industry for efficient, intelligent and scalable control systems.

[0038] In some embodiments, virtualization technology is used to deploy multiple virtual controllers on embedded hardware devices, virtual machines and / or cloud platform servers, wherein independent control logic is configured for each virtual controller, and computing resources are dynamically allocated to the virtual controllers based on the deployed functions.

[0039] Specifically, in this embodiment, virtualization technology is implemented through two virtualization platforms, Xen and VMware. Virtualization technology allows multiple virtual controllers to be deployed on a single physical server, and each virtual controller can run independently and be configured with independent control logic and processing tasks.

[0040] Xen virtualization: Xen is an open source virtualization platform that can be used to create multiple virtual machines on a physical server, each of which runs an independent operating system and application program. In this embodiment, the Xen virtualization platform is used to create multiple virtual controllers, each of which runs its independent control logic and tasks.

[0041] VMware virtualization: VMware, as another popular virtualization technology, is also used to deploy multiple virtual controllers on a physical server. VMware allocates hardware resources to different virtual controllers by providing a hypervisor. The virtual controllers run on VMware virtual machines and use shared computing resources to achieve efficient parallel processing.

[0042] Through virtualization technology, each virtual controller runs in a virtual machine and configures its independent control logic. The control logic of the virtual controller usually includes real-time control of industrial parameters such as temperature, pressure, and flow, and the configuration of the control logic is based on on-site needs.

[0043] Each virtual controller has an independent configuration in the virtual machine, allowing users to configure different control algorithms or parameters according to different task requirements. For example, one virtual controller can be configured as a temperature controller, and another virtual controller can be configured as a flow controller. In this way, multiple virtual controllers can run in parallel on the same virtual machine without interfering with each other.

[0044] The virtualization platform allows computing resources to be dynamically allocated based on the load requirements of each virtual controller. For example, when a virtual controller needs more computing resources to handle complex control tasks, the virtualization platform can allocate more CPU cores or memory resources to the controller. Conversely, when the load is light, the system automatically releases unnecessary resources, thereby improving overall resource utilization.

[0045] This dynamic resource allocation mechanism enables the virtual controller to flexibly respond to different workloads and ensure system stability and responsiveness under high load conditions.

[0046] Furthermore, in order to improve the reliability of the system, the virtual controller supports controller redundancy design, that is, maintaining redundant backups between multiple virtual controllers. This redundancy design can be achieved through dual Ethernet, that is, each virtual controller is equipped with two Ethernet links to ensure that the system can continue to operate stably even if one link fails.

[0047] Each virtual controller communicates with other devices (such as I / O modules, gateways, or other virtual controllers) through two independent Ethernet links. In this design, if one of the links fails, the system will automatically switch to the other link, thus avoiding single point failures that cause system unavailability.

[0048] Redundancy design is not limited to network links, but also includes backup of virtual controllers. When one virtual controller fails or requires maintenance, the redundant virtual controller takes over its tasks to ensure the continuity of control tasks.

[0049] This redundant design ensures high availability of the virtual controller in the face of hardware failures, improves the system's fault tolerance, and avoids long downtime caused by hardware problems.

[0050] The implementation process of this embodiment is as follows: First, virtual machines are created on a virtualization platform (Xen or VMware), and each virtual machine runs an independent virtual controller. The hardware resources (such as CPU, memory, and storage) of each virtual controller are dynamically allocated by the virtualization platform and optimized according to load requirements.

[0051] Next, the control logic and parameter configuration are loaded into the virtual controller through the engineering station, and the virtual controller runs independently according to different tasks. Each virtual controller independently handles a specific control task according to its configuration.

[0052] Then, dual Ethernet links are configured so that each virtual controller has a backup channel for communication with other devices to prevent communication interruption caused by link failure.

[0053] Finally, the virtualization platform dynamically allocates computing resources based on system load and computing requirements. When the load on a virtual controller increases, the system will allocate more resources to ensure its processing capacity; conversely, when the load is light, resources will be released to other virtual controllers.

[0054] This embodiment describes how to deploy multiple virtual controllers on a single virtual machine through virtualization technology, configure independent control logic for each virtual controller, and dynamically allocate computing resources according to load requirements. This virtualization deployment method not only improves the utilization efficiency of hardware resources, but also improves the flexibility, scalability and fault tolerance of the system. At the same time, the redundant design ensures the high availability and stability of the system through dual Ethernet communication and redundant controller switching.

[0055] In some embodiments, the virtual controller uses the field data mirror to simulate the process model and predicts faults based on the process model simulation results. The virtual controller is also used for configuration logic operations and multi-task parallel processing.

[0056] Specifically, in this embodiment, the virtual controller performs process model simulation by using the mirror image of the field data. Process model simulation is to copy the real-time data of the field equipment to form a virtual environment for simulating various processes and operating conditions in the production process. Through these simulations, the virtual controller can predict potential failures or accidents in advance, thereby improving the safety and preventive maintenance capabilities of the system.

[0057] Furthermore, the virtual controller collects real-time operation data of the field by exchanging data with field devices (such as sensors, actuators, etc.). These data include industrial parameters such as temperature, pressure, and flow. By mirroring these data, the virtual controller can reproduce the status and operation of field devices in a simulation environment.

[0058] Furthermore, the virtual controller simulates the production process in the process model simulation environment based on the mirrored field data. The process model can not only reflect the normal operating status of the production system, but also simulate abnormal situations that may occur in the system, such as equipment failure and operational errors. Through process model simulation, the virtual controller can predict faults and give corresponding early warning signals. For example, when the vibration level of a certain equipment increases abnormally, the virtual controller will predict the equipment failure based on the simulation results and issue an early warning to the operator.

[0059] Furthermore, based on the simulation model, the virtual controller can detect potential failure risks in a timely manner by comparing the deviation between real-time data and simulation results. When the simulation model predicts that a certain link may fail, the system will trigger the early warning mechanism in advance to notify maintenance personnel to conduct inspections and interventions, thereby avoiding production accidents.

[0060] The virtual controller not only supports multi-task parallel processing, but also can perform flexible control logic configuration and multi-task configuration through the IEC61131-3 standard.

[0061] IEC61131-3 is a standard for industrial automation control systems issued by the International Electrotechnical Commission, which specifies the programming language and task management method of the control system. In this embodiment, the virtual controller complies with the IEC61131-3 standard, supports the parallel execution of multiple tasks, and can configure independent operation cycles and priorities according to different control tasks. This enables the virtual controller to process multiple control loops at the same time, such as temperature control loops, pressure control loops, etc., while ensuring the response speed and stability of the system.

[0062] Through the split-core processing technology, the virtual controller can assign different control tasks to different CPU cores for processing, thereby achieving multi-task parallel execution. Each task can run independently without interfering with each other, thereby improving the computing power and real-time performance of the system. For example, temperature control and flow control can be performed simultaneously without waiting for the completion of other tasks.

[0063] The virtual controller supports configuration logic operations based on IEC61131-3, that is, the control logic is defined through a graphical interface and programming language. In actual applications, users can configure the control logic of the virtual controller through the engineering station to set and adjust the control algorithm. For example, users can drag and drop control modules on the graphical interface to set the parameters and logic of temperature and flow control. The virtual controller can perform corresponding control tasks according to these logics and make dynamic adjustments according to changes in field data.

[0064] The virtual controller not only supports standard industrial control networks, but also can be unified with the field bus, facilitating the interconnection between multiple devices and systems.

[0065] The virtual controller is compatible and can communicate with various industrial control networks, such as Ethernet / IP, Modbus, PROFIBUS, etc. This enables the virtual controller to interoperate with field devices from different manufacturers and standards, simplifying the complexity of system integration.

[0066] The virtual controller can also support fieldbus protocols to connect field devices (such as sensors, actuators, PLCs, etc.) to the control system. Through a unified bus communication protocol, the virtual controller can collect data from field devices and transmit control instructions to field devices. Whether it is a sensor signal or a control signal on site, efficient data transmission and control execution can be achieved through a unified communication protocol.

[0067] In some examples, the virtual controller is connected to the field equipment through the communication interface to collect real-time data such as temperature, pressure, flow, etc. The virtual controller copies this data to the memory to form a mirror image of the field data for subsequent process model simulation and fault prediction.

[0068] Based on the mirrored data, the virtual controller builds a process model in the simulation environment and predicts possible problems in the production process through simulation operation. When the simulation model finds an abnormality, the virtual controller will issue an alarm signal to prompt the operator or engineer to check.

[0069] The virtual controller configures the control logic according to the IEC61131-3 standard and supports multi-task parallel execution. Each virtual controller can execute multiple control tasks according to the configuration to ensure the smooth operation of the industrial control process.

[0070] The virtual controller ensures effective communication with field devices through the industrial control network and fieldbus protocol. Through standardized communication protocols, the virtual controller can exchange data with field devices to achieve precise control of the production process.

[0071] This embodiment realizes intelligent control and optimization in the production process through the process model simulation and fault prediction functions of the virtual controller, combined with the multi-task parallel processing supported by the IEC61131-3 standard. The virtual controller can not only efficiently perform traditional control tasks, but also predict potential faults through real-time simulation, improving the safety and reliability of the system. At the same time, the unified support of the industrial control network and fieldbus of the virtual controller ensures efficient collaboration between multiple devices.

[0072] In some embodiments, the resource usage status of the virtual controller is monitored in real time during system operation, and automatic alarms and fault diagnosis are performed when an abnormality occurs. The virtual controller is also used to automatically switch the main controller when a fault occurs.

[0073] Specifically, in this embodiment, the virtual controller has resource monitoring and fault diagnosis functions. The virtual controller uses a built-in resource monitoring module to track and record the resource usage of the virtual controller in real time, including CPU occupancy, memory usage, storage space, and network bandwidth. Through these data, the virtual controller can proactively identify potential resource bottlenecks or anomalies, and take measures when necessary to avoid system performance degradation or crashes.

[0074] The virtual controller monitors the usage of its various resources in real time to ensure that each controller's computing and communication tasks are supported by sufficient resources. For example, when the CPU core usage is higher than the predetermined threshold, the system will issue a warning that resources may be insufficient and that resources need to be expanded or control logic optimized. Monitoring memory usage and storage space also helps prevent system crashes due to resource exhaustion.

[0075] The monitoring module of the virtual controller also includes fault diagnosis function. By monitoring the resource usage status, the virtual controller can detect abnormal conditions (such as high CPU load, memory leak, hardware failure, etc.). Once an abnormality occurs, the virtual controller can automatically trigger the alarm system to notify engineers or operators to handle it. The alarm information usually includes the type of fault, the time of occurrence, and the possible scope of impact, helping technicians to quickly diagnose the problem and take countermeasures.

[0076] In addition to real-time alarms, the virtual controller can also provide fault diagnosis and repair suggestions based on historical data and current status. For example, when it is found that a task continues to occupy a large amount of computing resources, the virtual controller can analyze the cause and provide optimization suggestions, such as adjusting the priority of the task or adjusting the control logic.

[0077] Furthermore, in order to improve the reliability of the system, the virtual controller in this embodiment supports the main controller redundancy function. When the main controller fails or an abnormality occurs, the system can automatically switch to the redundant controller to ensure the continuity of the control task without manual intervention.

[0078] Each virtual controller supports setting up a redundant controller. When the main controller fails to operate normally, the redundant controller will take over the control task. The deployment of the redundant controller is almost the same as that of the main controller, but the redundant controller is usually in standby state and will only be enabled when the main controller fails.

[0079] When the main controller fails (such as CPU abnormality, memory overflow, etc.), the system will automatically detect the abnormality of the main controller and quickly switch to the redundant controller. This switching process is non-disruptive, that is, the redundant controller can seamlessly take over the control tasks of the main controller to ensure that the production process is not interrupted.

[0080] The switching process is transparent to operators and engineers, and the system does not require manual intervention during the switching process. Users can continue with their daily operations and the system will automatically return to normal.

[0081] The redundant controller shares the same computing resources and hardware configuration as the main controller, and the efficient operation of the redundant controller is ensured by allocating resources on the virtualization platform. The resources of the redundant controller will be in a low-load state when the main controller is operating normally, but once a switch occurs, the computing resources of the redundant controller will be fully invested in the control task.

[0082] After the virtual controller adopts virtualization technology, its computing power is significantly improved. Compared with traditional controllers, the virtual controller can better allocate computing resources and improve the overall performance of the system.

[0083] Through the virtualization platform, the virtual controller can dynamically allocate resources as needed. In traditional controllers, computing tasks are usually limited by the performance of physical hardware, but in a virtualized environment, the virtual controller can use the powerful computing power of the cloud platform to expand its computing capabilities. In this way, the virtual controller can efficiently process large amounts of data and complex calculations, significantly improving the response speed and accuracy of the control system.

[0084] Traditional controllers often require manual intervention and optimization under high load, but virtual controllers can automatically balance the load of each virtual controller through the resource scheduling function of the virtualization platform. When the load of a virtual controller is too high, the system can transfer some tasks to other virtual controllers, thereby avoiding excessive load on a single controller and improving the stability of the overall system.

[0085] The virtual controller distributes computing tasks to multiple CPU cores through split-core processing technology and supports multi-task parallel operation. This means that the virtual controller can handle multiple control loops or multiple tasks at the same time, such as temperature control, flow control and alarm processing, greatly improving the efficiency and responsiveness of the system.

[0086] In some examples, the implementation process and working principle of this embodiment are as follows: First, when the virtual controller starts running, it collects resource usage data such as CPU, memory, storage, and network bandwidth through the resource monitoring module. The system continuously monitors the resource status and immediately triggers an alarm mechanism to notify the operator or engineer if a resource anomaly (such as high CPU usage, memory overflow, etc.) is found.

[0087] Then, when a fault occurs, the virtual controller’s diagnostic module provides diagnostic information based on historical operating data and current status, and gives possible repair suggestions to help technicians troubleshoot.

[0088] Then, if the main controller fails, the system will automatically trigger the redundant controller to take over. The redundant controller will quickly switch from standby to main controller status and continue to perform control tasks to ensure that the production process is not interrupted.

[0089] Finally, when multiple tasks are executed in parallel, the virtual controller dynamically allocates computing resources according to load requirements. For example, when the load of a virtual controller increases, the system will allocate more resources as needed to ensure the smooth execution of tasks.

[0090] This embodiment describes how the virtual controller monitors the system status in real time and automatically alarms and repairs when an abnormality occurs through resource monitoring and fault diagnosis functions. Through the automatic switching of redundant controllers, the system can ensure the continuity and stability of the production process. In addition, the computing power of the virtual controller has been significantly improved, which can handle complex control tasks and reduce the load of traditional controllers. Through virtualization technology, the virtual controller not only enhances the reliability of the control system, but also improves the flexibility and intelligence level of the system.

[0091] In some embodiments, the virtualized control system also includes a system network and a redundant network, wherein the system network is used for data communication between the virtual controller and the control software, and the redundant network uses a dual-link redundancy mechanism to provide a backup link.

[0092] Specifically, in this embodiment, three independent networks are set in the virtualized control system: a system network, a control network, and a redundant network. Each network is responsible for different communication tasks, thereby ensuring the efficient operation of the system.

[0093] The system network is mainly responsible for the communication between the virtual controller and the control software. The control software includes the engineer station, operator station and history station, etc. The system network provides a data exchange channel between these devices and the virtual controller. Through the system network, users can monitor and control the status of the virtual controller in real time, view field data, input operation instructions, etc.

[0094] The system network supports the communication of terminal devices such as DCS engineer stations, operator stations and historical stations. It ensures that these terminal devices can be seamlessly connected with virtual controllers and other system modules to achieve real-time data transmission and display.

[0095] The system network adopts high-speed industrial Ethernet technology to ensure high efficiency and low latency of data transmission and meet the real-time requirements of the system.

[0096] Furthermore, the control network is a data communication network between the virtual controller and the I / O module. The I / O module connects the field devices (such as sensors, actuators, etc.) and is responsible for collecting field signals and transmitting them to the virtual controller. The main task of the control network is to ensure that the field device data can be stably and timely transmitted to the virtual controller and execute the corresponding control instructions.

[0097] The control network provides high-speed and reliable data transmission between the virtual controller and the field I / O devices. The control network connects the virtual controller and the field devices through industrial Ethernet technology to ensure efficient data collection and real-time feedback.

[0098] The control network supports two-way data transmission and can effectively carry large amounts of data traffic between field devices and virtual controllers, such as the transmission of industrial parameters such as temperature, pressure, and flow.

[0099] Furthermore, the redundant network provides backup links and ensures the reliability and stability of the system when a network failure occurs. The redundant network introduces a dual-link redundancy mechanism to ensure that when a link or node fails, the system can continue to operate and will not be affected by a single point of failure.

[0100] When a network failure occurs in the system, the redundant network switches to the backup link to ensure that the communication between the virtual controller and the control software and I / O modules is not interrupted. The design of the redundant network enables the entire control system to continue to operate in the face of a single point failure, avoiding production stagnation caused by network failures.

[0101] The redundant network adopts a dual-link redundancy mechanism, one link is the main link, and the other is the backup link. The redundant network will monitor the link status in real time. Once the main link fails, it will automatically switch to the backup link to ensure the continuous operation of the system.

[0102] Redundant network is one of the core components of virtualized control system, ensuring that the system can continue to operate stably when communication fails. The implementation of redundancy mechanism is through the following key steps: The redundant network adopts a dual-link redundancy mechanism to switch between the main link and the backup link in real time. When the main link of the network fails or fails, the system will automatically switch to the backup link to ensure uninterrupted communication between the virtual controller and the control software and field devices.

[0103] The redundant network continuously monitors the status of both links. When the primary link fails, the redundant network immediately detects this and switches to the backup link through a redundant network protocol (such as STP, RSTP).

[0104] The redundant network is designed for non-disruptive switching, that is, the system will not affect the data transmission and control task execution during the link switching process. In this way, the system can ensure that the real-time collection of field data and the accurate execution of control instructions can still be guaranteed when a network failure occurs.

[0105] The redundant network not only supports fault switching, but also achieves load balancing. The data flow between the two links can be dynamically adjusted according to the real-time network status. The redundant network can decide whether to enable the backup link to share the network traffic according to the load situation, further improving the overall communication efficiency of the system.

[0106] In some examples, the workflow and communication process of the three networks in this embodiment are as follows: When the system is operating normally, the virtual controller communicates with the control software and I / O modules through the system network and the control network, and all data transmission and instruction execution rely on these two networks.

[0107] The system network is used for communication between the virtual controller and the engineer station, operator station and historian station, while the control network carries the signal acquisition and feedback between the virtual controller and the field equipment.

[0108] When the redundant network detects a failure in the main link, it immediately switches to the backup link to ensure stable operation of the control system.

[0109] The switching process of the redundant network has no impact on the operator and the system. The system continues to operate without communication interruption or production downtime.

[0110] With the support of redundant networks, even if one link fails, the system can still maintain uninterrupted data transmission. The data transmission between the virtual controller and the field equipment will automatically switch to the backup link to ensure real-time and data integrity.

[0111] This embodiment describes the design and implementation of three networks in a virtualized control system, namely, the system network, the control network, and the redundant network. Through the collaboration of these three networks, the virtual control system can efficiently process the data communication between the virtual controller and the control software and the I / O module, and provide high-reliability communication guarantee through the redundant network. The dual-link redundancy mechanism of the redundant network not only improves the stability of the system, but also effectively avoids the paralysis of the entire system due to a single point failure, ensuring the high availability and fault tolerance of the industrial control system.

[0112] In some embodiments, the gateway uses Ethernet or 5G network to connect the virtual controller and the I / O module so that the virtual controller and the I / O module can communicate remotely and provide redundant links for remote communication.

[0113] Specifically, in a virtualized control system, the gateway's main task is to act as a bridge between the virtual controller and the I / O module, completing the conversion between different protocols and ensuring accurate data transmission. Specifically, the gateway implements the following functions: Protocol conversion: The gateway is responsible for protocol conversion between the virtual controller and the I / O module, especially the conversion between the Ethernet protocol and DP (Device Protocol). I / O modules usually use the DP protocol to communicate with field devices, while the virtual controller exchanges data through Ethernet, and the gateway plays the role of protocol adaptation.

[0114] Remote communication support: The gateway supports remote communication with the virtual controller via Ethernet or 5G network. With this design, the virtual controller can remotely access and control field devices, no longer limited to local control. Whether it is a virtual controller running on a cloud platform or a controller deployed through a virtual machine, it can remotely interact with the field I / O modules through the gateway.

[0115] Redundant link support: To improve system stability, the gateway supports data transmission through a dual-link redundancy mechanism. This means that even if one link fails, the gateway can still maintain communication with the virtual controller and I / O modules through the backup link, thus avoiding communication interruption caused by a single point of failure.

[0116] In some examples, the gateway communicates with the virtual controller and I / O modules in two main ways: 1) Ethernet communication: The gateway is connected to the virtual controller through a standard Ethernet interface, supporting high-speed and reliable data transmission. Through Ethernet, the virtual controller can exchange data with the on-site I / O modules, including the collection of sensor data and the issuance of control instructions.

[0117] Ethernet communication provides a high-speed, low-latency data transmission path, enabling the virtual controller and field devices to exchange information in real time. Through Ethernet, the virtual controller can obtain real-time status data of field devices, perform control tasks, and return control instructions to the I / O module.

[0118] 2) 5G network communication: In order to support more flexible and remote communication, the gateway also supports 5G network connection, making the communication between the virtual controller and the remote I / O module more convenient. The 5G network has the characteristics of low latency and high bandwidth, which can effectively support the high-speed data transmission requirements in industrial automation.

[0119] 5G network communication provides wider connectivity, enabling virtual controllers to communicate with field devices in real time over a larger range. It is especially suitable for large production lines or distributed control systems, which can transcend geographical limitations and maintain real-time data exchange.

[0120] Furthermore, to ensure the stability and high availability of the virtual control system in the face of network failures, the gateway is designed with redundant link support, which is implemented as follows: The gateway supports four independent DP links, two of which are used for primary data transmission and the other two as backup links. In this way, the gateway can provide high-reliability communication guarantee. If one of the links fails, the system can automatically switch to the backup link to ensure the stability of data transmission.

[0121] The design of redundant links can avoid the impact of single point failure on the system. Even if one link fails, the redundant link can take over immediately to ensure that the communication between the virtual controller and the I / O module is not interrupted.

[0122] Dual-link redundancy mechanism: In the communication between the gateway and the virtual controller, a dual-link redundancy mechanism is adopted. Two links are used to transmit data simultaneously and back up each other. When the main link fails, the backup link will automatically take over the data transmission to avoid system downtime or data loss.

[0123] The dual-link redundancy mechanism ensures that the system can continue to operate when any link fails, and the control task will not be interrupted due to a single link failure. The redundant link switching process is imperceptible, ensuring the high reliability of the system.

[0124] In some examples, the working principle and communication process of the gateway in this embodiment are as follows: First, the virtual controller communicates with the I / O module through the gateway. The gateway converts the control instructions from the virtual controller into DP protocol instructions that the I / O module can understand. Conversely, the gateway can also convert the feedback data of the I / O module back to Ethernet format and transmit it to the virtual controller.

[0125] Next, the virtual controller communicates remotely with the I / O module through the gateway. Depending on the system's network environment, the gateway chooses to exchange data with the virtual controller through Ethernet or 5G network to ensure the real-time and stability of the data.

[0126] Then, in the redundant link configuration, the gateway will monitor the link status in real time, and when a primary link failure is detected, it will automatically switch to the backup link to ensure continuous data transmission. Redundant link switching is transparent to system operations, and users and operators will not perceive any interruption.

[0127] Finally, the gateway ensures high availability and stability of communication through four DP links and dual-link redundancy mechanism. During data transmission, if a link failure occurs, the redundant link will take over immediately to avoid system downtime or data loss due to network failure.

[0128] This embodiment describes how the gateway can achieve remote communication between the virtual controller and the I / O module through Ethernet and 5G networks, and improve the reliability of the system through redundant link support. The gateway can not only complete the conversion between different protocols, but also ensure the stability and high availability of communication through redundancy mechanisms. This design enables the virtualized control system to efficiently and stably transmit data between multiple control loops, and automatically recover in the face of network failures, ensuring the continuous operation of the industrial automation system.

[0129] In some embodiments, the I / O module is connected to the field device via Ethernet. The I / O module includes an input module and an output module. The input module is used to collect analog signals and switch signals of the field device, and the output module is used to transmit the analog signals and switch signals to the virtual controller.

[0130] Specifically, the I / O module consists of two main parts: input module and output module. Each module is responsible for different types of signal transmission, ensuring real-time data exchange between field devices and virtual controllers.

[0131] The function of the input module is to collect signals from field devices, mainly including analog signals and switch signals. Analog signals are usually used to represent continuous physical quantities, such as temperature, pressure, flow, etc., while switch signals are used to represent switch states, such as on / off signals, sensor states, etc.

[0132] The input module converts the analog signal into a digital signal through the sensor interface and transmits it to the virtual controller. The analog signal is usually converted into digital form by an ADC (analog-digital converter) for processing by the virtual controller.

[0133] The switch signal is directly obtained from the contact (such as button, switch, relay, etc.) to indicate the switch state of the device. The input module converts these signals into "on" or "off" state and transmits them to the virtual controller.

[0134] Furthermore, the function of the output module is to transmit the control instructions (such as analog output and switch output) of the virtual controller to the field device. The virtual controller generates control instructions according to the control algorithm, and these instructions are transmitted to the device for execution through the output module.

[0135] The analog output instructions generated by the virtual controller are converted into analog signals through DAC (digital-to-analog converter) and transmitted to actuators, valves and other devices to control their operation. For example, the virtual controller can adjust the opening of a valve or the speed of a pump to control flow or pressure.

[0136] The switch output instructions generated by the virtual controller are transmitted to the field devices through relays or solid-state switches to perform on / off operations. These switch signals are usually used to control the start and stop of the equipment.

[0137] In some examples, I / O modules are connected to field devices via industrial Ethernet, providing an efficient data transmission channel. Industrial Ethernet is a network communication standard designed specifically for industrial environments, with high reliability, low latency and anti-interference capabilities, suitable for data exchange between field devices and control systems.

[0138] Industrial Ethernet protocols (such as Ethernet / IP, PROFINET, Modbus TCP, etc.) are used to ensure stable data transmission between I / O modules and virtual controllers. Each I / O module supports multiple protocols, and the communication protocol can be flexibly selected according to the needs of field devices.

[0139] The input module regularly collects real-time data from field devices and transmits the data to the virtual controller via Ethernet. After the virtual controller processes the data, it generates control instructions and returns them to the field devices via the output module. The delay in the data transmission process is extremely small, ensuring that the real-time requirements are met.

[0140] Through industrial Ethernet, I / O modules can transmit analog and switch signals to the virtual controller in real time and return control instructions to the field equipment in a timely manner. The virtual controller dynamically adjusts the control strategy based on the feedback data from the field equipment to maintain the stability of the production process.

[0141] In actual operation, the communication process between the virtual controller and the I / O module is as follows: First, the input module regularly collects analog signals and switch signals from field devices. For example, the analog signal provided by the temperature sensor will be converted into a digital signal by the input module and sent to the virtual controller via industrial Ethernet.

[0142] Then, the input module transmits the collected data to the virtual controller in real time through industrial Ethernet. The virtual controller executes the control algorithm based on the data and generates corresponding control instructions.

[0143] Then, the virtual controller converts the control instructions into analog signals or switch signals through the output module and transmits them to the field devices through industrial Ethernet. For example, the analog signal generated by the virtual controller to adjust the valve opening will be converted into an analog signal through DAC to control the operation of the valve.

[0144] Finally, the field device operates according to the control instructions of the virtual controller and feeds back new status data. The input module receives the feedback data of the field device and transmits it to the virtual controller. The virtual controller adjusts the control strategy based on the feedback to form a closed-loop control.

[0145] Furthermore, in order to ensure high availability of I / O modules in the face of network failures or device failures, the system is designed with redundancy mechanisms, including but not limited to the following aspects: Dual-link redundancy ensures uninterrupted communication between the I / O module and the virtual controller. The two links work simultaneously, and when one link fails, the redundant link immediately takes over to ensure the continuity of data transmission.

[0146] The I / O module can monitor the operating status of network links and devices in real time. When a link fails or a device is abnormal, the system will trigger an alarm mechanism to notify engineers to handle it.

[0147] In critical applications, redundant I / O modules can be deployed. When the main I / O module fails, the redundant I / O module can take over immediately to ensure the stable operation of the field equipment.

[0148] This embodiment describes how the I / O module is connected to the field device through industrial Ethernet, ensuring that the virtual controller can collect data from the field device in real time and execute control instructions. The input module collects analog and switch signals, and transmits control instructions to the field device through the output module, so that efficient and stable data exchange is achieved between the virtual controller and the field device. The redundant link and fault detection mechanism further enhance the reliability and high availability of the system, ensuring that the industrial control system can operate stably under any circumstances.

[0149] In some embodiments, the I / O module is further used to receive control instructions transmitted by the virtual controller, and transmit the control instructions to the field device for execution.

[0150] Specifically, in a virtualized control system, the I / O module is not only responsible for collecting data from field devices, but also for receiving control instructions from the virtual controller and passing them to field devices for execution. Control instructions usually include analog quantity control (such as adjusting temperature, pressure, etc.) and switch quantity control (such as start-stop control, switch state control, etc.).

[0151] The virtual controller transmits the processed control instructions to the I / O module through industrial Ethernet or other communication networks. The control instructions can be analog signals (such as temperature and flow set values) or switch signals (such as start and stop commands). These instructions are transmitted through the network and finally reach the I / O module.

[0152] The I / O module converts the received control instructions into physical signals that the field device can execute. For example, analog signals may be converted into current or voltage signals through a digital-to-analog converter (DAC), while switch signals directly drive relays or switches to perform specific operations.

[0153] Furthermore, the I / O module is responsible for converting different types of control instructions issued by the virtual controller into signals that can be executed by the field devices, including: Analog control usually involves regulating continuous physical quantities such as temperature, pressure, flow, etc. The virtual controller makes real-time adjustments based on these parameters and generates analog output signals.

[0154] The analog output part of the I / O module converts the digital control instructions transmitted by the virtual controller into analog signals through a digital-to-analog converter (DAC). For example, the virtual controller may send a command indicating temperature adjustment, and the I / O module converts the command into a current or voltage signal through the DAC, and then transmits it to the temperature control device (such as an electric heater, cooler, etc.) to perform the adjustment task.

[0155] Switching control is used to control the on / off state of a device, such as start / stop operation, device state switching, etc. The virtual controller generates switching output signals, which are usually "on" or "off" states, to control the start or stop of the device.

[0156] The switch output part of the I / O module directly drives the relay, contact or other control switch to control the start and stop of the field equipment. For example, the virtual controller generates a switch signal, and the I / O module transmits the signal to the relay to start or stop the equipment (such as pumps, fans, valves, etc.).

[0157] Furthermore, after the I / O module converts the control instruction into a corresponding physical signal, the field device performs the operation. For example, the temperature adjustment instruction issued by the virtual controller through the I / O module will cause the heater to heat or the cooler to work, and the field device adjusts its operating state according to the instruction.

[0158] After the field equipment performs an operation, it will generate feedback signals to reflect the current state of the equipment (such as temperature, pressure, etc.). These feedback signals are returned to the virtual controller through the input module for further control decisions and adjustments. Through closed-loop feedback control, the virtual controller can adjust the control instructions in real time to ensure that the field equipment maintains the set target state.

[0159] In some examples, in order to ensure that the I / O module can continue to perform control tasks when the system fails, the system also designs a redundancy mechanism: the I / O module supports a dual-link redundancy mechanism to ensure that when the main link fails, the backup link can immediately take over data transmission to ensure that the control task is not interrupted. In critical applications, the system can deploy redundant I / O modules. When the main I / O module fails, the redundant I / O module can take over immediately to ensure the stable operation of the field equipment.

[0160] This embodiment describes how the I / O module receives control instructions transmitted by the virtual controller in the virtualized control system and transmits these instructions to the field equipment for execution. Through analog and switch control, the I / O module can flexibly control the operating status of the field equipment. At the same time, through the design of redundant links and redundant I / O modules, the system can maintain high reliability and high availability in the face of failures. In this way, the virtual controller and the I / O module work together to ensure the stable and efficient operation of the industrial control system.

[0161] In some embodiments, the control software is used to provide the functions of an engineer station, an operator station, and a history station, and to perform data processing, data monitoring, and data operation management in the engineer station, the operator station, and the history station, and to provide an operation interface for users to perform data interaction and control operations.

[0162] Specifically, the control software in this embodiment uses an optimized version based on the traditional DCS software to ensure that the system can meet the needs of modern industry and maintain compatibility with the traditional DCS system. The control software in the virtualized control system of this application includes three main components: engineer station, operator station and history station. The functions of each station are as follows: Engineer Station: The Engineer Station is mainly used for system configuration and maintenance. Through the Engineer Station, users can perform logical configuration, task scheduling, and system parameter adjustment on virtual controllers. The Engineer Station also provides device management functions, allowing users to manage and diagnose virtual controllers, gateways, I / O modules, etc. The functions provided by the Engineer Station ensure the flexibility of the system and can quickly adjust the control strategy according to production needs.

[0163] Operator station: The operator station is used to monitor and control the operation of the system in real time. The operator can view real-time data in the production process, such as temperature, pressure, flow, etc., through the operator station, and can directly control the production equipment or issue scheduling instructions. The interface provided by the operator station is intuitive and friendly, which can help the operator make accurate decisions in the production process.

[0164] History Station: The history station is responsible for the storage and query of the system's historical data. All production data, including sensor signals, operation records, alarm information, etc., will be archived in the history station. The function of the history station is crucial for subsequent analysis and optimization. Users can query the data in the history station to analyze system performance, detect potential problems, and optimize control logic.

[0165] Furthermore, in this embodiment, the control software has the following technical features: First, the control software of MACS6.5.4 maintains the functional consistency with the traditional DCS system, including the processing of common control tasks such as temperature, pressure, flow, etc. This feature ensures that when transitioning to a virtualized system, users can easily transition without having to relearn and adapt to new control interfaces and operating procedures.

[0166] Secondly, the control software can process real-time data from virtual controllers and field devices, and ensure the accuracy and timeliness of data through data monitoring and management modules. In the engineer station, operator station and history station, users can interact with data, operate data and issue control instructions. The system ensures that various users can operate within different authority ranges through flexible authority management and operation interface design.

[0167] Finally, through the control software in the virtualized control system, users can not only operate the virtual controller in real time, but also remotely monitor the operating status of the virtual controller, including CPU usage, memory usage, and data processing progress. This remote management function, combined with the system's redundant network design, enables the control system to ensure stable and efficient control even in remote locations or large-scale industrial scenarios.

[0168] In the specific implementation, the virtual controller runs in a virtual machine on a cloud computing platform or a general computing server. The control software and the virtual controller are connected through the network, and the system network ensures the stability of data transmission. The specific workflow is as follows: First, when the system is initialized, the control software uploads the control logic configuration to the virtual controller through the engineering station. The engineering station allocates processing tasks and resources to the virtual controller and loads system parameters.

[0169] Then, the operator station monitors the operating status of the virtual controller in real time through the system network, displays various process data (such as temperature, pressure, flow, etc.), and provides the operator with the function of directly operating the equipment. The operator can view the real-time data of various equipment on the interface and make control adjustments.

[0170] Then, all the generated historical data is stored through the history station and archived in time series. Users can query the historical records through the history station, including alarm information, equipment status changes, and the execution of operation instructions. The storage of historical data not only helps with subsequent fault analysis, but also provides data support for system optimization and intelligent control.

[0171] In some cases, the design of the operation interface is crucial to the ease of use of the system. The control software provides a graphical interface that conforms to the DCS operation habits, allowing engineers and operators to quickly master the system operation. The key points of interface design can include the following: Data display: The operator station provides intuitive display of real-time data, including charts, dashboards, etc., to help users quickly understand the operating status of the system.

[0172] Alarm prompt: The history station and operator station provide real-time feedback of alarm information. The system can automatically generate alarm reports to help operators quickly locate problems and take measures.

[0173] Permission management: Through the control software, the system can manage the permissions of different users to ensure that only authorized users can configure and operate the system.

[0174] According to the system structure of the present embodiment, the control software of the virtualized control system effectively integrates the functions of the engineer station, operator station and history station, provides rich data processing, monitoring and operation management functions, and meets the needs of modern industry for efficient, reliable and intelligent control systems. The system can flexibly cope with complex industrial control tasks, and improves the scalability, reliability and maintainability of the system through virtualization technology.

[0175] In some embodiments, the technical indicators of the virtualized control system of the present application are as follows: 1) The relevant technical indicators of the virtual control system controller should meet or exceed the relevant technical indicators of the conventional DCS of the power plant; 2) The single-loop control cycle of the virtual control system should be less than or equal to 200ms, that is, the time response of the signal from the input module of the local remote IO cabinet, network acquisition and transmission, the virtual controller issuing instructions after calculation, and then to the output module of the local remote IO cabinet; 3) Operation signal response time (i.e. the time from the keyboard sending out an operation command to the LCD screen displaying the signal feedback), the switch signal operation time shall not exceed 1.0s, and the analog signal operation time shall not exceed 2.5s; 4) A single virtual controller supports adjustment of the scheduling time base to provide system scheduling accuracy. The POU task cycle can be set at 40ms, 100ms, 200ms, 500ms, and 1s; 5) When the virtual controller is running at maximum load, the load rate shall not exceed 40%; 6) A single virtual controller can support access to no less than 4,800 IO hard connections and ensure that latency meets requirements; 7) The maximum execution cycle of the analog processor module to complete all specified tasks should not exceed 250ms, and the maximum execution cycle of the switch processor module to complete all specified tasks should not exceed 100ms; 8) For analog and sequential control loops that require fast processing, the processing capacity should be executed once every 125ms and 50ms respectively; 9) Alarm filtering and alarm tracing rules are configurable; 10) Alarm filtering: more than 50% of invalid alarms; 11) In the parameter warning and auxiliary machine health diagnosis modules, the relative deviation between the predicted value and the actual value of each parameter under normal operating conditions is less than 5%; 12) The accuracy of the alarm tracing algorithm reaches 96%; 13) Any intelligent alarm screen should be fully displayed within 2 seconds (or less), and all displayed data should be updated once per second.

[0176] Compared with the traditional physical controller, the virtual controller of this application has the following advantages: 1) The virtual controller operation platform has the ability to run highly complex intelligent algorithms and simple logic algorithms in coordination, open up underlying data sharing, realize the convenient integration of IT and OT, and achieve control coordination of different control stations; 2) It has wireless access capabilities to meet the low latency, high reliability and availability requirements of industrial control, and can connect decentralized, remote, and even wide-area I / O; 3) The hardware platform has higher reliability, and IT technology is used to ensure data security, information security and long-term reliable operation of the controller; 4) With flexible software definition capabilities, a single server can support multiple virtual controllers, which has cost advantages compared to real controllers; 5) Reduce the cost of early deployment and subsequent maintenance and upgrade of traditional controllers; 6) The system structure is flexible and easy to expand functions; 7) Convenient data integration and sharing. The virtual controller can be easily integrated with other software systems to achieve data sharing and interaction. It has stronger data computing capabilities and can use the powerful computing power of computers to perform data analysis and calculations; 8) Improve the efficiency of product development and make testing and verification more convenient.

[0177] With the continuous development and innovation of Internet technology, cloud computing platforms based on virtualization technology have gradually become important data support platforms for enterprise management and production operations in all walks of life. The application scope of cloud computing platforms has become more and more extensive with the support of virtualization technology. In-depth research on the specific application of virtualization technology in cloud computing, and continuous exploration of cloud computing platform architecture design based on virtualization technology, and continuous improvement of the application value of virtualization technology in cloud computing can improve the efficiency and stability of cloud computing platform operation, and ultimately realize the maximization of resources and benefits of cloud computing platforms in the process of practical application.

[0178] The above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present application, and should all be included in the protection scope of the present application.

Claims

1. A virtualized control system, characterized in that: include: A virtual controller includes a plurality of functional modules, and uses software to define the functions implemented by each functional module, and deploys the virtual controller to an embedded hardware device, a virtual machine and / or a cloud platform server, and the virtual controller communicates data with a gateway and an I / O module through a controller network; A control network, used for data communication between the virtual controller and the I / O modules, gateways and control software; A gateway, used for protocol conversion between the virtual controller and the I / O module, communicating using Ethernet and DP protocols, and realizing remote communication between the virtual controller and the gateway; An I / O module is used to connect with the field device and transmit the collected field device data to the virtual controller; The control software is used to perform data monitoring and management tasks and communicate with the virtual controller through the system network.

2. The virtualization control system according to claim 1, characterized in that: The virtual controller combines different functional modules according to application requirements, and uses split-core processing technology to process calculation and communication management separately during operation.

3. The virtualization control system according to claim 2, characterized in that: Virtualization technology is used to deploy multiple virtual controllers on the embedded hardware device, virtual machine and / or cloud platform server, wherein independent control logic is configured for each virtual controller, and computing resources are dynamically allocated to the virtual controllers according to the deployed functions.

4. The virtualization control system according to claim 1, characterized in that: The virtual controller uses the on-site data mirror to simulate the process model and predicts faults based on the process model simulation results. The virtual controller is also used for configuration logic operations and multi-task parallel processing.

5. The virtualization control system according to claim 1, characterized in that: The resource usage status of the virtual controller is monitored in real time during system operation, and automatic alarm and fault diagnosis are performed when an abnormality occurs. The virtual controller is also used to automatically switch the main controller when a fault occurs.

6. The virtualization control system according to claim 1, characterized in that: The virtualized control system also includes a system network and a redundant network, wherein the system network is used for data communication between the virtual controller and the control software, and the redundant network uses a dual-link redundancy mechanism to provide a backup link.

7. The virtualization control system according to claim 1, characterized in that: The gateway uses Ethernet or 5G network to connect the virtual controller and the I / O module, so that the virtual controller and the I / O module can communicate remotely and provide a redundant link for the remote communication.

8. The virtualization control system according to claim 1, characterized in that: The I / O module is connected to the field device via Ethernet, and the I / O module includes an input module and an output module, the input module is used to collect analog signals and switch signals of the field device, and the output module is used to transmit the analog signals and switch signals to the virtual controller.

9. The virtualization control system according to claim 7, characterized in that: The I / O module is also used to receive control instructions transmitted by the virtual controller, and transmit the control instructions to the field device for execution.

10. The virtualization control system according to claim 1, characterized in that: The control software is used to provide the functions of an engineer station, an operator station and a history station, and to perform data processing, data monitoring and data operation management in the engineer station, the operator station and the history station, and to provide an operation interface for users to perform data interaction and control operations.

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