Modularized PLC system with extensible high computing power unit

Abstract

The invention provides a modular PLC (Programmable Logic Controller) system with an extensible high-computing-power unit, which comprises a basic control unit which is provided with an extensible framework, can be dynamically extended and accessed into a high-computing-power extension unit and a process package storage unit, receives an input signal, processes the input signal through pre-programmed logic, identifies parameters of the high-computing-power extension unit and stores the parameters of the high-computing-power extension unit; dynamic resources are distributed to a high computing power extension unit to execute program logic, and a control instruction is output to realize automatic control of an industrial process; the high computing power expansion unit is used for being dynamically connected with the basic control unit, automatically distributing computing tasks through a computing power evaluation algorithm and processing complex computing of the basic control unit; and the process package storage unit is used for dynamically loading a process model by adopting a parameterized configuration interface and comprises a parameterized template library generated based on an industrial standard control model, and the template library can perform process parameter configuration through an XML file.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial automation control, and in particular relates to a modular PLC system with an expandable high-computing power unit and an implementation method thereof. Background Art

[0002] At present, with the improvement of semiconductor technology and the development of software technology, major manufacturers have equipped PLC with CPUs with higher computing power, larger memory, higher bandwidth communication modules, and more optimized software algorithms. Some manufacturers have already put the computing power of artificial intelligence, special algorithms, high-density data processing, self-learning and other technologies for specific environment applications into PLC.

[0003] However, most of the existing PLC products are customized products for certain specific needs and can only be used in specific environments. The versatility and popularity of their products are still limited.

[0004] Traditional PLC has the following technical bottlenecks:

[0005] 1. Fixed computing architecture is difficult to cope with complex control requirements;

[0006] 2. The cost of industry application development is high, and professional engineers are required to develop the underlying algorithms;

[0007] 3. The hardware configuration is fixed, and computing resources cannot be flexibly adjusted according to application scenarios;

[0008] 4. The existing process control model has poor portability and cannot be used interchangeably between PLCs of different brands.

[0009] It is difficult for existing technologies to achieve high computing power to meet the various needs of various industries through open, general high computing power expansion units, and the production cost in the control field is high. Summary of the invention

[0010] In order to solve the problems existing in the prior art, the present invention proposes a modular PLC system with an expandable high-computing power unit, which achieves structural consistency in the application of PLC in high, medium and low-end markets, can be mass-produced, improves product reliability and safety, reduces production costs, and expands the scope of application.

[0011] In order to achieve the above object, the present invention adopts the following technical scheme.

[0012] The described modular PLC system with scalable high computing power units includes a basic control unit, a high computing power expansion unit, and an industry process package storage unit; among them, the basic control unit has a scalable architecture, can dynamically expand and access the high computing power expansion unit and the process package storage unit, receive input signals, process the input signals through pre-programmed logic, identify the parameters of the high computing power expansion unit, and use dynamic resource allocation to execute the program logic in the high computing power expansion unit, and output control instructions to achieve automatic control of the industrial process;

[0013] The high computing power expansion unit is used to be dynamically connected to the basic control unit, automatically allocate computing tasks through a computing power evaluation algorithm, and process complex calculations of the basic control unit;

[0014] The process package storage unit is used to dynamically load process models through a parameterized configuration interface, includes a parameterized template library generated based on industry standard control models, and the template library can configure process parameters through XML files.

[0015] Furthermore, it also includes,

[0016] The basic control unit is used for the scalable architecture of the modular PLC, sets a high-speed backplane bus interface, and uses hot plugging of the backplane bus to replace the high computing power expansion unit in the running state.

[0017] Furthermore, the basic control unit at least includes a central processor, a memory, an input / output unit, a power module, and a communication unit, among which,

[0018] The central processor is used to process programs and execute logical operations to achieve instruction parsing, process external data exchange, and coordinate the collaborative work of each hardware unit;

[0019] The memory is used to store system programs, user programs, and data;

[0020] The input / output unit is used to receive input signals, convert them into digital signals for processing by the central processor, and convert the digital signals processed by the central processor into output signals;

[0021] The power module is used for power supply, converting alternating current into direct current and stabilizing the voltage at the same time;

[0022] The communication unit is used for the communication between the PLC system and other devices.

[0023] Furthermore, the central processor dynamically allocates complex system control, mathematical model processing, and high-density data calculation and analysis resources to the high computing power expansion unit for high-speed processing.

[0024] Further, the high computing power expansion unit includes a high-performance computing unit, which is used to design a floating-point arithmetic unit, support floating-point addition and multiplication operations with at least one precision, and adopt a circuit structure and algorithm optimized for delay.

[0025] Further, the high computing power expansion unit includes a data interconnection and storage unit, which is used to adopt an efficient storage hierarchy to optimize the interconnection bandwidth between the storage and computing units.

[0026] Further, the process package storage unit includes a set of control models for different industrial production processes downloaded into the basic control unit, and the control models achieve automatic control according to basic field parameters.

[0027] To achieve the above object, the present invention also provides a modular PLC implementation method with an expandable high computing power unit, which applies the system described above, including:

[0028] Perform full-custom circuit design on the modular PLC, and optimize the PLC module according to specific process and performance requirements;

[0029] Customize and optimize the high computing power expansion unit in combination with the algorithm characteristics, and perform algorithm and software co-design;

[0030] Develop a software tool chain to support the development and application of high computing power chips.

[0031] To achieve the above object, the present invention also provides an electronic device, including a memory and a processor. A program is stored on the memory and runs on the processor. When the processor runs the program, it executes the steps of the modular PLC implementation method with an expandable high computing power unit described above.

[0032] To achieve the above object, the present invention also provides a computer-readable storage medium, on which computer instructions are stored. When the computer instructions run, they execute the steps of the modular PLC implementation method with an expandable high computing power unit described above.

[0033] The present invention proposes a modular PLC system and method with an expandable high computing power unit, which has the following beneficial effects:

[0034] The high computing power and process package PLC of the present invention have strong applicability and flexible structure. Each component works together to achieve efficient and stable control functions, reducing costs for enterprises and improving the intelligent level. In practical applications, users can select appropriate PLC configurations and options (hardware and software) according to specific needs to meet the requirements of industrial automation and intelligent control. Description of the Drawings

[0035] The accompanying drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention. In the accompanying drawings:

[0036] Figure 1 It is a schematic diagram of the modular PLC system architecture with an expandable high computing power unit according to the present invention;

[0037] Figure 2 It is a schematic diagram of the transfer function of the process package configuration model of the modular PLC system with an expandable high computing power unit according to the present invention;

[0038] Figure 3 It is a schematic diagram of the three - impulse control system according to the embodiment of the present invention;

[0039] Figure 4 It is a schematic diagram of the material flow control process according to the embodiment of the present invention. Detailed implementation manners

[0040] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to explain and illustrate the present invention and are not used to limit the present invention.

[0041] Embodiment 1

[0042] Figure 1 It is a schematic diagram of the modular PLC system architecture with an expandable high computing power unit according to the present invention. As Figure 1 shown, the modular PLC system with an expandable high computing power unit of the present invention includes a basic control unit, a high computing power expansion unit, and an industry process package storage unit. Among them, the basic control unit at least includes a central processing unit (CPU), a memory, an input / output (I / O) unit, a power supply module, and a communication unit. Among them,

[0043] The basic control unit is used for the expandable architecture of the modular PLC. It adopts the backplane bus hot - plug technology, sets a high - speed backplane bus interface, and supports replacing the high computing power module during operation. It adopts a dynamic resource allocation mechanism: automatically identifies the parameters of the expansion module through a hardware description file (HDF). Automatically adjusts the power output (range 24 - 48VDC) according to the number of access modules to achieve power adaption.

[0044] The central processing unit (CPU) is used to process programs and perform logical operations to achieve instruction parsing, and coordinate the collaborative work of each hardware unit. It includes scanning inputs, executing programs, and updating outputs.

[0045] The memory is divided into ROM and RAM, or EEPROM, which store system programs, user programs, and data respectively.

[0046] In the input / output (I / O) unit, the input module receives signals from sensors and converts them into digital signals for the CPU to process; the output module does the opposite, converting the CPU's signals into a form that can be used by actuators.

[0047] The power supply module is responsible for power supply, converting alternating current into direct current and stabilizing the voltage to ensure the stable operation of the system. If the power supply is unstable, the entire PLC may have problems.

[0048] The communication unit is used for the communication between the PLC and other devices, such as industrial networks, HMIs, and host computers. Different protocols such as Modbus, Profibus, Ethernet, etc.

[0049] The high computing power expansion unit is used to improve the computing power on the traditional PLC structure, automatically allocate computing tasks through a computing power evaluation algorithm, and solve scenarios that require high computing power such as complex system control, mathematical model processing, high-density data calculation and analysis, and AI intelligent control algorithms, and can balance cost, flexibility, and the realization of high computing power.

[0050] Optionally, the high computing power expansion unit includes an advanced process and architecture design unit, which is used to adopt advanced semiconductor process technologies, such as 7nm, 5nm, etc., to improve the integration and performance of transistors. Design an efficient chip architecture, such as a coarse-grained reconfigurable architecture and a memory-compute integrated architecture, to optimize data flow and computing efficiency.

[0051] Optionally, the high computing power expansion unit also includes a high-performance computing unit, which is used to design a high-performance floating-point arithmetic unit (FPU) that supports floating-point addition and multiplication operations with multiple precisions (such as single precision and double precision). Adopt a circuit structure and algorithm optimized for delay to improve the computing speed and reduce power consumption.

[0052] In this embodiment, the high computing power implementation method can be specifically executed as follows:

[0053] (1) Circuit design and optimization

[0054] In circuit design, adopt a full-custom design method and optimize it according to specific process and performance requirements. Use low-power design techniques, such as power gating and clock gating, to reduce the power consumption of the chip.

[0055] (2) Algorithm and software co-design

[0056] Combine the characteristics of the algorithm to customize and optimize the computing unit. Develop an efficient software toolchain, including compilers, debuggers, etc., to support the development and application of high computing power chips.

[0057] (3) High computing power heat dissipation and packaging technology

[0058] Adopt advanced heat dissipation technologies, such as heat pipes, liquid cooling, etc., to ensure the stable operation of the chip under high load.

[0059] Use advanced packaging technologies, such as 3D packaging, system-level packaging, etc., to improve the integration and reliability of the chip.

[0060] Optionally, the high computing power expansion unit further includes a data interconnection and storage unit, which is used to optimize the interconnection bandwidth between the storage and computing units and reduce data transmission latency.

[0061] In this embodiment, the data interconnection and storage unit adopts an efficient storage hierarchy, such as a cache and a main memory, to provide fast data access.

[0062] In this embodiment, the high computing power expansion unit is an optional unit. When the PLC does not select the high computing power expansion unit, the PLC at this time is a conventional traditional PLC, which realizes industrial automation functions, has all the functions and characteristics of a traditional PLC, and is suitable for a large number of mid- to low-end markets. The same is true for programming and debugging.

[0063] Optionally, when the PLC selects the high computing power expansion unit, the PLC becomes an HA-PLC at this time. The CPU of the HA-PLC is connected to the high computing power expansion unit through the internal bus or backplane bus of the PLC. The CPU can load complex system control, mathematical model processing, high-density data calculation and analysis, AI intelligent control algorithms, etc. into the high computing power expansion unit for high-speed processing. For example: the control of the speed, torque, and current multi-input multi-output MIMO system in the field of motor drive, the solution of differential equation systems in the field of mathematical model operations, the processing of high-density vibration and acoustic fingerprint data in the field of online monitoring, the AI algorithms and recognition processing of small and medium-sized models, etc. can all be completed by this high computing power expansion unit.

[0064] The process package storage unit is used to dynamically load process models through a parameterized configuration interface, including a parameterized template library generated based on industry standard control models. The template library can be configured with process parameters through an XML file and downloaded to the control models for different industry production processes inside the HA-PLC. This model only requires the user to provide basic on-site parameters to achieve automated and intelligent control, making industry applications simple and easy to use, easy to promote, and enabling everyone to become a control expert.

[0065] Optionally, the process package storage unit includes a parameterized configuration interface: providing a process parameter template in XML format; having a model verification mechanism: pre-verifying the process package in a virtual PLC environment; having an online update system: supporting OTA (Over-the-Air) update of the process model library.

[0066] In this embodiment, the process package storage unit is an industrial-grade eMMC memory, which is used to store process model libraries of eight major industries such as metallurgy, chemical industry, and mechanical manufacturing. Each process package contains: industry-specific control algorithms (MATLAB / Simulink generates C code), preset PID parameter libraries (including 20 control scenarios such as temperature and pressure), and equipment fault diagnosis databases (based on ISO13374 standards).

[0067] In this embodiment, there are few products that have downloaded production processes to PLCs in the form of general process packages. With the development of electronic technology, chip computing power is getting stronger and stronger, and the conditions for downloading production process packages to PLCs in the form of industry classic control system models are now available.

[0068] Optionally, according to the production mathematical models of various industries, classic production process packages of various industries are established for summary, and continuously optimized according to the actual on-site application environment, so that the process packages of various industries are gradually improved into a set of industry control experts.

[0069] In this embodiment, the industry process package is a comprehensive set of control models, which are usually used to guide the implementation of a specific production process or technology.

[0070] In this embodiment, the industry control process package refers to a detailed control strategy solution provided for a specific production process or engineering project in the chemical, pharmaceutical, machining, production line and other industries. It provides comprehensive control technology support for the construction, operation and maintenance of the production line, ensuring smooth and safe production.

[0071] In this embodiment, the development and design of process packages, including the development and design of industry control process packages, usually require the joint cooperation of multiple professions and different disciplines, including research and development, machining, chemical technology, process systems, analysis and testing, automatic control, materials, safety and health, environmental protection and other professions.

[0072] In this embodiment, the quality control of the process package design is the same as the quality control requirements of the relevant disciplines in the basic design / preliminary design stage specified in the company's design standards. In the chemical industry, the process package is the core of chemical production and plays a vital role in the chemical production process. For example, in the design of chemical plants such as synthetic ammonia, oil refining, and ethylene, the process package usually contains detailed production process flow, equipment selection, control scheme, etc., providing comprehensive technical support for the construction and operation of the plant.

[0073] In this embodiment, Figure 2 As shown, according to the transfer function, the process packages corresponding to the PLC control systems of different industries are generated and stored. The transfer function is:

[0074] E(s)=U(s)-G 2 (s)Y(s)

[0075] Y(s) = G 1 (s)E(s)

[0076] Y(s) = G 1 (s)[U(s) - G 2 (s)Y(s)] = G 1 (s)U(s) - G 1 (s)G 2 (s)Y(s)

[0077] [1 + G 1 (s)G 2 (s)]Y(s) = G 1 (s)U(s)

[0078]

[0079] Among them, U(S) is the given value; G 1 (S) is the transfer function of the controller and the controlled object; G 2 (S) is the transfer function of the feedback channel; E(S) is the deviation value; Y(S) is the measured value.

[0080] In this embodiment, the industrial control process package is a collection of professional automatic control theories and strategies, containing rich theoretical knowledge and detailed Laplace transforms. It provides comprehensive control technology support and guidance for the implementation of specific production processes, ensuring the smooth progress of process requirements and safe production. At the same time, the development and design of the process package require the joint cooperation of multiple professionals and different disciplines, reflecting the importance of cross-field collaboration.

[0081] In this embodiment, as Figure 3 and Figure 4 shown, all process packages can be optionally downloaded by users into the HA-PLC. Users only need to fill in the external parameters of this control system and perform simple configuration, for example: motor voltage, power, speed, and the speed and torque are fed back to the given value for comparison, etc. The complex operations are all solved by the process packages optimized by a large number of experts, professors, theories, and engineering practices. Users no longer need a large number of senior senior engineers to develop and maintain, but only ordinary employees can achieve the most professional control. This greatly improves the automation and intelligent level of the control system and greatly reduces the difficulty of use and maintenance for users. It can be understood that the complex configuration software that used to run on a high-configured industrial control computer is concentrated and transplanted into the HA-PLC. At the same time, the use and maintenance costs are greatly reduced. This trend will rapidly improve the automation and intelligent level of China's industry.

[0082] Optionally, the process package summarizes the control system models of production processes in all industrial sectors. Therefore, users can select the process package to be downloaded according to their own needs. During use, the process package will be continuously optimized based on the feedback from industry applications, making the functions of the process package more powerful. This can never form a positive feedback loop for the functions of the process package, continuously improving and benefiting enterprises.

[0083] A modular PLC system with an expandable high computing power unit proposed by the present invention summarizes the extensive requirements in the field of industrial control. The high computing power and process package PLC (HA-Programmable Logic Controller) achieve a flexible combination of traditional PLC basic units and high-performance computing modules through an innovative backplane bus architecture. The system integrates an industry process model library and adopts a parameterized configuration method to lower the usage threshold. Its structure is innovative and general, effectively solving the contradiction between computing resources and cost control in the field of industrial control, significantly improving the automation and intelligent control levels in the field of industrial automation systems, enhancing the convenience of users' use and maintenance, while reducing production costs and improving reliability.

[0084] The present invention also provides an electronic device, including a memory and a processor. A program is stored on the memory and runs on the processor. When the processor runs the program, it executes the steps of the above-mentioned modular PLC method with an expandable high computing power unit.

[0085] The present invention also provides a computer-readable storage medium, on which computer instructions are stored. When the computer instructions run, they execute the above-mentioned modular PLC method with an expandable high computing power unit. For the modular PLC method with an expandable high computing power unit, refer to the introduction in the foregoing part and will not be elaborated here.

[0086] Those of ordinary skill in the art can understand that the above are only the preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A modular PLC system with scalable high-computing power units, characterized in that: It includes basic control unit, high computing power expansion unit and industry process package storage unit; among them, The basic control unit is used to have an expandable architecture, can dynamically expand and access the high computing power expansion unit and the process package storage unit, receive input signals, process the input signals through pre-programmed logic, identify the parameters of the high computing power expansion unit, use dynamic resource allocation to the high computing power expansion unit to execute program logic, and output control instructions to realize automatic control of the industrial process; A high computing power expansion unit, which is used to dynamically connect with the basic control unit, automatically allocate computing tasks through a computing power evaluation algorithm, and process complex calculations of the basic control unit; The process package storage unit is used to dynamically load the process model using a parameterized configuration interface, and includes a parameterized template library generated based on an industry standard control model. The template library can configure process parameters through an XML file.

2. A modular PLC system with an expandable high computing power unit according to claim 1, characterized in that: Also includes, The basic control unit is used for the scalable architecture of the modular PLC, is provided with a high-speed backplane bus interface, and adopts hot plugging of the backplane bus to replace the high computing power expansion unit in the running state.

3. A modular PLC system with an expandable high computing power unit according to claim 1, characterized in that: The basic control unit at least includes a central processing unit, a memory, an input / output unit, a power module and a communication unit, wherein: The central processing unit is used to process programs and perform logical operations to implement instruction parsing, process external data exchange, and coordinate the collaborative work of various hardware units; The memory is used to store system programs, user programs and data; The input / output unit is used to receive input signals, convert them into digital signals for processing by the central processor, and convert the digital signals processed by the central processor into output signals; The power module is used to supply power, convert AC power into DC power, and stabilize the voltage; The communication unit is used for communication between the PLC system and other devices.

4. A modular PLC system with an expandable high computing power unit according to claim 3, characterized in that: The central processing unit dynamically allocates complex system control, mathematical model processing, and high-density data computing and analysis resources to the high-computing power expansion unit for high-speed processing.

5. A modular PLC system with an expandable high computing power unit according to claim 1, characterized in that: The high computing power expansion unit includes a high-performance computing unit, which is used to design a floating-point operation unit, supports floating-point addition and multiplication operations of at least one precision, and adopts a delay-optimized circuit structure and algorithm.

6. A modular PLC system with an expandable high computing power unit according to claim 1, characterized in that: The high computing power expansion unit includes a data interconnection and storage unit, which is used to adopt an efficient storage hierarchy and optimize the interconnection bandwidth between the storage and computing units.

7. A modular PLC system with an expandable high computing power unit according to claim 1, characterized in that: The process package storage unit includes a set of control models for production processes of different industries downloaded into the basic control unit, and the control model realizes automatic control according to basic field parameters.

8. A method for implementing a modular PLC with an expandable high-computing-power unit, using the modular PLC system with an expandable high-computing-power unit as claimed in claim 1, characterized in that: include: Adopt full customization to design the circuit of modular PLC and optimize the PLC module according to specific process and performance requirements; Customize and optimize high-computing expansion units based on algorithm characteristics, and perform collaborative design of algorithms and software; The development software tool chain supports the development and application of high-computing power chips.

9. An electronic device, characterized in that: It comprises a memory and a processor, wherein the memory stores a program running on the processor, and the processor executes the modular PLC implementation method with an expandable high computing power unit as described in claim 8 when running the program.

10. A computer-readable storage medium having computer instructions stored thereon, characterized in that: When the computer instructions are executed, the method for implementing a modular PLC with an expandable high-computing-power unit as described in claim 8 is executed.

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