Remote control system of PLC control cabinet

Abstract

The invention discloses a remote control system of a PLC (Programmable Logic Controller) control cabinet, which relates to the technical field of remote control of PLC control cabinets and comprises a path identification module, a path evaluation module, a signal cleaning module, a switching control module and a state connection module, the path evaluation module collects control state information of each output path in the to-be-released path set, is used for evaluating the non-released degree of each output path, and divides each output path into three types of paths which can be directly switched, paths which need to be switched after being cleared and paths which are forbidden to be switched according to an evaluation result; and the signal cleaning module is used for executing corresponding residual signal cleaning operation on all the output paths which are divided into the paths which need to be switched after being cleaned, and performing dynamic regulation and control in the operation process. According to the method, the problems of equipment failure and system instability caused by the fact that residual signals are not cleared away in time during PLC control logic switching are solved, and the safety of the system is ensured through accurate classification, dynamic clearing and intelligent switching.

Description

Technical Field

[0001] The present invention relates to the technical field of remote control of PLC control cabinets, and particularly relates to a remote control system for a PLC control cabinet. Background Art

[0002] A PLC control cabinet is a closed electrical control system with a programmable logic controller (PLC) as the core component, integrating electrical components such as a power module, input / output modules, relays, circuit breakers, and a human-machine interface (HMI), and is used to achieve automatic control and logic operation control of industrial equipment. It is widely used in scenarios such as production lines, equipment monitoring, municipal facilities, and building automation. Traditionally, PLC control cabinets rely on local manual operation and on-site monitoring. Once a fault occurs or parameters need to be adjusted, it is necessary to go to the site for processing, which is not only inefficient and slow to respond, but also has high maintenance costs and safety risks in the application of distributed devices or remote sites. The remote control technology for PLC control cabinets is precisely to solve this pain point. By integrating a communication module (such as 4G, Ethernet, Wi-Fi, etc.) with the PLC system, a data channel between the remote server and the control platform is established, enabling the operator to remotely monitor the PLC program in the control cabinet, modify parameters, diagnose faults, and issue commands, thereby realizing non-contact and real-time management of the entire automation system. Through remote control, not only can the equipment operation and maintenance efficiency be significantly improved and the frequency of manual inspections be reduced, but also a response can be made immediately when an abnormality occurs, enhancing the reliability and intelligence level of the system. Therefore, it has broad application value and development prospects in smart factories, urban infrastructure management, and industrial control in remote areas.

[0003] The existing remote control technology for PLC control cabinets mainly integrates a communication module and a supporting software platform on the basis of a traditional PLC control system to achieve remote access and control of the PLC control cabinet. Its basic working process usually includes links such as data acquisition, communication transmission, remote platform processing, and user interaction. Specifically, the PLC in the PLC control cabinet first collects the operating status of on-site equipment and sensor data through the I / O module, and performs local control processing according to the control logic; subsequently, the built-in or external communication module (such as a 4G / 5G industrial router, an Ethernet module, or a Wi-Fi gateway) uploads this data to the cloud platform or remote server through the network, and data encryption and protocol conversion processing (such as Modbus to MQTT, OPC UA, etc.) may be performed during this period; on the remote platform, this data is visually displayed, and the operator can view and analyze it through the web page or mobile APP, and can issue control instructions to the platform. These instructions are then transmitted back to the PLC through the communication link by the server, and the PLC executes the corresponding actions, such as modifying control parameters, starting / stopping equipment, or performing remote programming and debugging operations. The entire process also includes security mechanisms such as permission authentication, security encryption, and communication heartbeat monitoring to ensure the security and reliability of remote operations. Therefore, the remote control system is not only the construction of a data transmission channel, but also a systematic project covering multiple links such as acquisition, transmission, processing, interaction, and security.

[0004] The existing technology has the following deficiencies:

[0005] During the process of remotely controlling the PLC control cabinet, when the control platform executes the operation of switching the PLC control logic from "main control block A" to "standby control block B", the situation of control logic structure reconstruction will occur. At this time, although the control output in the original control block A has logically stopped running, the associated physical output path may still have residual control signals hanging and not being released in time, especially in control loops involving relay holding, pulse triggering, or non-feedback closed loops. Because these residual signals exist briefly at the hardware level, they will superimpose or interfere with the newly loaded control logic after the logical switch, resulting in inconsistent control states or mis-execution. However, the existing remote control technology for PLC control cabinets cannot dynamically regulate the residual signal cleaning behavior according to the degree of unreleased output path when the control logic switches. The reason is that the platform lacks the ability to identify and process the residual path state of the original control block, and the default logical switch means signal clearing. This misjudgment will cause the signal to be reused by the new logic without being cleared, thus triggering abnormal behaviors such as repeated equipment startup, unexpected motor operation, and valve misflipping, which may further cause equipment damage, action conflicts, or system instability. Moreover, this type of problem is extremely concealed and difficult to detect and locate in time through conventional remote status feedback means.

[0006] The above information disclosed in the background art section is only used to enhance the understanding of the background of the present disclosure, and thus it may include information that does not constitute the prior art known to those of ordinary skill in the art. Summary of the Invention

[0007] The object of the present invention is to provide a remote control system for a PLC control cabinet to solve the problems in the above background art.

[0008] To achieve the above object, the present invention provides the following technical solution: A remote control system for a PLC control cabinet, comprising a path recognition module, a path evaluation module, a signal cleaning module, a switching control module, and a state continuation module;

[0009] The path recognition module, when receiving a remote operation instruction to switch the PLC control logic from the current control logic to the standby control logic, pauses the logic switching process, identifies all output paths in the current control logic that are in an active state, and generates a set of paths to be released;

[0010] The path evaluation module collects control status information for each output path in the set of paths to be released, used to evaluate the unreleased degree of each output path, and classifies each output path into three categories: directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths according to the evaluation results;

[0011] The signal cleaning module performs corresponding residual signal cleaning operations on all output paths classified as paths that need to be cleared before switching, and performs dynamic regulation during the operation; for all output paths classified as directly switchable paths and prohibited switching paths, no residual signal cleaning operations are performed;

[0012] The switching control module, after completing the residual signal cleaning operation, performs corresponding control logic switching operations on all output paths classified as directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths respectively;

[0013] The state continuation module, after the standby control logic takes over the control task, performs a state continuation operation, and records the classification results of the output paths, the evaluation process data, the signal cleaning information, and the control logic switching execution results during the logic switching process.

[0014] Preferably, in the path evaluation module, control status information is collected for each output path in the set of paths to be released, and preprocessing is performed after collection; continuous activation status information and load control information are extracted from the preprocessed control status information, and analysis is performed after extraction to generate the continuous activation coefficient and residual influence index for each output path respectively; based on the continuous activation coefficient and residual influence index generated for each output path, the unreleased index for each output path is generated by weighted summation; a preset unreleased index threshold interval is determined, and after determination, it is compared with the unreleased index generated for each output path, and the unreleased degree of each output path is evaluated according to the comparison result, and each output path is classified into three categories: directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths according to the evaluation result.

[0015] Preferably, the acquisition logic of the continuous activation coefficient of each output path is as follows:

[0016] Extract continuous activation status information from the preprocessed control status information, specifically including three types of data: the continuous activation duration of each output path, the average voltage output value, and the time interval from the output control signal to receiving the corresponding feedback signal, and calibrate them respectively as 、 and , represents the continuous activation duration of the th output path, represents the average voltage output value of the th output path, represents the time interval from the output control signal to receiving the corresponding feedback signal of the th output path, , is a positive integer;

[0017] Determine the preset intervals corresponding to the three types of data in the continuous activation status information, and calibrate them respectively as 、 and , represents the preset interval corresponding to the continuous activation duration of the th output path, represents the preset interval corresponding to the average voltage output value of the th output path, represents the preset interval corresponding to the time interval from the output control signal to receiving the corresponding feedback signal of the th output path;

[0018] Calculate the proportional values corresponding to the three types of data, namely the continuous activation duration, the average voltage output value, and the time interval from the output control signal to the receipt of the corresponding feedback signal, for each output path. The specific calculation formulas are as follows:

[0019]

[0020]

[0021]

[0022] In the formula, is the proportional value corresponding to the continuous activation duration of the th output path, is the proportional value corresponding to the average voltage output value of the th output path, is the proportional value corresponding to the time interval from the output control signal to the receipt of the corresponding feedback signal of the th output path;

[0023] Calculate the continuous activity coefficient for each output path. The specific calculation formula is as follows:

[0024]

[0025] In the formula, is the continuous activity coefficient of the th output path.

[0026] Preferably, the acquisition logic of the residual influence index for each output path is as follows:

[0027] Extract the load control information from the preprocessed control status information, including three types of data: the load on / off frequency, the total output electrical energy per unit time, and the number of cross-references of the control logic for each output path, and label them as , and , represents the load on / off frequency of the th output path, represents the total output electrical energy per unit time of the th output path, represents the number of cross-references of the control logic of the th output path, , is a positive integer;

[0028] Determine the preset intervals corresponding to the three types of data in the load control information, and label them as , and , Indicates the preset interval corresponding to the load on-off frequency of the th output path, Indicates the preset interval corresponding to the total output electrical energy of the th output path per unit time, Indicates the preset interval corresponding to the number of cross-references of the control logic of the th output path;

[0029] Calculate the respective proportional values of the three types of data: the load on-off frequency, the total output electrical energy per unit time, and the number of cross-references of the control logic for each output path. The specific calculation formula is as follows:

[0030]

[0031]

[0032]

[0033] In the formula, is the proportional value corresponding to the load on-off frequency of the th output path, is the proportional value corresponding to the total output electrical energy per unit time of the th output path, is the proportional value corresponding to the number of cross-references of the control logic of the th output path;

[0034] Calculate the residual influence index of each output path. The specific calculation formula is as follows:

[0035]

[0036] In the formula, is the residual influence index of the th output path.

[0037] Preferably, based on the continuous activity coefficient and the residual influence index of each generated output path, generate the unreleased index of each output path through weighted summation. The specific calculation formula is as follows:

[0038]

[0039] In the formula, is the unreleased index of the th output path, and are respectively the continuous activity coefficient and the residual influence index non-zero weight coefficients, and .

[0040] Preferably, a preset unreleased index threshold interval is determined , and after determination, it is compared with the unreleased index of each generated output path. According to the comparison result, the unreleased degree of each output path is evaluated, and according to the evaluation result, each output path is divided into three categories: directly switchable path, switchable path after clearing, and prohibited switchable path. The specific comparison analysis and classification are as follows:

[0041] If , the unreleased degree of this output path is low, then this output path is divided into a directly switchable path;

[0042] If , the unreleased degree of this output path is medium, then this output path is divided into a switchable path after clearing;

[0043] If , the unreleased degree of this output path is severe, then this output path is divided into a prohibited switchable path.

[0044] Preferably, in the signal cleaning module, for all output paths divided into switchable paths after clearing, the corresponding residual signal cleaning operation is performed, and dynamic regulation is carried out during the operation, specifically:

[0045] For all output paths divided into switchable paths after clearing, when performing the cleaning operation, according to the unreleased degree of these output paths, the cleaning duration and intensity are dynamically adjusted until all the residual signals on these output paths are completely cleared, ensuring that these output paths meet the switching conditions.

[0046] Preferably, after the residual signal cleaning operation is completed, the corresponding control logic switching operations are respectively performed on all output paths divided into directly switchable paths, switchable paths after clearing, and prohibited switchable paths, specifically:

[0047] For all output paths divided into directly switchable paths, the control task is immediately switched to the standby control logic to ensure that the output path smoothly takes over the control task;

[0048] For all output paths divided into switchable paths after clearing, after confirming that the residual signal cleaning of the output path is completed, the control task is switched to the standby control logic; if the output path is not completely cleared, the switching operation is delayed until the output path meets the switching conditions;

[0049] For all output paths classified as prohibited switching paths, abort the switching operation and keep the output paths in the disabled state until the output paths meet the switching conditions.

[0050] In the above technical solution, the technical effects and advantages provided by the present invention are as follows:

[0051] 1. By finely managing the control logic switching in the PLC control cabinet, the present invention effectively solves the problems of equipment failures and system instability caused by the failure to clear residual signals in a timely manner in traditional systems. Through the collaborative work of the path recognition module and the path evaluation module, the system can identify and classify the states of different output paths in real time, ensuring that when switching the control logic, signal clearing operations are only performed on the paths that need to be cleared. This intelligent path classification and dynamic regulation mechanism can prevent incompletely released signals from affecting system switching, avoiding common problems such as repeated equipment startups, unexpected motor operations, and valve misflips, thereby improving the safety and reliability of the system.

[0052] 2. By dynamically clearing signals on the output paths through the signal clearing module, the system can flexibly adjust the clearing duration and intensity according to the degree of unreleased signals of the paths, thereby ensuring that residual signals are completely cleared. For paths that need to be cleared before switching, the signal clearing operation will adjust the clearing intensity and duration according to the actual situation of the paths, avoiding inaccurate switching caused by insufficient signal clearing. This dynamic regulation can not only adapt to complex control circuits (such as those involving relay holding, pulse triggering, etc.), but also optimize the clearing process, reduce unnecessary resource waste, and ensure that each path performs control logic switching in the most suitable state, improving the efficiency of the system.

[0053] 3. By introducing the state continuation module, the present invention ensures that after the control logic is switched, the system can accurately record the classification results, evaluation process data, signal clearing information, and execution results of control logic switching for all paths. This information recording and tracing mechanism provides complete operation transparency, can quickly locate and repair problems in case of failures, and ensures the maintainability and continuous reliable operation of the system. Through these technological innovations, this solution not only effectively improves the remote control accuracy of the PLC control cabinet, but also enhances the adaptability and stability of the system in various complex environments. Description of the Drawings

[0054] In order to more clearly illustrate the technical solutions in the embodiments of the present application or in the prior art, the following will briefly introduce the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings.

[0055] Figure 1 This is a schematic diagram of the modules of a remote control system for a PLC control cabinet according to the present invention. Specific embodiments

[0056] Example embodiments will now be described more fully with reference to the accompanying drawings. However, the example embodiments can be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, these example embodiments are provided so that this disclosure will be more complete and thorough, and will fully convey the concept of the example embodiments to those skilled in the art.

[0057] The present invention provides a remote control system for a PLC control cabinet as Figure 1 shown, including a path recognition module, a path evaluation module, a signal cleaning module, a switching control module, and a status continuation module;

[0058] The path recognition module, when receiving a remote operation instruction to switch the PLC control logic from the current control logic to the standby control logic, pauses the logic switching process, recognizes all output paths in the current control logic that are in the active state, and generates a set of paths to be released;

[0059] When receiving a remote operation instruction to switch the PLC control logic from the current control logic to the standby control logic, the purpose of pausing the logic switching process can be achieved by setting an instruction buffering mechanism in the remote control software. The specific method is that in the instruction receiving module, it is set that when the logic switching instruction is triggered, it is not directly transmitted to the PLC logic area, but first enters an intermediate buffer, and the "to be processed" status label is automatically assigned to it. At the same time, the software suspends the execution of the switching task through the control logic flow engine, prohibiting it from writing the control pointer or status bit, thereby achieving the suspension of the switching process. In addition, a "switching preprocessing flag bit" can also be added at the system level. When this flag bit is set to "incomplete", all switching-related operation instructions will be blocked to ensure that no logic reconstruction occurs before the subsequent status check is completed.

[0060] Identify all the active output paths in the current control logic and generate a set of paths to be released, which can be achieved by analyzing the mapping relationship between the current operating logic of the PLC and the IO status. First, the remote control software reads the operating logic data and output point status information of the PLC through the communication interface and establishes a real-time logical output mapping table. Then, in combination with the logic block configuration file or predefined output binding rules, the software compares which output paths are driven in the current logic and whose output status is active (such as high level, duty cycle valid). All paths that meet this condition will be marked as "paths to be released" and written into a structured data set, which not only contains the output path numbers but also records additional information such as their source logic blocks, current electrical states, and whether they are relay-holding type paths to support the precise execution of subsequent evaluation and cleaning processes.

[0061] The fundamental reason for such processing is that the control logic in the PLC control cabinet is not directly equivalent to the immediate termination of physical execution, especially when it comes to relay holding, electromagnetic delay, or pulse signal control. Even when the current logic has been deactivated, the corresponding output paths may still be in a transient active state at the hardware level. If a new logic block is directly switched to in this unreleased state, it may cause the residue of the old signal to be superimposed on the new instruction, resulting in control signal conflicts, which in turn may lead to problems such as incorrect device startup, action misalignment, and actuator damage. Therefore, by actively identifying and managing these output paths through software before logic switching, it not only provides a basis for perceiving the residual signals but also constructs a closed-loop control strategy to ensure the integrity and consistency of the control state during the remote logic switching process.

[0062] The path evaluation module collects the control state information of each output path in the set of paths to be released to evaluate the degree of unreleasedness of each output path. According to the evaluation results, each output path is classified into three categories: directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths.

[0063] In this embodiment, in the path evaluation module, the control state information of each output path in the set of paths to be released is collected and preprocessed after collection; the continuous activation state information and load control information are extracted from the preprocessed control state information and analyzed after extraction to generate the continuous activity coefficient and residual influence index of each output path respectively; based on the generated continuous activity coefficient and residual influence index of each output path, the unreleased index of each output path is generated by weighted summation; the pre-set unreleased index threshold interval is determined and compared with the generated unreleased index of each output path after determination. According to the comparison results, the degree of unreleasedness of each output path is evaluated, and each output path is classified into three categories: directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths.

[0064] In the path evaluation module, the acquisition of control status information can be achieved by polling or event triggering the real-time data channels of each output path in the PLC control cabinet. The specific acquisition content includes: the continuous activation duration, which can be achieved by recording the time length when a certain output state remains "high level" or "closed state" since activation; the current drive voltage amplitude, which can be achieved by performing real-time voltage sampling on the output relay or analog output interface connected to this path; the control-feedback response delay time, which can be calculated by identifying the interval between the moment when the output command is issued and the timestamp of the feedback signal from the controlled device. The above data can be periodically acquired between the PLC and the remote platform through a standard communication protocol (such as Modbus TCP, OPC UA) by software, and after the acquisition is completed, it enters the next-stage processing as "control status information".

[0065] The main purpose of preprocessing is to unify the data structure, eliminate abnormal fluctuations and sampling errors in the original data, and ensure the stability and accuracy of the data relied on for subsequent evaluation. First, for time-type data such as continuous activation duration and response delay, boundary constraint processing can be performed through software (such as excluding 0 values, negative values, and out-of-limit values), and the sliding window average method can be used to smooth occasional jitters; second, for analog quantity information such as drive voltage, amplitude normalization can be performed to convert the data of all paths into a standard unit value interval in a unified format, which is convenient for subsequent normalization ratio calculation; finally, for the data missing situation that appears in the acquisition time sequence, it can be completed through the linear interpolation algorithm within a short period. These preprocessing operations are all completed in the remote platform or local middleware through the analysis function chain defined in the control logic, without involving hardware intervention, and can ensure that the control status information before evaluation has cleanliness, continuity, and comparability.

[0066] Extracting the continuously active state information and load control information from the pre - processed control state information can be achieved through a software analysis module. First, the continuously active state information can be extracted by judging the state changes of each output path in the pre - processed data. For example, for the continuously active duration, from the collected time - series data, the time span of each output path from activation (high level or closed) to de - activation (low level or open) can be judged, and then its continuously active time can be calculated as the extraction result of the continuously active state information. For the load control information, it can be extracted by analyzing the power consumption data of the output path. First, the power consumption data per unit time is obtained in the pre - processing stage, and then it is compared with the preset load power curve to identify the working intensity and load change situation of this path under load control. All data extraction processes are docked with the PLC real - time data through a data access interface (such as Modbus or OPC UA) and processed in the software platform to ensure the automation, real - time performance, and accuracy of the extraction process.

[0067] The way to determine the preset unreleased index threshold range through software is to dynamically set it by combining historical data analysis and real - time monitoring. First, by analyzing the historical operation data, the distribution of the unreleased index values of each output path in different operation scenarios can be statistically analyzed, and the normal working range and outlier range can be extracted from it. These historical data will provide a basis for setting the threshold range. Second, according to the working requirements and safety standards of the equipment, combined with the tolerance and performance requirements of the equipment, a preliminary threshold range can be set through expert experience or system simulation models. For example, the upper and lower limits of the unreleased index can be determined with reference to the median or percentile (such as the 90th percentile value) in the historical data. In addition, the software system can also dynamically adjust by real - time monitoring the equipment state and combining the real - time collected control state information with a certain tolerance range (such as ±5%) to ensure that the unreleased index threshold range is continuously optimized as the equipment working environment or load changes. This process is completely software - implemented. Through data analysis algorithms and dynamic adjustment mechanisms, the threshold range can match the operation state and historical experience of the equipment.

[0068] In this embodiment, the acquisition logic of the continuous activity coefficient of each output path is as follows:

[0069] Extract the continuously active state information from the pre - processed control state information, which specifically includes three types of data: the continuously active duration of each output path, the average voltage output value, and the time interval from the output control signal to receiving the corresponding feedback signal, and they are respectively labeled as 、 and , represents the The continuous activation duration of the output path represents the average voltage output value of the th output path, represents the time interval from the output control signal to receiving the corresponding feedback signal for the , where n is a positive integer;

[0070] To obtain the three types of data, namely the continuous activation duration, the average voltage output value, and the time interval from the output control signal to receiving the corresponding feedback signal, for each output path, it can be achieved through software and combined with the monitoring interface of the hardware device for acquisition. First, the continuous activation duration refers to the time period from when a certain output path enters the activation state (such as when the PLC output is high level or the actuator action starts) to when it is deactivated (such as when the PLC output is low level or the actuator action stops). This data can be realized by the software to record timestamps in the PLC controller. When the state of the output path changes (for example, from low level to high level), record the time point when the event occurs, and calculate the time interval from this moment to the deactivation moment to obtain the continuous activation duration. Second, the average voltage output value represents the voltage fluctuation range of the output path within a certain time period. By real-time collecting the voltage signal of this path (through the analog input module of the PLC or an external voltage sensor), multiple sample data of the voltage can be obtained. Subsequently, the software calculates the average value of the voltage data within a certain time period to obtain the average voltage output value of this path. This operation is usually completed at the software level of the control system, and the sampling period and data processing period can be set according to the control requirements to ensure the real-time and accuracy of voltage data acquisition. Finally, the time interval from the output control signal to receiving the corresponding feedback signal refers to the response time of the actuator or device to the PLC after the control signal is sent. To obtain this data, a timestamp recording function can be set in the PLC control logic. Record the time when the control signal is sent, and then calculate the time difference between the two by comparing it with the timestamp of receiving the feedback signal. This is the response delay time. Usually, by software real-time monitoring the feedback time points during the signal transmission process, the response delay of each path can be accurately calculated. These data collection processes are based on the data collection module provided in the PLC control system, and the data is transmitted from the hardware to the software through communication protocols (such as Modbus, OPC, etc.) for real-time processing and analysis to ensure the accuracy, stability, and real-time of data collection.

[0071] Determine the preset intervals corresponding to each of the three types of data in the continuous activation state information, and respectively label them as , and , represents the The preset interval corresponding to the continuous activation duration of each output path represents the preset interval corresponding to the average voltage output value of the represents the preset interval corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal for the

[0072] To determine the preset intervals corresponding to the three types of data (continuous activation duration, average voltage output value, control - feedback response delay time) in the continuous activation status information, it can be achieved by analyzing the device's historical operation data, device specifications, and real - time monitoring data. First, for the preset interval of the continuous activation duration, the activation duration data of the device under different working conditions can be statistically analyzed. Combining with the normal working range of the device, the maximum and minimum values are set to ensure that these duration values are within a reasonable working interval. Second, for the preset interval of the average voltage output value, it can be set according to the rated voltage of the device and the voltage fluctuation range in actual operation. By analyzing historical sampling data, the maximum and minimum values of the voltage output are determined as the interval range. Finally, for the preset interval of the control - feedback response delay time, it can be obtained through experimental testing or from historical data. By analyzing the distribution of the device's response time, its maximum and minimum values are set as the preset interval. Through these methods, the software can dynamically set the preset intervals according to the working characteristics and historical data of the device to ensure the rationality and comparability of various types of data.

[0073] Calculate the proportional values corresponding to the three types of data (continuous activation duration, average voltage output value, and time interval from the output of the control signal to the receipt of the corresponding feedback signal) for each output path. The specific calculation formula is as follows:

[0074]

[0075]

[0076]

[0077] In the formula, is the proportional value corresponding to the continuous activation duration of the output path, is the proportional value corresponding to the average voltage output value of the output path, is the proportional value corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal for the output path;

[0078] The purpose of this is to ensure that the control status information of each output path can be quantified and compared under a unified standard. By converting the three types of data, namely the continuous activation duration, the average voltage output value, and the response delay time, into proportional values, the differences in different data units and magnitudes can be eliminated, enabling comprehensive analysis and evaluation of all data items in a unified manner. Through normalization, the parameters of different paths can be converted into a unified standardized value, which not only improves the accuracy of data processing but also makes the subsequent calculation results more stable, reducing the impact of abnormal data or errors on the final evaluation result. This method also has dynamic adaptability and can adaptively adjust the preset interval according to the working state and historical data of the device, thereby ensuring the flexibility and accuracy of the evaluation process.

[0079] Calculate the continuous activation coefficient of each output path. The specific calculation formula is as follows:

[0080]

[0081] In the formula, is the continuous activation coefficient of the th output path.

[0082] The formula for calculating the continuous activation coefficient comprehensively processes the proportional values corresponding to the three types of data, namely the continuous activation duration, the average voltage output value, and the response delay time, with the aim of accurately evaluating the unreleased state of each output path. The proportional values in the specific calculation steps include: the proportional value of the continuous activation duration , the proportional value of the driving voltage amplitude , and the proportional value of the response delay time . These proportional values are normalized to eliminate the magnitude differences of different data, enabling effective combination of each data item under the same standard. First, the proportional value of the continuous activation duration measures the position of the time when this path is in the activated state relative to the preset activation duration interval, reflecting whether the path remains activated for a long time; the proportional value of the driving voltage amplitude measures whether the voltage output of this path is within the preset normal range, reflecting the driving strength of the path; the proportional value of the response delay time Measure the delay between the control signal and the feedback signal, which reflects the stability of the path response. By multiplying these three proportional values, their effects can be comprehensively considered to calculate the activation strength and stability of the path. Since the influence of the delay time on the path release often has a non-linear relationship, the square root processing in the formula is used to emphasize the influence of the delay and avoid excessive amplification of the result by high delay. Finally, the purpose of using the logarithmic function is to smooth the result, ensure that the final sustained activation coefficient fluctuates within a certain range, avoid evaluation distortion caused by too large or too small values, and enhance the dynamic evaluation ability for different output paths. Therefore, this calculation method comprehensively considers various factors such as the sustained activation duration, drive voltage, and response delay, enabling the sustained activation coefficient to accurately reflect the unreleased state of each output path and providing a reliable basis for subsequent path classification.

[0083] The sustained activation coefficient of the output path reflects the unreleased degree of this path. Specifically, the formula comprehensively considers the activation strength, drive strength, and response delay of control feedback of this path through weighted operations on the proportional values of the sustained activation duration, drive voltage amplitude, and response delay time. A higher proportional value of the sustained activation duration indicates that this path is in an activated state for a long time, reflecting the possibility that this path is not fully released; a higher proportional value of the drive voltage indicates that the output voltage of this path is higher, usually meaning that this path undertakes a larger load during operation and has a higher probability of not being released; a higher proportional value of the response delay indicates that the feedback delay of this path is larger, and there may be a disconnection between the control signal and the feedback signal, further increasing the risk of non-release. By multiplying these three proportional values and applying square root processing, the activation persistence and potential instability of each path can be accurately reflected. The use of the logarithmic function smooths the influence of these factors and avoids excessive fluctuations in the final result caused by extreme values. Generally speaking, the higher the sustained activation coefficient, the more serious the unreleased degree of this path, because this means that the path has a long activation time, strong voltage output, and large feedback delay, which may cause the path to be unable to switch or release in time, increasing the instability and failure risk of the system. Therefore, the sustained activation coefficient provides an effective basis for subsequent path classification to evaluate whether each path can be safely switched.

[0084] In this embodiment, the acquisition logic of the residual influence index of each output path is as follows:

[0085] Extract the load control information from the preprocessed control state information, which specifically includes three types of data: the load on-off frequency, the total output electrical energy per unit time, and the number of control logic cross-references of each output path, and are respectively labeled as , and , represents the load on - off frequency of the th output path, represents the total output electrical energy per unit time of the th output path, represents the cross - reference count of the control logic of the th output path, , where \(n\) is a positive integer;

[0086] To obtain the three types of data, namely the load on - off frequency, the total output electrical energy per unit time, and the cross - reference count of the control logic for each output path. First, the load on - off frequency can be achieved by monitoring the switch state of each output path. The software records the switching time of each output path from the active state (such as high level or closed) to the non - active state (such as low level or open), and then calculates the number of these state switches per unit time to obtain the load on - off frequency. Second, the total output electrical energy per unit time can be calculated by collecting the voltage and current data of each output path. The software obtains the voltage and current signals in real - time through the analog input module in the PLC system, combines with the electrical energy formula \(E = V\times I\times t\) to calculate the electrical energy transmitted by the output path per unit time, and sums them up to get the total electrical energy. Finally, the cross - reference count of the control logic represents the degree of dependence of this output path in the entire control system. The software analyzes each function block in the PLC control program, especially the reference situation of the output path variables, and counts the number of times each path is referenced by other modules or function blocks in the control logic to obtain the cross - reference count. The acquisition of these data can be achieved through the symbol table or logic analysis tool in the PLC programming software. Through these data acquisition methods, the software can monitor and calculate the relevant parameters of each output path in real - time, providing an accurate basis for subsequent path evaluation and control decision - making.

[0087] Determine the preset intervals corresponding to each of the three types of data in the load control information, and respectively label them as , and , represents the preset interval corresponding to the load on - off frequency of the th output path, represents the preset interval corresponding to the total output electrical energy per unit time of the th output path, represents the preset interval corresponding to the cross - reference count of the control logic of the th output path;

[0088] To determine the respective preset intervals for the three types of data in the load control information (load on / off frequency, total output electrical energy per unit time, and number of control logic cross-references), it can be achieved through historical data analysis, equipment specifications, and operating conditions. First, for the preset interval of the load on / off frequency, the software can statistically analyze the long-term operating data of the equipment under different load conditions to determine the maximum and minimum on / off frequencies of each output path under normal operating conditions. For example, the software can analyze the number of switchings of each output path within a certain period of time to obtain the on / off frequency range when the path is operating normally. Second, the preset interval of the total output electrical energy per unit time can be determined by analyzing the rated power and operating data of the equipment. By collecting the current and voltage data of the equipment under different loads and combining the design specifications of the equipment, the software can calculate the electrical energy consumption of the equipment under different load conditions, and then set reasonable maximum and minimum electrical energy output value intervals for each output path. These intervals can be dynamically adjusted according to the distribution of historical operating data, combined with the power requirements and safety standards of the equipment design. Finally, the preset interval of the number of control logic cross-references can be determined through static analysis of the control program. The software can scan the cross-reference situation of each output path in the control program and count the number of times each output path is referenced in the control logic to determine its maximum and minimum reference number intervals. Usually, the software will set reasonable reference number intervals according to the importance, dependence degree of the path, and the complexity of the control logic. The setting of these preset intervals can ensure the accuracy and consistency of the evaluation of path control information in different operating environments through the combination of data analysis and equipment specifications.

[0089] Calculate the respective proportional values corresponding to the three types of data, namely the load on / off frequency, total output electrical energy per unit time, and number of control logic cross-references, for each output path. The specific calculation formulas are as follows:

[0090]

[0091]

[0092]

[0093] In the formula, is the proportional value corresponding to the load on / off frequency of the th output path, is the proportional value corresponding to the total output electrical energy per unit time of the th output path, is the proportional value corresponding to the number of control logic cross-references of the th output path;

[0094] By converting three types of data, namely the load on-off frequency, the total electrical energy output per unit time, and the number of cross-references in the control logic, into proportional values, the magnitudes of different data can be effectively unified, making them comparable and operable in subsequent calculations. First, these data may have different units and magnitudes (for example, the unit of the load on-off frequency is times / minute, the electrical energy output is watt-hour, and the number of cross-references is times). Through the calculation of proportional values, they can be standardized to a unified range (usually 0,10, 10,1), facilitating comprehensive evaluation. Second, through normalization calculation, the unit differences and fluctuations between devices can be eliminated, making the contribution degrees of various data more fair and balanced in subsequent weighted operations, and avoiding the excessive impact of abnormal fluctuations of a certain data item on the results. Through this standardized method, not only can the calculation accuracy and stability be improved, but also a reliable basis can be provided for subsequent path classification, un-released degree evaluation, etc., ensuring that the system can make accurate judgments and responses according to the actual operating state of the device.

[0095] Calculate the residual impact index of each output path. The specific calculation formula is as follows:

[0096]

[0097] In the formula, is the residual impact index of the th output path.

[0098] Calculate the residual impact index of each output path The formula for is obtained by performing a weighted operation on the proportional value of the load on-off frequency , the proportional value of the electrical energy output per unit time and the proportional value of the number of cross-references in the control logic , aiming to comprehensively evaluate the impact of the path on the un-released state of the system. First, the proportional value of the load on-off frequency and the proportional value of the electrical energy output per unit time respectively reflect the working frequency and power consumption intensity of the path. Their sum can quantify the working load and persistence of the path and have an impact on the un-released state. A higher load frequency and electrical energy consumption usually mean that the path occupies system resources for a long time and the possibility of being un-released is greater. Second, the proportional value of the number of cross-references in the control logic represents the degree of dependence of the path in the control logic. A high number of references indicates a higher importance of the path in the control system and may have a greater impact on the system. To balance the excessive impact of high-reference paths on the final result, the logarithmic function is used to process this proportional value, which can not only reduce the impact of high-reference paths but also enhance the impact of low-reference paths on the result. By weighted calculating these proportional values and performing smoothing processing through the logarithmic function, the final obtained residual impact index It can accurately reflect the potential interference degree of each output path on the unreleased state of the system, providing an effective basis for subsequent path classification and evaluation.

[0099] The residual influence index of the th output path reflects the unreleased degree of this path through its calculation formula. Specifically, the residual influence index is obtained by weighted combination of the load on-off frequency ratio value , the output electric energy ratio value per unit time , and the cross-reference quantity ratio value of the control logic, comprehensively considering the load intensity, energy consumption, and logic dependency of the path. A higher load on-off frequency and electric energy consumption ratio value ( and ) usually means that this path occupies more resources in the control system and may be in an active state for a long time, thus increasing the possibility of being unreleased. And a higher cross-reference quantity ratio value indicates that this path has a strong dependency in the control logic, which may make the path difficult to be released or cause conflicts, thus increasing the risk of being unreleased. By performing weighted summation and logarithmic transformation on these ratio values, the formula smooths the changes of these influencing factors and effectively integrates them into a comprehensive index. Therefore, the larger the residual influence index, the higher the unreleased degree of this path, because it reflects both the load pressure, control intensity of the path in the system and its importance in the logic.

[0100] In this embodiment, based on the continuous activity coefficients and residual influence indices of each generated output path, the unreleased index of each output path is generated through weighted summation, and the specific calculation formula is as follows:

[0101]

[0102] In the formula, is the unreleased index of the th output path, and are the non-zero weight coefficients of the continuous activity coefficient and residual influence index of each output path respectively, and .

[0103] To implement the weighted summation calculation of the unreleased index in this dependent claim, it is first necessary to calculate the continuous activity coefficient and residual influence index of each output path through software.These calculations are based on the actual control status data of the path, such as information like activation duration, voltage output, and response delay. Next, through weighted summation, these two metrics are combined into an unreleased index. The weight coefficients and are used to adjust the relative contributions of the continuously active coefficient and the residual influence index to the calculation of the unreleased index. The sum of the two is always 1, ensuring an appropriate influence ratio on the result. The specific setting of the weight coefficients can be adjusted through device characteristics, priority requirements of the control system, or through experimental data. For example, if the system attaches more importance to the activity level of the path, can be set to a larger value, while is set to a smaller value, and vice versa. In this way, the software system can customize the weight coefficients according to the actual situation of different paths to flexibly adjust the calculation result of the unreleased index, thereby more accurately evaluating the unreleased degree of each output path.

[0104] In this embodiment, a pre-set unreleased index threshold interval is determined, and after determination, it is compared with the unreleased index of each generated output path. According to the comparison result, the unreleased degree of each output path is evaluated, and each output path is divided into three categories: directly switchable path, switchable after clearing path, and prohibited switch path. The specific comparison analysis and classification are as follows:

[0105] If , the unreleased degree of this output path is low, then this output path is classified as a directly switchable path;

[0106] This situation means that the unreleased degree of the output path is relatively low, indicating that the path has basically completed the control task and the resource occupation is close to release. Since the unreleased degree is relatively low, the path no longer occupies a large amount of system resources, so the control logic can be switched safely and quickly. For the system, such paths can be switched immediately, which helps to improve the response speed and operation efficiency of the system. The system can seamlessly transfer the control task to the new path, avoiding unnecessary delays or downtime. This classification ensures the effective utilization of system resources and reduces the system risks caused by improper path states.

[0107] If , the unreleased degree of this output path is medium, then this output path is classified as a switchable after clearing path;

[0108] This situation indicates that the path still occupies system resources to a certain extent. Although not fully released, it is close to the condition for switching. At this time, the system needs to perform additional cleaning operations to ensure that the path can be switched smoothly and all necessary resources are released. This step may include some cleaning actions in software and hardware, such as releasing occupied control signals and unlocking resources. Although this process will slightly delay the switching operation, it can ensure system stability and avoid conflicts or resource contention caused by incomplete release. Through this classification, the system can handle medium-unreleased paths before switching to avoid potential risks or incorrect executions.

[0109] If , and the unreleased degree of this output path is at a severe level, then this output path is classified as a path that prohibits switching.

[0110] This situation indicates that the unreleased degree of the output path is very high, indicating that the path is still continuously occupying system resources and has not completed the release. Directly switching at this time may cause system instability or serious failures, such as device misoperations, control logic conflicts, or hardware damage. Due to the high unreleased degree, the system must prohibit the switching operation of this path until it completely releases the control resources and stabilizes. This classification means that the system needs to take additional measures for path release and cleaning to ensure system stability and security. Prohibiting the switching of such paths can prevent potential control conflicts and system crashes, ensuring that the system does not take risks in switching until the path is completely and safely released.

[0111] The signal cleaning module performs corresponding residual signal cleaning operations on all output paths classified as paths that need to be cleared before switching, and performs dynamic regulation during the operation; for all output paths classified as directly switchable paths and prohibited switching paths, no residual signal cleaning operations are performed;

[0112] In this embodiment, in the signal cleaning module, for all output paths classified as paths that need to be cleared before switching, corresponding residual signal cleaning operations are performed, and dynamic regulation is performed during the operation. Specifically:

[0113] For all output paths classified as paths that need to be cleared before switching, when performing the cleaning operation, the cleaning duration and intensity are dynamically adjusted according to the unreleased degree of these output paths until all residual signals on these output paths are completely cleared, ensuring that these output paths meet the switching conditions.

[0114] To perform the residual signal cleaning operation on the output path that is divided into the path to be cleared and then switched, and dynamically adjust the cleaning duration and intensity, the software first evaluates the unreleased degree of the path by monitoring the status data of each path in real time. These data include the activation duration of the path, output voltage, signal response delay, etc., and the actual operating status of the path is obtained through sensor data and control signal feedback. Based on these data, the software can set a predetermined threshold range, such as the maximum activation time and the maximum signal delay. By comparing the actual data of the path with the preset threshold, the unreleased degree of the path can be judged. If the unreleased degree of a certain path is relatively high, it indicates that the path may not have fully released resources. The software will then extend the duration of the cleaning operation and increase the intensity of signal cleaning, such as by increasing the frequency of the cleaning signal, increasing the amplitude of the control signal, or extending the execution time of the cleaning instruction. This adjustment mechanism ensures that the path will not be switched to the new control logic until the unreleased signal is completely cleared, avoiding switching conflicts or incorrect control caused by residual signals.

[0115] Specifically, on the path with a relatively high unreleased degree, the cleaning operation can enhance the cleaning effect by increasing the cleaning intensity of the path, adopting cleaning pulses with a higher frequency or extending the signal duration. The software adjusts the cleaning strategy in real time through dynamic monitoring of the path. For example, when the activation time of the path is too long, the software will increase the cleaning intensity; when the response delay of the path exceeds the predetermined threshold, the cleaning process will be extended accordingly to ensure that the path meets the switching conditions after the cleaning work is completed. Through this refined regulation, the path is allowed to switch only after reaching the condition of complete release, thus ensuring the accuracy of path switching and avoiding system instability or incorrect execution of control logic caused by unreleased signals.

[0116] This dynamic regulation method can flexibly adjust the cleaning process according to the different states of the path, avoid resource waste or incomplete cleaning caused by rigid regulations, ensure that the system can operate stably and reliably under various complex conditions, and thus improve the efficiency and safety of the entire automated control system.

[0117] In order to avoid the residual signal cleaning operation for all output paths divided into directly switchable paths and prohibited switchable paths, it can be achieved through the path status monitoring and path classification judgment mechanism in the software system. First, the software will monitor each output path in real time, collect the status data of the path (such as output signal, response time, feedback signal, etc.), and compare it with the preset switching conditions. For the output paths classified as "directly switchable paths", the software recognizes that the paths have been completely released and are in a state where they can be safely switched, so the residual signal cleaning operation is no longer performed. This is because these paths have completed the signal clearing in previous operations and meet the switching conditions, and directly entering the switching stage will not affect the system stability. For the output paths classified as "prohibited switchable paths", the software will detect the existence of unreleased residual signals based on the path status, so no signal cleaning is performed, but it is kept in a non-switching state. This is to prevent the path from being wrongly switched when the signals are not fully cleared, resulting in system instability or control logic conflicts. The prohibited switchable paths need to wait until the unreleased signals are completely cleared and meet the switching conditions before entering the switching state. The reason for this is that all the signals of the directly switchable paths have been cleared, and repeated execution of the cleaning operation will waste resources and is unnecessary. For the prohibited switchable paths, since the unreleased signals of the paths need to be cleared to ensure the safety of switching, performing unnecessary cleaning operations may cause unnecessary computational burden or delay. Through the state judgment and path classification of the software, it can be ensured that the cleaning operation is only performed on the paths that need to be cleaned, thereby improving the system efficiency, reducing resource waste, ensuring that each path can be switched in the best state during switching, and enhancing the stability and response speed of the automated system.

[0118] The switching control module, after completing the residual signal cleaning operation, performs corresponding control logic switching operations on all output paths divided into directly switchable paths, paths that need to be cleared before switching, and prohibited switchable paths respectively;

[0119] In this embodiment, after completing the residual signal cleaning operation, corresponding control logic switching operations are performed on all output paths divided into directly switchable paths, paths that need to be cleared before switching, and prohibited switchable paths respectively, specifically as follows:

[0120] For all output paths classified as directly switchable paths, immediately switch the control task to the standby control logic to ensure that the output paths smoothly take over the control task;

[0121] To implement for all output paths divided into directly switchable paths, the software first monitors the signal status of each path in real time, collects the feedback signals of the path, the response of the control signals, and other parameters related to signal release. When the path status meets the switching conditions, the system immediately executes the control logic switching operation and directly switches the control task to the standby control logic. This operation ensures that the path can seamlessly take over the control task without any delay. The purpose of this operation is to ensure that the path has been released completely, without residual signals, and can quickly take over the task when the switching conditions are met, avoiding unnecessary delays or conflicts and maintaining the high efficiency and stability of the system.

[0122] For all output paths divided into paths that need to be cleared before switching, after confirming that the residual signals of the output path have been cleared, the control task is switched to the standby control logic; if the output path is not completely cleared, the switching operation is delayed until the output path meets the switching conditions;

[0123] For all output paths divided into paths that need to be cleared before switching, the software continuously monitors the unreleased signal situation of the path. By collecting signal feedback and path status data in real time, the system evaluates the degree of unreleased of the path and dynamically adjusts the duration and intensity of the clearing operation according to the evaluation results. If the path is not completely cleared, the system will delay the switching operation and continue to clear until the signal is completely cleared before allowing the path to perform the control logic switching. This process ensures the sufficiency of signal clearing and avoids system instability or incorrect execution caused by incomplete clearing of residual signals. Through this dynamic regulation, the software can flexibly adjust the operation according to the specific clearing situation of each path to ensure that the path is switched only after fully meeting the switching conditions.

[0124] For all output paths divided into prohibited switching paths, abort the switching operation and keep the output path in the disabled state until the output path meets the switching conditions.

[0125] For all output paths divided into prohibited switching paths, the software monitors the release status of the path in real time to ensure that the path will not be wrongly switched when the signal clearing is not completed or other conditions are not met. When the path is determined to be in the prohibited switching state, the system aborts the switching operation and keeps the path in the disabled state until the path meets the switching conditions. During this process, the software continues to monitor the release progress of the path until it is confirmed that all residual signals on the path have been completely cleared and the status of the path is stable before allowing subsequent control logic switching. This measure ensures that switching will not be performed when the signal is not fully released, avoiding system failures or conflicts caused by unreleased resources and ensuring the safe and stable operation of the system.

[0126] The status continuation module performs status continuation operations after the standby control logic takes over the control task, and records the classification results of the output paths, evaluation process data, signal cleaning information, and control logic switching execution results during the logic switching process.

[0127] To implement the status continuation operation, the software needs to record and save the status of the current control task after the standby control logic takes over the control task. Specifically, the software will collect all the status information of the current path in real time, including the classification results of each output path, the signal cleaning progress, the satisfaction of path switching conditions, etc. By storing this information, the software can ensure that all relevant status information can be correctly continued after the control task is switched. During the continuation operation, the software will gradually apply the new control logic to the switched path to ensure that each output path in the system correctly executes tasks under the standby control logic, maintaining the stability and continuity of the system. The purpose of doing this is to avoid any missing status information or path data after the control logic is switched, ensuring a smooth and seamless switching process.

[0128] When implementing the recording of information during the logic switching process, the software will record the classification results of each path, evaluation process data, signal cleaning information, and control logic switching execution results through real-time monitoring and data acquisition technologies. By setting up a database or data log, the software automatically saves the relevant status information each time a switch occurs and provides query and traceback functions. This recording mechanism ensures that in case of an exception or error, it is possible to trace back to the specific switching process, analyze the status and operation process of each path, and thus quickly locate the problem. This process ensures the transparency and audibility of each logic switch, contributing to system maintenance and fault troubleshooting.

[0129] In this way, the status continuation operation and recording function achieve a smooth transition of the control task at the software level, ensuring that the classification information, evaluation data, and cleaning status of each path are accurately recorded. This approach not only improves the reliability of the system switching operation but also enhances the data consistency of the system during multiple switching processes, preventing information loss or incorrect switching. By recording the specific information of each switch, the system can better adapt to changes in different paths, ensuring efficient and stable performance in a complex operating environment.

[0130] The above formulas are all dimensionless and take their numerical values for calculation. The formula is obtained by collecting a large amount of data for software simulation to get a formula closest to the real situation. The preset parameters in the formula are set by technicians in this field according to the actual situation.

[0131] The above embodiments can be implemented in whole or in part by software, hardware, firmware, or any combination thereof. When implemented using software, the above embodiments can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, the processes or functions described in the embodiments of the present application are generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions can be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center by wired or wireless means (such as infrared, wireless, microwave, etc.). The computer-readable storage medium can be any available medium that can be accessed by a computer or a data storage device such as a server or data center that contains one or more collections of available media. The available media can be magnetic media (such as floppy disks, hard disks, magnetic tapes), optical media (such as DVDs), or semiconductor media. The semiconductor media can be a solid-state drive.

[0132] It should be understood that in various embodiments of the present application, the sequence numbers of the above processes do not imply the order of execution, and the order of execution of each process should be determined by its function and internal logic, and should not constitute any limitation to the implementation process of the embodiments of the present application.

[0133] Those of ordinary skill in the art can realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are executed in hardware or software depends on the specific application and design constraints of the technical solution. Professional technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of the present application.

[0134] In several embodiments provided in the present application, it should be understood that the disclosed systems and methods can be implemented in other ways. For example, the above-described embodiments are merely illustrative. For example, the division of the units is only a logical function division, and there can be other division methods in actual implementation. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections to each other can be indirect couplings or communication connections through some interfaces, devices, or units, and can be in electrical, mechanical, or other forms.

[0135] The unit described as the separation component may or may not be physically separated. The component shown as a unit may or may not be a physical unit, that is, it may be located in one place or distributed to multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0136] In addition, each functional unit in various embodiments of the present application may be integrated in a processing unit, may also exist physically alone for each unit, or two or more units may be integrated in one unit.

[0137] As described above, the above are only specific embodiments of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed in the present application can easily think of changes or substitutions, which should all be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A remote control system for a PLC control cabinet, characterized in that, It includes a path recognition module, a path evaluation module, a signal cleaning module, a switching control module, and a status continuation module; The path recognition module, when receiving a remote operation instruction to switch the PLC control logic from the current control logic to the standby control logic, pauses the logic switching process, recognizes all output paths in the current control logic that are in the active state, and generates a set of paths to be released; The path evaluation module collects control status information for each output path in the set of paths to be released to evaluate the unreleased degree of each output path, and classifies each output path into three categories: directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths according to the evaluation results; The signal cleaning module performs corresponding residual signal cleaning operations on all output paths classified as paths that need to be cleared before switching, and performs dynamic regulation during the operation process; for all output paths classified as directly switchable paths and prohibited switching paths, no residual signal cleaning operation is performed; The switching control module, after completing the residual signal cleaning operation, performs corresponding control logic switching operations on all output paths classified as directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths respectively; The status continuation module, after the standby control logic takes over the control task, performs a status continuation operation, and records the classification results of the output paths, the evaluation process data, the signal cleaning information, and the control logic switching execution results during the logic switching process.

2. The remote control system of a PLC control cabinet according to claim 1, characterized in that, In the path evaluation module, control status information is collected for each output path in the set of paths to be released, and preprocessing is performed after collection; continuous activation state information and load control information are extracted from the preprocessed control status information, and analysis is performed after extraction to generate the continuous activity coefficient and residual influence index of each output path respectively; based on the continuous activity coefficient and residual influence index of each output path generated, the unreleased index of each output path is generated by weighted summation; a preset unreleased index threshold interval is determined, and after determination, it is compared with the unreleased index of each output path generated, and the unreleased degree of each output path is evaluated according to the comparison result, and each output path is classified into three categories: directly switchable paths, paths that need to be cleared before switching, and prohibited switching paths according to the evaluation results.

3. The remote control system of a PLC control cabinet according to claim 2, wherein, The acquisition logic of the continuous activity coefficient of each output path is as follows: Extract the continuously activated state information from the preprocessed control state information, specifically including three types of data: the continuously activated duration of each output path, the average voltage output value, and the time interval from the output control signal to receiving the corresponding feedback signal, and label them respectively as , and , represents the continuously activated duration of the -th output path, represents the average voltage output value of the -th output path, represents the time interval from the output control signal to receiving the corresponding feedback signal of the -th output path, , is a positive integer; Determine the preset intervals corresponding to the three types of data in the continuous activation status information, and label them respectively as , and , indicating the preset interval corresponding to the continuous activation duration of the th output path, indicating the preset interval corresponding to the average voltage output value of the th output path, indicating the preset interval corresponding to the time interval from the output control signal to the receipt of the corresponding feedback signal for the th output path; Calculate the proportional values corresponding to the three types of data: the continuous activation duration, the average voltage output value, and the time interval from the output control signal to receiving the corresponding feedback signal of each output path. The specific calculation formula is as follows: In the formula, is the proportional value corresponding to the continuous activation duration of the th output path, is the proportional value corresponding to the average voltage output value of the th output path, is the proportional value corresponding to the time interval from the output control signal to the receipt of the corresponding feedback signal of the th output path; Calculate the continuous activity coefficient of each output path. The specific calculation formula is as follows: In the formula, is the continuous activity coefficient of the th output path.

4. The remote control system of a PLC control cabinet according to claim 3, wherein, The acquisition logic of the residual influence index of each output path is as follows: Extract load control information from the preprocessed control status information, specifically including three types of data: the load on / off frequency of each output path, the total output electrical energy per unit time, and the number of control logic cross-references, and label them respectively as , and , represents the load on / off frequency of the -th output path, represents the total output electrical energy per unit time of the -th output path, represents the number of control logic cross-references of the -th output path, , is a positive integer; Determine the preset intervals corresponding to the three types of data in the load control information, and label them respectively as , and , represents the preset interval corresponding to the load on / off frequency of the th output path, represents the preset interval corresponding to the total output electrical energy per unit time of the th output path, represents the preset interval corresponding to the number of cross-references of the control logic of the th output path; Calculate the proportional values corresponding to the three types of data: the load on-off frequency, the total output electrical energy per unit time, and the control logic cross-reference quantity of each output path. The specific calculation formula is as follows: Wherein, is the proportional value corresponding to the load on / off frequency of the th output path, is the proportional value corresponding to the total amount of electrical energy output per unit time of the th output path, is the proportional value corresponding to the number of cross-references of the control logic of the th output path; Calculate the residual influence index of each output path. The specific calculation formula is as follows: In the formula, is the residual influence index of the th output path.

5. The remote control system of a PLC control cabinet according to claim 4, characterized in that, Based on the continuous activity coefficients of each generated output path and the residual influence index , the unreleased index of each output path is generated by weighted summation. The specific calculation formula is as follows: Wherein, is the unreleased index of the th output path, and are respectively the continuous activity coefficients and the residual influence indexes of each output path, and the non-zero weight coefficients satisfy .

6. The remote control system of a PLC control cabinet according to claim 5, characterized in that, Determine the pre-set unreleased index threshold range , and after determination, compare it with the unreleased index of each generated output path , evaluate the unreleased degree of each output path according to the comparison result, and divide each output path into three categories: directly switchable path, switchable path after clearing, and prohibited switchable path according to the evaluation result. The specific comparison analysis and classification are as follows: If , and the unreleased degree of this output path is low, then this output path is classified as a directly switchable path; If , and the unreleased degree of this output path is medium, then this output path is classified as a path that needs to be cleared and then switched; If , and the unreleased degree of this output path is the severe degree, then this output path is classified as a prohibited switching path.

7. The remote control system of a PLC control cabinet according to claim 6, wherein In the signal cleaning module, for all output paths that are classified as those requiring residual signal cleaning before path switching, corresponding residual signal cleaning operations are performed, and dynamic regulation is carried out during the operation, specifically as follows: For all output paths that are classified as those requiring residual signal cleaning before path switching, when performing the cleaning operation, according to the unreleased degree of these output paths, the cleaning duration and intensity are dynamically adjusted until all the residual signals on these output paths are completely cleared, ensuring that these output paths meet the switching conditions.

8. A remote control system for a PLC control cabinet according to claim 7, characterized in that, After the residual signal cleaning operation is completed, corresponding control logic switching operations are respectively performed on all output paths classified as directly switchable paths, paths requiring residual signal cleaning before switching, and prohibited switching paths, specifically as follows: For all output paths classified as directly switchable paths, immediately switch the control task to the standby control logic to ensure that the output path smoothly takes over the control task; For all output paths classified as those requiring residual signal cleaning before path switching, after confirming that the residual signal cleaning of the output path is completed, switch the control task to the standby control logic; if the output path is not completely cleaned, delay the switching operation until the output path meets the switching conditions; For all output paths classified as prohibited switching paths, abort the switching operation and keep the output path in the disabled state until the output path meets the switching conditions.

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