A remote control system for a PLC control cabinet

Abstract

The present invention discloses a remote control system for a PLC control cabinet, which relates to the technical field of remote control of PLC control cabinets and includes a path identification module, a path evaluation module, a signal cleaning module, a switching control module, and a state continuation module; the path evaluation module collects control state information for each output path in a set of released paths, and is used to evaluate the degree of non-release of each output path, and classifies each output path into three categories according to the evaluation result: a path that can be directly switched, a path that needs to be switched after being cleared, and a path that is prohibited from switching; the signal cleaning module performs corresponding residual signal cleaning operations for all output paths that are classified as paths that need to be switched after being cleared, and performs dynamic regulation during the operation. The present invention solves the problem of equipment failure and system instability caused by the failure to clear residual signals in time when the PLC control logic is switched, and ensures the safety of the system through precise classification, dynamic cleaning, and intelligent switching.

Description

Technical Field

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

[0002] A PLC control cabinet, with a programmable logic controller (PLC) as its core component, integrates electrical components such as power modules, input / output modules, relays, circuit breakers, and a human-machine interface (HMI). These closed-loop electrical control systems are used to implement automated control and logic operations for industrial equipment. They are widely used in production lines, equipment monitoring, municipal infrastructure, building automation, and other scenarios. Traditionally, PLC control cabinets rely on local manual operation and on-site monitoring. Failures or parameter adjustments require on-site attention, resulting in low efficiency and slow response times. Furthermore, in distributed equipment or remote field applications, this introduces significant maintenance costs and safety risks. Remote control technology for PLC control cabinets aims to address this pain point. By integrating communication modules (such as 4G, Ethernet, and Wi-Fi) with the PLC system, a data channel is established between the PLC system and the remote server and control platform. This allows operators to remotely monitor the PLC program within the control cabinet, modify parameters, diagnose faults, and issue commands, thus enabling contactless, real-time management of the entire automation system. Through remote control, not only can the efficiency of equipment operation and maintenance be greatly improved and the frequency of manual inspections be reduced, but also responses can be made immediately when an abnormality occurs, thereby improving 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] Existing PLC control cabinet remote control technology primarily integrates communication modules and a supporting software platform with traditional PLC control systems to enable remote access and control of the PLC control cabinet. Its basic workflow typically includes data acquisition, communication transmission, remote platform processing, and user interaction. Specifically, the PLC within the control cabinet first collects the operating status and sensor data of field devices through I / O modules and performs local control processing based on control logic. Subsequently, a built-in or external communication module (such as a 4G / 5G industrial router, Ethernet module, or Wi-Fi gateway) uploads this data via the network to a cloud platform or remote server. This data may undergo data encryption and protocol conversion (such as Modbus to MQTT or OPC UA). On the remote platform, this data is visualized and can be viewed and analyzed by the operator through a webpage or mobile app. The operator can also issue control commands to the platform. These commands are then transmitted back to the PLC via a communication link via the server, and the PLC executes the corresponding actions, such as modifying control parameters, starting / stopping equipment, or performing remote programming and debugging. The entire process also includes security mechanisms such as permission authentication, security encryption, and communication heartbeat monitoring to ensure the safety 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 collection, transmission, processing, interaction, and security.

[0004] The existing technology has the following deficiencies:

[0005] During remote control of a PLC control cabinet, when the control platform switches the PLC control logic from "main control block A" to "backup control block B," the control logic structure is restructured. While the control outputs in the original control block A have logically ceased operation, their associated physical output paths may still contain residual control signals that have not been released in a timely manner. This is particularly common in control loops involving relay retention, pulse triggering, or non-feedback closed loops. Because these residual signals exist briefly at the hardware level, they can cause signal superposition or interference with the newly loaded control logic after the logic switch, resulting in inconsistent control states or erroneous execution. However, when executing logic block switching, the existing PLC control cabinet remote control technology cannot dynamically regulate the residual signal clearing behavior according to the degree of non-release of the output path when the control logic switches. The reason is that the platform lacks the ability to identify and process the residual path status of the original control block. The default logic switching means that the signal is cleared. This misjudgment will cause the signal to be reused by the new logic without being cleared, thereby causing abnormal behaviors such as repeated device startup, unexpected motor operation, and valve flipping. Further, it may cause equipment damage, action conflict or system instability. Moreover, such problems are extremely hidden and difficult to be discovered and located in time through conventional remote status feedback methods.

[0006] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the Invention

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

[0008] In order to achieve the above-mentioned object, the present invention provides the following technical solutions: a remote control system for a PLC control cabinet, comprising a path identification module, a path evaluation module, a signal cleaning module, a switching control module, and a state connection module;

[0009] The path identification module, upon receiving a remote operation instruction to switch the PLC control logic from the current control logic to the backup control logic, suspends the logic switching process, identifies all output paths in the current control logic that are active, 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 released paths to evaluate the degree of non-release of each output path. Based on the evaluation results, each output path is divided into three categories: a path that can be directly switched, a path that needs to be cleared before switching, and a path that is prohibited from switching.

[0011] The signal cleaning module performs the corresponding residual signal cleaning operation for all output paths that are classified as switching paths that need to be cleared, and dynamically adjusts the operation process; for all output paths that are classified as directly switchable paths and prohibited switching paths, the residual signal cleaning operation is not performed;

[0012] The switching control module, after performing the residual signal cleaning operation, performs corresponding control logic switching operations on all output paths that are divided into directly switchable paths, paths that need to be switched after cleaning, and paths that are prohibited from switching;

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

[0014] Preferably, in the path evaluation module, control state 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 state information, and analyzed after extraction to generate a continuous activity coefficient and a residual influence index for each output path respectively; based on the generated continuous activity coefficient and residual influence index of each output path, a non-release index of each output path is generated by weighted summation; a pre-set non-release index threshold interval is determined, and after determination, it is compared with the non-release index of each output path generated, and the non-release degree of each output path is evaluated according to the comparison result, and according to the evaluation result, each output path is divided into three categories: a path that can be directly switched, a path that needs to be switched after clearing, and a path that is prohibited from switching.

[0015] Preferably, the logic for obtaining the continuous activity coefficient of each output path is as follows:

[0016] The continuous activation state information is extracted from the pre-processed control state information, including the continuous activation time of each output path, the average voltage output value, and the time interval from outputting the control signal to receiving the corresponding feedback signal, and is calibrated as 、 and , Indicates the The duration of the continuous activation of the output path, Indicates the The average voltage output value of the output path, Indicates the The time interval from the output control signal to the receipt of the corresponding feedback signal of the output path, , is a positive integer;

[0017] Determine the preset intervals corresponding to the three types of data in the continuous activation state information and mark them as 、 and , Indicates the The preset interval corresponding to the continuous activation time of the output path, Indicates the The preset interval corresponding to the average voltage output value of the output path, Indicates the The preset interval corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal of the output path;

[0018] Calculate the corresponding proportional values ​​of the 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 the receipt of the corresponding feedback signal. The specific calculation formula is as follows:

[0019]

[0020]

[0021]

[0022] Where, For the The proportional value corresponding to the continuous activation duration of the output path, For the The proportional value corresponding to the average voltage output value of the output path, For the The proportional value corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal of the output path;

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

[0024]

[0025] Where, For the The continuous activity coefficient of the output path.

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

[0027] The load control information is extracted from the pre-processed control state information, including the load on-off frequency of each output path, the total amount of output power per unit time, and the number of control logic cross-references, and is calibrated as 、 and , Indicates the The load switching frequency of the output path, Indicates the The total amount of electrical energy output per unit time of the output paths, Indicates the The number of control logic cross-references for the output paths, , is a positive integer;

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

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

[0030]

[0031]

[0032]

[0033] Where, For the The proportional value corresponding to the load on-off frequency of the output path, For the The proportional value corresponding to the total amount of electrical energy output per unit time of the output path, For the The proportional value corresponding to the number of control logic cross-references of the output paths;

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

[0035]

[0036] Where, For the The residual influence index of the output path.

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

[0038]

[0039] Where, For the The unreleased index of output paths, and are the continuous activity coefficients of each output path and residual impact index The non-zero weight coefficient of .

[0040] Preferably, a preset threshold interval of the unreleased index is determined , and after determination, compare it with the unreleased index of each output path generated A comparison is performed, and the degree of non-release of each output path is evaluated based on the comparison results. Based on the evaluation results, each output path is divided into three categories: paths that can be switched directly, paths that need to be cleared before switching, and paths that are prohibited from switching. The specific comparison analysis and classification are as follows:

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

[0042] like , the degree of non-release of the output path is medium, then the output path is divided into a path that needs to be cleared and switched;

[0043] like , the degree of non-release of the output path is serious, then the output path is divided into a prohibited switching path.

[0044] Preferably, in the signal cleaning module, for all output paths that are classified as paths to be cleared and switched, corresponding residual signal cleaning operations are performed, and dynamic regulation is performed during the operation, specifically:

[0045] For all output paths that are 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 degree of non-release of these output paths until all 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 performed, corresponding control logic switching operations are performed on all output paths that are divided into directly switchable paths, paths that need to be switched after cleaning, and paths that are prohibited from switching, specifically:

[0047] For all output paths that are classified as directly switchable paths, the control tasks are immediately switched to the backup control logic to ensure that the output paths can smoothly take over the control tasks;

[0048] For all output paths that are classified as paths that need to be cleared before switching, after confirming that the residual signal of the output path has been cleared, the control task is switched to the backup 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, the switching operation is suspended, and the output paths are kept in a disabled state until the output paths meet the switching condition.

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

[0051] 1. The present invention effectively solves the problems of equipment failure and system instability caused by the failure to clear residual signals in a timely manner in traditional systems by finely managing the switching of control logic in the PLC control cabinet. Through the collaborative work of the path identification module and the path evaluation module, the system can identify and classify the status of different output paths in real time, ensuring that when switching the control logic, signal cleaning operations are only performed on the paths that need to be cleared. This intelligent path classification and dynamic control mechanism can prevent incompletely released signals from affecting the switching of the system, avoid common problems such as repeated startup of equipment, unexpected operation of motors, and erroneous reversal of valves, thereby improving the safety and reliability of the system.

[0052] 2. The present invention uses a signal cleaning module to dynamically clean the output path. The system can flexibly adjust the duration and intensity of the cleaning according to the degree of non-release of the path, thereby ensuring that the residual signal is completely cleared. For paths that need to be switched after cleaning, the signal cleaning operation will adjust the cleaning intensity and duration according to the actual situation of the path to avoid inaccurate switching caused by insufficient signal cleaning. This dynamic regulation can not only adapt to complex control loops (such as those involving relay retention, pulse triggering, etc.), but also optimize the cleaning process, reduce unnecessary resource waste, and ensure that each path performs control logic switching in the most suitable state, thereby improving system efficiency.

[0053] 3. By introducing a state continuity module, this invention ensures that the system accurately records the classification results, evaluation process data, signal cleanup information, and execution results of all control logic switches after a control logic switch. This information recording and backtracking mechanism provides complete operational transparency, enabling rapid problem location and repair when faults occur, ensuring the system's maintainability and continuous, reliable operation. Through these technological innovations, this solution not only effectively improves the remote control accuracy of PLC control cabinets but also enhances the system's adaptability and stability in various complex environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction to the drawings required for use in the embodiments will be given below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0055] Figure 1 The figure is a schematic diagram of a module of a remote control system of a PLC control cabinet according to the present invention. DETAILED DESCRIPTION

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

[0057] The present invention provides Figure 1 A remote control system for a PLC control cabinet shown includes a path identification module, a path evaluation module, a signal cleaning module, a switching control module, and a state connection module;

[0058] The path identification module, upon receiving a remote operation instruction to switch the PLC control logic from the current control logic to the backup control logic, suspends the logic switching process, identifies all output paths in the current control logic that are active, and generates a set of paths to be released;

[0059] When a remote operation instruction is received to switch the PLC control logic from the current control logic to the backup control logic, the purpose of pausing the logic switching process can be achieved by setting an instruction buffer mechanism in the remote control software. The specific approach is to set the logic switching instruction in the instruction receiving module so that when it is triggered, it is not directly passed to the PLC logic area, but first enters an intermediate buffer and automatically assigns it a "pending" status label. At the same time, the software suspends the execution of the switching task by controlling the logic process engine and prohibits it from writing the control pointer or status bit, thereby pausing the switching process. In addition, a "switch pre-processing flag" can be added at the system level. When this flag is set to "incomplete", all switching-related operation instructions will be blocked to ensure that logic reconstruction does not occur before the subsequent status check is completed.

[0060] Identifying all output paths that are active in the current control logic and generating a set of paths to be released 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 to establish a real-time logic output mapping table. Then, combined 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 (for example, 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. The set not only contains the output path number, but also records its source logic block, current electrical status, whether it is a relay holding type path, and other additional information to support the precise execution of subsequent evaluation and cleanup processes.

[0061] The fundamental reason for this treatment 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 retention, electromagnetic delay or pulse signal control. Even if the current logic has been deactivated, its corresponding output path may still be in a briefly activated state at the hardware level. If you switch directly to a new logic block in this unreleased state, it may cause the old signal residue and the new instruction to be superimposed, resulting in a control signal conflict, which in turn causes problems such as false start-up of equipment, misaligned action, and actuator damage. Therefore, by actively identifying and managing these output paths through software before the logic switch, it not only provides a basis for the perception of residual signals, but also builds a closed loop of control strategies to ensure the integrity and consistency of the control state during the remote logic switching process.

[0062] The path evaluation module collects control status information for each output path in the set of released paths to evaluate the degree of non-release of each output path. Based on the evaluation results, each output path is divided into three categories: a path that can be directly switched, a path that needs to be cleared before switching, and a path that is prohibited from switching.

[0063] In this embodiment, in the path evaluation module, control state 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 state information, and analyzed after extraction to generate a continuous activity coefficient and a residual influence index for each output path respectively; based on the generated continuous activity coefficient and residual influence index of each output path, a non-release index of each output path is generated by weighted summation; a pre-set non-release index threshold interval is determined, and after determination, it is compared with the non-release index of each output path generated, and the non-release degree of each output path is evaluated based on the comparison result, and each output path is divided into three categories according to the evaluation result: a path that can be directly switched, a path that needs to be switched after clearing, and a path that is prohibited from switching.

[0064] In the path assessment module, control status information can be collected by polling the real-time data channels of each output path in the PLC control cabinet or by event triggering. Specific collection content includes: continuous activation duration, which can be achieved by recording the length of time a certain output state remains "high" or "closed" from activation; the current drive voltage amplitude, which can be achieved by real-time voltage sampling of the output relay or analog output interface connected to the path; and the control-feedback response delay time, which can be calculated by identifying the interval between the time the output command is issued and the timestamp of the feedback signal from the controlled device. The above data can be collected periodically by software between the PLC and the remote platform through standard communication protocols (such as Modbus TCP and OPC UA). After collection is completed, it enters the next stage of 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 raw data, and ensure the stability and accuracy of the data relied upon for subsequent evaluation. First, for time-related data such as continuous activation duration and response delay, boundary constraints can be processed through software (such as excluding zero values, negative values, and out-of-limit values), and occasional jitter can be smoothed using a sliding window averaging method. Second, for analog information such as drive voltage, amplitude normalization can be performed, converting the data of all paths into a standard unit value interval in a unified format to facilitate subsequent normalization ratio calculations. Finally, missing data in the acquisition time series can be supplemented using a linear interpolation algorithm within a short period. These preprocessing operations are completed on the remote platform or local middleware through the analysis function chain defined in the control logic, without hardware intervention, to ensure the cleanliness, continuity, and comparability of the control state information before evaluation.

[0066] Extracting continuous activation state information and load control information from preprocessed control state information can be accomplished through a software analysis module. First, continuous activation state information can be extracted by determining the state changes of each output path in the preprocessed data. For example, the duration of continuous activation can be determined from the collected time series data by determining the time span from activation (high level or closed) to deactivation (low level or open) of each output path. This duration is then calculated and used as the continuous activation state information. Load control information can be extracted by analyzing the power consumption data of the output path. First, a preprocessing phase obtains energy consumption data per unit time. This data is then compared with a preset load power curve to identify the operating intensity and load variations of the path under load control. All data extraction processes are connected to real-time PLC data through data access interfaces (such as Modbus or OPC UA) and processed within the software platform, ensuring automated, real-time, and accurate extraction.

[0067] Software can dynamically determine the pre-set threshold range for the unreleased index by combining historical data analysis with real-time monitoring. First, historical operating data can be analyzed to determine the distribution of unreleased index values ​​for each output path under different operating scenarios, identifying normal operating and abnormal ranges. This historical data provides a foundation for setting the threshold range. Second, preliminary threshold ranges can be set based on the equipment's operating requirements and safety standards, combined with its tolerance and performance requirements, through expert experience or system simulation models. For example, the upper and lower limits of the unreleased index can be determined based on the median or percentile (e.g., the 90th percentile) in historical data. Furthermore, the software system can dynamically adjust the unreleased index threshold range within a certain tolerance range (e.g., ±5%) based on real-time monitoring of the equipment's status and combined with real-time collected control status information, ensuring continuous optimization of the unreleased index threshold range as the equipment's operating environment or load changes. This process is entirely software-based, using data analysis algorithms and dynamic adjustment mechanisms to ensure that the threshold range is aligned with the equipment's operating conditions and historical experience.

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

[0069] The continuous activation state information is extracted from the pre-processed control state information, including the continuous activation time of each output path, the average voltage output value, and the time interval from outputting the control signal to receiving the corresponding feedback signal, and is calibrated as 、 and , Indicates the The duration of the continuous activation of the output path, Indicates the The average voltage output value of the output path, Indicates the The time interval from the output control signal to the receipt of the corresponding feedback signal of the output path, , is a positive integer;

[0070] To obtain three types of data for each output path—the duration of continuous activation, the average voltage output value, and the time interval between outputting a control signal and receiving the corresponding feedback signal—these can be achieved through software and integrated with the hardware device's monitoring interface. First, the duration of continuous activation refers to the time from when an output path enters the activated state (e.g., a PLC output is high or an actuator is started) to when it is deactivated (e.g., when the PLC output is low or an actuator is stopped). This data can be obtained by software by timestamping the PLC controller. When the output path changes state (e.g., from low to high), the time of the event is recorded and the time interval from that moment to the deactivation is calculated to obtain the duration of continuous activation. Second, the average voltage output value represents the voltage fluctuation range of the output path over a specified time period. By acquiring the voltage signal of the path in real time (via the PLC's analog input module or an external voltage sensor), multiple voltage samples can be obtained. The software then calculates the average voltage output value of the path by averaging the voltage data over a specified time period. This operation is typically performed at the control system software level. The sampling and data processing cycles can be configured based on control requirements to ensure real-time and accurate voltage data acquisition. Finally, the time interval between outputting a control signal and receiving the corresponding feedback signal refers to the response time it takes for the actuator or device to provide feedback to the PLC after the control signal is sent. To capture this data, a timestamp recording function can be configured in the PLC control logic. The time when the control signal is issued is recorded and then compared with the timestamp of the received feedback signal to calculate the time difference between the two, which is the response delay. Typically, by using software to monitor the feedback timing during signal transmission in real time, the response delay for each path can be accurately calculated. This data acquisition process is based on the data acquisition module provided by the PLC control system. Data is transmitted from the hardware to the software via communication protocols (such as Modbus and OPC) for real-time processing and analysis, ensuring accurate, stable, and real-time data acquisition.

[0071] Determine the preset intervals corresponding to the three types of data in the continuous activation state information and mark them as 、 and , Indicates the The preset interval corresponding to the continuous activation time of the output path, Indicates the The preset interval corresponding to the average voltage output value of the output path, Indicates the The preset interval corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal of the output path;

[0072] To determine the corresponding preset intervals for the three types of data in the continuous activation status information (continuous activation duration, average voltage output, and control-feedback response delay), analysis can be performed on the device's historical operating data, device specifications, and real-time monitoring data. First, the preset intervals for the continuous activation duration can be determined by collecting data on the device's activation duration under different operating conditions. Based on the device's normal operating range, maximum and minimum values ​​can be set to ensure these durations are within a reasonable operating range. Second, the preset intervals for the average voltage output can be set based on the device's rated voltage and the voltage fluctuation range during actual operation. By analyzing historical sampling data, the maximum and minimum voltage output values ​​can be determined as the intervals. Finally, the preset intervals for the control-feedback response delay can be determined experimentally or from historical data. By analyzing the distribution of device response times and setting the maximum and minimum values ​​as the preset intervals, the software can dynamically set the preset intervals based on the device's operating characteristics and historical data, ensuring the rationality and comparability of the various data types.

[0073] Calculate the corresponding proportional values ​​of the 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 the receipt of the corresponding feedback signal. The specific calculation formula is as follows:

[0074]

[0075]

[0076]

[0077] Where, For the The proportional value corresponding to the continuous activation duration of the output path, For the The proportional value corresponding to the average voltage output value of the output path, For the The proportional value corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal of 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, so that all data can be comprehensively analyzed and evaluated 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 subsequent calculation results more stable, reducing the impact of abnormal data or errors on the final evaluation results. This method also has dynamic adaptability and can adaptively adjust the preset interval according to the working status and historical data of the equipment, thereby ensuring the flexibility and accuracy of the evaluation process.

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

[0080]

[0081] Where, For the The continuous activity coefficient of the output path.

[0082] Calculating the continuous activity coefficient The formula comprehensively processes the proportional values ​​corresponding to the three types of data: continuous activation duration, average voltage output value, and response delay time, in order to accurately evaluate the unreleased state of each output path. The specific calculation steps include the proportional values ​​of continuous activation duration, average voltage output value, and response delay time. , driving voltage amplitude ratio and response delay time ratio , these ratio values ​​are normalized to eliminate the magnitude differences of different data, so that each data item can be effectively combined under the same standard. First, the continuous activation duration ratio value It measures the time that the path is in the active state relative to the preset activation time interval, reflecting whether the path remains in the active state for a long time; the driving voltage amplitude ratio value Measures whether the voltage output of the path is within the preset normal range, reflecting the driving strength of the path; response delay time ratio value This measures the delay between the control signal and the feedback signal, reflecting the stability of the path response. By multiplying these three proportional values, their impact can be comprehensively considered to calculate the path's activation strength and stability. Because the effect of delay time on path release often has a nonlinear relationship, the square root process in the formula is used to emphasize the impact of delay and avoid over-amplification of the results due to high delay. Finally, the purpose of using a logarithmic function is to smooth the results, ensuring that the final sustained activity coefficient fluctuates within a certain range, avoiding evaluation distortion caused by excessively large or small values, and enhancing the dynamic evaluation capabilities of different output paths. Therefore, this calculation method, by comprehensively considering multiple factors such as sustained activation duration, drive voltage, and response delay, enables the sustained activity coefficient to accurately reflect the unreleased state of each output path and provide a reliable basis for subsequent path classification.

[0083] No. The continuous activity coefficient of the output path The calculation formula reflects the degree of non-release of a path. Specifically, the formula comprehensively considers the path's activation strength, drive strength, and control feedback response delay by weighting the sustained activation duration ratio, drive voltage amplitude ratio, and response delay ratio. A higher sustained activation duration ratio indicates that the path remains activated for a longer period, suggesting the possibility of incomplete release. A higher drive voltage ratio indicates a higher output voltage, typically implying a heavier load and a higher probability of non-release. A higher response delay ratio indicates a longer feedback delay, potentially indicating a disconnect between the control and feedback signals, further increasing the risk of non-release. By multiplying these three ratios and taking the square root, we can accurately reflect the activation persistence and potential instability of each path. The use of a logarithmic function smooths the impact of these factors, preventing extreme values ​​from causing excessive fluctuations in the final result. Overall, a higher sustained activity coefficient indicates a more severe non-release of the path, as it indicates a longer activation time, stronger voltage output, and greater feedback delay. This can prevent the path from switching or releasing in a timely manner, increasing system instability and the risk of failure. Therefore, the continuous activity coefficient provides an effective basis for subsequent path classification to evaluate whether each path can be switched safely.

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

[0085] The load control information is extracted from the pre-processed control state information, including the load on-off frequency of each output path, the total amount of output power per unit time, and the number of control logic cross-references, and is calibrated as 、 and , Indicates the The load switching frequency of the output path, Indicates the The total amount of electrical energy output per unit time of the output paths, Indicates the The number of control logic cross-references for the output paths, , is a positive integer;

[0086] To obtain three types of data for each output path: load on / off frequency, total output energy per unit time, and control logic cross-reference count, the software first monitors the on / off state of each output path. The software records the time it takes each output path to switch from an active state (e.g., high or closed) to an inactive state (e.g., low or open). The software then calculates the number of these state transitions per unit time to obtain the load on / off frequency. Secondly, the total output energy per unit time can be calculated by collecting voltage and current data from each output path. The software obtains these signals in real time from the analog input modules in the PLC system and, using the energy formula E = V × I × t, calculates the energy transmitted by the output path per unit time and aggregates these data to obtain the total energy. Finally, the control logic cross-reference count indicates the degree of dependency of the output path within the entire control system. The software analyzes each function block in the PLC control program, particularly the references to 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. This data can be obtained using the symbol table or logic analysis tools in the PLC programming software. Through these data collection 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 decisions.

[0087] Determine the preset intervals corresponding to the three types of data in the load control information and mark them as 、 and , Indicates the The preset interval corresponding to the load on-off frequency of the output path, Indicates the The preset interval corresponding to the total amount of electrical energy output per unit time of the output path, Indicates the The preset interval corresponding to the number of control logic cross-references of the output paths;

[0088] Determining the preset ranges for each of the three types of data in load control information (load on / off frequency, total energy output per unit time, and number of control logic cross-references) can be accomplished through historical data analysis, device specifications, and operating conditions. First, for the preset ranges for load on / off frequency, the software can statistically analyze long-term operating data from the device under different load conditions to determine the maximum and minimum on / off frequencies for each output path under normal operating conditions. For example, the software can analyze the number of on / off cycles per output path over a specific period of time to determine the on / off frequency range for that path under normal operation. Second, the preset ranges for total energy output per unit time can be determined by analyzing the device's rated power and operating data. By collecting current and voltage data from the device under different loads and combining it with the device's design specifications, the software can calculate the device's energy consumption under different load conditions, thereby setting reasonable maximum and minimum energy output ranges for each output path. These ranges can be dynamically adjusted based on the distribution of historical operating data, the device's design power requirements, and safety standards. Finally, the preset range for the number of cross-references in the control logic can be determined through static analysis of the control program. The software scans the cross-references of each output path in the control program, counting the number of times each output path is referenced in the control logic, and thus determining its maximum and minimum reference ranges. Typically, the software sets reasonable reference count ranges based on the importance and dependency of the path, as well as the complexity of the control logic. These preset ranges can be established through a combination of data analysis and device specifications to ensure that the evaluation of path control information remains accurate and consistent under different operating environments.

[0089] Calculate the corresponding proportional values ​​of the three types of data: load on / off frequency, total output energy per unit time, and control logic cross-reference quantity for each output path. The specific calculation formula is as follows:

[0090]

[0091]

[0092]

[0093] Where, For the The proportional value corresponding to the load on-off frequency of the output path, For the The proportional value corresponding to the total amount of electrical energy output per unit time of the output path, For the The proportional value corresponding to the number of control logic cross-references of the output paths;

[0094] By converting three types of data—load on / off frequency, total energy output per unit time, and the number of control logic cross-references—into proportional values, the magnitudes of these different data are effectively unified, making them comparable and operational in subsequent calculations. First, these data may have different units and magnitudes (for example, load on / off frequency is measured in cycles / minute, energy output is measured in watt-hours, and the number of cross-references is measured in cycles). By calculating proportional values, these data can be normalized to a consistent range (typically 0, 10, 10, 1), facilitating comprehensive evaluation. Second, normalization eliminates unit differences and fluctuations between devices, ensuring a more equitable and balanced contribution of each type of data in subsequent weighted calculations and preventing abnormal fluctuations in a single data item from significantly impacting the results. This standardized approach not only improves calculation accuracy and stability but also provides a reliable basis for subsequent decisions such as path classification and non-release assessment, ensuring that the system can make accurate judgments and responses based on the actual operating status of the device.

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

[0096]

[0097] Where, For the The residual influence index of the output path.

[0098] Calculate the residual influence index of each output path The formula is based on the load on-off frequency ratio value , Output power ratio per unit time and control logic cross-reference quantity ratio value The weighted calculation is performed to comprehensively evaluate the impact of the path on the system's unreleased state. First, the load on-off frequency ratio value And the output power ratio per unit time Respectively reflect the operating frequency and power consumption intensity of the path. Their sum can quantify the workload and persistence of the path, and have an impact on the unreleased state. Higher load frequency and power consumption usually mean that the path occupies system resources for a long time and is more likely to be unreleased. Secondly, the ratio of the number of cross-references of the control logic is Indicates the degree of dependence of the path in the control logic. A high number of references indicates that the path is more important in the control system and may have a greater impact on the system. In order to balance the excessive impact of highly referenced paths on the final result, a logarithmic function is used. The residual impact index is obtained by weighting these ratios and smoothing them with a logarithmic function. It can accurately reflect the potential interference degree of each output path to the unreleased state of the system, providing an effective basis for subsequent path classification and evaluation.

[0099] No. Residual influence index of output paths The calculation formula reflects the degree of non-release of the path. Specifically, the residual impact index is calculated by the load on-off frequency ratio value. , Output power ratio per unit time and control logic cross-reference quantity ratio value The weighted combination of the load intensity, energy consumption and logic dependency of the path is considered comprehensively. and ) usually means that the path occupies more resources in the control system and may be active for a long time, which increases the possibility of not being released. This indicates a strong dependency on the path within the control logic, potentially making it difficult to release or causing conflicts, increasing the risk of non-release. By weighting and logarithmically transforming these proportional values, the formula smooths the variations in these influencing factors and effectively integrates them into a comprehensive index. Therefore, a larger residual impact index indicates a higher degree of non-release for the path, as it simultaneously reflects the path's load pressure in the system, its control intensity, and its importance within the logic.

[0100] In this embodiment, based on the continuous activity coefficient of each output path generated and residual impact index , the unreleased index of each output path is generated by weighted summation. The specific calculation formula is as follows:

[0101]

[0102] Where, For the The unreleased index of output paths, and are the continuous activity coefficients of each output path and residual impact index The non-zero weight coefficient of .

[0103] To achieve the weighted summation of the weights in the calculation of the unreleased index First, the continuous activity coefficient of each output path needs to be calculated by software and residual impact index These calculations are based on the actual control status data of the path, such as activation duration, voltage output, and response delay. Next, these two indicators are combined into the unreleased index through weighted summation. Weight coefficient and Used to adjust the relative contributions of the continuous activity coefficient and the residual impact index to the calculation of the unreleased index. The sum of the two is always 1, ensuring that they have an appropriate impact ratio on the result. The specific setting of the weight coefficient can be adjusted by equipment characteristics, control system priority requirements or experimental data. For example, if the system pays more attention to the activity of the path, Can be set to a larger value, while Set it to a smaller value, and vice versa. In this way, the software system can customize the weight coefficient according to the actual situation of different paths to flexibly adjust the calculation results of the unreleased index, thereby more accurately evaluating the unreleased degree of each output path.

[0104] In this embodiment, the preset threshold interval of the unreleased index is determined. , and after determination, compare it with the unreleased index of each output path generated A comparison is performed, and the degree of non-release of each output path is evaluated based on the comparison results. Based on the evaluation results, each output path is divided into three categories: paths that can be switched directly, paths that need to be cleared before switching, and paths that are prohibited from switching. The specific comparison analysis and classification are as follows:

[0105] like , the unreleased degree of the output path is low, then the output path is divided into a directly switchable path;

[0106] This indicates that the output path has a low level of unreleased resources, indicating that the path has essentially completed its control task and is nearing resource release. Because the unreleased resources are low, the path no longer consumes significant system resources, allowing for safe and rapid control logic switching. For the system, this type of path allows for immediate switchover, improving responsiveness and operational efficiency. The system can seamlessly transfer control tasks to the new path, avoiding unnecessary delays or downtime. This classification ensures efficient utilization of system resources and reduces system risks associated with improper path status.

[0107] like , the degree of non-release of the output path is medium, then the output path is divided into a path that needs to be cleared and switched;

[0108] This indicates that the path still occupies some system resources. While not fully released, it is close to being ready for a switchover. At this point, the system requires additional cleanup to ensure a smooth path switchover and release all necessary resources. This step may include software and hardware cleanup actions, such as releasing occupied control signals and releasing locked resources. While this process will slightly delay the switchover, it ensures system stability and avoids conflicts or resource contention caused by incomplete release. This classification allows the system to prioritize moderately unreleased paths before a switchover, preventing potential risks or incorrect execution.

[0109] like , the degree of non-release of the output path is serious, then the output path is divided into a prohibited switching path.

[0110] This condition indicates that the output path has a very high level of unreleased resources, indicating that the path continues to occupy system resources and has not been fully released. Switching over directly at this point could lead to system instability or serious failures, such as device malfunction, control logic conflicts, or hardware damage. Due to the high level of unreleased resources, the system must prohibit switching operations on this path until it has fully released control resources and stabilized. This classification means that the system needs to take additional measures to release and clean up the path to ensure system stability and security. Prohibiting switching over such paths prevents potential control conflicts and system crashes, ensuring that the system does not risk switching over until the path is fully and safely released.

[0111] The signal cleaning module performs the corresponding residual signal cleaning operation for all output paths that are classified as switching paths that need to be cleared, and dynamically adjusts the operation process; for all output paths that are classified as directly switchable paths and prohibited switching paths, the residual signal cleaning operation is not performed;

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

[0113] For all output paths that are 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 degree of non-release 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 residual signal cleanup on output paths designated as requiring post-clearance switching and dynamically adjust the cleanup duration and intensity, the software first assesses the path's level of non-release by monitoring each path's status data in real time. This data includes the path's activation duration, output voltage, signal response delay, and other parameters. Sensor data and control signal feedback are used to determine the path's actual operating status. Based on this data, the software sets a predetermined threshold range, such as maximum activation time and maximum signal delay. Comparing the path's actual data with the preset thresholds determines the path's level of non-release. If a path's level of non-release is high, indicating that the path may not have fully released resources, the software will extend the cleanup duration and increase the signal cleanup intensity, such as by increasing the frequency of the cleanup signal, increasing the amplitude of the control signal, or extending the execution time of the cleanup instruction. This adjustment mechanism ensures that the path will not be switched to the new control logic until the non-release signal is completely cleared, thus avoiding switching conflicts or incorrect control caused by residual signals.

[0115] Specifically, cleaning operations can enhance the cleaning effect on paths with a high degree of unreleased signals by increasing the path's clearing intensity, using higher-frequency cleaning pulses, or extending the signal duration. The software dynamically monitors the paths to adjust the cleaning strategy in real time. For example, if a path's activation time is too long, the software will increase the cleaning intensity. When the path's response delay exceeds a 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 it meets the conditions for full release, thereby ensuring the accuracy of path switching and avoiding system instability or incorrect execution of control logic due to unreleased signals.

[0116] This dynamic control method can flexibly adjust the cleaning process according to the different states of the path, avoiding resource waste or incomplete cleaning caused by rigid regulations, ensuring that the system can operate stably and reliably in various complex situations, thereby improving the efficiency and safety of the entire automation control system.

[0117] To avoid performing residual signal cleanup on all output paths categorized as directly switchable or prohibited switching, the software system utilizes path status monitoring and path classification mechanisms. First, the software monitors each output path in real time, collecting path status data (such as output signal, response time, and feedback signal) and comparing it with pre-set switching conditions. For output paths categorized as "directly switchable," the software recognizes that the paths have been fully released and are in a safe state for switching, and therefore no longer performs residual signal cleanup. This is because these paths have already completed signal cleanup in previous operations and meet switching conditions, allowing them to proceed directly to the switching phase without impacting system stability. For output paths categorized as "prohibited switching," the software detects any residual signal remaining in these paths based on their status. Therefore, signal cleanup is omitted and the paths remain in a non-switching state. This prevents erroneous switching if the paths are not fully cleared, potentially leading to system instability or control logic conflicts. Prohibited switching paths wait until the remaining signal is completely cleared and the switching conditions are met before they enter the switching state. The reason for this is that all signals on directly switchable paths have already been cleared, and repeated clearing operations waste resources and are unnecessary. For paths that prohibit switching, because the unreleased signals on the paths must be cleared to ensure switching safety, performing unnecessary clearing operations can cause unnecessary computational overhead or delays. Software status assessment and path classification ensure that clearing operations are performed only on paths that require it, thereby improving system efficiency, reducing resource waste, and ensuring that each path performs optimally during switching, thereby enhancing the stability and responsiveness of the automation system.

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

[0119] In this embodiment, after the residual signal cleaning operation is performed, corresponding control logic switching operations are performed on all output paths that are divided into directly switchable paths, paths that need to be switched after cleaning, and paths that are prohibited from switching. Specifically, the following operations are performed:

[0120] For all output paths that are classified as directly switchable paths, the control tasks are immediately switched to the backup control logic to ensure that the output paths can smoothly take over the control tasks;

[0121] To achieve this for all output paths that have been divided into directly switchable paths, the software first monitors the signal status of each path in real time, collecting the path's feedback signal, the response of the control signal, and other parameters related to signal release. When the path status meets the switching conditions, the system will immediately execute the control logic switching operation, switching the control task directly to the backup 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 and there is no residual signal. When the switching conditions are met, the task can be taken over quickly, avoiding unnecessary delays or conflicts, and maintaining the efficiency and stability of the system.

[0122] For all output paths that are classified as paths that need to be cleared before switching, after confirming that the residual signal of the output path has been cleared, the control task is switched to the backup 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 that are classified as paths that need to be cleared before switching, the software will continuously monitor the path's unreleased signals. By collecting real-time signal feedback and path status data, the system evaluates the degree of unreleased paths and dynamically adjusts the duration and intensity of the cleanup operation based on the evaluation results. If the path is not completely cleared, the system will delay the switching operation and continue cleaning until the signal is completely cleared, allowing the path to switch control logic. This process ensures the adequacy of signal cleaning and avoids system instability or erroneous execution caused by incomplete cleaning of residual signals. Through this dynamic regulation, the software can flexibly adjust operations based on the specific cleaning status of each path, ensuring that the path is switched only after it fully meets the switching conditions.

[0124] For all output paths classified as prohibited switching paths, the switching operation is suspended, and the output paths are kept in a disabled state until the output paths meet the switching condition.

[0125] For all output paths designated as prohibited switching paths, the software monitors the path's release status in real time to ensure that the path is not mistakenly switched if signal clearing or other conditions are not met. When a path is determined to be in a prohibited switching state, the system aborts the switching operation and keeps the path disabled until the switching conditions are met. During this process, the software continues to monitor the path's release progress until it confirms that all residual signals on the path have been completely cleared and the path's status is stable, allowing subsequent control logic switching. This ensures that switching will not occur without complete signal release, avoiding system failures or conflicts caused by unreleased resources and ensuring safe and stable system operation.

[0126] The state succession module performs the state succession operation after the backup control logic takes over the control task, and records the classification results of the output path, evaluation process data, signal cleaning information and control logic switching execution results during the logic switching process.

[0127] In order to achieve state continuation operation, the software needs to first record and save the status of the current control task after the backup control logic takes over the control task. Specifically, the software will collect all status information of the current path in real time, including the classification results of each output path, signal cleaning progress, and satisfaction of path switching conditions. 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 performs the task under the backup control logic and maintains the stability and continuity of the system. The purpose of this is to avoid any missing status information or path data after the control logic is switched, and to ensure that the switching process is smooth and seamless.

[0128] To record information during the logic switching process, the software uses real-time monitoring and data acquisition technology to record the classification results, evaluation process data, signal cleanup information, and control logic switching execution results for each path. By setting up a database or data log, the software automatically saves relevant status information after each switch occurs and provides query and backtracking capabilities. This recording mechanism ensures that in the event of anomalies or errors, the specific switching process can be traced back, and the status and operation of each path can be analyzed to quickly locate the problem. This process ensures transparency and auditability of each logic switch, facilitating system maintenance and troubleshooting.

[0129] In this way, state transition and recording functions enable a smooth transition of control tasks at the software level, ensuring that classification information, evaluation data, and cleanup status for each path are accurately recorded. This approach not only improves the reliability of system switching operations but also enhances data consistency across multiple switchovers, preventing information loss or erroneous switching. By recording detailed information for each switchover, the system can better adapt to changes in different paths, ensuring efficient and stable performance even in complex operating environments.

[0130] The above formulas are all dimensionless and numerical calculations. The formulas are obtained by collecting a large amount of data and performing software simulation to obtain the most recent real situation. The preset parameters in the formulas are set by technicians in this field according to actual conditions.

[0131] The above embodiments can be implemented in whole or in part via software, hardware, firmware, or any other 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 comprises one or more computer instructions or computer programs. When loaded or executed on a computer, the processes or functions described in the embodiments of this application are fully or partially performed. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. 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 via wired or wireless means (e.g., infrared, wireless, microwave, etc.). The computer-readable storage medium can be any available medium accessible by a computer or a data storage device such as a server or data center that contains a collection of one or more available media. The available medium can be magnetic media (e.g., floppy disks, hard disks, magnetic tapes), optical media (e.g., DVDs), or semiconductor media. The semiconductor media can be a solid-state drive.

[0132] It should be understood that in the various embodiments of the present application, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present application.

[0133] Those skilled in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0134] In the several embodiments provided in this application, it should be understood that the disclosed systems and methods can be implemented in other ways. For example, the embodiments described above are merely illustrative. For example, the division of the units is merely a logical function division. In actual implementation, there may be other division methods, such as 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 mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, which can be electrical, mechanical or other forms.

[0135] The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed across multiple network units. Some or all of these units may be selected to achieve the purpose of this embodiment according to actual needs.

[0136] In addition, each functional unit in each embodiment of the present application may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit.

[0137] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.

Claims

1. A remote control system for a PLC control cabinet, characterized in that: It includes a path identification module, a path evaluation module, a signal cleaning module, a switching control module and a state connection module; The path identification module, upon receiving a remote operation instruction to switch the PLC control logic from the current control logic to the backup control logic, suspends the logic switching process, identifies all output paths in the current control logic that are active, 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 released paths to evaluate the degree of non-release of each output path. Based on the evaluation results, each output path is divided into three categories: a path that can be directly switched, a path that needs to be cleared before switching, and a path that is prohibited from switching. In the path evaluation module, control state information is collected for each output path in the set of paths to be released and preprocessed after collection; continuous activation state information and load control information are extracted from the preprocessed control state information and analyzed after extraction to generate a continuous activity coefficient and a residual influence index for each output path; based on the generated continuous activity coefficient and residual influence index of each output path, a non-release index of each output path is generated by weighted summation; a pre-set non-release index threshold range is determined and compared with the generated non-release index of each output path after determination, and the non-release degree of each output path is evaluated based on the comparison result. Based on the evaluation result, each output path is divided into three categories: a path that can be directly switched, a path that needs to be cleared before switching, and a path that is prohibited from switching; The signal cleaning module performs the corresponding residual signal cleaning operation for all output paths that are classified as switching paths that need to be cleared, and dynamically adjusts the operation process; for all output paths that are classified as directly switchable paths and prohibited switching paths, the residual signal cleaning operation is not performed; The switching control module, after performing the residual signal cleaning operation, performs corresponding control logic switching operations on all output paths that are divided into directly switchable paths, paths that need to be switched after cleaning, and paths that are prohibited from switching; The state succession module performs the state succession operation after the backup control logic takes over the control task, and records the classification results of the output path, evaluation process data, signal cleaning information and control logic switching execution results during the logic switching process.

2. A remote control system for a PLC control cabinet according to claim 1, characterized in that: The logic for obtaining the continuous activity coefficient of each output path is as follows: The continuous activation state information is extracted from the pre-processed control state information, including the continuous activation time of each output path, the average voltage output value, and the time interval from outputting the control signal to receiving the corresponding feedback signal, and is calibrated as 、 and , Indicates the The duration of the continuous activation of the output path, Indicates the The average voltage output value of the output paths, Indicates the The time interval from the output control signal to the receipt of the corresponding feedback signal of the output path, , is a positive integer; Determine the preset intervals corresponding to the three types of data in the continuous activation status information and mark them as 、 and , Indicates the The preset interval corresponding to the continuous activation time of the output path, Indicates the The preset interval corresponding to the average voltage output value of the output path, Indicates the The preset interval corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal of the output path; Calculate the corresponding proportional values ​​of the 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 the receipt of the corresponding feedback signal. The specific calculation formula is as follows: Where, For the The proportional value corresponding to the continuous activation duration of the output path, For the The proportional value corresponding to the average voltage output value of the output path, For the The proportional value corresponding to the time interval from the output of the control signal to the receipt of the corresponding feedback signal of the output path; Calculate the continuous activity coefficient of each output path. The specific calculation formula is as follows: Where, For the The continuous activity coefficient of the output path.

3. A remote control system for a PLC control cabinet according to claim 2, characterized in that: The logic for obtaining the residual influence index of each output path is as follows: The load control information is extracted from the pre-processed control state information, including the load on-off frequency of each output path, the total amount of output power per unit time, and the number of control logic cross-references, and is calibrated as 、 and , Indicates the The load switching frequency of the output path, Indicates the The total amount of electrical energy output per unit time of the output paths, Indicates the The number of control logic cross-references for the output paths, , is a positive integer; Determine the preset intervals corresponding to the three types of data in the load control information and mark them as 、 and , Indicates the The preset interval corresponding to the load on-off frequency of the output path, Indicates the The preset interval corresponding to the total amount of electrical energy output per unit time of the output path, Indicates the The preset interval corresponding to the number of control logic cross-references of the output paths; Calculate the corresponding proportional values ​​of the three types of data: load on / off frequency, total output energy per unit time, and control logic cross-reference quantity for each output path. The specific calculation formula is as follows: Where, For the The proportional value corresponding to the load on-off frequency of the output path, For the The proportional value corresponding to the total amount of electrical energy output per unit time of the output path, For the The proportional value corresponding to the number of control logic cross-references of the output paths; Calculate the residual influence index of each output path. The specific calculation formula is as follows: Where, For the The residual influence index of the output path.

4. A remote control system for a PLC control cabinet according to claim 3, characterized in that: Based on the continuous activity coefficient of each generated output path and residual impact index , the unreleased index of each output path is generated by weighted summation. The specific calculation formula is as follows: Where, For the The unreleased index of output paths, and are the continuous activity coefficients of each output path and residual impact index The non-zero weight coefficient of .

5. A remote control system for a PLC control cabinet according to claim 4, characterized in that: Determine the pre-set threshold interval for the unreleased index , and after determination, compare it with the unreleased index of each output path generated A comparison is performed, and the degree of non-release of each output path is evaluated based on the comparison results. Based on the evaluation results, each output path is divided into three categories: paths that can be switched directly, paths that need to be cleared before switching, and paths that are prohibited from switching. The specific comparison analysis and classification are as follows: like , the unreleased degree of the output path is low, then the output path is divided into a directly switchable path; like , the degree of non-release of the output path is medium, then the output path is divided into a path that needs to be cleared and switched; like , the degree of non-release of the output path is serious, then the output path is divided into a prohibited switching path.

6. A remote control system for a PLC control cabinet according to claim 5, characterized in that: In the signal cleaning module, for all output paths that are classified as switching paths that need to be cleared, the corresponding residual signal cleaning operation is performed, and dynamic control is performed during the operation, specifically: For all output paths that are 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 degree of non-release of these output paths until all residual signals on these output paths are completely cleared, ensuring that these output paths meet the switching conditions.

7. A remote control system for a PLC control cabinet according to claim 6, characterized in that: After the residual signal cleaning operation is completed, the corresponding control logic switching operation is performed on all output paths that are divided into directly switchable paths, paths that need to be switched after cleaning, and paths that are prohibited from switching. Specifically, For all output paths that are classified as directly switchable paths, the control tasks are immediately switched to the backup control logic to ensure that the output paths can smoothly take over the control tasks; For all output paths that are classified as paths that need to be cleared before switching, after confirming that the residual signal of the output path has been cleared, the control task is switched to the backup control logic; if the output path is not completely cleared, the switching operation is delayed until the output path meets the switching conditions; For all output paths classified as prohibited switching paths, the switching operation is suspended, and the output paths are kept in a disabled state until the output paths meet the switching condition.

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