Computer industrial controller and control system thereof

Abstract

The invention discloses a computer industrial controller and a control system thereof, and relates to the technical field of industrial controllers. The computer industrial controller and the control system thereof comprise an industrial controller hardware module and a control system software module, and the industrial controller hardware module comprises a core processing module, a storage module, a communication module, a power management module, a safety module, an input and output module and a display module. The control system software module comprises an operating system, an AI application module, a data processing and management module, a communication management module and an equipment management module, the computer industrial controller and the control system thereof have the advantages that the system is autonomous, controllable and safe in supply chain, all components are domestic, 100% autonomous and controllable are realized, and the safety of the supply chain is effectively guaranteed.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial controllers, and in particular to a computer industrial controller and a control system thereof. Background Art

[0002] In today's industrial field, the importance of computer industrial controllers and their control systems is increasing day by day. Their performance and functions are directly related to the efficiency, quality and safety of industrial production. However, existing computer industrial controllers and their control systems have many problems that need to be solved; AI computing power: Traditional controllers have weak local AI reasoning capabilities. Processing complex AI tasks requires transmitting data to the cloud, which carries risks such as high transmission latency, network dependence, and easy data leakage.

[0003] Communication and scalability: Traditional controllers have a single communication protocol, poor wireless communication capabilities, no flexible positioning function, fixed software and no OTA upgrade capability, making it difficult to meet the needs of Industry 4.0. Summary of the Invention

[0004] The purpose of the present invention is to solve at least one of the technical problems existing in the prior art and to provide a computer industrial controller and a control system thereof, which can solve problems such as the weak local AI reasoning capability of traditional controllers.

[0005] To achieve the above objectives, the present invention provides the following technical solutions: a computer industrial controller and its control system, comprising an industrial controller hardware module and a control system software module, wherein the process controller hardware module comprises a core processing module, a storage module, a communication module, a power management module, a security module, an input / output module, and a display module; The control system software modules include operating system, AI application module, data processing and management module, communication management module and equipment management module.

[0006] Preferably, the core processing module: Processor: Using quad-core ARM Cortex-A55 domestic processor; NPU: A domestically produced NPU with integrated 1TOPS computing power, supports INT8 / FP16 quantization models, and can efficiently run TensorFlow Lite and ONNX lightweight AI models.

[0007] Preferably, the storage module: Memory: Supports 32-bit DDR4 / 3 / 3L / LPDDR4 / 4X / 3 memory types. DDR4 and DDR3 also support ECC (error checking and correction) function, which effectively improves the accuracy and stability of data storage and ensures the integrity of data during long-term system operation. Storage expansion: Equipped with eMMC 5.1 and SFC interfaces, supports TF card expansion storage.

[0008] Preferably, the communication module: Wired communication: It has dual 100M network ports, adopts domestic PHY chips and adopts redundant design to ensure the reliability of network connection, and supports RS485 and RS232 serial port communications; Wireless Communication: Integrates a domestically produced 4G / 5G module and supports Cat.4 / Cat.12 standards, enabling high-speed, low-latency wireless data transmission. Built-in MQTT protocol support enables highly reliable data upload to the cloud under low-bandwidth conditions, synchronizing device status to the cloud in real time. In addition, it is also equipped with a Wi-Fi module. Positioning module: Adopts domestic Beidou / GPS dual-mode chip, with high-precision positioning capability of ±1.5 meters.

[0009] Preferably, the power management module: It uses domestic PMIC chips, supports 24V isolated power input, and has anti-surge and electrostatic protection functions. On the one hand, it provides a stable and reliable power supply for the controller, ensuring that the equipment is not affected by power fluctuations in complex industrial environments; on the other hand, it effectively prevents damage to the equipment caused by static electricity and surges.

[0010] Preferably, the security module: It integrates a domestic encryption engine, supports SM4 / SM3 encryption algorithms, and combines secure boot mechanism and firewall functions to build a multi-level security protection system, ensuring the security of the system from device startup to data transmission.

[0011] Preferably, the input and output module: Digital Input (DI): Provides eight 24V digital input channels, supports sink and source inputs, and can connect to various sensors and switching devices to collect real-time status information on industrial sites, such as the start and stop status of equipment and sensor trigger signals. Digital output (DO): It has 8 24V PWM output channels, which can be used to control various actuators, such as motor speed regulation and valve opening control, to achieve precise control of industrial equipment. Both input and output adopt isolation protection design.

[0012] Preferably, the display module is equipped with an HDMI 2.0 interface and can be connected to a display.

[0013] Preferably, the AI application module: based on the powerful computing power of NPU, integrates multiple AI application functions, and realizes abnormal detection of equipment status, image recognition, and predictive maintenance functions through preloaded or user-defined AI models.

[0014] Preferably, the data processing and management module is responsible for real-time processing, storage and management of the collected industrial data, and performing filtering and denoising preprocessing operations on the raw data collected by the sensor; The communication management module unifies the management of various communication interfaces of the controller, realizes the conversion and data interaction between different communication protocols, automatically selects the optimal communication method according to the device requirements and network conditions, ensures efficient and stable data transmission, and packages and unpacks data to ensure accurate data transmission between different devices and systems. Among them, the equipment management module is used to centrally manage various industrial equipment connected to the controller and monitor the operating status of the equipment in real time, including the equipment's online status, working parameters, and fault information.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. This computer industrial controller and its control system have powerful edge AI computing capabilities and lightweight AI model deployment accelerated by NPU, which enables the device to have local AI reasoning capabilities, completing complex AI tasks such as anomaly detection and image recognition on the industrial site, reducing data transmission delays and dependence on the cloud, and improving system response speed and security.

[0016] 2. This computer industrial controller and its control system are highly reliable and stable, with industrial-grade design standards, including a 24V isolated power supply, ECC memory, a wide operating temperature range of 40°C to +85°C, and a high degree of protection (optional IP65 enclosure). These features ensure stable and reliable operation in harsh industrial environments, with a mean time between failures (MTBF) greater than 200,000 hours, effectively reducing equipment maintenance costs and improving production efficiency.

[0017] 3. The computer industrial controller and its control system have rich communication and scalability, support multiple industrial communication protocols and wireless communication methods, and have strong communication capabilities. At the same time, through software-defined functions and OTA upgrades, it can flexibly adapt to the upgrade requirements of Industry 4.0, support 5G and GPS positioning expansion functions, and meet the company's ever-evolving business needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a diagram of the industrial controller device of the present invention; Figure 2 This is a schematic diagram of the hardware module of the industrial controller of the present invention; Figure 3 This is a schematic diagram of the software modules of the control system of the present invention; Figure 4 This is a structural block diagram of the industrial controller of the present invention. DETAILED DESCRIPTION

[0019] This section will describe in detail the specific embodiments of the present invention. The preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the accompanying drawings is to supplement the description of the text part of the specification with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present invention, but it should not be understood as a limitation on the scope of protection of the present invention.

[0020] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0021] In the description of this invention, terms such as "greater than," "less than," and "exceed" are understood to exclude the number itself, while terms such as "above," "below," and "within" are understood to include the number itself. The use of terms such as "first" and "second" is solely for the purpose of distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0022] In the description of the present invention, unless otherwise clearly defined, terms such as setting, installing, and connecting should be understood in a broad sense, and technicians in the relevant technical field can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0023] See also Figure 1-4 The present invention provides a technical solution: a computer industrial controller and its control system, including an industrial controller hardware module and a control system software module. The process controller hardware module includes a core processing module, a storage module, a communication module, a power management module, a security module, an input / output module, and a display module. The control system software modules include operating system, AI application module, data processing and management module, communication management module and equipment management module; Among them, the core processing module: Processor: It uses a domestically produced quad-core ARM Cortex-A55 processor with powerful computing capabilities, which can easily handle complex computing tasks and provide a solid foundation for the stable operation of the system and efficient data processing. Whether it is real-time data calculation in industrial production or the execution of complex control algorithms, it can be completed quickly and accurately. NPU: The controller integrates a domestically developed NPU with 1TOPS computing power, supports INT8 / FP16 quantization models, and can efficiently run TensorFlow Lite and ONNX lightweight AI models. This gives the controller excellent edge AI computing capabilities, enabling local anomaly detection and OCR recognition functions, reducing reliance on the cloud and improving response speed and data security. Among them, the storage module: Memory: Supports 32-bit DDR4 / 3 / 3L / LPDDR4 / 4X / 3 memory types. DDR4 and DDR3 also support ECC (error checking and correction) function, which effectively improves the accuracy and stability of data storage and ensures the integrity of data during long-term system operation. Storage expansion: Equipped with eMMC 5.1 and SFC interfaces, it supports TF card expansion storage, allowing users to flexibly increase storage capacity according to actual needs and meet the storage needs of large amounts of data, such as historical data records in industrial production processes and AI model training data; Among them, the communication module: Wired communication: It has dual 100M network ports, uses domestic PHY chips and adopts redundant design to ensure the reliability of network connection. It also supports RS485 and RS232 serial communication, which can achieve stable data transmission with a variety of industrial equipment. It is widely adapted to different types of industrial field buses and equipment to meet the diverse needs of industrial communication. Wireless Communication: Integrates a domestically produced 4G / 5G module and supports Cat.4 / Cat.12 standards, enabling high-speed, low-latency wireless data transmission. Built-in MQTT protocol support enables highly reliable data upload to the cloud even under low-bandwidth conditions, synchronizing device status to the cloud in real time. Furthermore, it is equipped with a Wi-Fi module for easy communication with surrounding wireless devices, expanding the device's connectivity flexibility. Positioning module: Using a domestically produced Beidou / GPS dual-mode chip, it offers high-precision positioning capabilities of ±1.5 meters and can be applied to industrial scenarios requiring precise positioning, such as tracking mobile industrial equipment and collecting geographic information-related industrial data. Among them, the power management module: It uses a domestically produced PMIC chip, supports 24V isolated power input, and features surge and electrostatic protection. This provides a stable and reliable power supply for the controller, ensuring the device is unaffected by power fluctuations in complex industrial environments. It also effectively prevents damage to the device caused by static electricity and surges, extending its service life and improving system stability and reliability. Among them, the security module: It integrates a domestic encryption engine, supports SM4 / SM3 encryption algorithms, and combines secure boot mechanisms and firewall functions to build a multi-level security protection system. From device startup to data transmission, it comprehensively guarantees system security, prevents data leakage and malicious attacks, and ensures the security and reliability of industrial production data. Among them, input and output modules: Digital Input (DI): Provides eight 24V digital input channels, supports sink and source inputs, and can connect to various sensors and switching devices to collect real-time status information on industrial sites, such as the start and stop status of equipment and sensor trigger signals. Digital Output (DO): Equipped with eight 24V PWM output channels, it can be used to control various actuators, such as motor speed regulation and valve opening control, to achieve precise control of industrial equipment. Both input and output adopt isolation protection design to effectively prevent external interference from affecting the system and ensure the accuracy and stability of data transmission. Among them, the display module: Equipped with an HDMI2.0 interface, it can be connected to a monitor, allowing users to view equipment operating status, system parameters, and monitoring data information in real time, providing an intuitive interactive interface for on-site operators; Among them, the operating system supports KylinOS, Huawei's openEuler, Hongmeng OpenHarmony and open source Linux, and multiple domestic operating systems. Users can choose the appropriate operating system according to actual needs and application scenarios, giving full play to the advantages of domestic operating systems in security, stability and adaptability, while also facilitating deep integration with the domestic software ecosystem. The AI application module leverages the powerful computing power of the NPU and integrates a variety of AI application functions. Through pre-loaded or user-defined AI models, it enables equipment status anomaly detection, image recognition, and predictive maintenance. It uses AI algorithms to analyze large amounts of data from industrial production processes, identifying potential faults in advance and providing strong support for enterprises to optimize production processes and reduce costs. The data processing and management module is responsible for real-time processing, storage, and management of collected industrial data. It performs filtering and denoising preprocessing on the raw data collected by sensors to improve data quality. The processed data is stored in local storage devices or uploaded to the cloud, allowing users to query and analyze historical data at any time. At the same time, it provides data retrieval and statistical analysis functions to provide data support for enterprise decision-making. The communication management module unifies the management of various communication interfaces of the controller, realizes the conversion and data interaction between different communication protocols, automatically selects the optimal communication method according to the device requirements and network conditions, ensures efficient and stable data transmission, and packages and unpacks data to ensure accurate data transmission between different devices and systems. The device management module is used to centrally manage various industrial devices connected to the controller and monitor the operating status of the devices in real time, including their online status, operating parameters, and fault information. It also provides device configuration functions, allowing users to set and adjust device parameters. It also supports remote device upgrades, allowing enterprises to update device software and firmware in a timely manner to improve device performance and functionality. Furthermore, the system boasts powerful edge AI computing capabilities and lightweight AI model deployment accelerated by the NPU, enabling devices to perform local AI reasoning. This allows them to complete complex AI tasks such as anomaly detection and image recognition on industrial sites, reducing data transmission latency and cloud reliance, and improving system responsiveness and security. Furthermore, the system boasts high reliability and stability, and industrial-grade design standards, including a 24V isolated power supply, ECC memory, a wide operating temperature range of 40°C to +85°C, and a high degree of protection (optional IP65 enclosure). These features ensure the controller operates stably and reliably in harsh industrial environments, with a mean time between failures (MTBF) exceeding 200,000 hours, effectively reducing equipment maintenance costs and improving production efficiency. Furthermore, the system's rich communication and scalability supports a variety of industrial communication protocols and wireless communication methods, and has powerful communication capabilities. At the same time, through software-defined functions and OTA upgrades, it can flexibly adapt to the upgrade needs of Industry 4.0, support 5G and GPS positioning expansion functions, and meet the company's ever-evolving business needs.

[0024] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the scope of knowledge possessed by ordinary technicians in the technical field without departing from the scope of the present invention.

Claims

1. A computer industrial controller and its control system, comprising an industrial controller hardware module and a control system software module, characterized in that: The process controller hardware module includes a core processing module, a storage module, a communication module, a power management module, a security module, an input and output module and a display module; The control system software modules include operating system, AI application module, data processing and management module, communication management module and equipment management module.

2. A computer industrial controller and control system thereof according to claim 1, characterized in that: The core processing module: Processor: Using quad-core ARM Cortex-A55 domestic processor; NPU: The domestically produced NPU integrates 1TOPS computing power, supports INT8 / FP16 quantization models, and can efficiently run TensorFlowLite and ONNX lightweight AI models.

3. The computer industrial controller and control system thereof according to claim 1, characterized in that: The storage module: Memory: Supports multiple memory types including 32-bit DDR4 / 3 / 3L / LPDDR4 / 4X / 3. DDR4 and DDR3 also support ECC (error checking and correction) function, which effectively improves the accuracy and stability of data storage and ensures the integrity of data during long-term system operation. Storage expansion: Equipped with eMMC 5.1 and SFC interfaces, supports TF card expansion storage.

4. The computer industrial controller and control system thereof according to claim 1, characterized in that: The communication module: Wired communication: It has dual 100M network ports, adopts domestic PHY chips and performs redundant design to ensure the reliability of network connection, and supports RS485 and RS232 serial port communications; Wireless communication: It integrates domestic 4G / 5G modules and supports Cat.4 / Cat.12 standards to achieve high-speed, low-latency wireless data transmission. Built-in MQTT protocol support enables the device to achieve highly reliable data upload to the cloud under low bandwidth conditions and synchronize device status to the cloud in real time. In addition, it is also equipped with a Wi-Fi module; Positioning module: Adopts domestic Beidou / GPS dual-mode chip, with high-precision positioning capability of ±1.5 meters.

5. The computer industrial controller and control system thereof according to claim 1, characterized in that: The power management module: It uses domestic PMIC chips, supports 24V isolated power input, and has anti-surge and electrostatic protection functions. On the one hand, it provides a stable and reliable power supply for the controller, ensuring that the equipment is not affected by power fluctuations in complex industrial environments; on the other hand, it effectively prevents damage to the equipment caused by static electricity and surges.

6. The computer industrial controller and control system thereof according to claim 1, characterized in that: The security module: It integrates a domestic encryption engine, supports SM4 / SM3 encryption algorithms, and combines secure boot mechanism and firewall functions to build a multi-level security protection system, ensuring the security of the system from device startup to data transmission.

7. The computer industrial controller and control system thereof according to claim 1, characterized in that: The input and output modules: Digital Input (DI): Provides eight 24V digital input channels, supports sink and source input, and can be connected to various sensors and switching devices to collect real-time status information on industrial sites, such as the start and stop status of equipment and sensor trigger signals; Digital Output (DO): Equipped with eight 24V PWM output channels, it can be used to control various actuators, such as motor speed regulation and valve opening control, to achieve precise control of industrial equipment. Both input and output adopt isolation protection design.

8. The computer industrial controller and control system thereof according to claim 1, characterized in that: The display module is equipped with an HDMI 2.0 interface and can be connected to a display.

9. The computer industrial controller and control system thereof according to claim 1, characterized in that: The AI application module: based on the powerful computing power of the NPU, integrates multiple AI application functions, and realizes abnormal detection of equipment status, image recognition, and predictive maintenance functions through pre-loaded or user-defined AI models.

10. The computer industrial controller and control system thereof according to claim 1, characterized in that: The data processing and management module is responsible for real-time processing, storage and management of the collected industrial data, and filtering and denoising preprocessing operations on the raw data collected by the sensor; The communication management module unifies the management of various communication interfaces of the controller, realizes the conversion and data interaction between different communication protocols, automatically selects the optimal communication method according to the device requirements and network conditions, ensures efficient and stable data transmission, and packages and unpacks data to ensure accurate data transmission between different devices and systems. Among them, the equipment management module is used to centrally manage various industrial equipment connected to the controller and monitor the operating status of the equipment in real time, including the equipment's online status, working parameters, and fault information.

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