Edge controller system

Abstract

The invention provides an edge controller system. The edge controller system comprises a redundant controller, a communication module and a redundant I / O module, the redundant I / O module is connected with the redundant controller; the communication module is connected with the redundant controller; the redundant controller comprises a master controller and a slave controller which are connected with each other; the master controller is used for receiving, processing and sending data based on the communication module and the redundant I / O module, and the slave controller is used for receiving and processing data based on the communication module and the redundant I / O module and sending data only when the master controller breaks down. The edge controller system can realize data acquisition, processing and operation on the edge side, can be connected with a cloud server, has a redundancy control function, and thus meets the requirements of actual application scenes.

Description

Technical Field

[0001] The present invention relates to the technical field of controllers, and in particular to an edge controller system. Background Art

[0002] With the continuous advancement of automation and control technology, traditional industrial control systems urgently need to be optimized and upgraded. However, traditional industrial control systems, such as PLCs and DCSs, can no longer simultaneously meet the requirements for system reliability, stability, strong interface capabilities, high computing power, and good real-time performance, let alone remote diagnosis and maintenance capabilities. Reliability, stability, and remote diagnosis and maintenance are particularly important for industrial control equipment in remote and uninhabited areas.

[0003] Therefore, how to build an effective industrial control system has become a hot research topic. Summary of the Invention

[0004] In view of the shortcomings of the prior art described above, the purpose of the present invention is to provide an edge controller system that can realize data collection, processing, and calculation on the edge side, and can be connected to the cloud server and has redundant control functions, thereby meeting the needs of actual application scenarios.

[0005] To achieve the above-mentioned objectives and other related objectives, the present invention provides an edge controller system, comprising a redundant controller, a communication module, and a redundant I / O module; the redundant I / O module is connected to the redundant controller; the communication module is connected to the redundant controller; the redundant controller includes a connected master controller and a slave controller; the master controller is used to receive, process, and send data based on the communication module and the redundant I / O module, and the slave controller is used to receive and process data based on the communication module and the redundant I / O module, and only sends data when the master controller fails.

[0006] In one embodiment of the present invention, the redundant I / O module includes a connected master I / O module and a slave I / O module, the master I / O module includes a master input module and a master output module, and the slave I / O module includes a slave input module and a slave output module;

[0007] The master input module and the slave input module collect upload data simultaneously, the master input module reports the upload data to the master controller and the slave controller simultaneously, and the slave input module reports the upload data to the master controller and the slave controller simultaneously only when the master input module fails;

[0008] The master output module and the slave output module simultaneously receive the sent data sent by the redundant controller, the master output module outputs the sent data, and the slave output module outputs the sent data only when the master output module fails.

[0009] In one embodiment of the present invention, the communication module includes one or more combinations of a wireless communication module, an Ethernet communication module, and a serial communication module.

[0010] In one embodiment of the present invention, the serial communication module includes one or a combination of an RS485 interface module and an RS232 interface module.

[0011] In one embodiment of the present invention, the wireless communication module includes one or a combination of a 4G module and a 5G module.

[0012] In one embodiment of the present invention, the Ethernet communication module includes one or a combination of an expandable Ethernet module and a redundant Ethernet module.

[0013] In one embodiment of the present invention, the main input module and the slave input module both include one or more combinations of a temperature acquisition module, a voltage acquisition module, a current acquisition module, a pressure acquisition module and a switch quantity acquisition module; the main output module and the slave output module both include one or more combinations of a current output module, a voltage output module and a switch quantity output module.

[0014] In one embodiment of the present invention, a cloud server is further included, which is connected to the redundant controller and is used to receive data provided by the redundant controller and send instructions to the redundant controller.

[0015] In one embodiment of the present invention, the cloud server and the redundant controller are connected based on a wireless communication module.

[0016] As described above, the edge controller system of the present invention has the following beneficial effects:

[0017] (1) It can realize data collection, processing, and calculation, and can be connected to the cloud server with redundant control function;

[0018] (2) It can meet the system's requirements for reliable and stable operation, strong interface capabilities, good real-time performance, and remote diagnosis and maintenance functions;

[0019] (3) It is particularly suitable for remote and uninhabited environments, effectively expanding the application scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Shown is a schematic structural diagram of an edge controller system according to an embodiment of the present invention;

[0021] Figure 2 Shown is a schematic diagram of the working principle of an edge controller system according to one embodiment of the present invention;

[0022] Figure 3 Shown is a schematic structural diagram of a serial communication module according to an embodiment of the present invention;

[0023] Figure 4 FIG. 1 is a schematic structural diagram of a master I / O module and a slave I / O module in one embodiment of the present invention. DETAILED DESCRIPTION

[0024] The following describes the implementation of the present invention through specific embodiments. People skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0025] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for understanding and reading by those familiar with this technology, and are not used to limit the conditions for implementation of the present invention. Therefore, they have no substantial technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size should still fall within the scope of the technical content disclosed by the present invention without affecting the efficacy and purpose that can be achieved by the present invention. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description and are not used to limit the scope of implementation of the present invention. Changes or adjustments in their relative relationships should also be regarded as the scope of implementation of the present invention without substantially changing the technical content.

[0026] The edge controller of the present invention is a programmable industrial controller based on PC and also has PLC functions. It integrates multiple field functions such as PC, PLC controller, gateway, I / O data acquisition module, field bus, machine vision, etc., and can realize data collection, processing, and calculation. It can also be connected to the cloud, thereby coordinating with the remote industrial cloud platform on the edge side to realize intelligent production line control, which is extremely practical.

[0027] like Figure 1 and Figure 2 As shown, the edge controller system of the present invention includes a redundant controller 1, a communication module 2 and a redundant I / O module 3.

[0028] The redundant I / O module 3 is connected to the redundant controller 1 and is used to implement data transmission and reception of the redundant controller 1. The redundant I / O module 3 can ensure the reliability and effectiveness of data transmission and reception through the redundant setting of the I / O module.

[0029] The communication module 2 is connected to the redundant controller 3 and is used to realize the communication between the redundant controller 1 and the external device. In this embodiment, the communication module includes one or more combinations of wireless communication modules, Ethernet communication modules, and serial communication modules, so that it can communicate with the external device through wireless communication, Ethernet communication, and serial communication. Figure 3 As shown, the serial communication module includes an RS485 interface module and an RS232 interface module. The wireless communication module includes a 4G module and a 5G module. The Ethernet communication module includes an expandable Ethernet module and a redundant Ethernet module.

[0030] The redundant controller 1 comprises a connected master controller 11 and a slave controller 12, which are used to implement a redundant controller setting to ensure the effectiveness and reliability of the control function. In one embodiment, the master controller and the slave controller are both based on PCs and have PLC functions.

[0031] The master controller 11 is configured to receive, process, and transmit data based on the communication module 2 and the redundant I / O module 3. The slave controller 12 is configured to receive and process data based on the communication module 2 and the redundant I / O module 3, and transmit data only when the master controller 11 fails. In other words, the master controller 11 and the slave controller 12 simultaneously receive data from the communication module 2 and the redundant I / O module 3. Each of the master controller 11 and the slave controller 12 performs operations on the received data, but only the master controller 11 reports and transmits data; the slave controller 12 does not. If the master controller 11 fails, the slave controller 12 immediately replaces the master controller and initiates data reporting and transmission. The switchover between the master controller 11 and the slave controller 12 is completed within a single data cycle. Therefore, the practice of each master controller 11 and the slave controller 12 receiving and processing data independently ensures data accuracy and real-time performance during master-slave switching.

[0032] In one embodiment, the redundant I / O module 3 includes a connected master I / O module 31 and a slave I / O module 32. The master I / O module 31 includes a master input module and a master output module, and the slave I / O module 32 includes a slave input module and a slave output module.

[0033] During actual use, the master input module and the slave input module simultaneously collect upload data, and the master input module reports the upload data to the master controller and the slave controller simultaneously, while the slave input module does not report the upload data; the slave input module only reports the upload data to the master controller and the slave controller simultaneously when the master input module fails. Therefore, the practice of the master input module and the slave input module each collecting upload data can ensure the accuracy and real-time performance of the data during master-slave switching. In addition, the master output module and the slave output module simultaneously receive the downlink data sent by the redundant controller, and the master output module outputs the downlink data, while the slave output module only outputs the downlink data when the master output module fails. Therefore, the practice of the master output module and the slave output module receiving data simultaneously can ensure the accuracy and real-time performance of the data during master-slave switching.

[0034] like Figure 4 As shown, in one embodiment, the master input module and the slave input module each include one or more combinations of a temperature acquisition module, a voltage acquisition module, a current acquisition module, a pressure acquisition module, and a switch value acquisition module; and the master output module and the slave output module each include one or more combinations of a current output module, a voltage output module, and a switch value output module. This configuration of input and output modules can meet the data input and output requirements of various application scenarios, effectively expanding the application scenarios.

[0035] To achieve remote maintenance and diagnostic functions, in one embodiment of the present invention, the edge controller system of the present invention further includes a cloud server connected to the redundant controller 1, configured to receive data provided by the redundant controller 1 and issue instructions to the redundant controller 1. The cloud server and the redundant controller 1 are connected via a wireless communication module.

[0036] Specifically, when a fault occurs, the cloud server sends instructions to the redundant controller via the wireless communication module. The redundant controller then outputs the instructions to each execution module via the redundant I / O module, and the execution module executes the corresponding instructions. At the same time, the redundant controller receives and processes data from each execution module via the redundant I / O module, and reports the processed data to the cloud server via the wireless communication module, thereby realizing edge-side collaboration with the remote industrial cloud platform to achieve intelligent production line control.

[0037] In summary, the edge controller system of the present invention enables data acquisition, processing, and computation, can connect to cloud servers, and possesses redundant control capabilities. It meets the system's requirements for reliable and stable operation, strong interface capabilities, and excellent real-time performance, while also providing remote diagnosis and maintenance capabilities. It is particularly suitable for remote and uninhabited environments, effectively expanding its application scenarios. Therefore, the present invention effectively overcomes the various shortcomings of existing technologies and possesses high industrial value.

[0038] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. An edge controller system, characterized in that: Including redundant controllers, communication modules and redundant I / O modules; The redundant I / O module is connected to the redundant controller; The communication module is connected to the redundant controller; The redundant controller includes a connected master controller and a slave controller; the master controller is used to receive, process and send data based on the communication module and the redundant I / O module, and the slave controller is used to receive and process data based on the communication module and the redundant I / O module, and sends data only when the master controller fails.

2. The edge controller system according to claim 1, wherein: The redundant I / O module includes a connected master I / O module and a slave I / O module, the master I / O module includes a master input module and a master output module, and the slave I / O module includes a slave input module and a slave output module; The master input module and the slave input module collect upload data simultaneously, the master input module reports the upload data to the master controller and the slave controller simultaneously, and the slave input module reports the upload data to the master controller and the slave controller simultaneously only when the master input module fails; The master output module and the slave output module simultaneously receive the sent data sent by the redundant controller, the master output module outputs the sent data, and the slave output module outputs the sent data only when the master output module fails.

3. The edge controller system according to claim 1, wherein: The communication module includes one or more combinations of a wireless communication module, an Ethernet communication module, and a serial communication module.

4. The edge controller system according to claim 3, wherein: The serial communication module includes one or a combination of an RS485 interface module and an RS232 interface module.

5. The edge controller system according to claim 3, wherein: The wireless communication module includes one or a combination of a 4G module and a 5G module.

6. The edge controller system according to claim 3, wherein: The Ethernet communication module includes one or a combination of an expandable Ethernet module and a redundant Ethernet module.

7. The edge controller system according to claim 1, wherein: The main input module and the slave input module both include one or more combinations of a temperature acquisition module, a voltage acquisition module, a current acquisition module, a pressure acquisition module and a switch quantity acquisition module; the main output module and the slave output module both include one or more combinations of a current output module, a voltage output module and a switch quantity output module.

8. The edge controller system according to claim 1, wherein: It also includes a cloud server connected to the redundant controller, which is used to receive data provided by the redundant controller and send instructions to the redundant controller.

9. The edge controller system according to claim 8, wherein: The cloud server and the redundant controller are connected based on a wireless communication module.

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