Hardware-in-loop testing device

Abstract

The invention provides a hardware-in-the-loop test device. The hardware-in-the-loop test device comprises a simulation model verification system used for obtaining real-time data of input and output of an IO terminal of a DCS system in various operation states; the real-time data is transmitted to the fault state detection system; the fault state detection system is used for converting real-time data into a control signal and transmitting the control signal to the simulation data signal IO system; the simulation data signal IO system is used for converting the control signal into an electric signal; the electric signal is transmitted to a fault signal injection system; and the fault signal injection system is used for superposing the fault signal on the electric signal to obtain various types of faults, and transmitting the electric signal superposed with the fault signal to the DCS. According to the invention, the hardware-in-the-loop test device simulates each external signal fault of the DCS system, and injects the fault signal into the DCS system, thereby verifying and improving the robustness of the DCS system and a simulation model, and meeting the reliability test of the DCS system under an extreme working condition.

Description

Technical Field

[0001] The present disclosure relates to the technical field of hardware-in-the-loop detection, and in particular to a hardware-in-the-loop testing device. Background Art

[0002] As the core control platform for process industries, the reliability of distributed control systems (DCSs) directly impacts production safety and efficiency. With the advancement of Industry 4.0 and intelligent manufacturing, modern DCSs must handle more complex control algorithms, even those incorporating multimodal intelligent algorithms. These systems also require larger I / O points and higher real-time performance. Traditional software-only simulations are no longer sufficient for DCS system reliability testing under extreme operating conditions, such as simulating I / O point failures caused by environmental factors like vibration, high temperatures, and electromagnetic interference. Summary of the Invention

[0003] The technical problem to be solved by the present disclosure is to provide a hardware-in-the-loop testing device to overcome the defect that the traditional pure software simulation in the prior art cannot meet the reliability test of the DCS system under extreme working conditions.

[0004] The present disclosure solves the above technical problems through the following technical solutions:

[0005] The present disclosure provides a hardware-in-the-loop testing device, comprising a simulation model verification system, a fault state detection system, a simulation data signal IO system, a fault signal injection system, and a DCS system;

[0006] The simulation model verification system is used to obtain real-time input and output data of the IO terminals of the DCS system under various operating conditions; and transmit the real-time input and output data of the IO terminals to the fault state detection system;

[0007] The fault state detection system is used to convert the real-time data input and output of the IO terminal into a control signal, and transmit the control signal to the simulation data signal IO system;

[0008] The simulated data signal IO system is used to convert the control signal into the electrical signal involved on the IO terminal; and transmit the electrical signal to the fault signal injection system;

[0009] The fault signal injection system is used to generate a fault signal, superimpose the fault signal on the electrical signal of each channel of the simulation data signal IO system to obtain various types of faults, and transmit the electrical signal after superimposing the fault signal to the DCS system.

[0010] Preferably, the DCS system is used to operate the electrical signal superimposed with the fault signal to monitor the operating status of the DCS system.

[0011] Preferably, it further includes a DCS system; the simulation data signal IO system is further used to obtain electrical signals from the DCS system, convert the electrical signals into data, and feed the data back to the simulation model verification system.

[0012] Preferably, it also includes a wiring operating system;

[0013] The wiring operating system is used to connect the signal outgoing lines of the simulation data signal IO system, the signal outgoing lines of the DCS system and the switching matrix of the fault signal injection system.

[0014] Preferably, the fault status detection system includes an engineer station and an operator station;

[0015] The engineer station is used to obtain IO variable information from the DCS system, calculate the mapping relationship between engineering quantities and analog quantities, obtain the simulation variable name corresponding to the IO variable information from the simulation model verification system, and obtain the card number and port number of the IO variable information in the simulation data signal IO system to generate a configuration file, and transmit the configuration file to the operator station;

[0016] The operator station is used to read the configuration file and display IO variable information.

[0017] Preferably, the operator station is also used to select the fault point and fault type, control the fault status detection system and the simulation data signal IO system to input and output normal signals and fault signals, and feed back the fault signal to the simulation model verification system.

[0018] Preferably, it also includes a monitoring and control system;

[0019] The monitoring and control system is used to control the switching between the simulation data signal IO system and the fault signal injection system.

[0020] Preferably, the fault signal injection system is further used to load the fault signal into a channel and verify the function of injecting the fault into the DCS system.

[0021] Preferably, the electrical signal includes at least one of an on-off signal, a current signal, a voltage signal, and a resistance signal.

[0022] Preferably, the various types of faults include at least one of open circuit, short circuit, bridge connection, adjacent channel bridge connection, burr, short circuit to ground, short circuit to power supply, adjustable value exceeding the range, signal noise, and impedance.

[0023] On the basis of conforming to the common sense in this field, the above-mentioned preferred conditions can be arbitrarily combined to obtain the preferred embodiments of the present disclosure.

[0024] The positive progress of this disclosure is:

[0025] The present disclosure can integrate a hardware-in-the-loop test device through a simulation model verification system, a simulation data signal IO system, a fault state detection system, and a fault signal injection system when a real DCS system is fully powered on and running. The device can simulate various external signal faults of the DCS system and inject the fault signals into the DCS system, thereby verifying and improving the robustness of the DCS system and the simulation model, and meeting the reliability test of the DCS system under extreme working conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a structural diagram of the hardware-in-the-loop testing device provided in Example 1 of the present disclosure.

[0027] Figure 2 This is a test flow chart of the hardware-in-the-loop test device provided in Example 1 of the present disclosure. DETAILED DESCRIPTION

[0028] The present disclosure is further illustrated below by way of examples, but the present disclosure is not limited to the scope of the examples.

[0029] In the embodiments of the present disclosure, prefixes such as "first" and "second" are used only to distinguish different description objects, and have no limiting effect on the position, order, priority, quantity or content of the described objects. In the embodiments of the present disclosure, the use of prefixes such as ordinal numbers to distinguish description objects does not constitute a limitation on the described objects. For the statement of the described objects, please refer to the description in the context of the claims or embodiments, and no unnecessary limitations should be constituted due to the use of such prefixes. In addition, in the description of this embodiment, unless otherwise specified, the meaning of "plurality" is two or more.

[0030] In the embodiments of the present disclosure, the collection, storage, use, processing, transmission, provision and disclosure of user personal information involved comply with the provisions of relevant laws and regulations and do not violate public order and good morals.

[0031] Example 1

[0032] Figure 1 This is a structural diagram of a hardware-in-the-loop test device provided in Example 1 of the present disclosure, such as Figure 1 As shown, it includes a fault injection service station U1, a simulation data signal IO system U2, a fault signal injection system U3, a wiring operation system U4 and a DCS system (not shown in the figure); the fault injection service station U1 includes a simulation model verification system and a fault state detection system;

[0033] The simulation model verification system is used to obtain the real-time input and output data of the IO terminals of the DCS system under various operating conditions; and transmit the real-time input and output data of the IO terminals to the fault status detection system;

[0034] In this embodiment, the simulation model verification system is responsible for digital simulation of power generation processes in industrial fields such as various power plants, including real-time data models of power plant processes under normal power operation conditions and start-up and shutdown process conditions.

[0035] The simulation model verification system is in the DCS hardware-in-the-loop test device and is responsible for real-time calculation of the input and output real-time data of the IO terminals of the DCS system under various actual operating states.

[0036] A fault status detection system is used to convert the real-time data of the input and output of the IO terminal into a control signal and transmit the control signal to the simulation data signal IO system;

[0037] In this embodiment, the fault status detection system includes an operator station and an engineer station; the fault status detection system provides a set of monitoring system software human-machine interface. The test engineer configures it according to the actual wiring between the simulated data signal IO system and the DCS system, and at the same time selects the fault point type and whether to inject faults to control the overall process of hardware-in-the-loop testing.

[0038] The simulated data signal IO system is used to convert the control signal into the electrical signal involved on the IO terminal; and transmit the electrical signal to the fault signal injection system;

[0039] In this embodiment, the simulation data signal IO system is responsible for converting the real-time numerical values ​​in the simulation model verification system into the electrical signals involved in the IO terminals of the DCS system. The electrical signals include at least one of an on / off signal, a current signal, a voltage signal, and a resistance signal. It is also responsible for converting the on / off signal, current signal, voltage signal, and resistance signal into digitized signals and feeding them back to the simulation model verification system. The simulation data signal IO system is also used to obtain electrical signals including on / off signals, current signals, voltage signals, and resistance signals from the DCS system, convert the electrical signals into real-time data, and feed the real-time data back to the simulation model verification system.

[0040] Specifically, the simulated data signal IO system is used to generate normal electrical signals of various devices and send them to the DCS system under test or receive electrical signals generated by the devices, and superimpose fault signals on the electrical signals.

[0041] The simulated data signal IO system of this embodiment has high real-time performance and completely simulates the signal acquisition and control output of external sensors of the DCS system in real application scenarios.

[0042] The fault signal injection system is used to generate fault signals, superimpose the fault signals on the electrical signals of each channel of the simulated data signal IO system to obtain various types of faults, and transmit the electrical signals with the superimposed fault signals to the DCS system.

[0043] In this embodiment, the fault signal injection system consists of a fault signal source and a fault channel switching card. The fault signal source generates various types of faults by superimposing various interference signals or blocking signals on the electrical signals of each channel of the normal simulation data signal IO system. The fault channel switching card controls the state of fault source injection and disconnection. Fault types include but are not limited to: open circuit, short circuit, bridging, bridging of adjacent channels; burrs (as a separate fault source); short circuit to ground, short circuit to power supply; adjustable value beyond the range; signal noise (triangle wave, sine wave, square wave, etc.); impedance; three types of impedance: medium, high and low.

[0044] Specifically, the fault signal injection system is used to generate a fault signal and load it into the channel. After completion, it is integrated with the DCS system platform under test to verify the fault injection function.

[0045] This embodiment integrates a hardware-in-the-loop testing system with a fully powered-on DCS system. This system simulates external signal faults in the DCS system and injects these fault signals into the DCS system, verifying and improving the robustness of the DCS system and simulation model, meeting the requirements for DCS reliability testing under extreme operating conditions. Furthermore, this embodiment simulates various electrical faults in the input and output of DCS system sensors in an actual operating DCS system, flexibly injecting these faults into the DCS system under test to detect and determine the operational stability of the DCS system and process simulation model under fault conditions.

[0046] In an optional embodiment, the DCS system is used to operate the electrical signal after the fault signal is superimposed to monitor the operating status of the DCS system.

[0047] In this embodiment, the test is performed when the entire hardware of the DCS system is powered on. The logic control and operation control in the DCS system are consistent with the actual industrial control process, and the operating status of the DCS system is monitored in a real and effective state.

[0048] This embodiment uses digital process models (physical changes, chemical reactions) in the industrial control field to support testing of various industrial control operating states of the DCS system. That is, the real-time values ​​of each external port of the DCS system vary widely, allowing full-scale testing and covering the testing of the actual dynamic changes in the operation of the DCS system.

[0049] Furthermore, hardware-in-the-loop (HIL) testing originated in the aerospace field. In the DCS field, the core breakthroughs of HIL testing lie in: real-time assurance: adopting a deterministic communication cycle of <1ms; high-precision modeling: based on physics-based sensor / actuator models; fault injection capability: supporting the simulation of fault modes such as short circuits and signal drift.

[0050] Compared with the aerospace and automotive fields, the DCS system in the industrial field has more than 5,000 data points for industrial process control and requires synchronous simulation of I / O points. Therefore, when designing the hardware-in-the-loop test of the DCS system, a high-real-time simulation data signal IO system is mainly used to provide various fault selection functions, flexibly inject control faults into the DCS system, realize continuous operation testing, and verify the stability and reliability of the DCS system when electrical signal failures occur in extreme environments.

[0051] In an optional embodiment, a DCS system is further included; a simulation data signal IO system is also used to obtain electrical signals from the DCS system, convert the electrical signals into data, and feed the data back to the simulation model verification system.

[0052] This embodiment provides a research basis for effective measures to improve the robustness of the DCS system by monitoring changes in system stability and abnormal responses when the DCS system under test is disturbed during the electrical signal acquisition or transmission process. At the same time, by monitoring the state changes of the process model when receiving abnormal input from the DCS system, a research basis is provided for effective software improvements to improve the fault tolerance of the process model.

[0053] In an optional embodiment, it further includes a wiring operating system;

[0054] Wiring operating system, used to connect the signal outgoing lines of the simulation data signal IO system, the signal outgoing lines of the DCS system and the switching matrix of the fault signal injection system.

[0055] In this embodiment, the wiring operation system (i.e., the wiring terminal block) is used to connect the signal output lines of the simulation data signal IO system, the signal output lines of the DCS system, and the switching matrix of the fault signal injection system to complete the connection of the test link.

[0056] In an optional embodiment, the fault status detection system includes an engineer station and an operator station;

[0057] The engineer station is used to obtain IO variable information from the DCS system, calculate the mapping relationship between engineering quantities and analog quantities, obtain the simulation variable names corresponding to the IO variable information from the simulation model verification system, and obtain the card number and port number of the IO variable information in the simulation data signal IO system to generate a configuration file and transmit the configuration file to the operator station;

[0058] Operator station, used to read configuration files and display IO variable information.

[0059] In this embodiment, Figure 2 This is a test flow chart of the hardware-in-the-loop test device, such as Figure 2 As shown in the figure, the software of the fault injection DCS hardware-in-the-loop test device is installed on the fault injection service station U1. In addition to the process simulation model, it is divided into two software systems: the engineer station and the operator station:

[0060] 1) The engineer station is used to generate configuration files: Specifically, it obtains IO variable information from the DCS system, calculates the mapping relationship between engineering quantities and analog quantities, obtains the simulation variable names corresponding to the IO variable information from the simulation model verification system, and through the interactive interface, the operator can fill in the card number and port number (corresponding to the hardware wiring) of the IO variable information in the simulation data signal IO system to generate the configuration file.

[0061] 2) The operator station reads the configuration file and displays the IO variable information on the interface. The operator can select the fault point and fault type on the interface, control the fault signal injection into the FIU system and the simulation data signal IO system to input and output normal signals and fault signals, and feed back the fault output to the simulation model verification system for verification of the simulation model verification system.

[0062] In an optional embodiment, the operator station is also used to select the fault point and fault type, control the fault status detection system and the simulation data signal IO system to input and output normal signals and fault signals, and feed back the fault signal to the simulation model verification system.

[0063] In this embodiment, the fault location and fault type can be freely selected according to the test requirements. When the fault injection sources are relatively limited, the wiring between the DCS system and the device can be flexibly configured. Selecting the fault location through software to inject faults into the DCS system is a very effective solution.

[0064] In an optional embodiment, it further includes a monitoring control system;

[0065] The monitoring and control system is used to control the switching between the simulation data signal IO system and the fault signal injection system.

[0066] In this embodiment, a monitoring and control system is installed to control the switching between the simulation data signal IO system and the fault signal injection system; and the industrial control process digital model software required by the DCS system bottom layer is installed.

[0067] In an optional embodiment, the electrical signal includes at least one of an on-off signal, a current signal, a voltage signal, and a resistance signal.

[0068] In an optional embodiment, each type of fault includes at least one of open circuit, short circuit, bridge, adjacent channel bridge, glitch, short to ground, short to power supply, adjustable value out of range, signal noise, and impedance.

[0069] The fault injection DCS hardware-in-the-loop testing device of this embodiment integrates a simulation model verification system, a simulation data signal I / O system, a fault signal injection system, and the DCS system under test into a loop testing device. By providing software interface control, it monitors the entire DCS hardware-in-the-loop testing process. In addition to the DCS system under test, the simulation model verification system, the simulation data signal I / O system, and the fault injection system are modularly designed as a single device. Specifically, the fault injection DCS hardware-in-the-loop testing device can realistically simulate interference with the DCS system's electrical signals, transmitting them into the process simulation model to verify the stability of the process simulation model and improve the fault tolerance and authenticity of the simulation model verification system. It also provides offline configuration software and online monitoring and operation software, enabling flexible injection of desired faults at large points in the DCS system. Furthermore, it provides a process simulation model that is 1:1 customized to the industrial control process. Without requiring actual sensor connection to the DCS system, it can provide real-time sensor data under the industrial control, communicate in real time, participate in the DCS system's logical control operations, and verify the DCS system's logical operation functions. In addition, the simulation model verification system can simulate various industrial control systems of the DCS system, providing a full-range hardware-in-the-loop test environment.

[0070] While specific embodiments of the present disclosure have been described above, those skilled in the art will appreciate that these are merely illustrative and that the scope of protection of the present disclosure is defined by the appended claims. Those skilled in the art may make various changes or modifications to these embodiments without departing from the principles and essence of the present disclosure, and such changes and modifications are intended to fall within the scope of protection of the present disclosure.

Claims

1. A hardware-in-the-loop testing device, characterized in that: Including simulation model verification system, fault status detection system, simulation data signal IO system, fault signal injection system and DCS system; The simulation model verification system is used to obtain real-time input and output data of the IO terminals of the DCS system under various operating conditions; and transmitting the real-time input and output data of the IO terminal to the fault status detection system; The fault state detection system is used to convert the real-time data input and output of the IO terminal into a control signal, and transmit the control signal to the simulation data signal IO system; The simulated data signal IO system is used to convert the control signal into the electrical signal involved on the IO terminal; and transmit the electrical signal to the fault signal injection system; The fault signal injection system is used to generate a fault signal, superimpose the fault signal on the electrical signal of each channel of the simulation data signal IO system to obtain various types of faults, and transmit the electrical signal after superimposing the fault signal to the DCS system.

2. The hardware-in-the-loop testing device according to claim 1, wherein: The DCS system is used to operate the electrical signal superimposed with the fault signal to monitor the operating status of the DCS system.

3. The hardware-in-the-loop testing device according to claim 1, wherein: It also includes a DCS system; the simulation data signal IO system is also used to obtain electrical signals from the DCS system, convert the electrical signals into data, and feed the data back to the simulation model verification system.

4. The hardware-in-the-loop testing device according to claim 1, wherein: Also included is a wiring operating system; The wiring operating system is used to connect the signal outgoing lines of the simulation data signal IO system, the signal outgoing lines of the DCS system and the switching matrix of the fault signal injection system.

5. The hardware-in-the-loop testing device according to claim 1, wherein: The fault status detection system includes an engineer station and an operator station; The engineer station is used to obtain IO variable information from the DCS system, calculate the mapping relationship between engineering quantities and analog quantities, obtain the simulation variable name corresponding to the IO variable information from the simulation model verification system, and obtain the card number and port number of the IO variable information in the simulation data signal IO system to generate a configuration file, and transmit the configuration file to the operator station; The operator station is used to read the configuration file and display IO variable information.

6. The hardware-in-the-loop testing device according to claim 5, wherein: The operator station is also used to select the fault point and fault type, control the fault status detection system and the simulation data signal IO system to input and output normal signals and fault signals, and feed back the fault signal to the simulation model verification system.

7. The hardware-in-the-loop testing device according to claim 1, wherein: It also includes monitoring and control systems; The monitoring and control system is used to control the switching between the simulation data signal IO system and the fault signal injection system.

8. The hardware-in-the-loop testing device according to claim 1, wherein: The fault signal injection system is further used to load the fault signal into the channel and verify the function of injecting the fault into the DCS system.

9. The hardware-in-the-loop testing device according to claim 1, wherein: The electrical signal includes at least one of an on-off signal, a current signal, a voltage signal, and a resistance signal.

10. The hardware-in-the-loop testing device according to claim 1, wherein: The various types of faults include at least one of open circuit, short circuit, bridge connection, adjacent channel bridge connection, burr, short circuit to ground, short circuit to power supply, adjustable value exceeding the range, signal noise, and impedance.

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