A programmable logic control system

Abstract

The application relates to the technical field of editable logic control, and relates to a programmable logic control system, which comprises a control module, a response module and a plurality of input-output components connected in sequence. The current input-output component is configured to collect monitoring data, acquire data required for updating the current input-output component according to the interaction information, update self data, write the self data and / or the monitoring data of the current input-output component into the interaction information, send the changed interaction information to the next input-output component, and finally send the changed interaction information to the control module. The control module receives the changed interaction information, judges whether the input-output component in the response module is replaced according to the changed interaction information, generates and sends the interaction information to the response module again if the input-output component is replaced, and updates the data in the response module again. The application solves the problem of poor flexibility of module replacement or recombination.

Description

Technical Field

[0001] This application relates to the field of programmable logic control technology, and in particular to a programmable logic control system. Background Technology

[0002] With the widespread application of Programmable Logic Controllers (PLCs) in various fields such as motion control, manufacturing, and new energy, the input / output (IO) modules in PLC systems need to be further expanded and have multiple functions to meet the technical requirements of these fields.

[0003] Currently, in PLC systems, the controller and I / O modules are commonly connected via a bus. During the information exchange between the controller and I / O modules via the bus, multiple I / O modules are connected to the bus.

[0004] When in use, if any IO module fails or is replaced, the communication of the entire line will be interrupted, which will seriously affect data communication. The flexibility of module replacement and reconfiguration is poor. Summary of the Invention

[0005] This application provides a programmable logic control system to at least solve the problem of poor flexibility in module replacement and reconfiguration in related technologies.

[0006] In a first aspect, embodiments of this application provide a programmable logic control system, including: The control module is configured to generate and send interactive information; The response module includes multiple input / output components connected sequentially. The input / output components closest to the control module are connected to the control module, and any one of the input / output components is connected to an external device to be acquired. In the direction of transmitting interactive information from the control module to the response module, any one of the input / output components is set as the current input / output component, the input / output component adjacent to and close to the control module is the previous input / output component, and the input / output component adjacent to and far from the control module is the next input / output component. The current input / output component is configured to: acquire monitoring data from the external device to be acquired; receive the interactive information sent by the control module or the previous input / output component, generate response information, and send the response information to the previous input / output component; obtain the data required for updating the current input / output component based on the interactive information, update its own data, and write its own data and / or monitoring data into the interactive information; determine whether it has received the response information sent by the previous input / output component; if yes, send the modified interactive information to the next input / output component; if no, send the modified interactive information to the control module. After receiving the modified interaction information, the control module determines whether the input / output component in the response module has been replaced based on the modified interaction information. If so, it generates and sends the interaction information to the response module again and updates the data in the response module again.

[0007] In some embodiments, the interaction information includes addressing information, which includes addressing function codes and module counters, and the data required for updating the current input / output component includes address offsets; The current input / output component is further configured to: after receiving the addressing information, calculate the address offset of the current input / output component based on the addressing information, and update its own offset address; According to the addressing function code, the component type of the current input / output component is written into the addressing information, and the number of module counters in the addressing information is incremented by one. After changing the addressing information, it is sent.

[0008] In some embodiments, the interaction information includes a function code, and in the event that any of the input / output components fails and is replaced, the offset address of the replaced input / output component and the offset address of the subsequent input / output components are both in an abnormal state. The current input / output component is further configured to: when the offset address is in an abnormal state, change the function code in the interaction information to a fault function code, and send the changed interaction information to the control module; The control module is further configured to: after receiving the interaction information with the fault function code, regenerate and send the interaction information, and reconfigure the offset address in the input / output component.

[0009] In some embodiments, the interaction information includes configuration information, which includes multiple first data areas, and the parameter information set in each first data area is the data required for updating the current input / output component; The current input / output component is further configured to: after receiving the configuration information, determine its corresponding first data area among multiple first data areas according to the offset address of the current input / output component, and read the parameter information therein; Based on the read parameter information, configure the parameters of the current input / output component for controlling the acquisition and monitoring of data and for maintaining safety; Write the current operating status information of the input / output component into its corresponding first data area; After changing the configuration information, send it out.

[0010] In some embodiments, the interaction information includes instruction information, which includes a plurality of second data areas; The current input / output component is further configured to: collect monitoring data from the external device to be collected according to the instruction information; Based on the offset address of the current input / output component, determine the second data area corresponding to itself among multiple second data areas, and write the monitoring data into the second data area corresponding to itself; After modifying the instruction information, issue it.

[0011] In some embodiments, when the control module receives the modified interaction information, the control module is further configured to: determine whether the received interaction information is correct; if not, regenerate and send the interaction information again, and perform data interaction with the connected response module again.

[0012] In some embodiments, during the process of sending the modified interaction information to the control module when the current input / output component does not receive the response information, each input / output component located between the current input / output component and the control module is further configured to: receive the modified interaction information sent by the next input / output component and send it to the previous input / output component or the control module.

[0013] In some embodiments, two communication interfaces are provided on both sides of any input / output component. When any input / output component is connected to an adjacent input / output component, the two corresponding communication interfaces are connected to form two paths, and the two paths independently transmit the interactive information.

[0014] In some embodiments, the priority of information transmitted by the communication interface of the previous input / output component is higher than the priority of information transmitted by the communication interface of the next input / output component. The two adjacent and connected communication interfaces are further configured to: monitor the communication status of the path formed by the two communication interfaces; if the communication status of the path is idle, the communication interfaces transmit the interactive information in descending order of priority.

[0015] In some embodiments, the input / output components further include a power supply, and hot-plug protection components are provided on the power supply and the communication interface, respectively.

[0016] Compared to related technologies, the programmable logic control system provided in this application provides a timely determination of whether the response module has been replaced through information interaction between the response module and the control module, and reconfigures the address and parameters of the response module accordingly. This solves the problems of poor module replacement and module flexibility in the prior art, and can flexibly configure the number of input and output components according to actual needs to ensure smooth communication of the overall system.

[0017] Details of one or more embodiments of this application are set forth in the following drawings and description to make other features, objects and advantages of this application more readily apparent. Attached Figure Description

[0018] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a structural block diagram of a programmable logic control system according to an embodiment of this application; Figure 2 This is a structural block diagram of a programmable logic control system according to an embodiment of this application; Figure 3 This is a structural block diagram of a programmable logic control system according to an embodiment of this application; Figure 4 This is a flowchart illustrating the operation of a programmable logic control system according to an embodiment of this application; Figure 5 This is a schematic diagram of addressing information in a programmable logic control system according to an embodiment of this application; Figure 6 This is a schematic diagram of another addressing information in a programmable logic control system according to an embodiment of this application; Figure 7 This is a schematic diagram of configuration information in a programmable logic control system according to an embodiment of this application; Figure 8 This is a schematic diagram of instruction information in a programmable logic control system according to an embodiment of this application; Figure 9 This is a flowchart illustrating the operation of a programmable logic control system according to an embodiment of this application.

[0019] In the picture: 101. Control module; 102. Response module; 1021. Input / output component; 201. Main controller; 202. Coupler; 1011. First communication port; 1012. Second communication port; 301. First interface; 302. Second interface; 203. Third interface; 204. Fourth interface. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this application clearer, the application is described and illustrated below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application. All other embodiments obtained by those skilled in the art based on the embodiments provided in this application without inventive effort are within the scope of protection of this application.

[0021] Obviously, the accompanying drawings described below are merely some examples or embodiments of this application. Those skilled in the art can apply this application to other similar scenarios based on these drawings without any creative effort. Furthermore, it is understood that although the efforts made in this development process may be complex and lengthy, for those skilled in the art related to the content disclosed in this application, any changes to design, manufacturing, or production based on the technical content disclosed in this application are merely conventional technical means and should not be construed as insufficient disclosure of this application.

[0022] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment that is mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application may be combined with other embodiments without conflict.

[0023] Unless otherwise defined, the technical or scientific terms used in this application shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms “a,” “an,” “an,” “the,” and similar words used in this application do not indicate quantity limitation and may indicate singular or plural. The terms “comprising,” “including,” “having,” and any variations thereof used in this application are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or device that includes a series of steps or modules (units) is not limited to the listed steps or units, but may also include steps or units not listed, or may include other steps or units inherent to these processes, methods, products, or devices. The terms “connected,” “linked,” “coupled,” and similar words used in this application are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. “Multiple” used in this application refers to two or more. “And / or” describes the relationship between related objects, indicating that three relationships may exist; for example, “A and / or B” can represent: A alone, A and B simultaneously, and B alone. The character " / " generally indicates that the preceding and following objects are in an "or" relationship. The terms "first," "second," and "third" used in this application are merely to distinguish similar objects and do not represent a specific ordering of the objects.

[0024] Programmable Logic Controller (PLC) systems are widely used in industrial automation fields such as motion control, manufacturing, and new energy. A PLC system mainly consists of a main controller, couplers, and input / output (I / O) modules. The main controller implements the required logic control, while the couplers convert the communication interface between the main controller and the I / O modules to connect remotely expanded I / O modules. I / O modules have analog input / output and digital input / output functions.

[0025] With the continuous development of PLC systems, the demand for miniaturization and modularization is increasing. To meet this demand, extended I / O modules with multiple functions have been designed. In existing technologies, the communication schemes for extended I / O modules can use serial ports, Serial Peripheral Interface (SPI), Controller Area Network (CAN), or Modbus industrial communication protocols, etc., and these communication rates generally do not exceed 5Mbps.

[0026] In addition, Ethernet based on the EtherCAT (Ethernet for Control Automation Technology) protocol can be used for communication. Although it has a high communication speed and is easily scalable, it requires the expansion IO module to be used as an EtherCAT slave, which increases the cost of the IO module.

[0027] The communication scheme that combines off-the-shelf Field-Programmable Gate Array (FPGA) with Low-Voltage Differential Signaling (LVDS) is currently also used for communication between PLC and IO modules. However, it does not support hot-swapping. If a module needs to be replaced after the equipment is put into operation, it is often necessary to shut down the equipment and power it off. The shutdown of large equipment will inevitably result in losses.

[0028] To address the aforementioned problems, this invention provides a programmable logic control system that ensures smooth system communication and enables flexible configuration of I / O modules. Furthermore, it allows for the expansion of both remote and local I / O modules, and provides unified management of these expanded I / O modules.

[0029] like Figure 1 , Figure 2 As shown, this embodiment provides a programmable logic control system, including a control module 101 and a response module 102.

[0030] The control module 101 is configured to generate and send interactive information.

[0031] The control module 101 includes a main controller 201 and a coupler 202.

[0032] Furthermore, multiple couplers 202 are connected sequentially. The coupler 202 closest to the main controller 201 is connected to the main controller 201. Data interaction can occur between couplers 202 and between couplers 202 and the main controller 201. It should be understood that, through the above structure, a series path is formed between the main controller 201 and the couplers 202. The first coupler 202 directly connected to the main controller 201 is capable of bidirectional data interaction, and adjacent couplers 202 can interact with each other. Therefore, other couplers 202 connected in series behind the first coupler 202 can interact with the main controller 201 through the series path.

[0033] The main controller 201 employs a multiprocessor system-on-a-chip (MPSoC), comprising a programmable logic side and a processor side. The processor side is used for developing PLC programs and running the EtherCat main protocol stack, while the programmable logic side is used to implement communication with the response module 102 and to place the data returned by the response module 102 into a buffer. Data in this buffer can be transferred between the programmable logic side and the processor side via the high-speed bus inside the multiprocessor system-on-a-chip.

[0034] Coupler 202 adopts a design combining a communication chip and an FPGA. The communication chip runs the EtherCAT slave protocol and communicates with the master controller 201, while the FPGA is used to communicate with the response module 102.

[0035] The response module 102 includes multiple input / output components 1021 connected in sequence. Input / output components 1021 closer to the control module 101 are connected to the control module 101, and any input / output component 1021 is connected to an external device to be acquired. It should be understood that the control module 101 and the multiple input / output components 1021 form a series communication link. The control module 101 and the input / output components 1021 directly connected to it can communicate bidirectionally, and adjacent input / output components 1021 can communicate bidirectionally. The communication link originates from the control module 101.

[0036] The input / output component 1021 can be configured as an I / O board. The I / O board uses a Complex Programmable Logic Device (CPLD) as the main control chip to realize functions such as analog input / output and digital input / output.

[0037] The CPLD itself has LVDS pins, which connect the pins of two adjacent I / O boards to serve as the physical layer interface for communication between I / O boards. Multiple I / O boards are connected sequentially to form a response module 102.

[0038] The response module 102 comprises multiple groups. One main controller 201 can be connected to one response module 102. One coupler 202 can be connected to one response module 102. Depending on expansion requirements, the response module 102 connected to the main controller 201 can be expanded into a local I / O expansion module, and the response module 102 connected to the coupler 202 can be expanded into a remote I / O expansion module.

[0039] The number of input / output components 1021 in a response module 102 can be set according to actual needs.

[0040] The system supports the flexible addition, removal, or replacement of input / output components 1021, and can automatically identify and reconfigure them, improving the system's scalability and ease of maintenance.

[0041] In the direction of transmitting interactive information from the control module to the response module, any input / output component is set as the current input / output component, the input / output component adjacent to the current input / output component and closer to the control module is the previous input / output component, and the input / output component adjacent to the current input / output component and farther away from the control module is the next input / output component.

[0042] The current input / output component 1021 is configured to collect monitoring data from an external device. It receives interaction information from the control module 101 or the previous input / output component 1021, generates response information, and sends the response information to the previous input / output component 1021. Based on the interaction information, it obtains the data required for updating the current input / output component 1021, updates its own data, and writes its own data and / or monitoring data into the interaction information. It determines whether it has received a response information from the previous input / output component 1021; if so, it sends the modified interaction information to the next input / output component 1021. If not, it sends the modified interaction information to the control module 101.

[0043] After receiving the modified interaction information, the control module 101 determines whether the input / output component 1021 in the response module 102 has been replaced based on the modified interaction information. If so, it generates and sends the interaction information to the response module 102 again and updates the data in the response module 102 again.

[0044] The control module 101 generates and sends interactive information. The main controller 201 generates this interactive information and transmits it to the coupler 202, which then transmits it to the connected response module 102. The first input / output component 1021 receives and processes this information, and subsequent components process the interactive information sequentially through a series connection. This achieves automated information interaction between the control module 101 and the multi-node input / output components 1021, enabling data acquisition, transmission, and updating without manual intervention. Through response judgment and information forwarding, the orderly flow of interactive information among the series components is ensured, preventing data congestion or loss.

[0045] In some embodiments, the interaction information includes addressing information, which includes addressing function codes and module counters, and the data required for the current input / output component 1021 to update includes address offsets.

[0046] The current input / output component 1021 is further configured to, after receiving addressing information, calculate the address offset of the current input / output component 1021 based on the addressing information and update its own offset address.

[0047] According to the addressing function code, the component type of the current input / output component 1021 is written into the addressing information, and the number of module counters in the addressing information is incremented by one.

[0048] After changing the addressing information, send it out.

[0049] Once all input / output components 1021 in the entire link are completed, the addressing information received by the control module 101 includes the component type, quantity, and address offset of each input / output component 1021. This achieves automatic addressing of the input / output components 1021, eliminating the need for manual address setting and significantly reducing operational costs during system deployment and expansion. Furthermore, the module counter and component type recording allow the control module 101 to monitor the quantity and type of input / output components 1021 in real time, providing foundational data for subsequent configuration and management. Standardized addressing logic also ensures that different types of input / output components 1021 can be compatiblely connected in series, improving system compatibility.

[0050] In some embodiments, the interaction information includes a function code, in the event that any input / output component 1021 fails and is replaced, the offset address of the replaced input / output component 1021 and the offset address of subsequent input / output components 1021 are in an abnormal state.

[0051] The current input / output component 1021 is further configured to change the function code in the interaction information to a fault function code when the offset address is in an abnormal state, and send the changed interaction information to the control module 101.

[0052] The control module 101 is further configured to, after receiving the interactive information with the fault function code, generate and send the interactive information again to reconfigure the offset address in the input / output component 1021.

[0053] By using function codes to identify fault states, the transmission and processing logic of fault information is simplified, improving the system's fault tolerance. Control module 101 automatically detects received information and can accurately locate faults based on the function codes, enabling the detection of component replacements or address anomalies without manual troubleshooting. After a fault, address reconfiguration is automatically triggered, ensuring the system quickly returns to normal operation, reducing downtime and improving reliability.

[0054] In some embodiments, the interaction information includes configuration information, which includes multiple first data areas, and the parameter information set in each first data area is the data required for updating the current input / output component 1021.

[0055] The current input / output component 1021 is further configured to, after receiving configuration information, determine its corresponding first data area among multiple first data areas based on the offset address of the current input / output component 1021, and read the parameter information therein.

[0056] Based on the read parameter information, configure the parameters of the current input / output component 1021 for controlling the acquisition and monitoring of data and for maintaining safety.

[0057] Write the current operating status information of the input / output component 1021 into its corresponding first data area.

[0058] After changing the configuration information, send it out.

[0059] Each input / output component 1021 has its own corresponding first data area. It updates its own configuration based on the configuration information in the first data area to achieve accurate parameter configuration, avoid parameter confusion, and improve configuration accuracy.

[0060] The operating status information of the input / output component 1021 is transmitted back in real time, enabling the control module 101 to comprehensively monitor the working status of each component and facilitate timely detection of abnormalities.

[0061] In some embodiments, the interaction information includes instruction information, which includes multiple second data areas.

[0062] The current input / output component 1021 is further configured to collect monitoring data from an external device to be collected, based on instruction information.

[0063] Based on the offset address of the current input / output component 1021, determine the corresponding second data area among multiple second data areas, and write the monitoring data into the corresponding second data area.

[0064] After modifying the instruction information, issue it.

[0065] Each input / output component 1021 independently stores the monitoring data it collects in its corresponding second data area, realizing structured uploading of monitoring data, which facilitates rapid identification and processing by the control module 101. The input / output components 1021 perform actions according to instruction information, and data acquisition is bound to instruction execution, ensuring that the control module 101 can trigger the acquisition process as needed, improving the flexibility of data acquisition.

[0066] In some embodiments, when the control module 101 receives the modified interaction information, the control module 101 is further configured to determine whether the received interaction information is correct. If it is incorrect, the control module 101 generates and sends the interaction information again and interacts with the connected response module 102 again.

[0067] The control module 101 automatically determines the correctness of information, correcting transmission errors without manual intervention and reducing system maintenance costs. Through information verification and retransmission mechanisms, the impact of data transmission errors on the system is significantly reduced, improving the reliability of interaction. This ensures the accuracy of the data acquired by the control module 101, providing a reliable basis for subsequent decision-making.

[0068] In some embodiments, during the process of sending modified interactive information to the control module 101 when the current input / output component 1021 does not receive a response, each input / output component 1021 located between the current input / output component 1021 and the control module 101 is further configured to: receive the modified interactive information sent by the next input / output component 1021, and send it to the previous input / output component 1021 or the control module 101.

[0069] After the control module 101 transmits information to the input / output component 1021, the input / output component 1021 completes the information processing and needs to transmit the processed information back to the control module 101. During the process of transmitting back to the control module 101, the last input / output component 1021 sends the information to be transmitted. All input / output components 1021 located between the last input / output component 1021 and the control module 101 only receive the information to be transmitted from the next input / output component 1021 and send the information to the previous input / output component 1021 without making any changes to the information to be transmitted.

[0070] On the one hand, this system supports bidirectional information transmission, enhancing system flexibility and fault tolerance, ensuring that local node failures do not affect the overall information flow. On the other hand, it accelerates information transmission speed and improves system operating efficiency.

[0071] Furthermore, based on this two-way communication, the input / output component 1021 at the end can actively report errors to the control module 101 according to its own situation, which facilitates system maintenance.

[0072] In practical applications, such as Figure 4 As shown, the communication process between the control module 101 and the response module 102 is divided into three stages.

[0073] The first stage is the addressing stage, where the control module 101 sends addressing information to the response module 102, such as... Figure 5 As shown, the addressing information includes the addressing function code and the module counter.

[0074] The input / output component 1021 in the response module 102 receives the addressing information, calculates its own address offset based on the addressing information, increments the number of modules recorded in the module counter in the addressing information by one, and writes its own component type code into the addressing information. Then, it sends the modified addressing information to the next input / output component 1021. In the next input / output component 1021, the addressing information is rewritten again in the same way, until the last input / output component 1021 in the entire link.

[0075] Since the last input / output component 1021 did not receive a response from the next input / output component 1021, the addressing information is rewritten and then transmitted back to the control module 101. During the transmission process, the rewritten addressing information passes through each input / output component 1021 in sequence, and the rewritten addressing information is only transmitted without being parsed in each input / output component 1021, thus shortening the data transmission time.

[0076] like Figure 6 As shown, after receiving the returned addressing information, the control module 101 obtains the number of input / output components 1021 in the response module 102 and the type of each input / output component 1021.

[0077] The second stage is the parameter configuration stage, where the control module 101 sends configuration information to the response module 102, such as... Figure 7 As shown, the configuration information includes configuration function codes, module counters, and multiple first data areas, each storing the configuration parameters corresponding to each input / output component 1021.

[0078] The input / output component 1021 has analog input / output and digital input / output functions. When inputting analog or digital signals, parameters such as filtering time can be configured. When outputting analog or digital signals, parameters such as safety guidance status can be configured.

[0079] After receiving the configuration information, the input / output component 1021 finds the corresponding first data area according to its own address offset, reads the data in it, updates its own parameters, writes its own running status into the corresponding first data area, and then sends the rewritten configuration information to the next input / output component 1021. In the next input / output component 1021, the configuration information is rewritten again in the same way, until the last input / output component 1021 in the entire link.

[0080] The process of returning the rewritten configuration information is the same as the process of returning the addressing information.

[0081] The third stage is the periodic interaction stage, in which the control module 101 sends instruction information to the response module 102, such as... Figure 8As shown, the instruction information includes instruction function codes, module counters, and multiple second data areas. Each of the multiple second data areas stores the output status commands corresponding to each input / output component 1021.

[0082] After receiving the instruction information, the input / output component 1021 locates the corresponding second data area based on its own address offset, reads the data therein, and writes the monitoring data it has collected into the corresponding second data area according to the output status command. Then, it sends the modified instruction information to the next input / output component 1021. In the next input / output component 1021, the instruction information is rewritten again in the same way, until the last input / output component 1021 in the entire link.

[0083] The process of returning the rewritten instruction information is the same as the process of returning the addressing information.

[0084] The control module 101 receives the rewritten addressing information, the rewritten configuration information, and the rewritten instruction information in sequence, and determines whether there are any errors. If there are any errors, the addressing stage, configuration stage, and periodic interaction stage are executed again in sequence.

[0085] In some of these embodiments, such as Figure 3 As shown, each input / output component 1021 has two communication interfaces on its two sides. When each input / output component 1021 is connected to an adjacent input / output component 1021, the two corresponding communication interfaces are connected to form two paths, and the two paths independently transmit interactive information.

[0086] Two parallel pathways transmit interactive information independently without interference. If one pathway fails, the other can continue transmitting. This dual-path design provides communication redundancy, significantly improving the system's fault tolerance and preventing communication interruptions caused by a single pathway failure. Furthermore, the standardized interface design facilitates rapid component connection and replacement, reducing maintenance complexity.

[0087] The input / output component 1021 adopts a daisy-chain dual-channel redundant cascade method to form two paths. Multiple communication interfaces pass through one path. The communication interfaces have serializer and deserializer functions. The interactive information is converted into high-speed LVDS signals through the bidirectional buffer of the CPLD's bidirectional port.

[0088] Specifically, the control module 101 includes two communication ports, namely a first communication port 1011 and a second communication port 1012. The input / output component 1021 includes a first interface 301, a second interface 302, a third interface 203, and a fourth interface 204.

[0089] The first interface 301 of the input / output component 1021 near the control module 101 is connected to the first communication port 1011 of the control module 101. The second interface 302 of the input / output component 1021 near the control module 101 is connected to the second communication port 1012 of the control module 101. The third interface 203 of the input / output component 1021 near the control module 101 is connected to the first interface 301 of the next input / output component 1021. The fourth interface 204 of the input / output component 1021 near the control module 101 is connected to the second interface 302 of the next input / output component 1021.

[0090] Except for the input / output component 1021 located near the control module 101, the first interface 301 of the current input / output component 1021 is connected to the third interface 203 of the previous input / output component 1021, the second interface 302 of the current input / output component 1021 is connected to the fourth interface 204 of the previous input / output component 1021, the third interface 203 of the current input / output component 1021 is connected to the first interface 301 of the next input / output component 1021, and the fourth interface 204 of the current input / output component 1021 is connected to the second interface 302 of the next input / output component 1021.

[0091] Along the direction of transmitting interactive information from the control module 101 to the response module 102, the first interface 301 of the last input / output component 1021 is connected to the third interface 203 of the previous input / output component 1021, and the second interface 302 is connected to the fourth interface 204 of the previous input / output component 1021.

[0092] Both the communication port and the communication interface use bidirectional LVDS communication, forming two redundant paths between the input / output components 1021. The two paths operate independently and are switched redundantly via the main controller 201 or coupler 202. When processing data, if one data path fails, the other data path is switched for processing, improving system reliability.

[0093] In some embodiments, the priority of information sent by the communication interface of the previous input / output component 1021 is higher than the priority of information sent by the communication interface of the next input / output component 1021. The two adjacent and connected communication interfaces are further configured to: monitor the communication status of the path formed by the two communication interfaces; if the communication status of the path is idle, the communication interfaces transmit interactive information in descending order of priority.

[0094] By employing a priority scheduling mechanism, conflicts between two-way information are avoided in the transmission path, communication delays and data loss are reduced, the efficiency of path utilization is improved, and two-way information transmission is carried out in an orderly manner.

[0095] The control module 101 is equipped with a communication port, and the information sent from the communication port of the control module 101 has a higher priority than the information sent from the communication interface of the input / output component 1021. This ensures that the interactive information sent by the control module 101 is transmitted first, guaranteeing the timeliness of the core system operations.

[0096] Specifically, between adjacent input / output components 1021, each pair of connected communication interfaces maintains bidirectional peer-to-peer communication. During the communication process, the communication interfaces at both ends of the path will monitor the communication status of the path. If there is a data change on the path, it means that the path is occupied. If there is no data change on the path within a certain period of time, it means that the path is idle.

[0097] The communication interfaces at both ends of the path monitor the communication status of the path in real time. When the path is idle, the data transmission priority of the communication interface of the previous input / output component 1021 is higher than the data transmission priority of the communication interface of the current input / output component 1021. During data transmission, when the path is occupied, the lower-priority communication interface must wait for the higher-priority communication interface to complete its data transmission before it can send its own data.

[0098] Furthermore, in order to better transmit data, the control module 101 needs to set a reasonable transmission cycle when sending instruction information; otherwise, high-priority communication interfaces will continuously occupy the channel, causing channel data congestion, thereby improving the utilization rate of communication bandwidth and shortening the data update cycle.

[0099] Furthermore, during the periodic interaction phase, the control module 101 issues multiple instruction messages within one transmission cycle. During the addressing phase, the control module 101 issues one addressing message. During the configuration phase, the control module 101 issues one configuration message.

[0100] In some embodiments, the input / output component 1021 further includes a power supply, and hot-swap protection components are provided for the power supply and the communication interface, respectively.

[0101] Hot-swap protection prevents electrical signal interference or damage during the insertion and removal process, extending equipment lifespan. It supports online replacement of the 1021 input / output components, allowing maintenance without downtime, significantly improving system availability and continuous operation. This reduces maintenance complexity and enhances system operability, making it particularly suitable for industrial scenarios requiring 24-hour continuous operation.

[0102] The communication interface employs data collision avoidance technology, improving communication speed and bandwidth utilization. It also enables the response module 102 to be hot-swappable, enhancing system reliability and maintainability.

[0103] like Figure 9As shown, during normal interaction between the control module 101 and the response module 102, if all input / output components 1021 in the response module 102 are operating normally, and the function codes and offset addresses are normal, then the interaction information is updated normally, and the interaction information is transmitted to the next input / output component 1021. The last input / output component 1021 transmits information to the control module 101. If one input / output component 1021 in the response module 102 fails, causing a power outage and disconnection, then the failed input / output component 1021 and all subsequent input / output components 1021 will lose communication with the control module 101, while the input / output components 1021 preceding the failed input / output component 1021 can still communicate normally with the control module 101.

[0104] The faulty input / output component 1021 was removed and replaced with a new input / output component 1021. After being reconnected to the circuit, the newly connected input / output component 1021 and subsequent input / output components 1021, due to power failure and subsequent power-on restart, had their offset addresses restored to the initial values. Therefore, they could not correctly identify their corresponding first and second data areas in the interactive information.

[0105] The input / output component 1021 also has the function of identifying its own bias address. When the input / output component 1021 detects that its own offset address is abnormal, it only changes the function code in the interaction information when processing the interaction information, rewriting the function code as a fault function code, and does not operate the first data area and the second data area.

[0106] When the newly connected input / output component 1021 receives an interaction message with a fault function code, it only transmits the data. Finally, the interaction message with the fault function code will be sent back to the control module 101. After receiving the fault function code, the control module 101 will re-execute the addressing phase, configuration phase, and periodic interaction phase in sequence to realize the hot-plug communication recovery of the response module 102.

[0107] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0108] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A programmable logic control system, characterized in that, include: The control module is configured to generate and send interactive information; The response module includes multiple input / output components connected in sequence, with the input / output component closest to the control module connected to the control module, and any one of the input / output components connected to an external device to be acquired; In the direction of transmitting the interactive information from the control module to the response module, any one of the input / output components is set as the current input / output component, the input / output component adjacent to and close to the control module is the previous input / output component, and the input / output component adjacent to and far from the control module is the next input / output component; the current input / output component is configured to: collect monitoring data from the external device to be collected; The system receives the interaction information sent by the control module or the previous input / output component, generates response information, and sends the response information to the previous input / output component; based on the interaction information, it obtains the data required for updating the current input / output component, updates its own data, and writes the current input / output component's own data and / or the monitoring data into the interaction information; it determines whether it has received the response information sent by the previous input / output component, and if so, sends the modified interaction information to the next input / output component. If not, the modified interaction information will be sent to the control module; After receiving the modified interaction information, the control module determines whether the input / output component in the response module has been replaced based on the modified interaction information. If so, it generates and sends the interaction information to the response module again and updates the data in the response module again.

2. The programmable logic control system according to claim 1, characterized in that, The interactive information includes addressing information, which includes addressing function code and module counter. The data required for updating the current input / output component includes address offset. The current input / output component is further configured to: after receiving the addressing information, calculate the address offset of the current input / output component based on the addressing information, and update its own offset address; According to the addressing function code, the component type of the current input / output component is written into the addressing information, and the number of module counters in the addressing information is incremented by one. After changing the addressing information, it is sent.

3. The programmable logic control system according to any one of claims 2, characterized in that, The interaction information includes function codes. If any of the input / output components fails and is replaced, the offset address of the replaced input / output component and the offset address of the subsequent input / output components are all in an abnormal state. The current input / output component is further configured to: when the offset address is in an abnormal state, change the function code in the interaction information to a fault function code, and send the changed interaction information to the control module; The control module is further configured to: after receiving the interaction information with the fault function code, regenerate and send the interaction information, and reconfigure the offset address in the input / output component.

4. The programmable logic control system according to claim 2, characterized in that, The interactive information includes configuration information, which includes multiple first data areas. The parameter information set in each first data area is the data required for updating the current input / output component. The current input / output component is further configured to: after receiving the configuration information, determine its corresponding first data area among multiple first data areas according to the offset address of the current input / output component, and read the parameter information therein; Based on the read parameter information, configure the parameters of the current input / output component for controlling the acquisition and monitoring of data and for maintaining safety; Write the current operating status information of the input / output component into its corresponding first data area; After changing the configuration information, send it out.

5. The programmable logic control system according to claim 4, characterized in that, The interactive information includes instruction information, and the instruction information includes multiple second data areas; The current input / output component is further configured to: collect the monitoring data from the external device to be collected according to the instruction information; Based on the offset address of the current input / output component, determine the second data area corresponding to itself among multiple second data areas, and write the monitoring data into the second data area corresponding to itself; After modifying the instruction information, issue it.

6. The programmable logic control system according to any one of claims 1-5, characterized in that, When the control module receives the modified interaction information, the control module is further configured to: determine whether the received interaction information is correct; if it is incorrect, generate and send the interaction information again, and perform data interaction with the connected response module again.

7. The programmable logic control system according to any one of claims 1-5, characterized in that, During the process of sending the modified interaction information to the control module when the current input / output component does not receive the response information, each input / output component located between the current input / output component and the control module is further configured to: receive the modified interaction information sent by the next input / output component, and send it to the previous input / output component or the control module.

8. The programmable logic control system according to claim 1, characterized in that, Each of the input / output components has two communication interfaces on its two sides. When any input / output component is connected to an adjacent input / output component, the two corresponding communication interfaces are connected to form two paths, and the two paths independently transmit the interactive information.

9. The programmable logic control system according to claim 8, characterized in that, The priority of information sent by the communication interface of the previous input / output component is higher than the priority of information sent by the communication interface of the next input / output component. The two adjacent and connected communication interfaces are further configured to: monitor the communication status of the path formed by the two communication interfaces; if the communication status of the path is idle, the communication interfaces transmit the interactive information in descending order of priority.

10. The programmable logic control system according to claim 8, characterized in that, The input / output components also include a power supply, and hot-swap protection components are respectively provided on the power supply and the communication interface.

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