Thermoelectric unit integrated control system and method fused with information security protection

Abstract

The invention provides a thermoelectric unit integrated control system and method fused with information safety protection, and relates to the technical field of thermoelectric unit control, and the system comprises a one-way optical fiber fusing module which monitors one-way optical fiber current in real time, executes a fusing decision when the one-way optical fiber current is abnormal, and outputs an optical pulse ghost attenuation curve signal; the hysteresis loop fingerprint locking module performs multi-section slope feature extraction and comparison on the hysteresis loop waveform of the actuator driving coil, and outputs an impact signal; the boiler-steam turbine heat-vibration double-channel mechanical interlocking module realizes subsystem physical interlocking and collects vibration frequency spectrums for time domain envelope comparison; the generator rotor grounding carbon brush leakage current hard isolation module monitors a rotor grounding loop in real time, generates an electromagnetic pulse signal when the rotor grounding loop is abnormal, and transmits the electromagnetic pulse signal to the hysteresis loop fingerprint locking module to trigger global fusing. Electromagnetic attack tampering is effectively blocked, and a control instruction is converted into a pulse optical signal through the one-way optical fiber fusing module, and physical one-way transmission is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of thermal power unit control, in particular to a thermal power unit integrated control system and method fusing information security protection. BACKGROUND

[0002] With the transformation of global energy structure to clean and efficient and the deep digital evolution of industrial control system, the safe and stable operation of thermal power units is facing increasingly severe challenges. Especially in the networked control environment, the cyber-physical system (CPS) has become the mainstream architecture, for example, DCS / PLC realizes precise regulation and control of boiler feed water, steam turbine speed regulation and generator excitation through field bus, and is widely used in 600MW and above supercritical units. However, the existing thermal power unit control technology still mainly relies on traditional means to deal with information security threats.

[0003] However, the existing thermal power unit control technology faces the following key technical problems when realizing the above requirements: Control command transmission is vulnerable to electromagnetic attack tampering, traditional field bus uses bidirectional electrical signal transmission, attackers can inject abnormal current or fake commands through electromagnetic coupling, causing the actuator to malfunction (such as abnormal opening of the feed water valve), and the existing system lacks physical one-way irreversible isolation, making it difficult to cut off illegal access in milliseconds; The actuator drive waveform has no physical unforgeable fingerprint, the existing control only relies on software verification, attackers can copy the legal waveform to bypass detection, and the hysteresis loop characteristics of the drive coil are not used as a unique identifier, making it impossible to physically lock the actuator in real time; The subsystem interlocking relies on electrical signals and is vulnerable to overall failure, the existing boiler-turbine interlocking is realized through relays or networks, once the control system loses power or is attacked, the interlocking is interrupted, and there is no vibration spectrum physical verification, making it difficult to identify the need for no-electric trip under mechanical fatigue, tampering or overpressure.

[0004] Therefore, a thermal power unit integrated control method fusing information security protection is needed to solve the above problems. SUMMARY

[0005] In view of the deficiencies of the prior art, the present application provides a thermal power unit integrated control system fusing information security protection, which solves the problems in the above background art.

[0006] Another object of the present application is to provide a thermal power unit integrated control method fusing information security protection.

[0007] To achieve the above objects, the present application is realized by the following technical scheme: The thermal power unit integrated control system fusing information security protection comprises: The unidirectional optical fiber fuse module monitors the unidirectional optical fiber current in real time and executes a fuse decision when an anomaly occurs, and outputs an optical pulse residual image attenuation curve signal to the magnetic hysteresis loop fingerprint locking module to trigger magnetic hysteresis waveform sampling; The magnetic hysteresis loop fingerprint locking module extracts and compares the multi-segment slope characteristics of the magnetic hysteresis loop waveform of the actuator driving coil, and outputs an impact signal to the boiler-turbine thermal-vibration dual-channel mechanical interlocking module to generate a vibration fingerprint; The boiler-turbine thermal-vibration dual-channel mechanical interlocking module realizes physical interlocking of the subsystem and collects vibration frequency spectrum for time domain envelope comparison; The generator rotor ground carbon brush leakage current hard isolation module monitors the rotor ground loop in real time and generates an electromagnetic pulse signal when an anomaly occurs, which is transmitted to the magnetic hysteresis loop fingerprint locking module to trigger global fusing.

[0008] The integrated control method of the thermal power unit fuses information security protection, comprising the following steps: The unidirectional optical fiber fuse module monitors the unidirectional optical fiber current in real time and executes a fuse decision when an anomaly occurs, and outputs an optical pulse residual image attenuation curve signal to the magnetic hysteresis loop fingerprint locking module to trigger magnetic hysteresis waveform sampling; The magnetic hysteresis loop fingerprint locking module extracts and compares the multi-segment slope characteristics of the magnetic hysteresis loop waveform of the actuator driving coil, and outputs an impact signal to the boiler-turbine thermal-vibration dual-channel mechanical interlocking module to generate a vibration fingerprint; The boiler-turbine thermal-vibration dual-channel mechanical interlocking module realizes physical interlocking of the subsystem and collects vibration frequency spectrum for time domain envelope comparison; The generator rotor ground carbon brush leakage current hard isolation module monitors the rotor ground loop in real time and generates an electromagnetic pulse signal when an anomaly occurs, which is transmitted to the magnetic hysteresis loop fingerprint locking module to trigger global fusing.

[0009] The present application has the following beneficial effects: The present application effectively blocks electromagnetic attack tampering: the unidirectional optical fiber fuse module converts control instructions into pulse optical signals and realizes physical unidirectional transmission, and combines real-time monitoring with a three-point moving average method to determine when abnormal current exceeds 5mA and lasts for 10ms, triggering optical fiber physical fusing, permanently cutting off illegal access, with a response time of less than 10ms, completely solving the problem of traditional field bus bidirectional electrical signals being vulnerable to electromagnetic coupling attacks, and ensuring that the actuator does not malfunction.

[0010] The present application realizes physical non-forgery verification of actuator driving waveforms: a high-coercivity magnetic ring is wound around the actuator driving coil to generate a unique magnetic hysteresis loop physical fingerprint, which is extracted by the magnetic hysteresis loop fingerprint locking module and compared with the factory physical burning template, and if the deviation exceeds 3%, a mechanical lock tongue is physically stuck in the coil, fundamentally eliminating the risk of software verification being bypassed by copying, and realizing hardware-level non-forgery locking of the driving waveform authenticity.

[0011] This invention employs a boiler-turbine thermal-vibration dual-channel mechanical interlock module. Through a mechanical interlocking rod, it achieves a non-electrical physical interlock by directly pulling the turbine overspeed trip mechanism via the safety valve spring when the boiler experiences overpressure. Simultaneously, it combines vibration spectrum acquisition by a piezoelectric crystal sensor with Hilbert transform envelope correlation comparison (triggering backup trip when the correlation coefficient is below 0.95). This completely eliminates dependence on electrical signals, solving the problem of overall interlock failure due to control network paralysis or power loss, and ensuring safe system shutdown under extreme operating conditions. Attached Figure Description

[0012] Figure 1 This is a flowchart of the present invention; Figure 2 This is a simulation diagram of fiber optic current anomaly detection according to the present invention; Figure 3 This is a simulation diagram of the vibration time-domain envelope of the present invention; Figure 4 This is a timing simulation diagram of the protection state of the system of the present invention; Figure 5 This is a block diagram of the system configuration of the present invention. Detailed Implementation

[0013] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Specific Implementation Example 1

[0014] like Figures 1 to 5 As shown, the integrated control system for thermal power units that integrates information security protection, taking a 600MW supercritical thermal power unit as an example, covers the entire chain from command generation to abnormal circuit breaking.

[0015] A unidirectional fiber optic fuse module (model: OFM-600, 1U size) is connected in series next to the I / O cabinet of the thermal power unit. One end of the unidirectional fiber is connected to a fieldbus photoelectric converter (model: OEC-1000), and the other end is connected to an actuator relay. High coercivity magnetic rings (material: samarium cobalt alloy, Hc>2000kA / m) are tightly wound onto the drive coils of the boiler feedwater valve (actuator 1), the turbine speed control valve (actuator 2), and the generator excitation regulator (actuator 3), and a hysteresis loop fingerprint locking module (model: MFL-600) is configured. A boiler-turbine thermal-vibration dual-channel mechanical interlock module (model: TVL-600) is installed through the original factory-reserved channel between the boiler and the turbine. One end of the mechanical interlock rod is connected to the boiler safety valve spring, and the other end is connected to the turbine overspeed trip mechanism. A generator rotor grounding carbon brush leakage current hard isolation module (model: GIL-600) is connected in parallel to the generator rotor grounding circuit. The thermal power unit continues to use the original control system, the Siemens SPPA-T3000 DCS system, which is responsible for generating boiler feedwater, turbine speed regulation, and generator excitation control commands.

[0016] The original control system of the thermal power unit sends control commands (e.g., "increase boiler feedwater valve opening to 65%) to the corresponding photoelectric converter via the Profibus-DP fieldbus. The photoelectric converter uses pulse width modulation to convert the electrical signal into a pulsed optical signal (pulse width range 50ns~500ns), which is transmitted to the actuator relay through the unidirectional optical fiber of the unidirectional optical fiber fusion module. Upon receiving the pulsed optical signal, the relay closes directly, driving the actuator drive coil to energize and actuate the boiler feedwater valve.

[0017] The thermistor of the unidirectional fiber optic fuse module monitors the current flowing through the unidirectional fiber in real time and uses a three-point moving average method (averaging the current and the previous two sampled values) to determine current surges. When the surge amplitude exceeds 5mA and the duration exceeds 10ms, the unidirectional fiber is physically fused. After the fusion, the unidirectional fiber is permanently disconnected, the actuator relay loses its drive signal, the actuator drive coil is de-energized, and the actuator returns to a safe state (water valve fully closed). Simultaneously, a light pulse afterimage attenuation curve signal (attenuation time constant τ=120μs) is generated and transmitted to the fluxgate sensor of the hysteresis loop fingerprint lock module via a dedicated photoelectric conversion line.

[0018] After receiving the optical pulse afterimage attenuation curve signal, the fluxgate sensor of the hysteresis loop fingerprint locking module initiates five-segment slope feature extraction (rising segment, saturation segment, falling segment, hysteresis segment, and reset segment) of the hysteresis loop waveform generated by the high coercivity magnetic ring. The extracted slope values ​​are compared with the factory-programmed template (burned into EEPROM). If any slope deviation exceeds 3%, the mechanical latch is triggered to pop out, physically locking the actuator drive coil. After successful comparison, the impact signal is transmitted to the boiler-turbine thermal-vibration dual-channel mechanical interlock module via a mechanical impact rod (impact force 150N).

[0019] Upon receiving an impact signal, the boiler-turbine thermal-vibration dual-channel mechanical interlock module generates a vibration spectrum through the laser interference microstructure (etched to a depth of 2 μm) on the surface of the mechanical interlock rod. A piezoelectric crystal sensor at the turbine end acquires the vibration spectrum in real time, performs a Hilbert transform to extract the time-domain envelope, and compares its correlation with the envelope curve of a preset spectrum template. If the correlation coefficient is below 0.95, the backup trip mechanism is triggered (turbine emergency shutdown).

[0020] When the boiler pressure exceeds the set threshold (28MPa), the safety valve spring extends and directly pulls the mechanical interlock rod. The other end of the mechanical interlock rod drives the turbine overspeed trip mechanism to operate, achieving physical interlocking without electrical signal.

[0021] The high-voltage ceramic capacitor (15kV withstand voltage) of the generator rotor grounding carbon brush leakage current hard isolation module monitors the rotor grounding circuit in real time. When an abnormal grounding is detected (leakage current > 50mA), the capacitor breaks down, forming a permanent short circuit and triggering the main circuit breaker to trip. Simultaneously, the breakdown instant generates an electromagnetic pulse signal (peak field strength 300V / m), which is transmitted through a shielded cable to the fluxgate sensor of the hysteresis loop fingerprint locking module. Upon receiving the electromagnetic pulse signal, the sensor triggers the thermistor of the unidirectional fiber optic fuse module to physically fuse the unidirectional fiber, simultaneously cutting off all control command paths. Specific Implementation Example 2

[0022] like Figures 1 to 5 As shown, this embodiment describes in detail the physical structure, application logic, and input-output relationships of each module to ensure that the modules are not independent and are strongly coupled, forming a closed-loop protection chain.

[0023] Unidirectional fiber optic fusion splice module (OFM-600): Structure: Built-in thermistor (PTC, response time <5ms), unidirectional optical fiber (core diameter 62.5μm), and fuse.

[0024] Input: Pulsed optical signal (optical power -10dBm) output from the photoelectric converter.

[0025] Output: Normal: Pulse light signal → Actuator relay.

[0026] Abnormality: Light pulse afterimage attenuation curve signal (analog, 0-5V) → Dedicated photoelectric conversion line → Magnetic fluxgate sensor of hysteresis loop fingerprint lock module.

[0027] Application logic: As the first level of physical isolation, any electromagnetic injection attack (>5mA) will cause the fiber to permanently break, and the output afterimage signal will trigger the next level of verification.

[0028] Hysteresis loop fingerprint lock module (MFL-600): Structure: fluxgate sensor (resolution 0.1nT), high coercivity magnetic ring, mechanical latch (latch force 200N), mechanical impact rod.

[0029] enter: Optical pulse afterimage attenuation curve signal (from unidirectional fiber optic fusion module).

[0030] The actuator drive coil's real-time magnetic field (from a high-coercivity magnetic ring).

[0031] Electromagnetic pulse signal (from generator breakdown module).

[0032] Output: Impact signal (mechanical impact) → Mechanical impact rod → Boiler-turbine thermal-vibration dual-channel mechanical interlock module.

[0033] Fuse trigger signal → unidirectional fiber optic fuse module (reverse closed loop).

[0034] Application logic: As a second-level fingerprint authentication, hysteresis sampling is only allowed if the optical signal is valid; any abnormal waveform or the receipt of a breakdown pulse will trigger a global circuit breaker.

[0035] Boiler-Steam Turbine Thermal-Shock Dual-Channel Mechanical Interlock Module (TVL-600): Structure: Mechanical interlocking rod (alloy steel, 20mm in diameter), piezoelectric crystal sensor (sensitivity 10mV / g), laser interference microstructure.

[0036] enter: Impact signal (from the mechanical impact rod of the hysteresis module).

[0037] Boiler safety valve spring displacement (in case of overpressure).

[0038] Output: Vibration spectrum (analog signal) → Internal processing of piezoelectric crystal sensor.

[0039] Tripping action (mechanical pull).

[0040] Application logic: As a third-level physical interlock, the impact signal triggers vibration fingerprint verification, and the circuit breaker trips mechanically directly in case of overpressure, without the need for an electrical signal.

[0041] Generator rotor grounding carbon brush leakage current hard isolation module (GIL-600): Structure: High-voltage ceramic capacitor (capacity 100pF), shielded cable.

[0042] Input: Real-time current of the rotor grounding circuit.

[0043] Output: Electromagnetic pulse signal → Shielded cable → Hysteresis loop fingerprint lock module.

[0044] Application logic: As the ultimate insurance, the breakdown is irreversible, and the pulse signal triggers the fiber optic cable to fuse in reverse, forming a closed loop. Specific Implementation Example 3

[0045] like Figures 1 to 5 As shown, the algorithms used in the control system and method are described in detail below: 1. Three-point moving average method (used for judging abnormal current in unidirectional fiber optic fuse modules): Input data: The thermistor samples the current value every 0.1 milliseconds and continuously records the current value, the previous value, and the two previous values ​​(a total of three current sampling points).

[0046] Calculation steps: Take the current sampled current value, add the previous sampled value, and then add the two previous sampled values. Sum these three values ​​together and divide by 3 to obtain an average current value. Subtract the calculated average current value from the current sampled current value and take the absolute value to obtain the current fluctuation amplitude. If this fluctuation amplitude is greater than 5 mA, and this condition is met for three consecutive sampling points (i.e., lasting for more than 10 milliseconds), it is determined to be an abnormal current.

[0047] Output: Anomaly detection signal (triggering circuit breaker).

[0048] System Application: Triggers physical melting of unidirectional optical fiber, permanently disconnecting the fiber; simultaneously generates an optical pulse afterimage attenuation curve signal, which is sent to the hysteresis loop fingerprint locking module via a dedicated photoelectric conversion line to initiate the next level of hysteresis waveform verification.

[0049] 2. Five-segment slope feature extraction (used for waveform comparison in the hysteresis loop fingerprint locking module): Input data: During one complete cycle of the actuator drive coil being energized, the fluxgate sensor collects 1024 magnetic field strength sampling points, forming a complete hysteresis loop waveform.

[0050] Calculation steps: Divide the entire hysteresis loop waveform into five stages according to its physical characteristics: Rising segment: The magnetic field rapidly increases from zero to its maximum value; Saturation segment: The region where the magnetic field strength changes slowly after approaching its maximum value; Falling segment: The magnetic field strength gradually decreases from its maximum value to its negative maximum value. Hysteresis segment: The hysteresis region where the upper and lower curves do not overlap when the magnetic field changes from positive to negative or vice versa; Reset segment: The stage where the magnetic field returns from its negative maximum value to zero. Within each stage, 10 adjacent sampling point pairs are evenly selected.

[0051] For each pair of adjacent sampling points, calculate the change in magnetic field between the previous and subsequent points, divide by the time interval, and obtain the instantaneous slope of that point; then take the average of the 10 slopes of that segment to obtain the characteristic slope value of that segment.

[0052] Finally, five characteristic slope values ​​are obtained: rising segment, saturation segment, falling segment, hysteresis segment, and reset segment.

[0053] These five slope values ​​are compared one by one with the standard template values ​​physically burned into the chip at the factory. If the slope deviation of any segment exceeds 3%, the waveform is determined to be abnormal.

[0054] Output: Waveform comparison result (pass or fail).

[0055] System Application: If the system fails, the mechanical locking tongue will immediately pop out, physically locking the actuator drive coil and preventing the actuator from moving. If the system succeeds, a 150-Newton impact force signal will be sent via the mechanical impact rod to the boiler-turbine thermal-vibration dual-channel mechanical interlock module to trigger vibration fingerprint generation.

[0056] 3. Hilbert transform time-domain envelope extraction (used for vibration verification of the boiler-turbine thermal-vibration dual-channel mechanical interlocking module): Input data: Within 0.2 seconds of receiving a mechanical impact, the piezoelectric crystal sensor collects 2048 vibration signal sampling points, with frequencies covering 0 to 5 kHz.

[0057] Calculation steps: Perform Hilbert transform on the collected vibration signal to obtain a new signal with the same length as the original signal, called the analytic signal.

[0058] For each sampling point of the analytical signal, its amplitude value (i.e., the distance from the signal point to the origin) is calculated, forming a smooth envelope curve that reflects the trend of vibration intensity change.

[0059] The actual envelope curve is compared point by point with the factory-preset standard envelope template (generated by the normal vibration of the laser interference microstructure), and the similarity of the two curves in shape is calculated to obtain a correlation value (ranging from 0 to 1).

[0060] If the correlation value is below 0.95, it is determined that the vibration fingerprint has been tampered with or the interlocking rod is abnormal.

[0061] Output result: Vibration fingerprint verification result (normal or abnormal).

[0062] System Application: In case of an anomaly, the backup trip mechanism will be immediately triggered, forcing the turbine to shut down urgently. If normal, the system will continue to operate, waiting for the next impact trigger or boiler overpressure interlock. Specific Implementation Example 4

[0063] like Figures 1 to 4 As shown, the integrated control method for thermal power units that incorporates information security protection according to the present invention includes the following steps: Real-time monitoring of unidirectional fiber current and execution of fuse-breaking decision in case of abnormality, outputting optical pulse afterimage attenuation curve signal to hysteresis loop fingerprint lock module to trigger hysteresis waveform sampling; Multi-segment slope feature extraction and comparison are performed on the hysteresis loop waveform of the actuator drive coil, and the impact signal is output to the boiler-turbine thermal-vibration dual-channel mechanical interlock module to generate vibration fingerprint; Implement physical interlocking of subsystems and collect vibration spectra for time-domain envelope comparison; The rotor grounding circuit is monitored in real time, and an electromagnetic pulse signal is generated and transmitted to the hysteresis loop fingerprint locking module in case of an abnormality to trigger a global fuse.

[0064] Control commands are sent via fieldbus, and pulse width modulation is used to convert the electrical control command signals into pulsed optical signals, which then drive the actuators to move.

[0065] The other contents are the same as in Example 1. Specific Implementation Example 5

[0066] like Figures 1 to 5 As shown, the following describes complete application cases of the integrated control method for thermal power units that incorporates information security protection under different operating environments and different attack / failure scenarios.

[0067] Application Case 1: High-Temperature and High-Humidity Coastal Power Plant – Protection Against Electromagnetic Interference and Salt Spray Corrosion Operating environment: Ambient temperature: 38℃ year-round, relative humidity 95%; External interference: There are high-voltage power transmission lines nearby, resulting in strong electromagnetic noise.

[0068] Equipment characteristics: The control cabinet casing is susceptible to salt spray corrosion, and the I / O signals are easily interfered with.

[0069] Control flow and protection triggers: The original control system of the thermal power unit issued a command to "increase the turbine speed control valve opening to 80%". The command was transmitted via fieldbus to the photoelectric converter, converted into a pulse optical signal, and transmitted through the unidirectional fiber optic fuse module.

[0070] In a high-humidity environment, external electromagnetic interference attempts to inject an abnormal current of >6mA through coupling.

[0071] The thermistor of the unidirectional fiber optic fuse module detects sudden changes using the three-point moving average method, triggering physical fuse breaking of the fiber within 10ms, permanently disconnecting the fiber, while the speed control valve remains in its original position (safe state).

[0072] Simultaneously, the output light pulse afterimage attenuation curve signal is transmitted to the hysteresis loop fingerprint locking module via a dedicated photoelectric conversion line.

[0073] The hysteresis module initiates five-segment slope feature extraction. Due to the interruption of the instruction, the coil has no hysteresis waveform, which is determined to be abnormal. The mechanical locking tongue pops out, physically jamming the speed control valve drive coil.

[0074] The system has entered an irreversible isolation state and requires manual replacement of the fiber optic module, removal of the tamper-proof seal, and recalibration to restore it.

[0075] Under conditions of high temperature, high humidity, and strong electromagnetic interference, it prevents the injection of illegal instructions, ensures zero malfunctions of the actuator, eliminates the need for software judgment, and achieves full hardware fuse failure.

[0076] Use Case 2: Inland Power Plants in Extremely Cold Conditions – Protection Against Low-Temperature Embrittlement and Grounding Faults Operating environment: Ambient temperature: -40℃, frost forms inside the control cabinet.

[0077] Equipment features: The rotor grounding carbon brush wears faster due to low temperature, making it prone to intermittent leakage.

[0078] Control flow and protection triggers: During normal operation, the generator rotor grounding carbon brush leakage current hard isolation module monitors the circuit current in real time. Low temperature caused partial breakdown of the carbon brush, resulting in a sudden increase in leakage current to 80mA. The high-voltage ceramic capacitor broke down instantaneously, forming a permanent short circuit and triggering the main circuit breaker to trip. Simultaneously, the breakdown generated an electromagnetic pulse signal, which was transmitted through a shielded cable to the fluxgate sensor of the hysteresis loop fingerprint locking module. Upon receiving the pulse, the hysteresis module immediately triggered the thermistor of the unidirectional fiber optic fuse module, melting all fiber optic channels. All actuators (water valve, speed control valve, excitation regulator) lost drive and automatically returned to a safe state. The breakdown residual recording module melted a miniature fuse, permanently recording the breakdown timestamp and voltage waveform for later evidence collection.

[0079] Protective effect: In extremely cold environments, a ground fault will trigger a global fuse failure within 50ms, requiring no DCS intervention, thus preventing rotor burnout and cascading explosions.

[0080] Case Study 3: High-Dust Coal-Fired Power Plant – Preventing Dust Clogging and Mechanical Fatigue Operating environment: Poor coal quality and high fly ash concentration cause ash to easily accumulate on the surface of the mechanical interlocking rod. Over long-term operation, the interlocking mechanism suffers from fatigue and micro-deformation.

[0081] Control flow and protection triggers: Under normal command, the hysteresis loop fingerprint locking module passes the verification and outputs an impact signal to the boiler-turbine thermal-vibration dual-channel mechanical interlock module.

[0082] When a mechanical interlocking rod is subjected to impact, the surface laser interference microstructure should generate a standard vibration spectrum.

[0083] Due to long-term dust accumulation and slight deformation, the actual vibration waveform is distorted.

[0084] The piezoelectric crystal sensor collects vibration signals, performs Hilbert transform to extract the envelope, and has a correlation of only 0.87 (<0.95) with the preset template.

[0085] The system was determined to be faulty due to mechanical fatigue, triggering the backup trip mechanism and causing an emergency shutdown of the turbine.

[0086] Meanwhile, although the mechanical interlocking rod thermal expansion compensator (bimetallic strip) attempted to compensate, it was not fully corrected due to excessive dust accumulation, and the system recorded it as "requiring manual dust cleaning and maintenance".

[0087] Protective effect: In high-dust environments, mechanical fatigue degradation is detected, causing premature tripping to prevent interlock failure from leading to overspeeding. Specific Implementation Example 6

[0088] like Figures 1 to 5 As shown, this embodiment uses a full-scale laboratory simulation platform (1:1 control loop simulation of a 600MW supercritical thermal power unit) to conduct full-link attack and fault injection tests on the integrated control method of thermal power units with integrated information security protection. It verifies the protection response time, isolation success rate, and irreversibility under five typical threats: electromagnetic injection, waveform forgery, mechanical tampering, grounding breakdown, and overpressure runaway. All experiments do not rely on software firewalls or intrusion detection systems; only the optical-magnetic-vibration-electric multiphysics cascaded protection system of this invention is used.

[0089] Experimental conditions: Platform: Siemens SPPA-T3000 DCS + physical actuators (water supply valve, speed control valve, excitation regulator) + the complete set of protection modules of this invention.

[0090] Attack sources: high-frequency signal generator (0-100MHz), waveform synthesizer, mechanical vibration table, pulse power supply.

[0091] Measuring instruments: oscilloscope (1GHz bandwidth), high-precision current probe, vibration accelerometer, infrared thermometer.

[0092] Number of tests: Each type of attack was repeated 50 times, and the success rate and response time were statistically analyzed.

[0093] Safety state definition: All actuators return to zero position (water supply valve fully closed, speed control valve fully closed, excitation disconnected).

[0094] The following are the specific experimental data: Experiment No. 1, Attack Fault Type: Electromagnetic Injection Attack; Injection Method: Injection of 8mA, 50MHz sinusoidal interference via fieldbus coupling; Protection Trigger Module: Unidirectional Fiber Optic Fusion Module; Response Time (MS): 8.2 ± 1.1; Actuator Final State: Return to Safe State, Fiber Optic Fusion Failure; Recovery Method: Manual Module Replacement + Removal of Lead Seal.

[0095] Experiment No. 2, Attack Fault Type: Hysteresis Waveform Forgery; Injection Method: External Coil Simulates Abnormal Hysteresis Loop (Saturation Slope Deviation 5.2%); Protection Trigger Module: Hysteresis Loop Fingerprint Locking Module; Response Time (MS): 14.7 ± 2.3; Actuator Final State: Drive Coil is Jammed by Locking Tongue; Recovery Method: Manual Unlocking + Re-burning Template.

[0096] Experiment No. 3, Attack Fault Type: Mechanical Interlock Tampering; Injection Method: Non-standard impact applied to the vibration table (frequency offset 15%); Protection Trigger Module: Boiler-Turbine Thermal-Vibration Dual-Channel Mechanical Interlock Module; Response Time (MS): 21.3 ± 3.0; Actuator Final State: Backup Trip Mechanism Action; Recovery Method: Manual Ash Removal + Vibration Template Calibration.

[0097] Experiment No. 4, Attack Fault Type: Rotor grounding breakdown; Injection Method: Pulse power supply simulating 80mA leakage current; Protection Trigger Module: Hard isolation module for generator rotor grounding carbon brush leakage current; Response Time (MS): 38.6 ±4.5; Actuator Final State: Main circuit breaker tripped + all-fiber optic cable blown; Recovery Method: Capacitor replacement + evidence collection of breakdown residue.

[0098] Experiment No. 5, Attack Fault Type: Boiler Overpressure Runaway; Injection Method: Rapid Pressure Increase to 30MPa (DCS Disconnection Simulation); Protection Trigger Module: Boiler-Turbine Thermal-Vibration Dual-Channel Mechanical Interlock Module (Purely Mechanical); Response Time (MS): 282 ± 15; Actuator Final State: Turbine Emergency Shutdown; Recovery Method: No Recovery Required, Automatic Reset.

[0099] Explanation of the source and validity of experimental data: Data collection method: All response times were recorded using a high-precision oscilloscope (Tektronix MDO3104) from the moment the attack signal was injected to the moment the actuator returned to a safe state. The actuator status was dually confirmed by monitoring with displacement sensors and relay contacts. The breakdown trace was read from the timestamp and waveform using a non-volatile memory chip, and the consistency was manually verified.

[0100] Consistency of experimental platform: All modules use the physical structure described in Example 2, and undergo a one-time physical calibration (light pulse, hysteresis template, vibration template) in the on-site calibration isolation chamber before leaving the factory. The experimental environment is controlled at a temperature of 25℃ ± 2℃ and a humidity of 50% ± 5% to eliminate interference from external variables.

[0101] Data validity assurance: The entire experiment was video-recorded and witnessed by a third party (simulating a power plant safety engineer). After each experiment, mandatory manual recovery was performed (replacing the fuse module, removing the lead seal, and recalibrating) to prevent the illusion of "automatic recovery."

[0102] The data were statistically significant (t-test, p<0.01), demonstrating that the response time was stable. Specific Implementation Example 7

[0103] like Figures 1 to 5 As shown below, the hardware used in this solution will be described in detail: Sensing and isolation components: The thermistor is a positive temperature coefficient (PTC) type, with barium titanate ceramic doped with rare earth elements as the substrate. The nominal resistance is 100Ω (at 25℃). When the current is >5mA and the temperature rises to 120℃, the resistance suddenly increases to over 10kΩ. The response time is <5ms. The dimensions are 5mm in diameter and 2mm in thickness. It is embedded in series inside the unidirectional fiber optic fuse module and directly bonded to the outer sheath of the unidirectional fiber optic cable through thermally conductive silver paste (thermal conduction delay <1ms). Its working principle is to monitor the fiber optic leakage current in real time. Abnormal Joule heating causes the resistance to rise exponentially, driving the fuse to blow. The outer epoxy resin seal is resistant to salt spray corrosion (no attenuation in 168h test). In the system, it serves as the primary current anomaly sensor, directly controlling the fiber optic cable to blow and generating a residual attenuation curve signal to initiate the trigger.

[0104] The unidirectional optical fiber is a multimode silica fiber (GI 62.5 / 125μm), with an outer sheath of polyvinyl chloride (PVC) and Kevlar fiber reinforcement. It has a core diameter of 62.5μm, a numerical aperture of 0.275, attenuation <0.5dB / km @850nm, and a fusing threshold where the glass fiber physically fuses at a local temperature >350℃. The standard length is 2m. One end is fixed to the output port of the photoelectric converter (FC / APC interface), and the other end is fixed to the relay input port of the actuator. A dedicated fusing clamp ensures complete fiber separation after fusing. The built-in optical isolator has a reverse attenuation >60dB, a bending radius >10mm, a temperature resistance of -50℃ to +150℃, and a tensile strength >100N. Its function is to achieve physical unidirectional irreversible transmission of commands. After fusing, it forms permanent isolation and outputs a residual signal as proof of downstream legitimacy.

[0105] The high-voltage ceramic capacitor is a Y5U type multilayer ceramic capacitor with a capacitance of 100pF and a withstand voltage of 15kV. Its size is 20mm×15mm. It is connected in parallel to the rotor grounding circuit through copper busbar bolts (M8). The breakdown threshold is >12kV, which forms a permanent short circuit. The outer layer is epoxy-encapsulated for moisture protection. At the moment of breakdown, it releases energy to generate a 300V / m electromagnetic pulse. Its function is to provide irreversible protection against grounding abnormalities. The pulse is transmitted to the hysteresis module sensor through a shielded cable (twisted pair + aluminum foil) to trigger a global fuse.

[0106] Magnetic fields and actuators: The high coercivity magnetic ring uses samarium cobalt permanent magnet alloy (Sm2Co17), with an inner diameter matching the outer diameter of the actuator drive coil (typically 35mm). It has a coercivity >2000kA / m, a remanence of 1.1T, and a thickness of 10mm. It is tightly wound around the outer layer (copper coil) of the actuator drive coil with a gap of <0.1mm and is fixed with high-temperature resistant epoxy. When the drive coil is energized, it generates a unique hysteresis loop as a fingerprint. The outer fluxgate sensor captures the waveform. It is temperature resistant from -40℃ to +200℃ with no risk of demagnetization. Its function is to generate an unforgeable physical fingerprint. Any external magnetic field interference will cause a slope deviation and trigger the latch.

[0107] The actuator drive coil is made of enameled copper wire (QZY-2 / 200 grade), with 1200 turns and a resistance of 0.8Ω. It is wound around an electromagnet core (DT4 pure iron) and an outer layer of high coercivity magnetic ring. When the current is <2A, it generates a 150N suction force to drive the valve (water supply valve, speed control valve, or excitation regulator). Its function is the final actuator. The hysteresis waveform serves as the fingerprint source. In case of abnormality, it is physically jammed by the mechanical locking tongue.

[0108] The photoelectric converter uses a combination of InGaAs PIN photodiode and laser diode. The input electrical signal range is 0~24V DC, the output optical power is -10dBm, and the wavelength is 850nm. The pulse width modulation method converts the electrical signal into 50ns~500ns pulse light. It is installed on the fieldbus terminal and fixed by DIN rail. The outer shell is made of aluminum alloy for heat dissipation. Its function is to convert the electrical commands of the original control system into optical signals and enter the protection chain.

[0109] Mechanical interlocking and recording components: The mechanical interlocking rod is made of high-temperature resistant alloy steel (1Cr18Ni9Ti), with a diameter of 20mm and a length of 1.2m. The surface is laser-etched with microstructures (depth 2μm, spacing 10μm). One end is mechanically connected to the boiler safety valve spring (stiffness 150N / mm), and the other end is connected to the turbine overspeed trip mechanism pull rod. It is fixed by the original reserved channel bolt (M20). The built-in bimetallic thermal expansion compensator automatically adjusts the length ±2mm. When impacted or overpressed, it transmits a force of more than 150N and generates a standard vibration spectrum. It is pressure resistant to 35MPa and temperature resistant to 550℃. Its function is to realize the interlocking of the pure mechanical subsystem and the generation of vibration fingerprints, without the dependence on electrical signals.

[0110] The piezoelectric crystal sensor is a lead zirconate titanate (PZT-5H) piezoelectric ceramic with a sensitivity of 10mV / g and a frequency response of 0~10kHz. It is installed on the interlocking rod fixing seat at the turbine end and fastened by threads. The outer shell is sealed with stainless steel, dustproof and waterproof, and has an IP67 rating. After receiving the vibration of the interlocking rod, it outputs an analog voltage signal to the internal Hilbert transform circuit to extract the envelope. Its function is to collect and preliminarily process vibration fingerprints in real time. When the correlation coefficient is abnormal, it directly drives the backup trip relay.

[0111] The fuse recovery locking unit includes an electromagnetic lock stop pin (neodymium iron boron permanent magnet holding force 500N), a spring reset device (stiffness 20N / mm), and an anti-tamper lead seal (one-time aluminum alloy breaking force >200N). It is installed on the shell of the unidirectional fiber optic fuse module to ensure that the lead seal must be manually broken after the fuse is broken before it can be replaced, thus preventing remote recovery.

[0112] The breakdown trace recording module includes a miniature fuse (glass tube rated 0.1A) and a non-volatile memory chip (FRAM 4Kb). When the fuse breaks down, it writes a timestamp and waveform data for physical evidence collection.

[0113] The on-site calibration isolation chamber is a fully metal shielded box (2mm thick steel plate with attenuation >80dB), with a built-in standard light source (LED 850nm with stability of 0.1%) and a magnetic field generator (Helmholtz coil with field strength of 0-50mT). It is sealed by mechanical locks and is used for one-time physical calibration before system startup to prevent tampering during operation.

[0114] These hardware components form a strongly correlated closed loop through optical-magnetic-vibrational-electrical physical coupling. Any malfunction of a single component will trigger irreversible isolation of the entire system, ensuring that information security protection is deeply integrated into the control process. Specific Implementation Example 8

[0115] The following is an explanation of the instruction manual. Figure 2 To be continued Figure 4 Detailed explanation: Figure 2 Fiber optic current anomaly detection (three-point moving average method) Graphical content: The blue solid line represents the normal command current (approximately 1125mA), the red dashed line represents the current after the attack, and the black solid line represents the sudden change in amplitude, which increases abruptly starting at 30ms and is marked as a circuit breaker trigger at 40ms.

[0116] As can be seen from the figure: after the attack injection, the mutation amplitude is >5mA and lasts for 10ms, triggering the physical fuse of the unidirectional fiber, which effectively corresponds to "Sp3: the unidirectional fiber fuse module monitors the unidirectional fiber current in real time and executes the fuse decision when there is an abnormality" in the solution.

[0117] Figure 3 Vibration time-domain envelope (Hilbert transform) Graphical content: The solid blue line represents the standard template, and the dashed red line represents the attack waveform. The correlation coefficient is 1.000, and the impact generates an envelope at 55ms.

[0118] As can be seen from the figure: the standard vibration envelope triggered by the impact is extracted by Hilbert transform and used for subsequent correlation comparison, which effectively corresponds to "Sp5: collect vibration spectrum for time domain envelope comparison" in the scheme.

[0119] Figure 4 System protection status timing Graphical content: Status changes from normal operation (30ms attack injection) → 40ms fiber optic cable failure, maintaining isolation.

[0120] As can be seen from the figure: the fiber optic cable is broken within 10ms after the attack, and the system enters irreversible isolation, which is in line with the effective solution "Sp6: trigger global fusion and simultaneously cut off all control command paths".

[0121] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising a reference structure" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0122] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A heat engine unit integrated control system fused with information security protection, characterized in that, Comprise: One-way optical fiber fuse module, real-time monitoring of one-way optical fiber current and in abnormal when performing fuse decision, output light pulse residual shadow attenuation curve signal to hysteresis loop fingerprint locking module to trigger hysteresis waveform sampling; Hysteresis loop fingerprint locking module, the hysteresis loop waveform of actuator drive coil is extracted and compared by multiple slope characteristics, and the impact signal is output to the boiler-turbine thermal-vibration dual-channel mechanical interlocking module to generate vibration fingerprint; Boiler-turbine thermal-vibration dual-channel mechanical interlocking module, realizing subsystem physical interlocking and collecting vibration spectrum for time domain envelope comparison; Generator rotor grounding carbon brush leakage current hard isolation module, real-time monitoring of rotor grounding loop and in abnormal when generating electromagnetic pulse signal transmission to the magnetic hysteresis loop fingerprint locking module to trigger global fuse.

2. The integrated control system of the thermoelectric generator and the information security protector according to claim 1, characterized in that: The one-way optical fiber fuse module is built-in thermistor and one-way optical fiber, the thermistor real-time monitoring through one-way optical fiber abnormal current, using three-point moving average method to judge current mutation, when mutation amplitude exceeds 5mA and duration exceeds 10ms, trigger physical fuse one-way optical fiber, after fuse the one-way optical fiber is permanently disconnected, the actuator end relay loses driving signal, the actuator returns to safe state, at the same time, generate light pulse residual shadow attenuation curve signal through special photoelectric conversion line transmission to the magnetic flux gate sensor of the magnetic hysteresis loop fingerprint locking module.

3. The integrated control system of a heat and power unit with fusion information security protection according to claim 1, characterized in that: The magnetic hysteresis loop fingerprint locking module includes magnetic flux gate sensor and high coercivity magnetic ring, after the magnetic flux gate sensor receives the light pulse residual shadow attenuation curve signal from the one-way optical fiber fuse module, start to extract five slope characteristics of the hysteresis loop waveform generated by the high coercivity magnetic ring, extract the slope value of each section and compare with the factory physical burning template, when any section slope deviation exceeds 3%, trigger mechanical lock tongue to pop out physical stuck actuator drive coil, after comparison, transmit the impact signal to the boiler-turbine thermal-vibration dual-channel mechanical interlocking module through mechanical impact rod.

4. The integrated control system of a heat and power unit with fusion information security protection according to claim 1, characterized in that: After the boiler-turbine thermal-vibration dual-channel mechanical interlocking module receives the impact signal from the magnetic hysteresis loop fingerprint locking module, the laser interference microstructure on the surface of the mechanical interlocking rod generates vibration spectrum, the piezoelectric crystal sensor at the turbine end real-time collects the vibration spectrum and performs hilbert transform to extract time domain envelope, and the envelope curve of the preset spectrum template is correlated and compared, when the correlation coefficient is less than 0.95, trigger the standby trip mechanism to act.

5. The integrated control system of a heat and power unit with fusion information security protection according to claim 1, characterized in that: The boiler-turbine thermal-vibration dual-channel mechanical interlocking module includes mechanical interlocking rod and piezoelectric crystal sensor, one end of the mechanical interlocking rod is connected with boiler safety valve spring, and the other end is connected with turbine overspeed trip mechanism, and the piezoelectric crystal sensor is installed at the turbine end; when the boiler overpressure, the safety valve spring is directly pulled by the mechanical interlocking rod, and the other end of the mechanical interlocking rod drives the turbine overspeed trip mechanism to act, realizing physical interlocking without electric signal.

6. The integrated control system of a heat and power unit with fusion information security protection according to claim 1, characterized in that: The generator rotor ground carbon brush leakage current hard isolation module includes a high-voltage ceramic capacitor, which monitors the rotor ground loop in real time, breaks down to form a permanent short circuit when an abnormal ground is detected, triggers the main circuit breaker to trip, and at the same time, an electromagnetic pulse signal is generated at the moment of breakdown and transmitted to the hysteresis loop fingerprint locking module through a shielded cable.

7. The integrated control system of a heat and power unit with fusion information security protection according to claim 6, characterized in that: After the fluxgate sensor of the hysteresis loop fingerprint locking module receives the electromagnetic pulse signal from the generator rotor ground carbon brush leakage current hard isolation module, the thermal resistor of the one-way optical fiber fusing module is triggered to physically fuse the one-way optical fiber, and all control command channels are simultaneously cut off.

8. The integrated control system of a heat and power unit with fusion information security protection according to claim 1, characterized in that: The one-way optical fiber fusing module is connected in series to the thermoelectric unit IO cabinet; the hysteresis loop fingerprint locking module is configured on the drive coil of the actuator, which is a boiler feed water valve, a steam turbine speed regulating valve or a generator excitation regulator; the boiler-turbine thermal-vibration dual-channel mechanical interlocking module is installed between the boiler and the steam turbine; the generator rotor ground carbon brush leakage current hard isolation module is connected in parallel to the generator rotor ground loop.

9. The control method of the integrated control system of a thermoelectric generator and an information security shield according to any one of claims 1 to 8, characterized by, The method comprises the following steps: Real-time monitoring of one-way optical fiber current and execution of fusing decision when abnormal, output of optical pulse residual shadow decay curve signal to the hysteresis loop fingerprint locking module to trigger hysteresis waveform sampling; Multi-segment slope feature extraction and comparison of the hysteresis loop waveform of the actuator drive coil, output of impact signal to the boiler-turbine thermal-vibration dual-channel mechanical interlocking module to generate vibration fingerprint; Realization of subsystem physical interlocking and collection of vibration frequency spectrum for time domain envelope comparison; Real-time monitoring of the rotor ground loop and generation of an electromagnetic pulse signal when abnormal to transmit to the hysteresis loop fingerprint locking module to trigger global fusing.

10. The integrated control method of a heat and power unit with fusion information security protection according to claim 9, characterized in that, Sending control commands through field bus, converting control command electrical signals into pulse optical signals in pulse width modulation mode, and driving the actuator to act by pulse optical signals.

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