Cloud edge collaborative virtual controller architecture, adaptation method and implementation method

Abstract

The invention discloses a cloud edge collaborative virtual controller architecture, an adaptation method and an implementation method, and relates to the technical field of industrial automation control. The virtual controller adopts a three-layer architecture of a cloud / upper engineering layer, an edge control layer and a field equipment layer, a core control unit is established by industrial control software and an industrial-grade industrial personal computer, and high-real-time and high-stability control of an industrial field is realized; according to the operation mechanism, through a closed loop process of upper computer programming configuration, edge side Runtime starting initialization, program downloading verification and real-time communication cooperation, traditional logic sequence defects are corrected, and control reliability is ensured; and the protocol adaptation module supports interconnection, intercommunication and conversion of a plurality of industrial protocols such as Modbus, EtherCAT, Profinet and the like. The method does not need to depend on a complex hardware architecture, solves the problems of poor compatibility, insufficient real-time performance and low deployment flexibility of a traditional controller protocol through deep collaborative optimization of software and industrial-grade hardware, is suitable for various industrial automation scenes, and has a wide application prospect through third-party detection verification. The protocol communication success rate and the control response performance meet the harsh requirements of an industrial site.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, and more specifically, to a cloud-edge collaborative virtual controller architecture, adaptation and implementation method, which is applicable to industrial scenarios such as process industries and discrete industries that require multi-protocol collaboration and high real-time control. Background Technology

[0002] The manufacturing industry is accelerating its transformation towards flexibility and intelligence. Traditional programmable logic controllers (PLCs) are increasingly revealing numerous limitations in complex industrial scenarios: First, poor protocol compatibility. Most traditional PLCs adopt a closed architecture, supporting only specific brands or a few types of industrial protocols, making it difficult to achieve collaborative work between devices using different protocols. This leads to prominent "information silos" in industrial settings, hindering production efficiency. Second, unreasonable operational logic design. Some existing virtual controller solutions have a logic defect where the program download starts before the runtime environment, easily causing program loading failures and abnormal control logic execution, affecting system stability. Third, low deployment flexibility. Traditional PLCs have highly bundled hardware and software; changing control logic or expanding functions requires replacing hardware modules, resulting in high deployment costs and long cycles, making it difficult to adapt to the dynamic needs of flexible production. Fourth, insufficient protocol adaptation capabilities. Existing virtual controllers are mostly designed for single or a few industrial protocols, lacking dedicated adaptation logic for mainstream protocols, making it difficult to guarantee the accuracy and real-time performance of data interaction.

[0003] Virtual PLCs (vPLCs) simulate the functions of traditional PLCs through software and, combined with industrial-grade hardware, offer a new technological approach to solving the aforementioned problems. However, existing virtual controllers still suffer from limitations such as limited protocol compatibility, insufficient adaptability of operating mechanisms to industrial environments, and inability to meet stringent industrial requirements in terms of stability. To address these shortcomings, this invention proposes a cloud-edge collaborative virtual controller architecture, adaptation, and operating mechanism. Through a three-layer architecture design, a rational sequence of operating logic, and dedicated protocol adaptation logic, it enables collaborative control of multi-protocol devices, improves system real-time performance and reliability, and fills a gap in existing technology. Summary of the Invention

[0004] The purpose of this invention is to provide a cloud-edge collaborative virtual controller architecture, adaptation and implementation method. Through a three-layer architecture design, a reasonable operating logic sequence and dedicated protocol adaptation logic, it enables collaborative control of multi-protocol devices and improves the real-time performance and reliability of the system.

[0005] The technical solution adopted by the present invention to achieve the above objectives is as follows:

[0006] The cloud-edge collaborative virtual controller architecture includes:

[0007] The cloud / upper-level engineering layer is equipped with industrial control software and dedicated support software. It is used to configure hardware resources that meet the development and simulation requirements of control logic through the industrial control software, and to interact with the edge control layer through the TCP / IP protocol.

[0008] The edge control layer is used to perform logical operations on the physical quantity data collected by the field device layer, generate control commands, and send them to the field device layer through a dedicated industrial interface.

[0009] The field device layer is used to collect physical quantity data from the industrial field and send it to the edge control layer through a dedicated industrial interface, as well as to execute corresponding actions according to control commands.

[0010] The industrial control software supports multiple programming languages ​​and has functions such as control logic programming, simulation debugging, communication parameter configuration, IO mapping, equipment status monitoring, and fault alarm.

[0011] The edge control layer includes:

[0012] Runtime environment is used for protocol adaptation module initialization, control program verification and loading, data acquisition and processing, control command generation, communication link maintenance and fault information feedback;

[0013] The protocol adaptation module is used to identify the communication characteristics of the corresponding protocol through various dedicated protocol adaptation components, convert the format of the protocol data sent by the field device layer, and maintain the communication link with the field device layer.

[0014] The data caching unit is used to temporarily store the collected field equipment data and the control commands to be issued.

[0015] The field device layer includes:

[0016] Sensors are used to collect physical quantity data in industrial settings;

[0017] The actuator is used to execute control commands issued by the edge control layer;

[0018] IO modules are used to expand the input / output interfaces of a device.

[0019] The implementation method of the cloud-edge collaborative virtual controller architecture includes the following steps:

[0020] 1) Program the control logic in the industrial control software at the cloud / upper-level engineering layer, configure the communication parameters, IO mapping relationships and startup parameters according to the industrial control requirements, and verify the correctness of the program logic through offline simulation;

[0021] 2) Start the runtime environment of the edge control layer, initialize the protocol adaptation module, detect the connection status between each module and the communication link connectivity with the cloud / upper-level engineering layer. If there is an abnormality, feedback the fault information and continue to retry until the status is normal.

[0022] 3) Once the Runtime is ready and the communication link is established, the completed control program is downloaded to the industrial-grade control computer at the edge control layer via the TCP / IP protocol, and the control computer verifies the integrity of the program.

[0023] 4) The runtime environment loads and executes the verified control program, collects sensor data from the field equipment layer in real time through the protocol adaptation module, and calculates and generates control commands based on the control logic;

[0024] 5) The control commands are sent to the actuators at the field equipment layer through the protocol adaptation module to control their actions; at the same time, the equipment operation status data is fed back to the cloud / upper-level engineering layer to realize real-time monitoring and fault alarm.

[0025] The protocol adaptation module is designed with dedicated adaptation logic for three industrial protocols: Modbus, EtherCAT, and Profinet. It automatically identifies the protocol type of the field device and calls the corresponding protocol library to complete data format conversion, communication link establishment, and fault handling. Specifically, the adaptation logic is as follows:

[0026] For Modbus protocol adaptation: Configure communication parameters through ModbusTCP master-slave mode, set the address, port, response timeout and reconnection mechanism to adapt to industrial scenarios, realize data interaction through function code configuration, and establish association between protocol data and control logic variables through IO mapping;

[0027] For EtherCAT protocol adaptation: Configure the master and slave station synchronization unit allocation, process data mapping and startup parameters, use the EtherCAT protocol to realize device management and real-time data transmission, and support the interaction of digital and analog quantities;

[0028] For Profinet protocol adaptation: Configure the communication parameters and real-time communication categories of master and slave stations, set the sending period and watchdog mechanism, and realize the mapping and collaborative interaction of input and output data through IO configuration.

[0029] Control systems based on a cloud-edge collaborative virtual controller architecture include:

[0030] The task scenario building module is used to build a control logic programming environment in the cloud / upper-level engineering layer, configure communication parameters and IO mapping relationships, and verify the correctness of the program through offline simulation.

[0031] The Runtime startup initialization module is used to start the edge control layer Runtime environment, initialize the multi-protocol adaptation module, and detect the device connection, communication link and hardware resource status.

[0032] The program includes a verification module, which is used to transmit control programs via TCP / IP protocol, and uses verification algorithms to verify and store the integrity of the program.

[0033] The real-time control execution module is used to load the control program, collect and process field equipment data, and generate and issue control commands.

[0034] The data feedback monitoring module is used to receive the execution results of the device, determine the execution status, and feed back to the cloud / upper-level engineering layer to realize real-time monitoring and fault alarm.

[0035] The multi-protocol adaptation module is used for adapting and converting data using Modbus, EtherCAT, and Profinet protocols.

[0036] A computer-readable storage medium storing a computer program, which, when executed by a processor, implements the method for implementing the cloud-edge collaborative virtual controller architecture.

[0037] The present invention has the following beneficial effects and advantages:

[0038] 1. Strong protocol compatibility: Through multi-protocol adaptation modules and dedicated adaptation logic, it achieves interconnection and interoperability of various mainstream industrial protocols such as Modbus, EtherCAT, and Profinet, supports seamless collaboration of devices with different protocols, and completely solves the problems of poor protocol compatibility and "information silos" in traditional controllers; the industrial control software has a built-in complete protocol library, and new protocol support can be added through extension interfaces, making it highly adaptable.

[0039] 2. High operational reliability: The operating mechanism follows a reasonable logical sequence of "Runtime startup - program download - control execution", correcting the defect in the existing solution where program download precedes Runtime startup; it includes multiple protection mechanisms such as program verification, fault retry, link maintenance, and hardware resource monitoring to ensure stable system operation. It has been verified by third-party testing and meets the stringent reliability requirements of industrial sites.

[0040] 3. High deployment flexibility: Based on domestically produced industrial control software and industrial-grade industrial control computers, the control logic can be flexibly modified through software without replacing hardware modules; the control program scanning cycle can be flexibly configured according to the needs of industrial scenarios, and can adapt to different types of control needs such as process industries and discrete industries.

[0041] 4. Excellent ease of maintenance: It has comprehensive fault alarm and diagnostic functions, which can monitor equipment faults, communication abnormalities, program execution errors and abnormal hardware resource usage in real time, and record detailed fault information (alarm time, type, location and description), which makes it easy for operators to quickly locate and troubleshoot problems and reduce maintenance costs. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the method of the present invention;

[0043] Figure 2 This is a topology diagram of the system architecture of the method of the present invention. Detailed Implementation

[0044] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0045] A cloud-edge collaborative virtual controller adopts a three-layer architecture, and the functions and connections of each layer are as follows:

[0046] 1) The cloud / upper-level engineering layer serves as the core decision-making layer, built upon an industrially compatible operating system and deployed with industrial control software and dedicated support software. The industrial control software adheres to the IEC 61131-3 international standard, supports four programming languages: LD (Ladder Diagram), ST (Structured Text), FBD (Function Block Diagram), and SFC (Sequential Function Chart), and possesses integrated functions such as control logic programming, simulation debugging, communication parameter configuration, I / O mapping, equipment status monitoring, and fault alarms. This layer utilizes an industrial computer, configured with hardware resources sufficient for control logic development and simulation. A stable communication link is established with the edge control layer via TCP / IP protocol to ensure reliable transmission of control programs, configuration commands, and status data.

[0047] 2) The edge control layer, acting as the execution hub, uses an industrial-grade PC as its core hardware. This PC has undergone industrial-grade stability testing, supports long-term continuous operation, and possesses excellent environmental adaptability. This layer deploys a runtime environment, a protocol adaptation module, and a data caching unit. The runtime environment has functions such as program parsing, communication management, data processing, and fault alarms, capable of performing operations such as protocol adaptation module initialization, control program verification and loading, acquired data processing, control command generation, communication link maintenance, and fault information feedback. The protocol adaptation module includes dedicated adaptation components for Modbus, EtherCAT, and Profinet protocols, capable of identifying the communication characteristics of the corresponding protocols and realizing protocol data format conversion and communication link maintenance. The data caching unit is used to temporarily store acquired field device data and control commands to be issued, ensuring data transmission continuity. The edge control layer communicates with the cloud / upper-level engineering layer via TCP / IP protocol and connects to the field device layer through dedicated industrial interfaces (such as Ethernet interfaces and dedicated bus interfaces), supporting industrial-grade data transmission rates.

[0048] 3) The field device layer, acting as the sensing and execution terminal, consists of various types of sensors, actuators, and I / O modules. Sensors are used to collect physical quantity data from the industrial field; actuators, including various output modules, motors, valves, etc., are used to execute control commands issued by the edge control layer; I / O modules are used to expand the input and output interfaces of the devices and improve system scalability. All devices support at least one mainstream industrial protocol (Modbus, EtherCAT, or Profinet), and can establish stable communication with the corresponding protocol adapter components of the edge control layer. Physical connections are established with the protocol adapter modules of the edge control layer through dedicated industrial buses or Ethernet to ensure the real-time performance and reliability of data transmission.

[0049] 4) Communication connection relationship: The cloud / upper-level engineering layer and the edge control layer establish a stable communication link through the TCP / IP protocol for transmitting control programs, configuration parameters and equipment status data; the edge control layer and the field device layer realize the data transmission of different industrial protocols through a multi-protocol adaptation module to ensure collaborative work between cross-protocol devices.

[0050] An operating mechanism based on the above-mentioned virtual controller includes the following steps:

[0051] 1) Control Logic Programming and Configuration: In the industrial control software at the cloud / upper-level engineering layer, write control logic programs according to industrial control requirements. These programs must include data acquisition logic, computation logic, control command generation logic, and fault handling logic. Configure communication parameters (including TCP / IP communication parameters between the cloud / upper-level engineering layer and the edge control layer, and protocol adaptation parameters between the edge control layer and the field device layer), IO mapping relationships (establishing a one-to-one correspondence between protocol data and control logic variables), and startup parameters according to the actual application scenario. Verify the correctness of the program logic using the offline simulation function of the industrial control software. During the simulation, simulate the input data of the field devices and observe whether the output results of the control program meet expectations. Only after the simulation passes can the next step be performed.

[0052] 2) Runtime Startup and Initialization: The Runtime environment of the edge control layer is started. The Runtime automatically loads the system configuration, initializes the multi-protocol adaptation module, and detects the hardware connection status and identification information of each protocol adaptation component. If no module is detected or the module identification is abnormal, a module fault alarm is immediately sent to the cloud / upper-level engineering layer. The alarm information includes the faulty module type and the time of the fault occurrence. At the same time, the connectivity of the communication link between the edge control layer and the cloud / upper-level engineering layer is detected, and the link status is confirmed through a handshake signal. If the link is abnormal, the Runtime will continuously retry at reasonable intervals. In addition, the Runtime will also detect the hardware resource status of the edge control layer (including CPU load, memory usage, storage space, etc.). If the hardware resource usage exceeds the preset reasonable range, a resource warning signal is sent to the cloud / upper-level engineering layer. After all status checks are normal, the Runtime sends a "ready" signal to the cloud / upper-level engineering layer, indicating that the control program download can be received.

[0053] 3) Program Download and Verification: After receiving the "Ready" signal, the cloud / upper-level engineering layer downloads the completed control program and configuration parameters to the industrial-grade control computer at the edge control layer via the TCP / IP protocol. Upon receiving the program data, the industrial control computer uses a dedicated verification algorithm to check the integrity of the program file. If the verification passes, the program is stored in a local dedicated directory; if the verification fails, a download failure message is sent, triggering the cloud / upper-level engineering layer to re-download. After the program is stored, the industrial control computer sends a successful download confirmation signal to the cloud / upper-level engineering layer via Runtime. Operators can view the download status on the industrial control software interface.

[0054] 4) Real-time Control Execution: The runtime environment loads and executes the validated control program. Following a configurable scanning cycle (flexibly adjustable according to industrial scenario requirements), it collects sensor data from field devices in real time via a protocol adaptation module. During data collection, initial screening removes obviously abnormal data. The collected data is standardized, converting non-standard data from different devices into a unified format for easier control logic operations. The control logic program then processes the processed data to generate control commands containing information such as the execution object, execution parameters, and execution time. The protocol adaptation module encapsulates the control commands according to the corresponding industrial protocol format and sends them to the target actuator. Upon receiving the commands, the actuator performs the corresponding control action.

[0055] 5) Data Feedback and Status Monitoring: After the field equipment executes a control action, it feeds back the execution results (including action completion status, current operating parameters, equipment fault information, etc.) to the edge control layer through the original communication link. The Runtime parses the feedback data, extracts key information, and determines whether the control action was successfully executed. If the execution fails, a retry mechanism is triggered, and the control command is reissued. If the retry still fails, the fault information is recorded and an alarm is sent to the cloud / upper-level engineering layer. The Runtime uploads real-time data from the field equipment, control command execution status, system operating status, and other information to the cloud / upper-level engineering layer in a unified format. The industrial control software in the cloud / upper-level engineering layer displays the data in real time through the monitoring interface. Continuous data is displayed in the form of curves, and the equipment operating status is displayed in the form of icons (normal and fault states are distinguished by different icons). When the data exceeds the preset threshold, or when there is a equipment fault or communication abnormality, an audible and visual alarm is triggered and an alarm log is recorded. The log includes information such as alarm time, alarm type, alarm location, and alarm description, which facilitates troubleshooting by operators.

[0056] A protocol adaptation method based on the aforementioned virtual controller is proposed, which designs dedicated adaptation logic for three mainstream industrial protocols: Modbus, EtherCAT, and Profinet, as detailed below:

[0057] 1) Modbus Protocol Adaptation: Communication parameters are configured using ModbusTCP master-slave mode, setting addresses, ports, response timeouts, and reconnection mechanisms suitable for industrial scenarios to ensure communication link stability. Data interaction types (such as coil read / write, register data interaction, etc.) are defined through function code configuration to achieve data transmission between master and slave stations. I / O mapping relationships are established, associating protocol data with control logic variables to ensure the control program can accurately read input data and issue output commands. The protocol adaptation module automatically identifies Modbus protocol devices and calls the corresponding protocol library to complete data format conversion, communication link establishment, and fault handling (such as retransmission mechanisms for data transmission timeouts and verification failures).

[0058] 2) EtherCAT Protocol Adaptation: Configure the synchronization unit allocation, process data mapping relationship, and startup parameters for the EtherCAT master and slave stations, clarifying the synchronization rules and data paths for data interaction. Device management is implemented using the corresponding protocol. The master station configures slave station control words through dedicated commands and reads slave station status words through dedicated commands, achieving effective control over slave station devices. Real-time data transmission uses Process Data Objects (PDOs). The master station encapsulates control commands into PDO data frames and sends them to the slave station. After receiving the data, the slave station executes the corresponding actions and returns the acquired data, supporting stable interaction between digital and analog signals. The protocol adaptation module monitors the communication status in real time. If a link anomaly or device failure is detected, a reconnection or alarm mechanism is triggered promptly.

[0059] 3) Profinet Protocol Adaptation: Configure the communication parameters (including station name, address, subnet mask, gateway, etc.) and real-time communication category for the Profinet master and slave stations, set a reasonable transmission cycle and watchdog mechanism to avoid control anomalies caused by communication delays or device offline. Input / output data mapping and collaborative interaction are achieved through IO configuration, clearly defining the address and format of data transmission. The master and slave stations use a producer-consumer model for IO data exchange. The master station receives input data from the slave station and sends control commands to the slave station. Real-time Ethernet technology is used to ensure real-time transmission. The protocol adaptation module monitors the slave station status in real time through diagnostic services. When a slave station disconnection is detected, a slave station search and reconnection process is initiated. Data interaction is automatically resumed after a successful connection.

[0060] 4) Automatic Protocol Identification and Extension: The protocol adaptation module can automatically identify the protocol type of field devices. It determines the industrial protocols supported by the devices based on handshake signals or protocol identification information, and then calls the corresponding protocol library to complete data format conversion, communication link establishment, and fault handling. This enables collaborative work between devices using different protocols without manual intervention. Furthermore, the industrial control software has a built-in complete protocol library that supports Modbus, EtherCAT, and Profinet protocols, as well as mainstream industrial protocols such as Modbus RTU, OPCUA, and CANopen. New communication protocols can be added through the extended protocol library interface without modifying the core control logic, thus improving the system's scalability and adaptability.

[0061] A cloud-edge collaborative virtual control system includes the following functional modules:

[0062] 1) Dependency Task Scenario Building Module: Deployed in the cloud / upper-level engineering layer, it is used to build a control logic programming environment, support operators to write control programs, configure communication parameters, IO mapping relationships and startup parameters, and verify the correctness of program logic through offline simulation function, providing a reliable program foundation for subsequent control execution.

[0063] 2) Runtime startup initialization module: Deployed in the edge control layer, it is used to start the runtime environment, initialize the multi-protocol adaptation module, detect the connection status of the protocol adaptation component, the connectivity of the communication link with the cloud / upper-level engineering layer and the hardware resource status of the edge control layer, and provide feedback on fault information or resource warning signals when abnormalities occur, ensuring that the system is ready to start before the program is downloaded.

[0064] 3) Program download verification module: It is used to transmit the control program of the cloud / upper-level engineering layer to the edge control layer via TCP / IP protocol. It uses a dedicated verification algorithm to complete the program integrity verification. If the verification is successful, the program is stored and a successful download signal is sent back. If the verification fails, a re-download is triggered to ensure the integrity and reliability of the program transmission.

[0065] 4) Real-time control execution module: Deployed at the edge control layer, it is used to load and execute the verified control program, collect field equipment data according to the preset scanning cycle, perform standardized processing and logical operations on the data, generate control commands and send them to the actuator through the protocol adaptation module to realize real-time control actions.

[0066] 5) Data feedback monitoring module: Used to receive the execution results of field equipment, judge the execution status of control actions, and trigger retry or alarm mechanisms when abnormalities occur; at the same time, it uploads information such as real-time data of field equipment, execution status of control commands, and system operation status to the cloud / upper-level engineering layer, and works with industrial control software to realize real-time monitoring and fault alarm.

[0067] 6) Multi-protocol adaptation module: Used to adapt and convert data for Modbus, EtherCAT and Profinet protocols, automatically identify the protocol type of field devices, call the corresponding protocol library to complete the establishment of communication links, data format conversion and fault handling, and support seamless collaboration of cross-protocol devices.

[0068] A computer-readable storage medium storing a computer program that, when executed by a processor, implements the cloud-edge collaborative virtual controller architecture, adaptation, and operation mechanism.

[0069] Example

[0070] The core implementation logic of this invention is as follows: a control infrastructure environment is built through a three-layer architecture, and the operational stability is ensured by the logical sequence of "Runtime startup initialization - program download and verification - real-time control execution". Multi-protocol device collaboration is achieved through dedicated protocol adaptation logic, ultimately meeting the high real-time and high reliability control requirements of industrial scenarios. Figure 1 The diagram shown is a schematic diagram of the method of the present invention. Figure 2The diagram shown is a system architecture topology diagram of the method of the present invention. The specific implementation process is as follows:

[0071] Step 1: Hardware Deployment

[0072] This embodiment is designed for industrial temperature control scenarios, and the following hardware environment is set up with specific configurations:

[0073] 1) Cloud / Upper-Level Engineering Layer: An industrial computer running Windows 10 is used, with hardware configuration meeting the requirements for control logic development and simulation. Industrial control software (version adapted to IEC61131-3 standard) is installed for control program writing, parameter configuration, simulation debugging, and equipment status monitoring. This industrial computer establishes a TCP / IP communication link with the edge control layer via an Ethernet interface to ensure data transmission rate and stability.

[0074] 2) Edge Control Layer: Multiple industrial-grade PCs are used as hardware carriers. Each PC has a runtime environment and is configured with dedicated adapter components for Modbus, EtherCAT, and Profinet protocols: one PC is configured with a Modbus adapter for interface with temperature and pressure sensors; one with an EtherCAT adapter for interface with digital output modules; and one with a Profinet adapter for interface with motors and valve actuators. Each PC also has a data cache unit for temporarily storing field-collected temperature data and motor control commands to be issued.

[0075] 3) Field Equipment Layer: Deploy temperature and pressure sensors supporting the Modbus protocol, digital output modules supporting the EtherCAT protocol, and cooling motors and shut-off valves supporting the Profinet protocol. Temperature and pressure sensors are connected to the Modbus adapter via corresponding interfaces; digital output modules are connected to the EtherCAT adapter via Ethernet interfaces; cooling motors and shut-off valves are connected to the Profinet adapter via the Profinet bus. All physical connections conform to industrial field cabling standards.

[0076] Step 2: Software Configuration

[0077] Based on the above hardware environment, the software configuration and program writing are carried out as follows:

[0078] 2.1 Control Program Development: A temperature control program was developed using the ST programming language in the industrial control software to implement the complete logic of "temperature acquisition - threshold judgment - equipment control - fault handling". The core logic of the program is defined as follows: when the real-time temperature acquired by the temperature sensor reaches the preset upper threshold, the cooling motor is started and the shut-off valve is opened; when the temperature drops to the preset lower threshold, the cooling motor is turned off and the shut-off valve is closed; if no temperature sensor data is received consecutively, a communication failure is determined, triggering an audible and visual alarm and recording a fault log.

[0079] 2.2 Parameter Configuration:

[0080] TCP / IP communication parameters: The industrial computers in the cloud / upper-level engineering layer and the industrial control computers in the edge control layer are configured with TCP / IP communication parameters via Ethernet to ensure stable communication links. The response timeout time and reconnection interval are set to reasonable values ​​adapted to the industrial scenario.

[0081] Protocol adaptation parameters:

[0082] 1) Modbus protocol: Configure master-slave communication parameters, select the function code and trigger cycle that are suitable for the data acquisition scenario, and map the temperature sensor data and pressure sensor data to the corresponding control logic variables through IO mapping configuration.

[0083] 2) EtherCAT protocol: Configure master station synchronization unit allocation and slave station process data index, and establish a mapping relationship between the channels of digital output modules and the corresponding control addresses.

[0084] 3) Profinet protocol: Configure master and slave station names and communication parameters, set the transmission period and real-time communication category to adapt to real-time control requirements, and keep the watchdog time and transmission period in sync.

[0085] 2.3 Simulation Verification: Using the offline simulation function of the industrial control software, simulate different ranges of temperature sensor input values ​​(below the lower threshold, between the upper and lower limits, and above the upper threshold) and observe whether the device control commands output by the program conform to the expected logic; simulate a sensor communication interruption scenario to verify whether the fault alarm function is triggered normally. After the simulation is passed, it is confirmed that the control program logic is correct.

[0086] Step 3: Running Process

[0087] According to the closed-loop process of the operating mechanism of this invention, the following operations are performed:

[0088] 3.1 Runtime Startup and Initialization: Operators send a "Start Runtime" command to each industrial control computer in the edge control layer via the cloud / upper-level engineering layer industrial control software. After the Runtime runtime environment starts, it automatically loads system configuration and protocol adaptation parameters, checks the hardware connection status and identification information of each protocol adaptation component, and, after confirming no abnormalities, sends a handshake signal to the cloud / upper-level engineering layer via the TCP / IP link to check the communication link connectivity. Simultaneously, it checks the hardware resource status of the industrial control computers; after confirming that everything is within a reasonable range, each industrial control computer sends a "Ready" signal to the cloud / upper-level engineering layer.

[0089] 3.2 Program Download and Verification: After receiving the "Ready" signal from all industrial control computers, the cloud / upper-level engineering layer downloads the temperature control program and configuration parameters to the corresponding industrial control computers via TCP / IP protocol. Upon receiving the program data, the industrial control computer uses a dedicated verification algorithm to check the integrity of the program file. If the verification passes, the program is stored in a local dedicated directory, and a successful download confirmation signal is sent to the cloud / upper-level engineering layer via Runtime. The industrial control software interface displays the download status as "Successful".

[0090] 3.3 Real-time Control Execution: The Runtime collects field equipment data in real time according to the configured scan cycle through corresponding protocol adapter components: the Modbus adapter component collects temperature and pressure sensor data, filtering out abnormal data exceeding reasonable ranges during the collection process; the EtherCAT adapter component collects the operating status of digital output modules; and the Profinet adapter component collects the current status of motors and valves. After standardization processing, the collected data is input into the control program logic. Based on the comparison between the temperature value and a preset threshold, corresponding equipment control commands are generated. These commands are then encapsulated by the protocol adapter components according to the corresponding industrial protocol format and sent to the target actuator. Upon receiving the commands, the actuator completes the corresponding control action.

[0091] 3.4 Data Feedback and Monitoring: After the motor and valve execute control actions, their operating status is fed back to the industrial control computer at the edge control layer via the original communication link. The Runtime parses the feedback data to confirm successful action execution. Simultaneously, the Runtime uploads real-time temperature data, equipment operating status, and system operating status to the cloud / upper-level engineering layer in a unified format. The industrial control software monitoring interface displays temperature change trends as curves and uses different colored icons to distinguish between normal and faulty equipment states. When the temperature exceeds the threshold or equipment communication malfunctions, an audible and visual alarm is triggered, and an alarm log is recorded. The log includes information such as alarm time, alarm type, alarm location, and alarm description.

[0092] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope defined by the claims of the present invention.

Claims

1. A cloud-edge collaborative virtual controller architecture, characterized in that, include: The cloud / upper-level engineering layer is equipped with industrial control software and dedicated support software. It is used to configure hardware resources that meet the development and simulation requirements of control logic through the industrial control software, and to interact with the edge control layer through the TCP / IP protocol. The edge control layer is used to perform logical operations on the physical quantity data collected by the field device layer, generate control commands, and send them to the field device layer through a dedicated industrial interface. The field device layer is used to collect physical quantity data from the industrial field and send it to the edge control layer through a dedicated industrial interface, as well as to execute corresponding actions according to control commands.

2. The cloud-edge collaborative virtual controller architecture according to claim 1, characterized in that, The industrial control software supports multiple programming languages ​​and has functions such as control logic programming, simulation debugging, communication parameter configuration, IO mapping, equipment status monitoring, and fault alarm.

3. The cloud-edge collaborative virtual controller architecture according to claim 1, characterized in that, The edge control layer includes: Runtime environment is used for protocol adaptation module initialization, control program verification and loading, data acquisition and processing, control command generation, communication link maintenance and fault information feedback; The protocol adaptation module is used to identify the communication characteristics of the corresponding protocol through various dedicated protocol adaptation components, convert the format of the protocol data sent by the field device layer, and maintain the communication link with the field device layer. The data caching unit is used to temporarily store the collected field equipment data and the control commands to be issued.

4. The cloud-edge collaborative virtual controller architecture according to claim 1, characterized in that, The field device layer includes: Sensors are used to collect physical quantity data in industrial settings; The actuator is used to execute control commands issued by the edge control layer; IO modules are used to expand the input / output interfaces of a device.

5. A method for implementing a cloud-edge collaborative virtual controller architecture, characterized in that, Includes the following steps: 1) Program the control logic in the industrial control software at the cloud / upper-level engineering layer, configure the communication parameters, IO mapping relationships and startup parameters according to the industrial control requirements, and verify the correctness of the program logic through offline simulation; 2) Start the runtime environment of the edge control layer, initialize the protocol adaptation module, detect the connection status between each module and the communication link connectivity with the cloud / upper-level engineering layer. If there is an abnormality, feedback the fault information and continue to retry until the status is normal. 3) Once the Runtime is ready and the communication link is established, the completed control program is downloaded to the industrial-grade control computer at the edge control layer via the TCP / IP protocol, and the control computer verifies the integrity of the program. 4) The runtime environment loads and executes the verified control program, collects sensor data from the field equipment layer in real time through the protocol adaptation module, and calculates and generates control commands based on the control logic; 5) The control commands are sent to the actuators at the field equipment layer through the protocol adaptation module to control their actions; at the same time, the equipment operation status data is fed back to the cloud / upper-level engineering layer to realize real-time monitoring and fault alarm.

6. The implementation method of the cloud-edge collaborative virtual controller architecture according to claim 5, characterized in that, The protocol adaptation module is designed with dedicated adaptation logic for three industrial protocols: Modbus, EtherCAT, and Profinet. It automatically identifies the protocol type of the field device and calls the corresponding protocol library to complete data format conversion, communication link establishment, and fault handling. Specifically, the adaptation logic is as follows: For Modbus protocol adaptation: Configure communication parameters through ModbusTCP master-slave mode, set the address, port, response timeout and reconnection mechanism to adapt to industrial scenarios, realize data interaction through function code configuration, and establish association between protocol data and control logic variables through IO mapping; For EtherCAT protocol adaptation: Configure the master and slave station synchronization unit allocation, process data mapping and startup parameters, use the EtherCAT protocol to realize device management and real-time data transmission, and support the interaction of digital and analog quantities; For Profinet protocol adaptation: Configure the communication parameters and real-time communication categories of master and slave stations, set the sending period and watchdog mechanism, and realize the mapping and collaborative interaction of input and output data through IO configuration.

7. A control system based on a cloud-edge collaborative virtual controller architecture, characterized in that, include: The task scenario building module is used to build a control logic programming environment in the cloud / upper-level engineering layer, configure communication parameters and IO mapping relationships, and verify the correctness of the program through offline simulation. The Runtime startup initialization module is used to start the edge control layer Runtime environment, initialize the multi-protocol adaptation module, and detect the device connection, communication link and hardware resource status. The program includes a verification module, which is used to transmit control programs via TCP / IP protocol, and uses verification algorithms to verify and store the integrity of the program. The real-time control execution module is used to load the control program, collect and process field equipment data, and generate and issue control commands. The data feedback monitoring module is used to receive the execution results of the device, determine the execution status, and feed back to the cloud / upper-level engineering layer to realize real-time monitoring and fault alarm. The multi-protocol adaptation module is used for adapting and converting data using Modbus, EtherCAT, and Profinet protocols.

8. A computer-readable storage medium, characterized in that, The storage medium stores a computer program, which, when executed by a processor, implements the cloud-edge collaborative virtual controller architecture implementation method as described in claim 5 or 6.

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