Universal industrial controller and fault response efficiency improving system thereof

Abstract

The invention belongs to the technical field of industrial automation control, and particularly relates to a universal industrial controller and a fault response efficiency improving system thereof.The method comprises the steps that firstly, core operation and protocol parameters of an access industrial device are collected, device adaptation analysis is completed, and a device control instruction and a module scheduling instruction are generated; then, on the basis of a module scheduling instruction, adaptive switching of multiple types of industrial communication interfaces is completed, and protocol conversion and two-way transmission of a control signal and an equipment feedback signal are achieved; on the basis, the equipment parameter acquisition, parameter analysis and adaptation unit of the self-adaptive main control module is linked with a multi-interface protocol conversion architecture of the multi-protocol communication module, so that universal adaptation of industrial equipment in different industries and different specifications is realized, and a special controller does not need to be customized for specific equipment; and enterprise equipment investment and maintenance cost are reduced.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, specifically to a general-purpose industrial controller and its fault response efficiency improvement system. Background Technology

[0002] Industrial controllers are core devices in industrial automation systems, often referred to as the "brain" or "central nervous system" of the entire system. They are specialized electronic devices used to acquire field signals (such as temperature, pressure, position, and switch status), process and calculate them according to preset programs, logic, or algorithms, and then output control commands (such as driving motors, opening valves, and adjusting frequency converters), thereby achieving automatic monitoring and precise control of production equipment, production lines, or the entire industrial process.

[0003] However, most current industrial controllers are dedicated designs, only compatible with specific models and scenarios of industrial equipment. Different industries and different specifications of equipment require different controllers, resulting in poor versatility and increasing equipment investment and maintenance costs for enterprises. At the same time, the fault response of existing industrial controllers mostly adopts a "passive detection after fault occurs - manual troubleshooting - handling" mode, lacking the ability to predict and quickly locate faults. The fault response delay is high, and there is no dynamic optimization mechanism in the fault handling process, making it difficult to adapt to the continuous and high-precision requirements of industrial production. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides the following technical solution: A general-purpose industrial controller, comprising: The adaptive main control module collects and accesses the core operating and protocol parameters of industrial equipment, completes equipment adaptation and parsing, and generates equipment control commands and module scheduling commands. The multi-protocol communication module, based on the module scheduling instructions output by the adaptive main control module, completes the adaptation and switching of multiple types of industrial communication interfaces, and realizes the protocol conversion and bidirectional transmission of control signals and equipment feedback signals; The fault pre-detection module, based on the module scheduling instructions output by the adaptive main control module, obtains real-time operating data of the controller and equipment through the multi-protocol communication module, completes data preprocessing, anomaly identification, hidden danger tracing, and outputs a fault pre-detection report. The safety protection module, based on the module scheduling instructions output by the adaptive main control module, collects safety-related signals from the controller and equipment, completes risk assessment, and executes corresponding protective actions.

[0005] As a preferred embodiment of the general-purpose industrial controller described in this invention, the adaptive main control module includes: The equipment parameter acquisition unit collects the core parameters of the connected industrial equipment. It achieves comprehensive parameter acquisition through the built-in multi-interface acquisition circuit and outputs the equipment parameter acquisition set. The parameter parsing and adaptation unit, based on the device parameter collection set output by the device parameter acquisition unit, uses a preset multi-protocol parsing algorithm and parameter matching model to parse the control requirements and communication standards of the device, selects the control parameter thresholds and communication protocols that are compatible with the device, and outputs the parameter parsing results and adaptation instructions. The main control scheduling unit, based on the parameter parsing results and adaptation instructions output by the parameter parsing and adaptation unit, calls the corresponding control logic algorithm to generate equipment operation control instructions. At the same time, it schedules the multi-protocol communication module, fault pre-detection module, and safety protection module to work together, receives feedback data from each module in real time, dynamically adjusts the control instructions, and outputs equipment control instructions and module scheduling instructions.

[0006] In a preferred embodiment of the general-purpose industrial controller described in this invention, the multi-protocol communication module includes: The communication interface unit integrates a variety of commonly used industrial communication interfaces, so that after receiving the module scheduling command output by the adaptive main control module, it outputs an interface switching signal and a communication preparation status signal. The protocol conversion unit, based on the interface switching signal and communication preparation status signal output by the communication interface unit, and combined with the communication protocol adaptation parameters, converts the controller's control commands into protocol signals that the device can recognize, and at the same time converts the device's operating data and fault signals into standard signals that the controller can process, and outputs the protocol-converted control signals and device feedback signals. The data transmission unit, based on the protocol-converted control signal and device feedback signal output by the protocol conversion unit, uses an encrypted transmission algorithm to output encrypted transmission data and transmission status feedback.

[0007] As a preferred embodiment of the general-purpose industrial controller described in this invention, the fault pre-detection module includes: The data acquisition unit operates by collecting the controller's operating parameters and the device's real-time operating parameters based on the module scheduling instructions output by the adaptive main control module, and outputs a real-time operating data acquisition set. The data preprocessing unit, based on the real-time running data collection set output by the running data acquisition unit, uses filtering, denoising, and normalization algorithms to remove abnormal and interfering data and outputs preprocessed valid running data. The abnormal feature identification unit, based on the preprocessed valid operating data output by the data preprocessing unit and combined with the preset fault feature library, identifies abnormal features in the data, determines whether there are potential fault hazards or whether a fault has occurred, and outputs the abnormal feature identification result. The fault hazard tracing unit, based on the abnormal feature identification results output by the abnormal feature identification unit, combined with the equipment's historical operating data and the controller's collaborative operation records, traces the source of the abnormal features and outputs a fault hazard tracing report. The pre-inspection result output unit generates a pre-inspection report based on the fault hazard tracing report output by the fault hazard tracing unit and the abnormal feature identification result output by the abnormal feature identification unit.

[0008] In a preferred embodiment of the general-purpose industrial controller described in this invention, the safety protection module includes: The safety signal acquisition unit, based on the module scheduling instructions output by the adaptive main control module, acquires safety-related signals from the controller and the equipment, and outputs a safety signal acquisition set; The safety risk assessment unit, based on the safety signal acquisition set output by the safety signal acquisition unit and combined with the preset safety risk assessment model, assesses the risk level corresponding to the safety signal, determines whether protective measures need to be activated, and outputs the safety risk assessment result and protection activation command. The protection execution unit, based on the security risk assessment results and protection start command output by the security risk assessment unit, initiates corresponding protection measures and feeds back the protection execution status to the adaptive main control module, outputting protection execution signals and status feedback signals.

[0009] A fault response efficiency improvement system for a general-purpose industrial controller, linked with the aforementioned general-purpose industrial controller, includes: The fault prediction and early warning module, based on the fault pre-inspection report, completes the analysis of potential faults, determines the early warning level, and outputs early warning execution signals and synchronized data with early warning information. The rapid fault location module integrates all fault-related information based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, completes fault feature matching, correlation analysis, and location optimization, and outputs accurate location results. The graded fault handling module, based on the accurate location results output by the rapid fault location module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the corresponding handling strategy, generates and executes fault handling instructions, and outputs a handling result verification report. The review and optimization module, based on the handling result verification report output by the graded fault handling module and combined with the accurate location results output by the rapid fault location module, completes fault data archiving, optimization analysis, and outputs strategy update signals and optimization parameter synchronization results.

[0010] As a preferred embodiment of the fault response efficiency improvement system for a general-purpose industrial controller described in this invention, the fault prediction and early warning module includes: The pre-inspection data receiving unit verifies the data based on the fault pre-inspection report and outputs the verified fault pre-inspection data. The fault hazard analysis unit, based on the verified fault pre-inspection data output by the pre-inspection data receiving unit and combined with the preset fault evolution model, analyzes the development trend of fault hazards, the types of faults that may be caused and the scope of impact, and outputs a fault hazard analysis report. The early warning level determination unit, based on the fault hazard analysis report and fault pre-inspection data output by the fault hazard analysis unit, classifies faults and hazards into four levels: Level I, Level II, Level III, and Level IV, and outputs the early warning level determination result and early warning trigger command. The early warning execution unit, based on the early warning level determination result and early warning trigger command output by the early warning level determination unit, activates the corresponding early warning mode and outputs early warning execution signal and early warning information synchronization data.

[0011] As a preferred embodiment of the fault response efficiency improvement system for a general-purpose industrial controller according to the present invention, the rapid fault location module includes: The fault information receiving unit, based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, and combined with the fault pre-inspection report, integrates fault-related information and outputs the integrated fault information set; The fault feature matching unit, based on the integrated fault information set output by the fault information receiving unit, calls a preset fault feature database and uses a deep learning algorithm to achieve accurate matching between fault features and fault locations, and outputs preliminary fault location results. The fault correlation analysis unit, based on the preliminary fault location results output by the fault feature matching unit and combined with the fault hazard tracing report, analyzes the correlation between the current fault and the controller and equipment, and outputs the fault correlation analysis results. The positioning accuracy optimization unit, based on the fault correlation analysis results output by the fault correlation analysis unit and combined with real-time feedback data from the equipment, corrects the positioning error, determines the specific location of the fault and associated fault points, and outputs accurate fault positioning results. The positioning result output unit synchronizes the accurate fault location result output by the positioning accuracy optimization unit to the graded fault handling module and the review and optimization module, and outputs the accurate positioning result.

[0012] As a preferred embodiment of the fault response efficiency improvement system for a general-purpose industrial controller described in this invention, the graded fault handling module includes: The handling strategy invocation unit, based on the accurate positioning result output by the rapid fault location module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the preset hierarchical handling strategy library and outputs the appropriate fault handling strategy. The fault handling instruction generation unit generates specific fault handling instructions based on the adapted fault handling strategy output by the fault handling strategy calling unit and in combination with the device control parameters of the controller, and outputs a fault handling instruction set. The fault handling instruction execution unit transmits the fault handling instruction set output by the fault handling instruction generation unit to the controller and the corresponding industrial equipment, executes fault handling operations, monitors the handling process in real time, and outputs the handling execution status. The disposal result verification unit, based on the disposal execution status output by the disposal instruction execution unit, collects the operating data of the controller and the equipment, and outputs a disposal result verification report.

[0013] As a preferred embodiment of the fault response efficiency improvement system for a general-purpose industrial controller described in this invention, the review and optimization module includes: The fault data archiving unit, based on the handling result verification report output by the hierarchical fault handling module and combined with the accurate location result output by the rapid fault location module, comprehensively archives the fault information, handling process, and handling result, establishes a fault file, and outputs the archived fault dataset. The optimization analysis unit, based on the archived fault dataset output by the fault data archiving unit, outputs an optimization analysis report through big data analysis algorithms; The strategy update unit updates the fault feature database, the hierarchical handling strategy library, and the fault prediction model based on the optimization analysis report output by the optimization analysis unit. At the same time, it synchronizes the optimization parameters to the controller and outputs the strategy update signal and the synchronization result of the optimization parameters.

[0014] Compared with existing technologies: 1. Through the device parameter acquisition, parameter parsing and adaptation unit of the adaptive main control module and the multi-interface protocol conversion architecture of the multi-protocol communication module, it can achieve universal adaptation of industrial equipment of different industries and specifications, without the need to customize a dedicated controller for specific equipment, thus reducing the enterprise's equipment investment and maintenance costs. 2. Through the linkage operation architecture of the controller's built-in fault pre-detection module and the system fault prediction and early warning module, it can realize real-time monitoring of the controller's own and connected equipment's operating status, advance prediction of potential faults and graded early warning, replacing the traditional passive detection mode after a fault occurs, and preventing the expansion of the fault range in advance. 3. Through the fault feature matching of the rapid fault location module, the linkage of the positioning accuracy optimization unit with the hierarchical strategy invocation and closed-loop execution architecture of the hierarchical fault handling module, it can achieve accurate fault location and hierarchical rapid fault handling, greatly shorten the fault investigation and handling cycle, and adapt to the needs of continuous and high-precision industrial production. 4. Through the deep linkage architecture between the general-purpose industrial controller and the fault response efficiency improvement system, it can realize real-time two-way synchronous interaction of controller operation data, fault pre-detection data and system handling instructions and optimization parameters, which solves the problems of poor data interaction and delayed fault information synchronization caused by the independence of traditional controllers and fault response systems. 5. Through the closed-loop operation architecture of the fault data archiving, optimization analysis and strategy update unit of the review and optimization module, it can realize the continuous dynamic optimization of the fault feature library, handling strategy library and prediction model, solve the problem of the lack of dynamic optimization mechanism in traditional fault handling, and improve the long-term applicability and fault response accuracy of the system. 6. Through the dual protection architecture of the controller's built-in safety protection module and the system's hierarchical fault handling mechanism, it can realize real-time monitoring, hierarchical assessment and precise protection of the safety risks of equipment and controller operation, avoid production accidents caused by the escalation of faults, and ensure the safety of industrial production and controller operation. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall framework of the universal industrial controller of the present invention; Figure 2 This is a schematic diagram of the adaptive main control module framework of the present invention; Figure 3 This is a schematic diagram of the multi-protocol communication module framework of the present invention; Figure 4 This is a schematic diagram of the fault pre-detection module framework of the present invention; Figure 5 This is a schematic diagram of the security protection module framework of the present invention; Figure 6 This is a schematic diagram of the overall framework of the fault response efficiency improvement system of the present invention; Figure 7 This is a schematic diagram of the fault prediction and early warning module framework of the present invention; Figure 8 This is a schematic diagram of the rapid fault location module framework of the present invention; Figure 9 This is a schematic diagram of the hierarchical fault handling module framework of the present invention; Figure 10 This is a schematic diagram of the review and optimization module framework of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0017] This invention provides a universal industrial controller; please refer to [link / reference]. Figure 1 ,include: The adaptive main control module collects and accesses the core operating and protocol parameters of industrial equipment, completes equipment adaptation and parsing, and generates equipment control commands and module scheduling commands. The multi-protocol communication module, based on the module scheduling instructions output by the adaptive main control module, completes the adaptation and switching of multiple types of industrial communication interfaces, and realizes the protocol conversion and bidirectional transmission of control signals and equipment feedback signals; The fault pre-detection module, based on the module scheduling instructions output by the adaptive main control module, obtains real-time operating data of the controller and equipment through the multi-protocol communication module, completes data preprocessing, anomaly identification, hidden danger tracing, and outputs a fault pre-detection report. The safety protection module, based on the module scheduling instructions output by the adaptive main control module, collects safety-related signals from the controller and equipment, completes risk assessment, and executes corresponding protective actions.

[0018] Please see Figure 2 The adaptive main control module includes: The equipment parameter acquisition unit collects the core parameters of the connected industrial equipment (including equipment model, rated power, operating threshold, communication protocol type, etc.), and achieves comprehensive parameter acquisition through the built-in multi-interface acquisition circuit, outputting the equipment parameter acquisition set; The parameter parsing and adaptation unit, based on the device parameter collection set output by the device parameter acquisition unit, uses a preset multi-protocol parsing algorithm and parameter matching model to parse the control requirements and communication standards of the device, selects the control parameter thresholds and communication protocols that are compatible with the device, and outputs the parameter parsing results and adaptation instructions. The main control scheduling unit, based on the parameter parsing results and adaptation instructions output by the parameter parsing and adaptation unit, calls the corresponding control logic algorithm to generate equipment operation control instructions. At the same time, it schedules the multi-protocol communication module, fault pre-detection module, and safety protection module to work together, receives feedback data from each module in real time, dynamically adjusts the control instructions, and outputs equipment control instructions and module scheduling instructions.

[0019] Please see Figure 3 The multi-protocol communication module includes: The communication interface unit integrates multiple commonly used industrial communication interfaces such as RS232, RS485, Ethernet, OPCUA, and MQTT, and supports automatic switching between different interfaces. After receiving the module scheduling command output by the adaptive main control module, it outputs an interface switching signal and a communication preparation status signal. The protocol conversion unit, based on the interface switching signal and communication preparation status signal output by the communication interface unit, and combined with the communication protocol adaptation parameters, converts the controller's control commands into protocol signals that the device can recognize, and at the same time converts the device's operating data and fault signals into standard signals that the controller can process, and outputs the protocol-converted control signals and device feedback signals. The data transmission unit, based on the protocol-converted control signals and device feedback signals output by the protocol conversion unit, uses an encrypted transmission algorithm to realize the transmission of control signals to the device, the transmission of device feedback signals to the adaptive main control module and the fault response system, and outputs encrypted transmission data and transmission status feedback.

[0020] Please see Figure 4 The fault pre-detection module includes: The data acquisition unit operates based on the module scheduling instructions output by the adaptive main control module, and collects the controller's operating parameters (such as voltage, current, temperature, and operating speed) and the device's real-time operating parameters (such as device load, operating error, and component wear), and outputs a real-time operating data acquisition set. The data preprocessing unit, based on the real-time running data collection set output by the running data acquisition unit, uses filtering, denoising, and normalization algorithms to remove abnormal and interference data, extract effective running feature data, and output preprocessed effective running data. The abnormal feature identification unit, based on the preprocessed valid operating data output by the data preprocessing unit and combined with the preset fault feature library (including common fault feature parameters of various equipment and controllers), identifies abnormal features in the data, determines whether there are potential fault hazards or whether a fault has occurred, and outputs the abnormal feature identification result. The fault hazard tracing unit, based on the abnormal feature identification results output by the abnormal feature identification unit, combined with the equipment's historical operating data and the controller's collaborative operation records, traces the source of abnormal features (such as aging of a certain module unit, wear and tear of equipment components, external interference sources, etc.), distinguishes whether the fault hazard is caused by the controller itself, the equipment itself, or the external environment, and outputs a fault hazard tracing report. The pre-inspection result output unit generates a fault pre-inspection report (including three states: no abnormality, fault hazard, and fault already occurred, as well as hazard tracing information) based on the fault hazard tracing report output by the fault hazard tracing unit and the abnormal feature identification result output by the abnormal feature identification unit. The pre-inspection result is then synchronously output to the adaptive main control module and the fault response system.

[0021] Please see Figure 5 The security protection module includes: The safety signal acquisition unit, based on the module scheduling instructions output by the adaptive main control module, acquires safety-related signals (such as overload signals, short-circuit signals, electromagnetic interference signals, and abnormal voltage signals) of the controller and equipment, and outputs a safety signal acquisition set. The safety risk assessment unit, based on the safety signal acquisition set output by the safety signal acquisition unit and combined with the preset safety risk assessment model, assesses the risk level (low, medium, high) corresponding to the safety signal, determines whether protective measures need to be activated, and outputs the safety risk assessment result and protection activation command. The protection execution unit, based on the safety risk assessment results and protection start command output by the safety risk assessment unit, initiates corresponding protection measures (such as overload protection, short circuit interruption, anti-interference shielding, and voltage regulation), and simultaneously feeds back the protection execution status to the adaptive main control module, outputting protection execution signals and status feedback signals.

[0022] The specific operating steps of a general-purpose industrial controller are as follows: S1, through the adaptive main control module, collects the core operation and protocol parameters of the connected industrial equipment, completes equipment adaptation parsing, and generates equipment control commands and module scheduling commands; S2, through the multi-protocol communication module, based on the module scheduling instructions output by the adaptive main control module, completes the adaptation and switching of multiple types of industrial communication interfaces, and realizes the protocol conversion and bidirectional transmission of control signals and equipment feedback signals; S3, through the fault pre-detection module, based on the module scheduling instructions output by the adaptive main control module, the real-time operating data of the controller and equipment is obtained through the multi-protocol communication module, and data preprocessing, anomaly identification, hidden danger tracing are completed and a fault pre-detection report is output; S4. Through the safety protection module, based on the module scheduling instructions output by the adaptive main control module, the safety-related signals of the controller and the equipment are collected, risk assessment is completed, and corresponding protective actions are executed.

[0023] A fault response efficiency improvement system for a general-purpose industrial controller, which is linked with the aforementioned general-purpose industrial controller, please refer to [link / reference]. Figure 6 ,include: The fault prediction and early warning module, based on the fault pre-inspection report, completes the analysis of potential faults, determines the early warning level, and outputs early warning execution signals and synchronized data with early warning information. The rapid fault location module integrates all fault-related information based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, completes fault feature matching, correlation analysis, and location optimization, and outputs accurate location results. The graded fault handling module, based on the accurate location results output by the rapid fault location module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the corresponding handling strategy, generates and executes fault handling instructions, and outputs a handling result verification report. The review and optimization module, based on the handling result verification report output by the graded fault handling module and combined with the accurate location results output by the rapid fault location module, completes fault data archiving, optimization analysis, and outputs strategy update signals and optimization parameter synchronization results.

[0024] Please see Figure 7 The fault prediction and early warning module includes: The pre-inspection data receiving unit verifies the data based on the fault pre-inspection report to ensure the integrity and accuracy of the data, and outputs the verified fault pre-inspection data. The fault hazard analysis unit, based on the verified fault pre-inspection data output by the pre-inspection data receiving unit and combined with the preset fault evolution model, analyzes the development trend of fault hazards, the types of faults that may be caused and the scope of impact, and outputs a fault hazard analysis report. The early warning level determination unit, based on the fault hazard analysis report and fault pre-inspection data output by the fault hazard analysis unit, classifies faults and hazards into four levels: Level I, Level II, Level III, and Level IV (Level I: No hazard; Level II: Minor hazard, no shutdown required; Level III: Serious hazard, shutdown required for investigation; Level IV: Fault has occurred, emergency handling required), and outputs the early warning level determination result and early warning trigger command. The early warning execution unit, based on the early warning level determination result and early warning triggering command output by the early warning level determination unit, activates the corresponding early warning mode (such as audible and visual early warning, upper computer pop-up early warning, mobile phone SMS early warning), and outputs early warning execution signal and early warning information synchronization data.

[0025] Please see Figure 8 The rapid fault location module includes: The fault information receiving unit, based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, and combined with the fault pre-inspection report, integrates fault-related information and outputs the integrated fault information set; The fault feature matching unit, based on the integrated fault information set output by the fault information receiving unit, calls a preset fault feature database (including the correspondence between various faults and feature parameters and fault locations), and uses a deep learning algorithm to achieve accurate matching between fault features and fault locations, and outputs preliminary fault location results. The fault correlation analysis unit, based on the preliminary fault location results output by the fault feature matching unit and combined with the fault hazard tracing report, analyzes the correlation between the current fault and the controller and equipment, determines whether there is a possibility of cascading faults or derivative faults, marks the associated fault points and assesses the scope of the associated impact, and outputs the fault correlation analysis results. The positioning accuracy optimization unit, based on the fault correlation analysis results output by the fault correlation analysis unit and combined with the real-time feedback data of the equipment, corrects the positioning error, determines the specific location of the fault (accurate to the module, unit or equipment component) and the associated fault points, and outputs accurate fault positioning results. The positioning result output unit synchronizes the accurate fault location result output by the positioning accuracy optimization unit to the hierarchical fault handling module and the review and optimization module, and simultaneously feeds it back to the controller to provide accurate basis for fault handling (including associated fault handling priority) and output accurate positioning results.

[0026] Please see Figure 9 The graded fault handling module includes: The handling strategy invocation unit, based on the accurate positioning results output by the rapid fault location module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the preset hierarchical handling strategy library (corresponding to handling methods for different early warning levels and different fault types) and outputs the appropriate fault handling strategy. The fault handling instruction generation unit generates specific fault handling instructions based on the adapted fault handling strategy output by the fault handling strategy calling unit and in combination with the device control parameters of the controller, and outputs a fault handling instruction set. The fault handling instruction execution unit transmits the fault handling instruction set output by the fault handling instruction generation unit to the controller and the corresponding industrial equipment, executes fault handling operations, monitors the handling process in real time, and outputs the handling execution status. The handling result verification unit, based on the handling execution status output by the handling instruction execution unit, collects the operating data of the controller and the equipment, verifies whether the fault has been eliminated and whether the equipment has returned to normal operation, and outputs a handling result verification report.

[0027] Please see Figure 10 The review and optimization module includes: The fault data archiving unit, based on the handling result verification report output by the hierarchical fault handling module and combined with the accurate location result output by the rapid fault location module, comprehensively archives the fault information, handling process, and handling result, establishes a fault file, and outputs the archived fault dataset. The optimization analysis unit, based on the archived fault dataset output by the fault data archiving unit, uses big data analysis algorithms to mine the patterns of fault occurrence, shortcomings in the handling process (such as location errors and handling delays), and deviations in fault prediction, and outputs an optimization analysis report. The strategy update unit updates the fault feature database, the hierarchical handling strategy library, and the fault prediction model based on the optimization analysis report output by the optimization analysis unit. At the same time, it synchronizes the optimization parameters to the controller to realize the continuous optimization of the fault response strategy and outputs the strategy update signal and the synchronization result of the optimization parameters.

[0028] The specific operation steps of the fault response efficiency improvement system for general-purpose industrial controllers are as follows: Step 1: Through the fault prediction and early warning module, based on the fault pre-inspection report, complete the fault hazard analysis, early warning level determination, and output early warning execution signal and early warning information synchronization data. Step 2: Through the rapid fault location module, based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, integrate all fault-related information, complete fault feature matching, correlation analysis, and location optimization, and output accurate location results. Step 3: Based on the accurate location results output by the rapid fault location module, the hierarchical fault handling module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the corresponding handling strategy, generates and executes the fault handling instruction, and outputs a handling result verification report. Step four: Through the review and optimization module, based on the handling result verification report output by the graded fault handling module and combined with the accurate location result output by the rapid fault location module, the fault data is archived, optimized and analyzed, and the strategy update signal and optimization parameter synchronization result are output.

[0029] Although the present invention has been described above with reference to embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, as long as there is no structural conflict, the features in the disclosed embodiments can be combined with each other in any manner. The lack of an exhaustive description of these combinations in this specification is merely for the sake of brevity and resource conservation. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A general-purpose industrial controller, characterized in that, include: The adaptive main control module collects and accesses the core operating and protocol parameters of industrial equipment, completes equipment adaptation and parsing, and generates equipment control commands and module scheduling commands. The multi-protocol communication module, based on the module scheduling instructions output by the adaptive main control module, completes the adaptation and switching of multiple types of industrial communication interfaces, and realizes the protocol conversion and bidirectional transmission of control signals and equipment feedback signals; The fault pre-detection module, based on the module scheduling instructions output by the adaptive main control module, obtains real-time operating data of the controller and equipment through the multi-protocol communication module, completes data preprocessing, anomaly identification, hidden danger tracing, and outputs a fault pre-detection report. The safety protection module, based on the module scheduling instructions output by the adaptive main control module, collects safety-related signals from the controller and equipment, completes risk assessment, and executes corresponding protective actions.

2. The general-purpose industrial controller according to claim 1, characterized in that, The adaptive master control module includes: The equipment parameter acquisition unit collects the core parameters of the connected industrial equipment. It achieves comprehensive parameter acquisition through the built-in multi-interface acquisition circuit and outputs the equipment parameter acquisition set. The parameter parsing and adaptation unit, based on the device parameter collection set output by the device parameter acquisition unit, uses a preset multi-protocol parsing algorithm and parameter matching model to parse the control requirements and communication standards of the device, selects the control parameter thresholds and communication protocols that are compatible with the device, and outputs the parameter parsing results and adaptation instructions. The main control scheduling unit, based on the parameter parsing results and adaptation instructions output by the parameter parsing and adaptation unit, calls the corresponding control logic algorithm to generate equipment operation control instructions. At the same time, it schedules the multi-protocol communication module, fault pre-detection module, and safety protection module to work together, receives feedback data from each module in real time, dynamically adjusts the control instructions, and outputs equipment control instructions and module scheduling instructions.

3. The general-purpose industrial controller according to claim 1, characterized in that, The multi-protocol communication module includes: The communication interface unit integrates a variety of commonly used industrial communication interfaces, so that after receiving the module scheduling command output by the adaptive main control module, it outputs an interface switching signal and a communication preparation status signal. The protocol conversion unit, based on the interface switching signal and communication preparation status signal output by the communication interface unit, and combined with the communication protocol adaptation parameters, converts the controller's control commands into protocol signals that the device can recognize, and at the same time converts the device's operating data and fault signals into standard signals that the controller can process, and outputs the protocol-converted control signals and device feedback signals. The data transmission unit, based on the protocol-converted control signal and device feedback signal output by the protocol conversion unit, uses an encrypted transmission algorithm to output encrypted transmission data and transmission status feedback.

4. A general-purpose industrial controller according to claim 1, characterized in that, The fault pre-detection module includes: The data acquisition unit operates by collecting the controller's operating parameters and the device's real-time operating parameters based on the module scheduling instructions output by the adaptive main control module, and outputs a real-time operating data acquisition set. The data preprocessing unit, based on the real-time running data collection set output by the running data acquisition unit, uses filtering, denoising, and normalization algorithms to remove abnormal and interfering data and outputs preprocessed valid running data. The abnormal feature identification unit, based on the preprocessed valid operating data output by the data preprocessing unit and combined with the preset fault feature library, identifies abnormal features in the data, determines whether there are potential fault hazards or whether a fault has occurred, and outputs the abnormal feature identification result. The fault hazard tracing unit, based on the abnormal feature identification results output by the abnormal feature identification unit, combined with the equipment's historical operating data and the controller's collaborative operation records, traces the source of the abnormal features and outputs a fault hazard tracing report. The pre-inspection result output unit generates a pre-inspection report based on the fault hazard tracing report output by the fault hazard tracing unit and the abnormal feature identification result output by the abnormal feature identification unit.

5. A general-purpose industrial controller according to claim 1, characterized in that, The security protection module includes: The safety signal acquisition unit, based on the module scheduling instructions output by the adaptive main control module, acquires safety-related signals from the controller and the equipment, and outputs a safety signal acquisition set; The safety risk assessment unit, based on the safety signal acquisition set output by the safety signal acquisition unit and combined with the preset safety risk assessment model, assesses the risk level corresponding to the safety signal, determines whether protective measures need to be activated, and outputs the safety risk assessment result and protection activation command. The protection execution unit, based on the security risk assessment results and protection start command output by the security risk assessment unit, initiates corresponding protection measures and feeds back the protection execution status to the adaptive main control module, outputting protection execution signals and status feedback signals.

6. A fault response efficiency improvement system for a general-purpose industrial controller, linked with the general-purpose industrial controller according to any one of claims 1-5, characterized in that, include: The fault prediction and early warning module, based on the fault pre-inspection report, completes the analysis of potential faults, determines the early warning level, and outputs early warning execution signals and synchronized data with early warning information. The rapid fault location module integrates all fault-related information based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, completes fault feature matching, correlation analysis, and location optimization, and outputs accurate location results. The graded fault handling module, based on the accurate location results output by the rapid fault location module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the corresponding handling strategy, generates and executes fault handling instructions, and outputs a handling result verification report. The review and optimization module, based on the handling result verification report output by the graded fault handling module and combined with the accurate location results output by the rapid fault location module, completes fault data archiving, optimization analysis, and outputs strategy update signals and optimization parameter synchronization results.

7. The fault response efficiency improvement system for a general-purpose industrial controller according to claim 6, characterized in that, The fault prediction and early warning module includes: The pre-inspection data receiving unit verifies the data based on the fault pre-inspection report and outputs the verified fault pre-inspection data. The fault hazard analysis unit, based on the verified fault pre-inspection data output by the pre-inspection data receiving unit and combined with the preset fault evolution model, analyzes the development trend of fault hazards, the types of faults that may be caused and the scope of impact, and outputs a fault hazard analysis report. The early warning level determination unit, based on the fault hazard analysis report and fault pre-inspection data output by the fault hazard analysis unit, classifies faults and hazards into four levels: Level I, Level II, Level III, and Level IV, and outputs the early warning level determination result and early warning trigger command. The early warning execution unit, based on the early warning level determination result and early warning trigger command output by the early warning level determination unit, activates the corresponding early warning mode and outputs early warning execution signal and early warning information synchronization data.

8. The fault response efficiency improvement system for a general-purpose industrial controller according to claim 6, characterized in that, The rapid fault location module includes: The fault information receiving unit, based on the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, and combined with the fault pre-inspection report, integrates fault-related information and outputs the integrated fault information set; The fault feature matching unit, based on the integrated fault information set output by the fault information receiving unit, calls a preset fault feature database and uses a deep learning algorithm to achieve accurate matching between fault features and fault locations, and outputs preliminary fault location results. The fault correlation analysis unit, based on the preliminary fault location results output by the fault feature matching unit and combined with the fault hazard tracing report, analyzes the correlation between the current fault and the controller and equipment, and outputs the fault correlation analysis results. The positioning accuracy optimization unit, based on the fault correlation analysis results output by the fault correlation analysis unit and combined with real-time feedback data from the equipment, corrects the positioning error, determines the specific location of the fault and associated fault points, and outputs accurate fault positioning results. The positioning result output unit synchronizes the accurate fault location result output by the positioning accuracy optimization unit to the graded fault handling module and the review and optimization module, and outputs the accurate positioning result.

9. The fault response efficiency improvement system for a general-purpose industrial controller according to claim 6, characterized in that, The graded fault handling module includes: The handling strategy invocation unit, based on the accurate positioning result output by the rapid fault location module, combined with the early warning execution signal and early warning information synchronization data output by the fault prediction and early warning module, calls the preset hierarchical handling strategy library and outputs the appropriate fault handling strategy. The fault handling instruction generation unit generates specific fault handling instructions based on the adapted fault handling strategy output by the fault handling strategy calling unit and in combination with the device control parameters of the controller, and outputs a fault handling instruction set. The fault handling instruction execution unit transmits the fault handling instruction set output by the fault handling instruction generation unit to the controller and the corresponding industrial equipment, executes fault handling operations, monitors the handling process in real time, and outputs the handling execution status. The disposal result verification unit, based on the disposal execution status output by the disposal instruction execution unit, collects the operating data of the controller and equipment, and outputs a disposal result verification report.

10. A fault response efficiency improvement system for a general-purpose industrial controller according to claim 6, characterized in that, The review and optimization module includes: The fault data archiving unit, based on the handling result verification report output by the hierarchical fault handling module and combined with the accurate location result output by the rapid fault location module, comprehensively archives the fault information, handling process, and handling result, establishes a fault file, and outputs the archived fault dataset. The optimization analysis unit, based on the archived fault dataset output by the fault data archiving unit, outputs an optimization analysis report through big data analysis algorithms; The strategy update unit updates the fault feature database, the hierarchical handling strategy library, and the fault prediction model based on the optimization analysis report output by the optimization analysis unit. At the same time, it synchronizes the optimization parameters to the controller and outputs the strategy update signal and the synchronization result of the optimization parameters.

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