A novel safe cascaded control method and system

Abstract

This invention relates to the field of safety control technology, specifically a novel safety-oriented cascaded control method and system, comprising the following steps: acquiring safety node signals and performing threshold correction to form a safety input signal; verifying node states and transmission relationships to obtain consistency results; deriving and optimizing signal transmission paths; identifying abnormal nodes and selecting backup paths; and reconstructing the loop structure to restore operational status. In this invention, by constructing a signal offset sequence and combining it with safety threshold boundaries for constraint substitution processing, the input signal is kept within a controllable range. Cross-verification is formed by comparing contact states with the consistency of both ends of the path. Association analysis is performed on node states and numbers to derive changing paths. Fault location and backup path selection are completed by combining abnormal identifiers and path indexes. The loop connection sequence and signal flow direction are reconstructed and verified. This closed-loop control process of correction, verification, derivation, switching, and reconstruction improves the stability and continuity of the cascaded structure.

Description

Technical Field

[0001] This invention relates to the field of safety control technology, and in particular to a novel safety-oriented cascaded control method and system. Background Technology

[0002] The field of safety control technology involves the permissioning and disconnection management of hazardous actions of industrial equipment. Core aspects include safety input acquisition and judgment, safety loop construction and maintenance, safety status propagation methods, safety output disconnection element driving, contact adhesion and disconnection detection, and reset condition determination and locking. Common implementations include emergency stop buttons, safety door switches, photoelectric safety devices with dual-channel input and consistency comparison, safety controllers or microcontrollers reading inputs and executing safety logic, and using forced-guided contact relays or safety contactors on the output side to form a dual-loop disconnection, with loop integrity monitoring completed through feedback of contact closure status. Among these, a traditional new... The safety-type cascaded control method and system refers to using a daisy-chain topology to connect multiple levels of safety nodes in series. Each safety node is equipped with a microcontroller and a cascaded safety monitoring circuit. The safety status input of this level is formed by acquiring the output status of the previous level's safety node. This level then performs logic judgment based on the output status of the previous level and the safety contact input of this level, and drives the safety output of this level. The cascaded link completes the overall safety status propagation by passing the output signal of the previous level level by level. The output of each node in the link uses relay contacts or equivalent switch contacts to form a series channel. The link status monitoring is realized by judging the consistency between the closed state of the node output contact feedback and the input channel.

[0003] Existing cascaded control methods focus on single-point threshold judgment and static path configuration during signal processing. When node signals fluctuate or contact states are abnormal for a short time, they are easily directly judged as faults, leading to frequent loop switching and control interruptions. The status verification between nodes lacks correlation analysis, and the signal transmission sequence and path structure are not dynamically derived in conjunction with real-time changes. Anomaly location relies on local detection results, making it difficult to accurately identify the fault initiation location and affected sections, thereby affecting the overall loop operation stability and safety reliability. Summary of the Invention

[0004] To address the technical problems existing in the prior art, embodiments of the present invention provide a novel safe cascaded control method; To achieve the above objectives, the present invention adopts the following technical solution: a novel safe cascaded control method, comprising the following steps: S1: Acquire security-related signals collected by security nodes. When signal fluctuations deviate from the security threshold, correct the security status, compare the input signal with the set threshold, correct the signal that deviates from the range, and obtain the corrected security input signal. S2: Based on the corrected safety input signal, analyze the node contact status, check the signal transmission relationship between nodes, compare the consistency of node contact status, and verify the status between nodes to obtain the node consistency verification result. S3: Based on the node consistency verification results, analyze the real-time signal status of the nodes in parallel, monitor the node security status, deduce the signal transmission path based on the status changes, and optimize the signal transmission route to obtain the signal transmission path. S4: Based on the signal transmission path, monitor the path status in real time, identify signal anomalies and path interruption nodes, locate the fault node, select a backup path to switch the signal, and obtain the fault recovery path selection result. S5: Based on the fault recovery path selection result, reconfigure the signal path in the circuit, select the backup path to transmit the signal, replan the circuit structure, restore the normal working state of the circuit, and obtain the circuit recovery state result.

[0005] As a further aspect of the present invention, the corrected safety input signal includes comparison results, correction range, and signal deviation value; the node consistency verification result includes consistency status, verification information, and status comparison results; the signal transmission path includes signal transmission path, optimized path, and path change; the fault recovery path selection result includes fault node location, fault path selection, and backup path; and the loop recovery status result includes loop structure, signal path configuration, and loop recovery status.

[0006] As a further aspect of the present invention, the corrected safety state refers to the state correction process that limits the abnormal signal to a safe range by threshold comparison and boundary substitution when the collected safety signal deviates from the preset safety threshold. The node contact status refers to the current on / off state of the contact determined based on the amplitude of the node input signal and the contact determination reference value.

[0007] As a further aspect of the present invention, the signal transmission relationship between nodes refers to the logical and physical connection relationship between secure nodes in which signal input and output are transmitted in accordance with the connection sequence. The loop structure refers to the overall signal transmission and control topology composed of multiple security nodes and signal connection paths.

[0008] As a further aspect of the present invention, the specific steps of S1 are as follows: S101: Acquire the output voltage and current signals of the dedicated sensor for the safety node, detect the fluctuation amplitude and sampling interval of the signal time series, compare the sampling points according to the preset upper and lower safety thresholds, extract the threshold boundary offset and offset direction of the sampling points, and obtain the signal offset sequence. S102: Based on the signal offset sequence, locate sampling points outside the safety threshold interval, read the original input threshold and the upper and lower boundary values ​​of the safety threshold of the corresponding sampling points, limit the value of the sampling points to between the lower limit of the safety threshold and the upper limit of the safety threshold, and obtain the threshold constraint result set. S103: Based on the threshold constraint result set, perform boundary substitution on the original input amplitude of the sampling points, replace the sampling values ​​that exceed the upper limit of the safety threshold with the upper limit value of the safety threshold, and replace the sampling values ​​that are lower than the lower limit of the safety threshold with the lower limit value of the safety threshold, so as to obtain the corrected safe input signal.

[0009] As a further aspect of the present invention, the specific steps of S2 are as follows: S201: Based on the corrected safety input signal, monitor the signal amplitude and on / off indication of the node contact, analyze the current conduction state of the contact according to the preset contact judgment benchmark value, extract the node contact state value and associate it according to the node number to obtain the contact state set. S202: Based on the set of contact states, retrieve the signal transmission path between nodes, detect the correspondence between the state values ​​at the input end and the state values ​​at the output end of the path, compare the consistency of the state values ​​at both ends of the same path, extract the state difference node pairs, and obtain the set of state difference node pairs; S203: Based on the set of state difference nodes, cross-verify the corresponding node contact state values, retrieve the amplitude of the corresponding safety input signal of the node and the contact judgment benchmark value to determine the state affiliation again, and obtain the node consistency verification result.

[0010] As a further aspect of the present invention, the specific steps of S3 are as follows: S301: Based on the node consistency verification result, monitor the real-time signal amplitude and contact conduction status of the node, extract the current state value of the node and correspond it with the node number, distinguish consistent nodes from deviating nodes according to the consistency verification identifier, associate the node number with the state value, and obtain the node state association set. S302: Based on the node state association set, retrieve the signal connection relationship between nodes, compare the state transmission order between consistent nodes and deviating nodes, analyze the correspondence between the state change starting node and the associated node, map the node state change direction and connection order, and obtain the state change path sequence. S303: Based on the state change path sequence, rearrange the node transmission order in the path, eliminate node segments with back transmission conflicts, retain continuous state node segments, map the optimized node connection order and corresponding transmission direction to obtain the signal transmission path.

[0011] As a further aspect of the present invention, the specific steps of S4 are as follows: S401: Based on the signal transmission path, monitor the real-time signal amplitude and transmission timing interval of nodes in the path, determine the benchmark value according to the preset path status and compare the continuity of node signals segment by segment, identify nodes with sudden changes in signal amplitude and nodes with timing breaks, associate the abnormal node number with the corresponding path segment number, and obtain the abnormal node identifier set. S402: Based on the abnormal node identifier set, retrieve the connection relationship between the nodes before and after the corresponding path segment, perform position backtracking and forward verification on the signal amplitude change node and the timing break node, analyze the fault start node number and the interruption segment range, map the correspondence between the fault node number and the path segment index, and obtain the fault node location set. S403: Based on the fault node location set, retrieve the preset backup path data, filter the path segment sequence that bypasses the fault node number, verify the consistency between the connection order of the backup path nodes and the correspondence between the input and output ports of the original path, associate the switchable path number with the fault segment number, and obtain the fault recovery path selection result.

[0012] As a further aspect of the present invention, the specific steps of S5 are as follows: S501: Based on the fault recovery path selection result, retrieve the corresponding backup path node sequence and port connection relationship, disconnect the fault section connection command in the original circuit, connect the matching backup path start port and the original input port, verify the connection between the backup path end port and the original output port, associate the node number and port number correspondence relationship, and obtain the path switching association set. S502: Based on the path switching association set, the connection order of nodes in the loop is reconstructed, the order of signal flow direction identifiers and node numbers is adjusted, the closed state of node input ports and output ports is verified, and the continuity of signal timing and the consistency of amplitude transmission are detected to obtain the loop structure reconstructing sequence. S503: Based on the reorganization sequence of the loop structure, verify the continuity of the signal transmission status of the entire loop, monitor the fluctuation range of the node signal amplitude and the change of the timing interval, analyze the node conduction status and maintain the continuous transmission relationship, associate the node operation status with the loop number correspondence, and obtain the loop recovery status result.

[0013] A novel safety-oriented cascaded control system includes: The safety signal acquisition module acquires safety-related signals collected by the safety node and makes a preliminary judgment on the signals. When the signal deviates from the set safety threshold, the safety status correction is initiated. The input signal is compared with the set threshold, and the signal that deviates from the range is corrected to obtain the corrected safety input signal. The node consistency verification module analyzes the state of the node contacts based on the corrected security input signal, checks the signal transmission relationship between nodes, compares whether the states of the node contacts are consistent, and verifies the states between nodes to obtain the node consistency verification result. Based on the node consistency verification results, the signal transmission path optimization module analyzes the real-time signal status of multiple nodes in parallel, monitors the security status of nodes, derives the signal transmission path, and optimizes the signal transmission route to obtain the signal transmission path. The fault detection and recovery module monitors the status of the signal transmission path in real time, identifies signal anomalies and path interruption nodes, locates the fault node, selects an alternative path to switch the signal, and obtains the fault recovery path selection result. Based on the fault recovery path selection result, the loop recovery control module reconfigures the signal paths in the loop, selects a backup path for signal transmission, replans the loop structure, restores the normal operation of the loop, and obtains the loop recovery status result.

[0014] Compared with the prior art, the advantages and positive effects of the present invention are as follows: In this invention, by constructing a signal offset sequence and combining it with a safety threshold boundary for constraint substitution processing, the input signal is kept within a controllable range. Cross-verification is formed by comparing the contact state with the consistency of both ends of the path. The node state and number are correlated and the change path is derived. Fault location and backup path selection are completed by combining anomaly identification and path index. The loop connection sequence and signal flow direction are reconstructed and verified. A closed-loop control process of correction, verification, derivation, switching and reconstruction is carried out to improve the stability and continuity of the cascaded structure. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the steps of the present invention; Figure 2 This is a detailed schematic diagram of S1 of the present invention; Figure 3 This is a detailed schematic diagram of S2 of the present invention; Figure 4 This is a detailed schematic diagram of S3 of the present invention; Figure 5 This is a detailed schematic diagram of S4 of the present invention; Figure 6 This is a detailed schematic diagram of S5 of the present invention; Figure 7 This is a system module diagram of the present invention. Detailed Implementation

[0017] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0018] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0019] Please see Figure 1 This invention provides a novel safe cascaded control method, comprising the following steps: S1: The security node acquires security-related signals through dedicated sensors, performs preliminary judgment on the acquired signals, and initiates a security status correction operation when the signal fluctuation deviates from the set security threshold. The input signal is compared with the set threshold, and the signal that deviates from the range is corrected to obtain the corrected security input signal. S2: Based on the corrected safety input signal, analyze the state of the node contact and check the signal transmission relationship between the nodes. Compare whether the state of the node contact is consistent. When the state of the node contact is inconsistent, verify the state between the nodes and obtain the node consistency verification result. S3: Based on the node consistency verification results, analyze the real-time signal status of multiple nodes in parallel, monitor the security status of nodes, deduce the signal transmission path according to the changes in node status, and optimize the signal transmission route to obtain the signal transmission path. S4: Based on the signal transmission path, monitor the status of the path in real time. When abnormalities or faults occur in the path, identify the nodes of signal abnormalities and path interruptions, locate the fault node, select an alternative path for switching, and obtain the fault recovery path selection result. S5: Based on the fault recovery path selection result, the signal path in the loop is reconfigured, a backup path is selected for signal transmission, and the loop structure is replanned to ensure uninterrupted signal transmission, restore the normal operation of the loop, and obtain the loop recovery status result.

[0020] The corrected safety input signal includes the comparison result, correction range, and signal deviation value. The node consistency verification result includes the consistency status, verification information, and status comparison result. The signal transmission path includes the signal transmission path, optimized path, and path change. The fault recovery path selection result includes the fault node location, fault path selection, and backup path. The loop recovery status result includes the loop structure, signal path configuration, and loop recovery status.

[0021] Please see Figure 2 The specific steps of S1 are as follows: S101: Acquire the output voltage and current signals of the dedicated sensor for the safety node, detect the fluctuation amplitude and sampling interval of the signal time series, compare the sampling points according to the preset upper and lower safety thresholds, extract the threshold boundary offset and offset direction of the sampling points, and obtain the signal offset sequence. First, high-sampling-frequency voltage sensors and precision Hall current sensors deployed at key monitoring nodes of the power grid are used to retrieve voltage waveforms from the bus side and current waveforms from the line side in real time. The sampling frequency is constantly set to 10,000 Hz, meaning a discrete data point is collected every 0.1 milliseconds, resulting in a monitoring time series consisting of 1,000 consecutive sampling points. By calculating the absolute difference between the maximum and minimum values ​​of this signal time series within a preset sliding window, the voltage fluctuation amplitude and current fluctuation amplitude are extracted. During the judgment process, safety threshold parameters pre-stored in local non-volatile memory are retrieved. These parameters are obtained by statistically analyzing 60 consecutive days of operating data under historical normal operating conditions and taking the boundary of a normal distribution with a confidence interval of 99.7%. The upper limit of the voltage safety threshold is set to 235 volts, the lower limit to 205 volts, the upper limit to 20 amperes, and the lower limit to 0 amperes. A sampling point comparison operation is performed. The real-time voltage amplitude of 240 volts is subtracted from the preset safety threshold upper limit of 235 volts. Subtracting the upper limit from the sampled value (240 minus 235 equals 5) yields a sampling point threshold boundary offset of 5 volts. The offset direction is determined to be positive upwards based on the sign of the value. If the instantaneous voltage is 198 volts, it is subtracted from the lower limit of the safety threshold of 205 volts. Subtracting the lower limit from the sampled value (198 minus 205 equals -7) yields an absolute offset of 7 volts, indicating a negative downward offset. The difference and direction corresponding to each sampling point in the entire time series are linearly arranged according to the chronological order of sampling time to obtain the signal offset sequence.

[0022] S102: Based on the signal offset sequence, locate the sampling points outside the safety threshold interval, read the original input threshold and the upper and lower boundary values ​​of the safety threshold of the corresponding sampling points, limit the value of the sampling points to between the lower limit and the upper limit of the safety threshold, and obtain the threshold constraint result set. First, the coordinate indices of the non-zero values ​​in the signal offset sequence are used to locate all abnormal sampling points outside the safe threshold range. For example, out of 1000 sampling points, consecutive abnormal points with index numbers 120 to 145 are identified. The original input voltage amplitude of 242 volts for these corresponding sampling points is read, along with the preset upper and lower safety threshold boundaries of 235 volts and 205 volts, respectively. Amplitude limiting is then performed. A logical judgment function is used to lock the boundary of each sampling point's value. The calculation logic is as follows: when the original input amplitude is greater than 235 volts, the constraint result for that point is forcibly reset to 235 volts; when the original input amplitude is less than 205 volts, the constraint result for that point is forcibly reset to 205 volts; for points within the 205 volt to 235 volt range, their original acquired values ​​are retained. In this way, the values ​​of all sampling points to be processed are strictly limited to the safe fluctuation range of 205 volts to 235 volts, resulting in a threshold constraint result set.

[0023] S103: Based on the threshold constraint result set, perform boundary substitution on the original input amplitude of the sampling points, replace the sampling values ​​that exceed the upper limit of the safety threshold with the upper limit of the safety threshold value, and replace the sampling values ​​that are lower than the lower limit of the safety threshold with the lower limit of the safety threshold value, so as to obtain the corrected safe input signal; First, the generated threshold constraint result set is traversed. For each time-series coordinate point in the sequence, a boundary substitution operation is performed on the original input amplitude of the sampling point. Sampling values ​​in the original observation sequence that are determined to exceed 235 volts are uniformly replaced with a constant upper limit value of 235 volts, and sampling values ​​that are below 205 volts and are non-zero are uniformly replaced with a constant lower limit value of 205 volts. For example, for the aforementioned sampling point No. 120 with an offset of 5 volts, its original observation value of 240 volts is replaced with 235 volts; for the point with an offset of -7 volts, its original observation value of 198 volts is replaced with 205 volts. Through this nonlinear saturation mapping process, the discrete original signal with drastically fluctuating characteristics is reconstructed into a continuous value that conforms to electrical safety regulations, resulting in a corrected safe input signal.

[0024] Please see Figure 3 The specific steps of S2 are as follows: S201: Based on the corrected safety input signal, monitor the signal amplitude and on / off indication of the node contact, analyze the current conduction state of the contact according to the preset contact judgment benchmark value, extract the node contact state value and associate it according to the node number to obtain the contact state set; First, the corrected safety input signal is retrieved, and the signal amplitude corresponding to the node contact is tracked in real time through high-sensitivity monitoring logic. Simultaneously, the on / off indicator reflecting the physical position of the contact is acquired. This indicator uses binary logic levels, with a value of 1 representing mechanical closure and a value of 0 representing mechanical openness. A preset contact judgment benchmark value is then called. This benchmark value is determined based on the expected voltage drop across the contact resistance at rated current, and the on / off judgment voltage benchmark value is set to 3 volts. A state analysis process is then executed, comparing the measured voltage drop across the contact with the judgment benchmark value. The judgment rules are as follows: if the measured voltage drop is less than or equal to 3 volts and the on / off indicator is 1, the contact is considered to be in good conduction, and the state value is marked as 1; if the measured voltage drop is greater than 3 volts and the on / off indicator is 1, it indicates excessive contact resistance, and the state is judged as abnormal conduction, with the state value marked as 0.5; if the on / off indicator is 0, regardless of the voltage drop value, the state is judged as open, and the state value is marked as 0. For example, when the measured voltage drop at node 10 is 1.5 volts and the indicated value is 1, it satisfies the condition that the voltage drop is less than or equal to 3 and the indicated value is 1, so the status is marked as 1. When the measured voltage drop at node 11 is 4.5 volts and the indicated value is 1, it satisfies the condition that the voltage drop is greater than 3 and the indicated value is 1, so the status is marked as 0.5. The obtained node status values ​​are associated one by one according to the node hardware number to obtain the contact status set.

[0025] S202: Based on the set of contact states, retrieve the signal transmission path between nodes, detect the correspondence between the state values ​​at the input end and the state values ​​at the output end of the path, compare the consistency of the state values ​​at both ends of the same path, extract the state difference node pairs, and obtain the set of state difference node pairs; First, the system retrieves the contact state set and the built-in topology map to identify the physical signal transmission paths between monitoring nodes, such as the cable connection path from the starting node A to the target node B. It then detects the logical correspondence between the state values ​​of the input end (node ​​A) and the output end (node ​​B) of this path. A consistency comparison operation is performed, calculating the absolute value of the difference between the state values ​​of node A and node B to obtain the state difference value. If both node A and node B are in state 1, the difference value is 0, indicating consistency in the path's state transmission. If node A is in state 1 and node B is in state 0, the difference value is 1. Since 1 is greater than the preset difference threshold of 0.2, node A and node B are defined as a pair of state-difference nodes. This comparison process is repeated until all active connection paths in the network are traversed, extracting all node combinations with mismatched states. These combinations are then associated with their respective path numbers to obtain a set of state-difference node pairs.

[0026] S203: Based on the set of state difference nodes, cross-verify the corresponding node contact state values, retrieve the amplitude of the corresponding safety input signal of the node and the contact judgment benchmark value to determine the state affiliation again, and obtain the node consistency verification result. First, the set of nodes with state differences is retrieved, and high-frequency cross-verification is performed on each group of nodes. The corresponding safety input signal amplitude and contact judgment benchmark values ​​for these nodes are retrieved again. To eliminate judgment dead zones, a multi-parameter weighted fusion discrimination logic is introduced to calculate a comprehensive conduction score. The calculation logic is as follows: multiply the normalized voltage value by 0.45, add the normalized current value multiplied by 0.45, and add the on / off indication value multiplied by 0.1. For example, if a node's voltage amplitude is 0.9 after normalization, its current amplitude is 0.85, and its indication value is 1, substituting these values ​​into the weighted logic yields: 0.405 + 0.3825 + 0.1 equals 0.8875. This score is compared with the secondary discrimination threshold of 0.85. Since 0.8875 is greater than 0.85, the node's state is determined to be in the conducting state, and a consistency verification flag is generated. If the secondary discrimination result still shows inconsistency between the two ends, the difference flag is maintained. Through the above deep verification, the node consistency verification result is obtained.

[0027] Please see Figure 4 The specific steps of S3 are as follows: S301: Based on the node consistency verification result, monitor the real-time signal amplitude and contact conduction status of the node, extract the current status value of the node and match it with the node number, distinguish consistent nodes from deviating nodes according to the consistency verification identifier, associate the node number with the status value, and obtain the node status association set; First, based on the node consistency verification results, the real-time signal amplitude and contact continuity status of each node in the current operating cycle are continuously monitored. The instantaneous state value of the node is extracted and mapped and stored with the node's unique physical number. According to the verification identifier carried in the consistency verification results, internal nodes are divided into consistent nodes and deviating nodes. Consistent nodes are those whose state transmission logic meets expectations and passes verification, while deviating nodes are those whose state changes abruptly and cannot be corrected. For example, node number 105 has a stable state of 1 and is marked as consistent, while node number 108 is marked as deviating because its state does not match the previous level. The node number, real-time state value, and consistency category label are multi-dimensionally associated to form a structured dataset, resulting in a node state association set.

[0028] S302: Based on the node state association set, retrieve the signal connection relationship between nodes, compare the state transmission order between consistent nodes and deviating nodes, analyze the correspondence between the state change starting node and the associated node, map the node state change direction and connection order, and obtain the state change path sequence. First, the signal connection topology between nodes is retrieved from the node state association set, focusing on comparing the spatial connection order of consistent and deviating nodes. Transmission analysis is performed to monitor the state change node pairs as the signal travels from a consistent node to a deviating node, locating the starting node of the state abrupt change. For example, a depth-first search algorithm reveals that the signal behaves normally at consistent node 110 with a state of 1, but becomes deviating and changes to a state of 0 when it reaches node 111, which is directly connected to it, thus identifying node 111 as the starting point of the state change. Further analysis of the hierarchical correspondence between this starting node and its subsequent affected associated nodes maps the direction of the state anomaly change and its connection order on the physical link. Through this topology backtracking logic, scattered state points are connected into a directional trajectory, yielding a sequence of state change paths.

[0029] S303: Based on the state change path sequence, rearrange the node transmission order in the path, eliminate node segments with back transmission conflicts, retain continuous state node segments, and map the optimized node connection order and corresponding transmission direction to obtain the signal transmission path. First, the state change path sequence is traversed, and the logical order of node transmission within the path is logically rearranged. This process detects and identifies signal backhaul phenomena that do not conform to physical characteristics. Conflict detection is then performed. If circular references to node numbers are found during signal transmission (e.g., a loop from 101 to 102 and back to 101), or if logically contradictory state values ​​are returned within a very short time, a backhaul conflict is identified in that path segment, and these conflicting node segments are physically removed. Only consecutive node segments with logically coherent state transitions and conforming to the unidirectional transmission pattern from the power source to the load are retained. The optimized node connection order and the corresponding signal transmission direction for each segment are remapped to ensure the uniqueness and determinism of the path, resulting in the signal transmission path.

[0030] Please see Figure 5 The specific steps of S4 are as follows: S401: Based on the signal transmission path, monitor the real-time signal amplitude and transmission timing interval of nodes in the path, determine the benchmark value according to the preset path status and compare the continuity of node signals segment by segment, identify nodes with sudden changes in signal amplitude and nodes with timing breaks, associate the abnormal node number with the corresponding path segment number, and obtain the abnormal node identifier set. First, based on the generated signal transmission path, the real-time signal amplitude of each node in the path and the transmission timing interval between adjacent nodes are monitored in real time during the signal flow process. A preset path state judgment benchmark value is invoked, setting the signal amplitude mutation judgment ratio to 25% and the timing break judgment threshold to 40 milliseconds. A segment-by-segment comparison operation is performed to calculate the signal amplitude change rate between adjacent nodes: that is, subtract the absolute value of the previous node's amplitude from the current node's amplitude, divide by the previous node's amplitude, and finally multiply by 100%. If the calculation result exceeds 25%, it is marked as a signal amplitude mutation node; simultaneously, the time difference of signal pulses arriving at adjacent nodes is monitored. If this time difference exceeds 40 milliseconds, it is identified as a timing break node. For example, if node 120 has an amplitude of 150 volts and the preceding node 119 has 210 volts, the calculated change rate is 28.57%. Since it is greater than 25%, node 120 is judged as a mutation node. The identified abnormal node numbers are strongly correlated with the specific path segment numbers they belong to, resulting in an abnormal node identifier set.

[0031] S402: Based on the abnormal node identifier set, retrieve the connection relationship between the preceding and following nodes of the corresponding path segment, perform position backtracking and forward verification on the signal amplitude change node and the timing break node, analyze the fault start node number and the interruption section range, map the correspondence between the fault node number and the path segment index, and obtain the fault node location set. First, the data in the abnormal node identifier set is read, and the logical connection relationship of nodes before and after the corresponding path segment is retrieved using a topology tracing algorithm. For nodes identified as having abrupt amplitude changes or timing breaks, a location backtracking operation is performed, i.e., the historical operating data of the preceding node 119 is retrieved and compared, and forward verification is performed, i.e., the theoretical output value that should be present if the current node 120 is operating normally is calculated. This theoretical value, considering line loss, should be around 210 volts. The starting node number of the fault is analyzed and located, for example, it is determined that the voltage amplitude change was caused by the internal insulation breakdown of node 120, and the specific segment range affected by the fault and causing the signal interruption is defined, such as the link failure from node 120 to the end node 125. The determined fault node number is precisely mapped to the index value of the global path segment to obtain the fault node location set.

[0032] S403: Based on the fault node location set, retrieve the preset backup path data, filter the path segment sequence that bypasses the fault node number, verify the consistency between the connection order of the backup path nodes and the correspondence between the input and output ports of the original path, associate the switchable path number with the fault segment number, and obtain the fault recovery path selection result. First, a pre-set backup path database is retrieved, which stores the status information of all redundant branches and backup switches in the power grid. Based on the fault range (120 to 125) provided by the fault node location set, path filtering logic is initiated to select all candidate path segment sequences from the backup database that do not contain the aforementioned fault node numbers. A topology consistency check is performed, comparing whether the physical connection order of the nodes in the backup path is logically equivalent to the input port (output of node 119) and output port (input of node 126) of the original path. The real-time on-resistance and current-carrying capacity of each backup path are calculated, and the backup path with the lowest impedance and the largest load margin is selected. Its unique number is then associated and locked with the number of the section affected by the fault. This process, through multi-criteria filtering, ensures the optimality of the recovery scheme, ultimately yielding the fault recovery path selection result.

[0033] Please see Figure 6 The specific steps of S5 are as follows: S501: Based on the fault recovery path selection result, retrieve the corresponding backup path node sequence and port connection relationship, disconnect the fault section connection command in the original circuit, connect the matching backup path start port and the original input port, verify the connection between the backup path end port and the original output port, associate the node number and port number correspondence, and obtain the path switching association set. First, based on the fault recovery path selection results, the detailed node sequence and port physical connection relationship of the corresponding backup path are retrieved. A disconnect command is sent to the underlying actuator to forcibly disconnect the electrical connection of nodes 120 to 125 in the faulty section of the original circuit, achieving physical isolation of the fault point. Simultaneously, the backup path access operation is executed, physically connecting the starting port of the backup path to the original signal input port, i.e., node 119, and performing a closure reliability check on the ending port of the backup path and the original signal output port, i.e., node 126, to ensure that the current can flow smoothly through the new path. A new mapping relationship between node numbers and port numbers is established and associated, the running mapping table is updated, and the path switching association set is obtained.

[0034] S502: Based on the path switching association set, the connection order of nodes in the loop is reconstructed, the order of signal flow direction identifiers and node numbers is adjusted, the closed state of node input and output ports is verified, and the continuity of signal timing and the consistency of amplitude transmission are detected to obtain the loop structure reconstructed sequence. First, the path switching association set is retrieved, and the node connection order in the overall operating loop is dynamically reconstructed, adjusting the signal flow identifiers and rearranging the logical numbering order of the nodes. A loop verification is performed after the reconstruction to check whether the closed state of the input and output ports of all nodes in the loop meets the conduction requirements. The timing continuity of the signal in the new path is monitored in real time, the end-to-end delay of the signal from the loop start point to the end point is calculated, and the consistency of amplitude transmission between each level of backup nodes is verified. The verification logic is: subtract the output amplitude from the input amplitude, divide by the input amplitude, and multiply by 100% to obtain the attenuation rate, ensuring that this ratio is less than 5%. If all parameters meet the preset operating standards, the loop structure reconstruction is completed, resulting in a loop structure reconstructed sequence.

[0035] S503: Based on the loop structure reorganization sequence, verify the continuity of the signal transmission status of the entire loop, monitor the fluctuation range of node signal amplitude and the change of timing interval, analyze the node conduction status and maintain the continuous transmission relationship, associate the node operation status with the loop number correspondence, and obtain the loop recovery status result. First, based on the reconstructed loop structure sequence, a final continuity verification of the signal transmission status of the entire loop is performed. The signal amplitude fluctuation range of each node in the reconstructed loop is continuously monitored to ensure it remains stable within the preset safe range of 205 volts to 235 volts. Simultaneously, the timing interval of the sampling points is observed to strictly adhere to a sampling period of 0.1 milliseconds. The conduction status values ​​of each node's contacts are analyzed to confirm that they all maintain a normal conduction state value of 1, and there are no instantaneous oscillations. The real-time operational health indicators of each node are persistently associated with the current loop number, recording the complete operational profile after loop restoration, thus obtaining the loop restoration status result.

[0036] Please see Figure 7 A novel safety-oriented cascaded control system includes: The safety signal acquisition module acquires safety-related signals collected by the safety node and makes a preliminary judgment on the signals. When the signal deviates from the set safety threshold, the safety status correction is initiated. The input signal is compared with the set threshold, and the signal that deviates from the range is corrected to obtain the corrected safety input signal. The node consistency verification module analyzes the state of node contacts based on the corrected safety input signal, checks the signal transmission relationship between nodes, compares whether the state of node contacts is consistent, and verifies the state between nodes to obtain the node consistency verification result. The signal transmission path optimization module analyzes the real-time signal status of multiple nodes in parallel based on the node consistency verification results, monitors the security status of nodes, derives the signal transmission path, and optimizes the signal transmission route to obtain the signal transmission path. The fault detection and recovery module monitors the status of the signal transmission path in real time, identifies signal anomalies and path interruption nodes, locates the fault node, selects an alternative path to switch the signal, and obtains the fault recovery path selection result. Based on the fault recovery path selection result, the loop recovery control module reconfigures the signal paths in the loop, selects backup paths for signal transmission, replans the loop structure, restores the normal operation of the loop, and obtains the loop recovery status result.

[0037] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A novel safety-oriented cascaded control method, characterized in that, Includes the following steps: S1: Acquire security-related signals collected by security nodes. When the signal fluctuation deviates from the security threshold, correct the security status, compare the input signal with the set threshold, correct the signal that deviates from the range, and obtain the corrected security input signal. S2: Based on the corrected safety input signal, analyze the node contact status, check the signal transmission relationship between nodes, compare the consistency of node contact status, and verify the status between nodes to obtain the node consistency verification result. S3: Based on the node consistency verification results, analyze the real-time signal status of the nodes in parallel, monitor the node security status, deduce the signal transmission path based on the status changes, and optimize the signal transmission route to obtain the signal transmission path. S4: Based on the signal transmission path, monitor the path status in real time, identify signal anomalies and path interruption nodes, locate the fault node, select an alternative path to switch the signal, and obtain the fault recovery path selection result. S5: Based on the fault recovery path selection result, reconfigure the signal path in the circuit, select the backup path to transmit the signal, replan the circuit structure, restore the normal working state of the circuit, and obtain the circuit recovery state result.

2. The novel safety-type cascaded control method according to claim 1, characterized in that, The corrected safety input signal includes comparison results, correction range, and signal deviation value; the node consistency verification result includes consistency status, verification information, and status comparison result; the signal transmission path includes signal transmission path, optimized path, and path change; the fault recovery path selection result includes fault node location, fault path selection, and backup path; and the loop recovery status result includes loop structure, signal path configuration, and loop recovery status.

3. The novel safety-type cascaded control method according to claim 1, characterized in that, The corrected safety state refers to the state correction process that limits the abnormal signal to a safe range by threshold comparison and boundary substitution when the collected safety signal deviates from the preset safety threshold. The node contact status refers to the current on / off state of the contact determined based on the amplitude of the node input signal and the contact determination reference value.

4. The novel safety-type cascaded control method according to claim 1, characterized in that, The signal transmission relationship between nodes refers to the logical and physical connection relationship between secure nodes in which signal input and output are transmitted in the order of connection. The loop structure refers to the overall signal transmission and control topology composed of multiple security nodes and signal connection paths.

5. The novel safety-type cascaded control method according to claim 1, characterized in that, The specific steps of S1 are as follows: S101: Acquire the output voltage and current signals of the dedicated sensor for the safety node, detect the fluctuation amplitude and sampling interval of the signal time series, compare the sampling points according to the preset upper and lower safety thresholds, extract the threshold boundary offset and offset direction of the sampling points, and obtain the signal offset sequence. S102: Based on the signal offset sequence, locate sampling points outside the safety threshold interval, read the original input threshold and the upper and lower boundary values ​​of the safety threshold of the corresponding sampling points, limit the value of the sampling points to between the lower limit of the safety threshold and the upper limit of the safety threshold, and obtain the threshold constraint result set. S103: Based on the threshold constraint result set, perform boundary substitution on the original input amplitude of the sampling points, replace the sampling values ​​that exceed the upper limit of the safety threshold with the upper limit value of the safety threshold, and replace the sampling values ​​that are lower than the lower limit of the safety threshold with the lower limit value of the safety threshold, so as to obtain the corrected safe input signal.

6. The novel safety-type cascaded control method according to claim 1, characterized in that, The specific steps of S2 are as follows: S201: Based on the corrected safety input signal, monitor the signal amplitude and on / off indication of the node contact, analyze the current conduction state of the contact according to the preset contact judgment benchmark value, extract the node contact state value and associate it according to the node number to obtain the contact state set. S202: Based on the set of contact states, retrieve the signal transmission path between nodes, detect the correspondence between the state values ​​at the input end and the state values ​​at the output end of the path, compare the consistency of the state values ​​at both ends of the same path, extract the state difference node pairs, and obtain the set of state difference node pairs; S203: Based on the set of state difference nodes, cross-verify the corresponding node contact state values, retrieve the amplitude of the corresponding safety input signal of the node and the contact judgment benchmark value to determine the state affiliation again, and obtain the node consistency verification result.

7. The novel safety-type cascaded control method according to claim 1, characterized in that, The specific steps of S3 are as follows: S301: Based on the node consistency verification result, monitor the real-time signal amplitude and contact conduction status of the node, extract the current state value of the node and correspond it with the node number, distinguish consistent nodes from deviating nodes according to the consistency verification identifier, associate the node number with the state value, and obtain the node state association set. S302: Based on the node state association set, retrieve the signal connection relationship between nodes, compare the state transmission order between consistent nodes and deviating nodes, analyze the correspondence between the state change starting node and the associated node, map the node state change direction and connection order, and obtain the state change path sequence. S303: Based on the state change path sequence, rearrange the node transmission order in the path, eliminate node segments with back transmission conflicts, retain continuous state node segments, map the optimized node connection order and corresponding transmission direction to obtain the signal transmission path.

8. The novel safety-type cascaded control method according to claim 1, characterized in that, The specific steps of S4 are as follows: S401: Based on the signal transmission path, monitor the real-time signal amplitude and transmission timing interval of nodes in the path, determine the benchmark value according to the preset path status and compare the continuity of node signals segment by segment, identify nodes with sudden changes in signal amplitude and nodes with timing breaks, associate the abnormal node number with the corresponding path segment number, and obtain the abnormal node identifier set. S402: Based on the abnormal node identifier set, retrieve the connection relationship between the nodes before and after the corresponding path segment, perform position backtracking and forward verification on the signal amplitude change node and the timing break node, analyze the fault start node number and the interruption segment range, map the correspondence between the fault node number and the path segment index, and obtain the fault node location set. S403: Based on the fault node location set, retrieve the preset backup path data, filter the path segment sequence that bypasses the fault node number, verify the consistency between the connection order of the backup path nodes and the correspondence between the input and output ports of the original path, associate the switchable path number with the fault segment number, and obtain the fault recovery path selection result.

9. The novel safety-type cascaded control method according to claim 1, characterized in that, The specific steps of S5 are as follows: S501: Based on the fault recovery path selection result, retrieve the corresponding backup path node sequence and port connection relationship, disconnect the fault section connection command in the original circuit, connect the matching backup path start port and the original input port, verify the connection between the backup path end port and the original output port, associate the node number and port number correspondence relationship, and obtain the path switching association set. S502: Based on the path switching association set, the connection order of nodes in the loop is reconstructed, the order of signal flow direction identifiers and node numbers is adjusted, the closed state of node input ports and output ports is verified, and the continuity of signal timing and the consistency of amplitude transmission are detected to obtain the loop structure reconstructing sequence. S503: Based on the reorganization sequence of the loop structure, verify the continuity of the signal transmission status of the entire loop, monitor the fluctuation range of the node signal amplitude and the change of the timing interval, analyze the node conduction status and maintain the continuous transmission relationship, associate the node operation status with the loop number correspondence, and obtain the loop recovery status result.

10. A novel safety-type cascaded control system, characterized in that, The system is used to implement a novel safety-oriented cascaded control method according to any one of claims 1-9, comprising: The safety signal acquisition module acquires safety-related signals collected by the safety node and makes a preliminary judgment on the signals. When the signal deviates from the set safety threshold, the safety status correction is initiated. The input signal is compared with the set threshold, and the signal that deviates from the range is corrected to obtain the corrected safety input signal. The node consistency verification module analyzes the state of the node contacts based on the corrected security input signal, checks the signal transmission relationship between nodes, compares whether the states of the node contacts are consistent, and verifies the states between nodes to obtain the node consistency verification result. Based on the node consistency verification results, the signal transmission path optimization module analyzes the real-time signal status of multiple nodes in parallel, monitors the security status of nodes, derives the signal transmission path, and optimizes the signal transmission route to obtain the signal transmission path. The fault detection and recovery module monitors the status of the signal transmission path in real time, identifies signal anomalies and path interruption nodes, locates the fault node, selects an alternative path to switch the signal, and obtains the fault recovery path selection result. Based on the fault recovery path selection result, the loop recovery control module reconfigures the signal paths in the loop, selects a backup path for signal transmission, replans the loop structure, restores the normal operation of the loop, and obtains the loop recovery status result.

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