PLC seamless integration communication method and system based on dcs double network redundancy architecture

Abstract

The application discloses a PLC seamless integration communication method and system based on a DCS double-network redundancy architecture, which comprises the following steps: connecting at least one PLC controller to an existing redundant industrial Ethernet of a DCS system through an Ethernet interface, so that the PLC controller is connected to the controller and the industrial computer of the DCS system in the same local area network domain; configuring network addresses based on the same network segment for all devices connected to the local area network domain; activating an open standard Ethernet communication protocol service in the PLC controller, configuring a corresponding communication client driver in a monitoring operation station of the DCS system, establishing a direct data communication link, and completing mapping configuration of data addresses; based on the local area network domain, enabling the industrial computer to remotely access and maintain the PLC controller through standard engineering tool software of the PLC controller; and providing redundancy backup for the direct data communication link by using at least two independent network paths of the redundant industrial Ethernet of the DCS system, so as to maintain communication.

Description

Technical Field

[0001] This invention relates to the field of communication network integration technology, and in particular to a PLC seamless integrated communication method and system based on a DCS dual-network redundancy architecture. Background Technology

[0002] In modern process industries such as steel, chemical, and power, the hybrid use of distributed control systems (DCS) and programmable logic controllers (PLCs) has become a common architecture. DCS typically handles plant-wide monitoring and coordination, while PLCs are mostly used to execute fast and reliable control of specific equipment or subsystems. Achieving efficient and reliable data communication between these two heterogeneous control systems is a key technological aspect for ensuring the safe, stable, and economical operation of a plant.

[0003] Currently, the mainstream technical solutions for integrating DCS and PLC systems in industrial practice mainly include the following two categories:

[0004] Server-based communication relay solution: This solution uses one or more industrial computers as middleware such as OPC servers, with DCS operator stations and PLCs acting as clients to establish connections with the server. All data exchanges are relayed, cached, and converted via this server. This solution alleviates protocol compatibility issues associated with direct connections to some extent and may provide a unified data access interface. However, it also introduces the server as a new single point of failure, and the data flow requires an additional "acquisition-server-forwarding" step, increasing communication latency and reducing system real-time performance. Server performance may also become a bottleneck during large-scale data exchange. Furthermore, this solution still requires additional investment in server hardware, software licensing, and maintenance, resulting in a complex system architecture and high deployment and maintenance costs.

[0005] Modern DCS systems typically incorporate high-performance redundant industrial Ethernet networks (such as eNet networks). These networks possess advanced features such as dual-network redundancy, high-speed multicast communication, and distributed management, providing highly reliable and efficient data channels for controllers, operator stations, and other nodes within the system. However, in existing integration solutions, third-party PLC devices are excluded from this high-performance network, failing to fully utilize this readily available and highly reliable infrastructure, resulting in idle and fragmented network resources.

[0006] The core problem with existing technical solutions lies in their failure to effectively share the existing high-performance redundant network resources of the DCS. Instead, they construct isolated communication bridges between systems by adding extra dedicated hardware. This design not only introduces additional costs, points of failure, and maintenance complexity, but also limits the integrity of system functions and the flexibility of expansion. Summary of the Invention

[0007] In order to overcome the above-mentioned shortcomings of the prior art, the purpose of this invention is to provide a PLC seamless integrated communication method and system based on a DCS dual-network redundancy architecture, so as to solve the problems mentioned in the background art.

[0008] The technical solution adopted by this invention to solve its technical problem is: a PLC seamless integrated communication method based on a DCS dual-network redundancy architecture, including...

[0009] Network integration: Connect at least one PLC controller to the existing redundant industrial Ethernet of the DCS system via an Ethernet interface, so that the PLC controller, the controller of the DCS system and the industrial control computer are connected to the same local area network.

[0010] Network configuration: Configure network addresses based on the same network segment for all devices connected to the local area network.

[0011] Communication protocol configuration: Activate the open standard Ethernet communication protocol service supported by the PLC controller, configure the corresponding communication client driver in the monitoring and operation station of the DCS system, establish a direct data communication link between the two that does not depend on a dedicated protocol conversion gateway, and complete the data address mapping configuration.

[0012] Channel establishment: Based on a unified local area network, the industrial control computer can directly access and maintain the PLC controller remotely through the standard engineering tool software installed on the PLC controller.

[0013] Communication assurance: At least two independent network paths of the DCS system’s redundant industrial Ethernet are used to provide redundancy backup for the direct data communication link, and in the event of failure of the primary path, the backup path is activated by address switching or path switching to maintain communication.

[0014] As a further improvement of the present invention: the network integration step includes:

[0015] Connect the Ethernet port of at least one PLC controller that supports Ethernet communication directly to the idle port of an existing redundant industrial Ethernet switch in the DCS system via a standard Ethernet cable, so that the PLC controller, the controller of the DCS system, and at least one industrial computer are connected to the same local area network.

[0016] As a further improvement of the present invention: the network configuration step includes:

[0017] Assign IP addresses belonging to the same network segment to DCS controllers, PLC controllers, and industrial control computers, and configure a unified subnet mask to enable all devices to communicate directly via IP at the network layer.

[0018] As a further improvement of the present invention: the communication protocol configuration step includes:

[0019] Enable the natively supported Modbus TCP server function in the PLC controller and set a fixed communication port; at the same time, add and configure the Modbus TCP client driver in the human-machine interface configuration software of the DCS system, establish a direct device connection with the PLC's IP address and port, and define the mapping relationship between DCS data tags and PLC internal data storage addresses.

[0020] As a further improvement of the present invention: the channel establishment step includes:

[0021] Standard programming and debugging software corresponding to the PLC controller model is installed on the industrial control computer, and the programming software is configured to directly access the IP address of the PLC controller via TCP / IP protocol through the same local area network, thereby establishing a remote maintenance channel for program uploading and downloading, variable monitoring and online debugging.

[0022] As a further improvement of the present invention: the communication guarantee step includes:

[0023] Utilizing the inherent dual-redundant network infrastructure of the DCS system, including network A and network B, the PLC controller is connected to network A at least, and network B is configured as a backup communication path. When a communication link failure is detected in network A, a preset network switching logic is executed to switch at least a portion of the communication traffic to network B in order to maintain communication.

[0024] As a further improvement of the present invention: the network configuration step further includes:

[0025] The IP address planning follows the original network address specifications of the DCS system and is extended accordingly. The DCS controller retains its preset fixed IP address, assigns a unique static IP address within the same network segment to each newly added PLC controller, and configures a corresponding fixed IP address for the industrial control computer. All devices have the same subnet mask.

[0026] A seamless integrated communication system for PLCs based on a DCS dual-network redundancy architecture for implementing the method described in any of the preceding claims, the system comprising:

[0027] The DCS system network unit includes at least one DCS system controller, at least one human-machine interface configuration software, and an industrial Ethernet switching device with multiple ports and a redundant architecture. The industrial Ethernet switching device constitutes the redundant backbone communication network of the DCS system.

[0028] At least one PLC controller with a standard Ethernet communication interface and embedded support for standard open Ethernet application layer protocols;

[0029] At least one industrial computer, which is equipped with standard programming and debugging software that is compatible with the PLC controller;

[0030] The PLC controller's Ethernet communication interface is directly connected to an idle port of the industrial Ethernet switching device via a network cable, enabling the PLC controller, DCS system controller, and industrial computer to jointly access the unified physical network formed by the industrial Ethernet switching device.

[0031] The human-machine interface configuration software is equipped with a communication client driver corresponding to the embedded protocol of the PLC controller. The communication client driver directly initiates a communication request to the network layer address of the PLC controller to establish an end-to-end data exchange link.

[0032] The DCS system includes a redundancy switching management module, which monitors the communication status of the PLC controller through different ports or network paths of the industrial Ethernet switching device, and controls the communication client driver or network device to switch the communication connection to a preset backup path when the primary path fails.

[0033] As a further improvement of the present invention, it also includes a centralized network address management module for unified planning and management of network layer address allocation for all devices within the unified physical network, ensuring that the DCS controller, the PLC controller, and the industrial control computer are configured with unique and fixed IP addresses belonging to the same IP subnet.

[0034] As a further improvement of the present invention, the redundancy switching management module specifically includes:

[0035] The status detection submodule periodically sends heartbeat detection messages to the primary network address of the PLC controller;

[0036] The fault determination submodule determines whether the primary communication link is healthy based on the response to the heartbeat detection message.

[0037] The switching execution submodule executes a predefined switching script or command when the primary communication link is determined to be faulty, in order to update the target address configuration of the communication client driver on the industrial control computer or adjust the network routing strategy.

[0038] Compared with the prior art, the beneficial effects of the present invention are:

[0039] This invention enables direct and reliable data interaction and remote maintenance between a DCS system and at least one PLC controller by reconstructing the network architecture and optimizing the communication protocol, without the need to add a dedicated communication gateway or server. By directly connecting the PLC controller to the existing redundant industrial Ethernet of the DCS system and establishing end-to-end direct communication based on open protocols, both technological advancements and economic benefits are achieved. Utilizing the inherent A / B dual-network redundancy architecture of the DCS, and through status monitoring and path switching mechanisms, the single-point failure risk of traditional dedicated gateways is completely eliminated, enabling the system communication availability to meet industrial-grade high reliability requirements. This eliminates the need for independent communication gateway hardware and corresponding wiring, reducing hardware costs by approximately 70% and simplifying installation and expansion processes. The industrial control computer can directly and remotely access the PLC via the same network, enabling program monitoring, debugging, and uploading / downloading. The average fault handling time can be reduced by more than 60%, significantly improving maintenance convenience. Direct connection using protocols such as Modbus TCP reduces data transfer latency and improves real-time performance. Furthermore, new devices only need to be connected to the existing network and configured with an IP address for integration, making expansion flexible and convenient. System expansion is no longer limited by the number of interfaces or protocol conversion capabilities of dedicated gateways, giving the system excellent scalability and adaptability. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the method flow of the present invention. Detailed Implementation

[0041] In order to clearly and completely understand the technical solution, the present invention will be further described in conjunction with the embodiments and accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0043] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0044] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0045] Embodiments of the present invention provide a seamless integrated communication method for PLCs based on a DCS dual-network redundancy architecture, including...

[0046] Network integration: Connect at least one PLC controller to the existing redundant industrial Ethernet of the DCS system via an Ethernet interface, so that the PLC controller, the controller of the DCS system and the industrial control computer are connected to the same local area network.

[0047] Network configuration: Configure network addresses based on the same network segment for all devices connected to the local area network.

[0048] Communication protocol configuration: Activate the open standard Ethernet communication protocol service supported by the PLC controller, configure the corresponding communication client driver in the monitoring and operation station of the DCS system, establish a direct data communication link between the two that does not depend on a dedicated protocol conversion gateway, and complete the data address mapping configuration.

[0049] Channel establishment: Based on a unified local area network, the industrial control computer can directly access and maintain the PLC controller remotely through the standard engineering tool software installed on the PLC controller.

[0050] Communication assurance: At least two independent network paths of the DCS system’s redundant industrial Ethernet are used to provide redundancy backup for the direct data communication link, and in the event of failure of the primary path, the backup path is activated by address switching or path switching to maintain communication.

[0051] This invention directly connects PLCs to the existing redundant network of the DCS, eliminating the need for dedicated communication gateways or independent OPC servers required in traditional solutions. This directly reduces core hardware procurement costs and corresponding rack space, cabling, and energy consumption expenses, resulting in a significant reduction in total cost of ownership. It fully utilizes the DCS system's native A / B dual-network and other redundant infrastructure, providing physical-level redundancy for core communication links. Combined with active monitoring and switching mechanisms, it completely eliminates single-point-of-failure bottlenecks found in traditional gateway solutions, elevating communication link reliability to the same level as the DCS core network and ensuring continuous and stable production processes. Based on a unified network domain, authorized engineers can remotely upload and download programs, monitor online, and debug field PLCs directly from the control room using standard software on an industrial computer. This eliminates the need for on-site visits, significantly shortens fault diagnosis and handling time, reduces maintenance difficulty and labor costs, and achieves an intelligent transformation of the operation and maintenance model. It uses standard protocols such as Modbus TCP to establish end-to-end direct communication, eliminating the need for data relay via gateways or servers. This not only reduces the latency caused by protocol conversion and improves the real-time performance of data exchange, but also avoids external servers becoming a performance bottleneck, thus fundamentally improving communication efficiency and system response speed.

[0052] In one embodiment of the present invention, the network integration step includes:

[0053] Connect the Ethernet port of at least one PLC controller supporting Ethernet communication directly to an idle port of an existing redundant industrial Ethernet switch in the DCS system via a standard Ethernet cable. This allows the PLC controller, the DCS system controller, and at least one industrial computer to access the same local area network. By directly connecting the PLC to an idle port of the existing industrial Ethernet switch in the DCS, the independent communication gateway module required for each PLC in traditional solutions is completely eliminated. This not only directly saves on gateway hardware procurement costs but also reduces the associated power supply, cabinet space, and dedicated cables, greatly simplifying the system structure. Traditional gateways are single points of failure in the communication link. This step fundamentally removes this reliability bottleneck by eliminating the dedicated gateway. The communication link no longer depends on a vulnerable independent device, improving the overall availability of the system. It fully utilizes the redundant network ports and switch capacity originally built by the DCS system for its high reliability but often idle or lightly loaded. Integrating the PLC into this network achieves deep sharing of existing high-quality infrastructure, avoiding redundant investment and resource waste caused by building a separate network for the PLC.

[0054] In one embodiment of the present invention, the network configuration step includes:

[0055] Assigning IP addresses belonging to the same network segment to DCS controllers, PLC controllers, and industrial PCs, and configuring a unified subnet mask, enables all devices to communicate directly via IP at the network layer. By assigning IP addresses from the same network segment and using a unified subnet mask, DCS controllers, PLCs, and industrial PCs are recognized as equal, directly addressable neighbors at the network layer. This eliminates the logical isolation between different network domains, clearing the way for subsequent end-to-end direct communication. A unified IP plane eliminates the need for gateway address translation or routing forwarding of data packets. Communication requests can be directly addressed at the IP layer and delivered to the target device, significantly shortening the communication path and reducing processing latency.

[0056] In one embodiment of the present invention, the communication protocol configuration step includes:

[0057] The PLC controller's natively supported Modbus TCP server function is enabled, and a fixed communication port is configured. Simultaneously, in the DCS system's HMI configuration software, a Modbus TCP client driver is added and configured to establish a direct device connection with the PLC's IP address and port, and the mapping relationship between DCS data tags and PLC internal data storage addresses is defined. By directly enabling the PLC's natively supported Modbus TCP server function and configuring the corresponding client driver on the DCS side, an end-to-end direct communication channel based on the standard Ethernet protocol is established. This completely eliminates the necessary physical or software protocol conversion between proprietary protocols and Modbus in traditional solutions. This not only saves on conversion hardware costs but, more importantly, eliminates data errors, additional delays, and single points of failure that may be introduced during protocol conversion, fundamentally improving the reliability and determinism of the communication link.

[0058] In one embodiment of the present invention, the channel establishment step includes:

[0059] Standard programming and debugging software corresponding to the PLC controller model is installed on the industrial control computer. Through the same local area network, the programming software is configured to directly access the PLC controller's IP address using the TCP / IP protocol, thus establishing a remote maintenance channel for program uploading / downloading, variable monitoring, and online debugging. Engineers can directly perform comprehensive remote operations on the field PLCs from the central control room, including program uploading / downloading, real-time variable monitoring, online logic debugging, and parameter modification. This completely changes the traditional operation and maintenance model that requires physical presence in humid, noisy, or high-risk industrial sites.

[0060] In one embodiment of the present invention, the communication protection step includes:

[0061] By leveraging the inherent dual-redundant network infrastructure of the DCS system (A and B networks), the PLC controller is connected to at least the A network, and the B network is configured as a backup communication path. When a communication link failure is detected on the A network, a preset network switching logic is executed to switch at least a portion of the communication traffic to the B network to maintain communication. This deeply integrates PLC communication into the existing, proven, high-reliability architecture of the DCS system. By utilizing the inherent A / B dual networks, dual redundancy at both the physical and data link layers is provided for the communication link to the PLC. When any link in the primary A network path fails, the system can automatically switch to the backup B network path. This fundamentally solves the two critical single points of failure in traditional gateway solutions—the communication gateway and the single network link—enabling the PLC communication reliability to reach the same industrial-grade standard as the DCS core control network.

[0062] In one embodiment of the present invention, the network configuration step further includes:

[0063] The IP address planning follows the existing network address specifications of the DCS system for expansion. The DCS controller retains its preset fixed IP address, and each newly added PLC controller is assigned a unique static IP address within the same network segment. The industrial control computer is also configured with a corresponding fixed IP address, and all devices share the same subnet mask. By strictly adhering to the existing DCS address specifications, the addresses of the newly added PLCs and industrial control computers are fully compatible with the DCS network that has been operating for many years. This fundamentally avoids IP address conflicts, routing chaos, or interference with the DCS's internal communication mechanisms that could result from arbitrary planning, ensuring a smooth and secure integration process without disrupting the existing stable core system. Assigning static, unique fixed IP addresses to all devices replaces the dynamic allocation mode, which could lead to address changes due to DHCP server failures, lease renewal delays, or reallocation. This greatly simplifies troubleshooting and completely eliminates the potential for unexpected communication interruptions due to address changes.

[0064] A seamless integrated communication system for PLCs based on a DCS dual-network redundancy architecture for implementing the method described in any of the preceding claims, the system comprising:

[0065] The DCS system network unit includes at least one DCS system controller, at least one human-machine interface configuration software, and an industrial Ethernet switching device with multiple ports and a redundant architecture. The industrial Ethernet switching device constitutes the redundant backbone communication network of the DCS system.

[0066] At least one PLC controller with a standard Ethernet communication interface and embedded support for standard open Ethernet application layer protocols;

[0067] At least one industrial computer, which is equipped with standard programming and debugging software that is compatible with the PLC controller;

[0068] The PLC controller's Ethernet communication interface is directly connected to an idle port of the industrial Ethernet switching device via a network cable, enabling the PLC controller, DCS system controller, and industrial computer to jointly access the unified physical network formed by the industrial Ethernet switching device.

[0069] The human-machine interface configuration software is equipped with a communication client driver corresponding to the embedded protocol of the PLC controller. The communication client driver directly initiates a communication request to the network layer address of the PLC controller to establish an end-to-end data exchange link.

[0070] The DCS system includes a redundancy switching management module, which monitors the communication status of the PLC controller through different ports or network paths of the industrial Ethernet switching device, and controls the communication client driver or network device to switch the communication connection to a preset backup path when the primary path fails.

[0071] In one embodiment of the present invention, a centralized network address management module is also included. This module is used to uniformly plan and manage the network layer address allocation of all devices within the unified physical network, ensuring that the DCS controller, PLC controller, and industrial control computer are configured with unique and fixed IP addresses belonging to the same IP subnet. This module unifies the previously scattered and manual IP address allocation, recording, and verification work into a controlled software platform for automated management. It can automatically detect new devices in the network and, based on a preset address pool and planning strategy, allocate unique and compliant static IP addresses to them, while automatically issuing configuration or generating configuration commands. This completely eliminates low-level errors such as address duplication, subnet mask errors, or inconsistent formats that may occur during manual configuration, ensuring the accuracy and consistency of network configuration from the source, and greatly improving the efficiency and reliability of initial deployment and expansion.

[0072] In one embodiment of the present invention, the redundancy switching management module specifically includes:

[0073] The status detection submodule periodically sends heartbeat detection messages to the primary network address of the PLC controller;

[0074] The fault determination submodule determines whether the primary communication link is healthy based on the response to the heartbeat detection message.

[0075] The switching execution submodule executes a predefined switching script or command when the primary communication link is determined to be faulty, in order to update the target address configuration of the communication client driver on the industrial control computer or adjust the network routing strategy.

[0076] This module replaces the inefficient traditional model that relies on manual observation, judgment, and operation with a closed-loop automated process of status detection, fault diagnosis, and switchover execution. The status detection submodule achieves continuous and proactive monitoring of the communication link status by periodically sending heartbeat messages. Once the fault diagnosis submodule confirms a fault within milliseconds to seconds based on response timeouts or erroneous content, the switchover execution submodule will immediately trigger predefined actions. This series of automated operations reduces fault detection and switchover recovery time from minutes or even hours of manual intervention to seconds or even sub-seconds, minimizing the impact of communication interruptions on production monitoring and control.

[0077] In summary, after reading this invention document, those skilled in the art can make various other corresponding modifications to the technical solutions and concepts based on this invention without creative mental effort, and all of these modifications fall within the scope of protection of this invention.

Claims

1. A seamless integrated communication method for PLCs based on a DCS dual-network redundancy architecture, characterized in that, include: Network integration: Connect at least one PLC controller to the existing redundant industrial Ethernet of the DCS system via an Ethernet interface, so that the PLC controller, the controller of the DCS system and the industrial control computer are connected to the same local area network. Network configuration: Configure network addresses based on the same network segment for all devices connected to the local area network. Communication protocol configuration: Activate the open standard Ethernet communication protocol service supported by the PLC controller, configure the corresponding communication client driver in the monitoring and operation station of the DCS system, establish a direct data communication link between the two that does not depend on a dedicated protocol conversion gateway, and complete the data address mapping configuration. Channel establishment: Based on a unified local area network, the industrial control computer can directly access and maintain the PLC controller remotely through the standard engineering tool software installed on the PLC controller. Communication assurance: At least two independent network paths of the DCS system’s redundant industrial Ethernet are used to provide redundancy backup for the direct data communication link, and in the event of failure of the primary path, the backup path is activated by address switching or path switching to maintain communication.

2. The PLC seamless integrated communication method based on DCS dual-network redundancy architecture according to claim 1, characterized in that, The network integration step includes: Connect the Ethernet port of at least one PLC controller that supports Ethernet communication directly to the idle port of an existing redundant industrial Ethernet switch in the DCS system via a standard Ethernet cable, so that the PLC controller, the controller of the DCS system, and at least one industrial computer are connected to the same local area network.

3. The PLC seamless integrated communication method based on DCS dual-network redundancy architecture according to claim 2, characterized in that, The network configuration steps include: Assign IP addresses belonging to the same network segment to DCS controllers, PLC controllers, and industrial PCs, and configure a unified subnet mask to enable all devices to communicate directly via IP at the network layer.

4. The PLC seamless integrated communication method based on DCS dual-network redundancy architecture according to claim 3, characterized in that, The communication protocol configuration step includes: Enable the natively supported Modbus TCP server function in the PLC controller and set a fixed communication port; at the same time, add and configure the Modbus TCP client driver in the human-machine interface configuration software of the DCS system, establish a direct device connection with the PLC's IP address and port, and define the mapping relationship between DCS data tags and PLC internal data storage addresses.

5. The PLC seamless integrated communication method based on DCS dual-network redundancy architecture according to claim 4, characterized in that, The channel establishment step includes: Standard programming and debugging software corresponding to the PLC controller model is installed on the industrial control computer, and the programming software is configured to directly access the IP address of the PLC controller via TCP / IP protocol through the same local area network, thereby establishing a remote maintenance channel for program uploading and downloading, variable monitoring and online debugging.

6. The PLC seamless integrated communication method based on DCS dual-network redundancy architecture according to claim 5, characterized in that, The communication assurance steps include: Utilizing the inherent dual-redundant network infrastructure of the DCS system, including network A and network B, the PLC controller is connected to network A at least, and network B is configured as a backup communication path. When a communication link failure is detected in network A, a preset network switching logic is executed to switch at least a portion of the communication traffic to network B in order to maintain communication.

7. The PLC seamless integrated communication method based on DCS dual-network redundancy architecture according to claim 6, characterized in that, The network configuration steps also include: The IP address planning follows the original network address specifications of the DCS system and is extended accordingly. The DCS controller retains its preset fixed IP address, assigns a unique static IP address within the same network segment to each newly added PLC controller, and configures a corresponding fixed IP address for the industrial control computer. All devices have the same subnet mask.

8. A PLC seamless integrated communication system based on a DCS dual-network redundancy architecture for implementing the method as described in any one of claims 1-7, the system comprising: The DCS system network unit includes at least one DCS system controller, at least one human-machine interface configuration software, and an industrial Ethernet switching device with multiple ports and a redundant architecture. The industrial Ethernet switching device constitutes the redundant backbone communication network of the DCS system. At least one PLC controller with a standard Ethernet communication interface and embedded support for standard open Ethernet application layer protocols; At least one industrial computer, which is equipped with standard programming and debugging software that is compatible with the PLC controller; The PLC controller's Ethernet communication interface is directly connected to an idle port of the industrial Ethernet switching device via a network cable, enabling the PLC controller, DCS system controller, and industrial computer to jointly access the unified physical network formed by the industrial Ethernet switching device. The human-machine interface configuration software is equipped with a communication client driver corresponding to the embedded protocol of the PLC controller. The communication client driver directly initiates a communication request to the network layer address of the PLC controller to establish an end-to-end data exchange link. The DCS system includes a redundancy switching management module, which monitors the communication status of the PLC controller through different ports or network paths of the industrial Ethernet switching device, and controls the communication client driver or network device to switch the communication connection to a preset backup path when the primary path fails.

9. The PLC seamless integrated communication system based on DCS dual-network redundancy architecture according to claim 8, characterized in that, It also includes a centralized network address management module, which is used to uniformly plan and manage the network layer address allocation of all devices within the unified physical network, ensuring that the DCS controller, the PLC controller and the industrial control computer are configured with unique and fixed IP addresses belonging to the same IP subnet.

10. The PLC seamless integrated communication system based on DCS dual-network redundancy architecture according to claim 8, characterized in that, The redundancy switching management module specifically includes: The status detection submodule periodically sends heartbeat detection messages to the primary network address of the PLC controller; The fault determination submodule determines whether the primary communication link is healthy based on the response to the heartbeat detection message. The switching execution submodule executes a predefined switching script or command when the primary communication link is determined to be faulty, in order to update the target address configuration of the communication client driver on the industrial control computer or adjust the network routing strategy.

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