An OPC and Modbus-based control data communication method for a smart thermal power plant

Abstract

The application discloses a control data communication method based on OPC and Modbus for a smart thermal power plant, and relates to the technical field of electric communication; the method comprises obtaining a control data communication device, the control data communication device comprises a hyper-converged server, a controller, an OPC host computer and a DCS network, the hyper-converged server is unidirectionally connected with the controller for communication and serves as a unique control data write-back channel, the controller is connected with the DCS network for unidirectional communication, the DCS network is connected with the OPC host computer for unidirectional communication, and the OPC host computer is connected with the hyper-converged server for unidirectional communication; the hyper-converged server bears data access, data storage, data processing, data forwarding and data display, and the data processing efficiency is improved; the unique control data write-back channel is an independent and safe channel, thereby realizing centralized management and isolated control of process data and application data, and the safety is better.

Description

Technical Field

[0001] This invention relates to the field of electrical communication technology, and in particular to a control data communication method based on OPC and Modbus for smart thermal power plants. Background Technology

[0002] With the development of digitalization and intelligentization in the energy industry, thermal power plants are accelerating their transformation towards smart systems. This is especially true in the production control area, where critical production equipment and control systems require extremely high levels of real-time performance and security. Meanwhile, existing distributed control systems (DCS) generally adopt a unified architecture and standards; therefore, smart system upgrades must be adapted and integrated without altering the original DCS architecture or affecting the stable operation of the existing power generation control system.

[0003] Traditional thermal power plants mainly rely on DCS controllers and configuration logic to complete all control tasks and logic operations. Although the hierarchy is clear, data exchange between systems is limited, and there is a lack of centralized processing and management, resulting in data silos. This leads to low scalability and data reuse rate, making it difficult to support the cross-system data fusion and in-depth analysis required for intelligent upgrades.

[0004] In recent years, the Intelligent Control System (ICS) for smart power plants has introduced server-side computing capabilities into the production control area. By deploying artificial intelligence (AI), large-scale models, and optimization algorithms, it achieves higher performance computing and decision support than traditional DCS configuration logic. Controller data is extended to centralized server processing and model calculations, promoting the deep integration of industrial automation and informatization. However, this process still faces key technological challenges that hinder the practical application of smart thermal power plants, particularly in areas such as real-time communication and ensuring the security of production control data networks.

[0005] The existing technology is insufficient, as explained below.

[0006] While existing thermal power plant control data communication and data fusion solutions already have communication technologies and interface devices that support industrial protocols such as OPC UA, Modbus TCP, and Modbus RTU, the following shortcomings still exist.

[0007] Insufficient network security protection: The current deployment of control data communication links has not formed a standardized system, lacks systematic network planning and security strategies, and the design phase has not implemented partition isolation, access control and communication path restrictions, which pose potential risks such as data leakage, unauthorized access and control command tampering.

[0008] Lack of a unified platform architecture: Communication between industrial control protocols and Ethernet protocols often operates as independent systems, lacking a centralized scheduling and unified management mechanism under a unified physical architecture. This makes it impossible to achieve efficient processing and forwarding of full data from multiple protocols, resulting in low system integration and high management complexity.

[0009] Insufficient adaptability to application scenarios: Existing solutions are mostly geared towards inter-controller communication or general industrial data acquisition, and have not been optimized for the special needs of smart thermal power plant production control areas in terms of high real-time performance, high security and high stability, making it difficult to support large-scale data applications such as smart upgrades and artificial intelligence.

[0010] Lack of standardized communication interface templates: The lack of directly reusable fixed communication interface templates means that when deploying upper-layer applications, it is necessary to repeatedly perform underlying communication testing and adaptation, which not only increases development and maintenance costs, but also reduces the efficiency of system expansion and upgrades.

[0011] Therefore, the inability to efficiently process and forward full data from multiple protocols during thermal power production has led to low system integration, high management complexity, and poor security, which are pressing technical problems that need to be addressed. Summary of the Invention

[0012] This invention provides a control data communication method based on OPC and Modbus for smart thermal power plants, which solves the technical problems of low data processing efficiency and poor security in thermal power production.

[0013] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A control data communication method based on OPC and Modbus for smart thermal power plants includes the following steps: Step S1: Obtain the control data communication device, which includes a hyper-converged server, a controller, an OPC host computer, and a DCS network. The hyper-converged server communicates unidirectionally with the controller and serves as the sole control data write-back channel. The controller is connected to the DCS network and communicates unidirectionally. The DCS network is connected to the OPC host computer and communicates unidirectionally. The OPC host computer is connected to the hyper-converged server and communicates unidirectionally.

[0014] A further technical solution is as follows: the hyperconverged server is a production control area server, the controller is a DCS controller, the DCS controller contains a Modbus TCP communication card, the architecture of the DCS network is an A and B dual-network redundant architecture, and the hyperconverged server is connected to the Modbus TCP communication card of the DCS controller and the OPC host computer separately to form an independent third communication link, namely the C network.

[0015] A further technical solution is that the control data communication device also includes an upper-layer application server, which is connected to and communicates with the hyper-converged server.

[0016] A further technical solution is that the upper-layer application server includes an air-cooling optimization model calculation server and a wall temperature prediction model calculation server. The air-cooling optimization model calculation server is connected to and communicates with the hyper-converged server, and the wall temperature prediction model calculation server is connected to and communicates with the hyper-converged server.

[0017] A further technical solution is that the control data communication device also includes a forward isolation gateway and a three-zone server, and the hyper-converged server is connected and communicates with the three-zone server through the forward isolation gateway.

[0018] A further technical solution is as follows: In step S1, the OPC host computer includes multiple units, and each unit and data access or write-back domain are divided using a virtual local area network, and IP-level isolated data communication is achieved through a firewall whitelist.

[0019] A further technical solution includes the following steps following step S1: Step S2: Obtain the data fusion platform on the hyperconverged server; Step S3: The data fusion platform reads the OPC data; Step S4: The controller writes back the data.

[0020] A further technical solution is that, in step S2, the data fusion platform includes a data access module, a data storage module, a data processing module, a data forwarding module, and a data display module. The data access module is used to access the full data of DCS through the OPC host computer, including historical station operation record data, NCS and gate power, and production control data. The data storage module is used to obtain raw data from the production control area, as well as intermediate and final results generated through data processing, analysis, or model calculation; The data processing module is used to clean and preprocess the raw data and the intermediate data after analysis and calculation, including the removal of null values ​​and outliers, logical calculations and format conversion; The data forwarding module is used to forward data to the server in the production control area for model calculation and control command generation, and to receive write-back data; it also forwards data to the information center in the three areas for backup and analysis. The data display module is used to visualize the collected data, analysis results, and model outputs through a visual interface, and transmit the display page to the central control room.

[0021] A further technical solution is that step S3 specifically includes the following steps: Step S31: Physical connection and network configuration; Establish a physical connection between the OPC host computer and the hyperconverged server through fiber optic cables and network cables. The connection process passes through firewalls and switches. Configure IP addresses and network security policies. Step S32: Point table management; Download the point table from the OPC host computer, organize, classify and verify the point table, and then upload it to the data fusion platform to complete data identification and mapping; Step S33: Permission configuration; Enable telemetry and tele-signaling permissions on the OPC host computer side, forward data as a whole on the OPC host computer, configure forwarding permissions for newly added data points separately, and manage data access dynamically; Step S34: Data reading; The data fusion platform obtains DCS control data in real time through the OPC host computer, centrally accesses and processes the full dataset, and provides a data foundation for upper-level analysis, model calculation and control command generation.

[0022] A further technical solution is that step S4 is specifically divided into the following steps: Step S41: Physical connection and network configuration; establish the write-back channel, the connection process passes through the firewall and switch, configure IP address and network security policies; Step S42: Master-Slave Configuration; Configure the master station as the communication card IP and the slave station as the data fusion platform IP on the controller, set the corresponding function codes, and realize the correct identification and transmission of control commands; Step S43: Data write-back; The data fusion platform sends control commands to the controller, and the controller receives the control commands.

[0023] The beneficial effects of adopting the above technical solution are as follows: A control data communication method based on OPC and Modbus for smart thermal power plants includes: obtaining a control data communication device, which comprises a hyper-converged server, a controller, an OPC host computer, and a DCS network. The hyper-converged server communicates unidirectionally with the controller and serves as the sole control data write-back channel. The controller is connected to the DCS network and communicates unidirectionally. The DCS network is connected to the OPC host computer and communicates unidirectionally. The OPC host computer is connected to the hyper-converged server and communicates unidirectionally. The hyper-converged server handles data access, data storage, data processing, data forwarding, and data display, improving data processing efficiency. The sole control data write-back channel is independent and secure, thereby achieving centralized management and isolated control of process data and application data, resulting in better security. Attached Figure Description

[0024] Figure 1 This is a block diagram illustrating the principle of control data communication based on OPC and Modbus. Detailed Implementation

[0025] To address the technical challenges in the current development of intelligent thermal power plants, it is necessary to propose a unified physical architecture based on a data fusion platform server, an OPC host computer, and a communication card. This architecture employs a network communication method that combines OPC UA interface reading with Modbus TCP interface writing to simultaneously meet the comprehensive requirements of intelligent thermal power plants in terms of security, real-time performance, robustness, and scalability. Furthermore, a standardized communication interface template that can be directly reused should be established to reduce the complexity of developing and deploying upper-layer applications.

[0026] Therefore, this application proposes a control data communication method based on OPC and Modbus for smart thermal power plants. This method addresses the shortcomings of traditional industrial control system data-server communication in terms of security, stability, replicability, and robustness, achieving effective management of the entire lifecycle of production control data and ensuring network and data security. Based on the platform built by this method, various intelligent systems, applications, and services in the production control area can achieve efficient acquisition of production data and secure write-back of control commands, providing a robust PaaS layer foundation for closed-loop control. Examples of these applications and services include: large-scale modeling, air-cooling optimization, wall temperature prediction, and intelligent monitoring.

[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit this application or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0028] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0029] Example 1: This invention discloses a control data communication method based on OPC and Modbus for smart thermal power plants, comprising the following steps: Step S1: Obtain control data communication device.

[0030] Obtain the physical and network architecture of the data fusion platform, OPC host computer, and controller. The OPC host computer includes an OPC UA interface, and the controller includes a Modbus TCP interface.

[0031] like Figure 1 As shown, this application constructs a unified physical architecture consisting of a data fusion platform, an OPC host computer, and a Modbus TCP communication card, and designs a network communication architecture for reading data via the OPC UA interface and writing data back via the Modbus TCP interface based on this architecture. Details are as follows.

[0032] Physical Architecture: The data fusion platform is deployed on the production control zone server, which is connected to the OPC host computer and communication card via a fiber optic physical link. Simultaneously, this server is physically connected to upper-layer application servers to provide control data sharing, processing, and write-back services. These upper-layer application servers include, for example, models for air-cooling optimization and wall temperature prediction. Furthermore, the data fusion platform server connects to the three-zone servers across a forward isolation gateway, enabling the forwarding of production control zone data to the three-zone SIS, the smart power plant's edge cloud platform, and the group network.

[0033] OPC host computer deployment: The OPC host computer is located at the engineer station, with network A and network B connected to the DCS network, and network C connected to the data fusion platform server.

[0034] Hyperconverged servers are data fusion platform servers or production control area servers.

[0035] ModbusTCP communication card deployment: The ModbusTCP communication card is deployed in the control cabinet of the electronics room and is physically connected to the dedicated DCS controller that needs to communicate. In addition, the ModbusTCP communication card is connected to the data fusion platform server through the C network.

[0036] Network Architecture and Security: The data fusion platform, OPC host computer, and Modbus TCP communication card are located on the same C network segment, independent of networks A and B, and protected by strict network security isolation. Virtual LANs are used to divide data access or write-back domains for different groups and systems, and IP-level isolated data communication is achieved through firewall whitelists. Firewalls are deployed between the data fusion platform and the OPC host computer, and between the data fusion platform and the Modbus TCP communication card, to ensure secure and controllable data transmission.

[0037] Step S2: Obtain the data fusion platform.

[0038] Obtain the data reading, retrieval, storage, and display functional architecture of the data fusion platform.

[0039] like Figure 1 As shown, the data fusion platform integrates core functional modules such as data access, data storage, data processing, data forwarding, and data display, enabling centralized management and efficient flow of control data in the production control area.

[0040] The data access module is mainly used to access the full data of DCS through the OPC host computer; at the same time, it can also access other production control data such as historical station operation record data, NCS, and gate power, so as to realize the unified collection of multi-source data.

[0041] The data storage module is used by the platform to store all raw data obtained from the production control area, as well as intermediate and final results generated through data processing, analysis, or model calculation, thereby achieving full lifecycle management of data.

[0042] The data processing module is used to clean and preprocess the raw data and intermediate data after analysis and calculation, including operations such as null value and outlier removal, logical calculation and format conversion, so as to provide a reliable data foundation for subsequent analysis, model calculation and write-back.

[0043] The data forwarding module is used to forward data to other servers in the production control area for model calculation and control command generation, and to receive write-back data; it also forwards data to the information center in the three zones for backup and analysis.

[0044] The data visualization module allows the platform to visualize the collected data, analysis results, and model outputs through a visual interface, and transmit the display page to the central control room to achieve centralized monitoring and real-time decision support for operators.

[0045] Step S3: The data fusion platform reads the OPC data.

[0046] This application provides a method for a data fusion platform to read data from an OPC host computer, and the specific steps are as follows.

[0047] Step S31: Physical Connection and Network Configuration. Establish a physical connection between the OPC host computer and the data fusion platform server via fiber optic cable and network cable. Both the data fusion platform and the OPC host computer are connected to the C-network. The connection process requires the use of security devices such as firewalls and switches. Based on this, configure IP addresses and network security policies to ensure the security and reliability of the data link.

[0048] Step S32: Point Table Management. Download the point table from the OPC host computer, organize, classify, and verify the point table, and then upload it to the data fusion platform to complete data identification and mapping.

[0049] Step S33: Permission Configuration. Enable telemetry and remote signaling permissions on the OPC host computer side to ensure that data can be read by the data fusion platform. Data can be forwarded as a whole on a unit basis, and flexible data forwarding strategies are also supported. Forwarding permissions can be configured individually for newly added data points to achieve dynamic data access management.

[0050] Step S34: Data Reading. The data fusion platform acquires DCS control data in real time through the OPC UA interface, enabling centralized access and processing of all data, and providing a data foundation for upper-level analysis, model calculation, and control command generation.

[0051] Step S4: The controller writes back the data.

[0052] The controller's Modbus TCP communication card writes back data.

[0053] This application provides a method for writing data back to the controller via a Modbus TCP communication card, the specific implementation of which is as follows.

[0054] Step S41: Physical Connection and Network Configuration. Connect the Modbus TCP communication card to the controller requiring write-back communication and establish a physical connection with the data fusion platform server. The data fusion platform and the Modbus TCP communication card are connected to the C network. The communication link must pass through security devices such as firewalls and switches. Simultaneously, configure the IP addresses and network security policies for both the communication card and the controller to ensure the security and stability of the data write-back process.

[0055] Step S42: Master-Slave Configuration. Configure the master station on the Modbus TCP communication card as the communication card IP and the slave station as the data fusion platform IP, and set the corresponding function codes to achieve correct recognition and transmission of control commands.

[0056] Step S43: Data Write-back. The data fusion platform sends control commands to the Modbus TCP communication card. The communication card writes the commands to the corresponding controller via the Modbus TCP protocol, thus achieving write-back to the controller. After the operation is completed, the register data can be verified on the controller to ensure that the commands were executed correctly.

[0057] Example 2: This invention discloses a control data communication method based on OPC and Modbus for smart thermal power plants, comprising the following steps: like Figure 1 The system architecture diagram shown is based on the control data communication method of OPC and Modbus, which clearly and completely describes the technical solution of this application.

[0058] This application introduces an independent third communication link, namely the C network, on the basis of the traditional A and B dual-network redundancy architecture of DCS networks. This C network is used to carry out the acquisition, processing, and write-back of control data. This design not only ensures the stability and security of the A and B networks, but also provides an independent and secure channel for cross-system data transmission, realizing centralized management and isolated control of process data and application data.

[0059] At the functional level, the data fusion platform provides full support for the entire process from access and storage to forwarding and write-back. The entire process connects the complete path of OPC host computer data access—data fusion platform data processing—Modbus TCP communication card data write-back, providing a clear implementation architecture for the closed-loop control of smart thermal power plants.

[0060] The OPC host computer connects to the DCS network via network A and network B. As the DCS data export node, the OPC host computer aggregates all measurement data from the unit's control system and then connects to the data fusion platform via network C. The data fusion platform is deployed in a hyper-converged server and handles data access, data storage, data processing, data forwarding, and data display. The Modbus TCP communication card connected to the DCS controller is connected to the network C, serving as the sole control data write-back channel. After the upper-layer application calls the measurement data provided by the data fusion platform, the generated optimized setpoints or control commands are uniformly encapsulated by the data fusion platform, sent to the communication card, and ultimately written to the controller, realizing the execution of closed-loop control.

[0061] The upper-level applications include, for example, air-cooling optimization and wall temperature prediction.

[0062] Example 3: This invention discloses a control data communication method based on OPC and Modbus for smart thermal power plants, comprising the following steps: Below is a case study of control data communication based on OPC and Modbus for a smart thermal power plant in a 2×1000 MW coal-fired power project.

[0063] The core equipment includes: a data fusion platform, an OPC host computer, and a controller. The OPC host computer uses an OPC UA interface, and the controller uses a Modbus TCP interface.

[0064] Step 31: Obtain the physical architecture.

[0065] The OPC host computer is physically connected to the data fusion platform to achieve data acquisition, and the overall architecture adopts a 1:1 primary-backup redundancy structure. In each unit, the primary and backup OPC host computers are connected through independent physical cabling to ensure link-level reliability. The four sets of OPC host computers, including Unit #1, Unit #2, common and auxiliary control, are uniformly deployed on the engineering station, and each unit is equipped with two primary and backup OPC host computers.

[0066] Each host computer independently connects to DCS-A, B networks, and the newly added C network via a switch. Among them, networks A and B maintain the original communication links with DCS, while network C serves as an independent secure channel. Each host computer needs to add a C network card and configure a unique C network IP to connect to the data fusion platform server, realizing the aggregation and transmission of all data from the unit.

[0067] The data fusion platform is deployed on a server in the network data center.

[0068] The DCS controller is deployed in the control cabinet of the boiler electronics room. Each pair of primary and backup redundant controllers can be equipped with one or more Modbus TCP communication cards, serving as the sole channel for writing back control commands. The number of communication cards can be flexibly expanded according to the data volume.

[0069] Step 32: Obtain the network architecture.

[0070] OPC host computers from different units, including Unit #1, Unit #2, auxiliary control, and common units, transmit real-time data to the data fusion platform via the C-network for centralized storage and unified processing. The platform, as the sole data aggregation node, is responsible for unified management and secure isolation of cross-unit data. Regarding security policies, access permissions for the OPC host computers are restricted through a dual mechanism of IP virtual security groups and whitelists. Authorized unit-level OPC real-time data can only be accessed by the data fusion platform; other servers or terminals on the same network segment as the data fusion platform cannot directly access the OPC host computers or receive their data. Therefore, the data fusion platform becomes the sole authorized recipient of OPC data, ensuring data link security and controllable access.

[0071] At the upper application layer, the data fusion platform provides data interfaces for systems such as air-cooling optimization and wall temperature prediction. Each application system obtains the necessary measurement point data from the platform's central data set. Each application uses the platform's real-time and historical data for model calculations. The results, such as optimized values, alarms, and commands, are received and verified by the platform before being written back to the corresponding controller via a Modbus TCP communication card. To ensure the security of the write-back link, the platform also employs an IP whitelist and virtual security group mechanism, allowing only the data fusion platform to access the target communication card IP, such as the communication card connected to the #1 unit controller DPU1050. This mechanism ensures that the write-back data can only be directed to the designated controller of the corresponding unit, avoiding cross-unit miswrites or abnormal interference.

[0072] Step 33: The data fusion platform reads the OPC data.

[0073] The process of the data fusion platform collecting control data from the OPC host computer mainly includes: point table acquisition, point table import and mapping, OPC forwarding configuration, data synchronization and consistency verification, and data services for upper-layer applications.

[0074] Step 331: Obtain the table.

[0075] Export four sets of measurement point tables in XLSX format from the DCS host computer, including measurement point tables for Unit #1, Unit #2, common and auxiliary control. The table fields should include at least: Chinese description of the measurement point, KKS code, measurement point address and equipment name.

[0076] Step 332: Import and map point tables.

[0077] Import the measurement point table into the data fusion platform. After parsing, the platform automatically creates a logical table and establishes an index using KKS encoding as the primary key. It also generates a mapping relationship with OPC for real-time data writing.

[0078] Step 333: OPC forwarding configuration.

[0079] Enable the measurement point forwarding function on the OPC host computer of the engineering station, including selecting the measurement points that need to be forwarded; specifying the target IP, i.e., the data fusion platform; and configuring the forwarding cycle to reduce redundant transmission.

[0080] Step 334: Data fusion platform accesses and verifies data.

[0081] After receiving the data forwarded by OPC, the data fusion platform classifies the received data according to the previously generated mapping relationship and KKS encoding, and imports it into the data fusion platform database.

[0082] Step 335: Provide data services to upper-layer applications.

[0083] After completing data access and verification, the data fusion platform opens read-only interfaces to application systems such as smart monitoring, air-cooling optimization, and wall temperature prediction. Each application can pull datasets as needed for model inference or optimization calculations.

[0084] Step 34: The data fusion platform reads, retrieves, stores, and displays data.

[0085] Step 341: Data access.

[0086] Enable the forwarding function in the OPC host computer, using KKS encoding as the index, to select and forward the required measurement points in batches.

[0087] Step 342: Data storage.

[0088] All incoming data is stored uniformly within the platform, covering raw control data, intermediate processing results, and final model output. Raw control data is accessed via OPC, intermediate processing results include data cleaning and intermediate quantities of data processing for display on the platform, and the final model output is forwarded by various application systems.

[0089] Time-series database: Real-time data is entered into an in-memory database, supporting millisecond-level writing and retrieval; historical data is stored in a distributed storage system, storing one month's worth of historical data, while data for longer periods is forwarded to the three-zone storage.

[0090] Data integrity: The platform automatically adds a timestamp and data source to each record, enabling traceability of the data throughout its entire lifecycle.

[0091] Step 343: Data processing.

[0092] Upon receiving the raw OPC data, the platform immediately performs cleaning and preprocessing to improve data reliability.

[0093] Data quality control: Remove null values, outliers, and data with logical errors, such as records where the main steam pressure is less than 0; Format standardization: Convert data from different sources into the platform's standard format to ensure compatibility across applications; Computational support: Performs online logical operations on some derived variables to reduce repetitive computation work on the application side. Derived variables include load and efficiency.

[0094] Step 344: Data forwarding.

[0095] Forwarding to application systems: The platform's data aggregate forwards the required measurement point data to various application systems for model calculations, such as air-cooling optimization and wall temperature prediction. Write back to the controller: Write the calculation results back to the corresponding DCS controller via ModbusTCP communication card. The calculation results are, for example, the optimal louver opening generated by the air-cooled optimization system. Forwarding to Zone 3: Forwarding raw and processed data to the Zone 3 Information Center for big data analysis, report statistics and long-term archiving; Step 345: Data presentation.

[0096] Real-time monitoring: Provides a visual interface for measuring point trend curves, alarm information, and key performance indicators, facilitating real-time monitoring by operators in the central control room.

[0097] Calculation results display: The optimization results of the upper-layer application are displayed in charts to facilitate the understanding and verification of operation and maintenance personnel. The optimization results include, for example, the louver opening setting value for air cooling optimization.

[0098] Step 346: Application Example.

[0099] In air-cooled optimization system applications, the data fusion platform collects real-time data from the OPC host computer, including cold-end temperature, ambient humidity, and wind speed. After cleaning and standardization, this data is written to the database. The air-cooled optimization model algorithm system uses the data fusion platform to call the required data points for real-time calculations, generating the optimal louver opening value for each sector. The calculation results are sent to the data fusion platform via HTTP, and then uniformly written back to the controller.

[0100] Step 35: Write back data via Modbus TCP communication card.

[0101] In this application, the data fusion platform writes the calculation results of each application system back to the DCS controller through the ModbusTCP communication card to achieve closed-loop control.

[0102] Step 351: Hardware deployment.

[0103] The DCS controller is deployed in the control cabinet of the boiler electronics room. Each pair of primary and backup redundant controllers can be equipped with one or more Modbus TCP communication cards, serving as the sole channel for control command write-back. The number of communication cards can be flexibly expanded according to the data transmission volume. The communication cards and controllers are directly connected via the cabinet bus to ensure real-time performance and anti-interference capabilities. The communication cards and the data fusion platform server are located on an independent CDMA network segment, connected to a switch and firewall to ensure physical isolation and secure transmission.

[0104] Step 352: Communication test.

[0105] In the engineering workstation configuration console, assign a unique IP address and register range to the communication card. After all ModbusTCP communication cards are configured, test the connectivity from the data fusion platform to the IP addresses of all ModbusTCP communication cards.

[0106] Step 353: The data fusion platform sends back the write-back data.

[0107] After the upper-layer application completes the optimization calculation or predictive inference, it writes the results into the data fusion platform database; The platform performs logical verification and format conversion on the results to form write-back data in a standard format; The data fusion platform sends the write-back data to the target Modbus TCP communication card via a C-network secure link; Step 354: Modbus TCP communication card receives.

[0108] Configure the master station and slave station, where the master station is the IP address of the Modbus TCP communication card and the slave station is the IP address of the data fusion platform.

[0109] Address translation: First, the target IP address in decimal is converted to hexadecimal, and then it is reassembled into a decimal register address according to byte order to generate the destination IP register value.

[0110] Online configuration: Open the dedicated configuration console on the engineer station host computer, select the corresponding communication card, write the register value obtained in the previous step into the "Device A / B Network IP Address" parameter, and save it to take effect.

[0111] Verification: After configuration, a link test is performed by sending a heartbeat signal. If the ModbusTCP communication card can successfully receive the test signal from the data fusion platform, it indicates that the link has been successfully established and can be officially put into the write-back task.

[0112] Data write-back application: Once the link is established, the controller can read data from the designated register and execute closed-loop control. Taking boiler optimization as an example, the application system uses real-time parameters such as main steam flow and furnace temperature collected by the data fusion platform to calculate and generate the target spray desuperheating valve opening value. After the set value is verified and encapsulated by the platform, it is written to the 10010 register of the relevant controller. The controller successfully receives the data, realizing intelligent closed-loop optimization control of the main steam temperature.

Claims

1. A control data communication method based on OPC and Modbus for smart thermal power plants, characterized in that: Includes the following steps, Step S1: Obtain the control data communication device, which includes a hyper-converged server, a controller, an OPC host computer, and a DCS network. The hyper-converged server communicates unidirectionally with the controller and serves as the sole control data write-back channel. The controller is connected to the DCS network and communicates unidirectionally. The DCS network is connected to the OPC host computer and communicates unidirectionally. The OPC host computer is connected to the hyper-converged server and communicates unidirectionally.

2. The control data communication method based on OPC and Modbus for smart thermal power plants according to claim 1, characterized in that: The hyperconverged server is a production control area server, the controller is a DCS controller, the DCS controller contains a Modbus TCP communication card, the architecture of the DCS network is an A and B dual-network redundancy architecture, the hyperconverged server is connected to the Modbus TCP communication card of the DCS controller and the OPC host computer respectively to form an independent third communication link, namely the C network.

3. The control data communication method based on OPC and Modbus for smart thermal power plants according to claim 1, characterized in that: The control data communication device also includes an upper-layer application server, which is connected to and communicates with the hyper-converged server.

4. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 3, characterized in that: The upper-layer application server includes an air-cooling optimization model calculation server and a wall temperature prediction model calculation server. The air-cooling optimization model calculation server is connected to and communicates with the hyper-converged server, and the wall temperature prediction model calculation server is connected to and communicates with the hyper-converged server.

5. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 1, characterized in that: The control data communication device also includes a forward isolation gateway and a three-zone server. The hyperconverged server is connected to and communicates with the three-zone server via the forward isolation gateway.

6. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 1, characterized in that: In step S1, the OPC host computer includes multiple units. Each unit and its data access or write-back domain are divided using a virtual local area network, and IP-level isolated data communication is achieved through a firewall whitelist.

7. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 1, characterized in that: It also includes the following steps after step S1, Step S2: Obtain the data fusion platform on the hyperconverged server; Step S3: The data fusion platform reads the OPC data; Step S4: The controller writes back the data.

8. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 7, characterized in that: In step S2, the data fusion platform includes a data access module, a data storage module, a data processing module, a data forwarding module, and a data display module. The data access module is used to access the full data of DCS through the OPC host computer, including historical station operation record data, NCS and gate power, and production control data. The data storage module is used to obtain raw data from the production control area, as well as intermediate and final results generated through data processing, analysis, or model calculation; The data processing module is used to clean and preprocess the raw data and the intermediate data after analysis and calculation, including the removal of null values ​​and outliers, logical calculations and format conversion; The data forwarding module is used to forward data to the server in the production control area for model calculation and control command generation, and to receive write-back data; it also forwards data to the information center in the three areas for backup and analysis. The data display module is used to visualize the collected data, analysis results, and model outputs through a visual interface, and transmit the display page to the central control room.

9. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 7, characterized in that: Step S3 is specifically divided into the following steps. Step S31: Physical connection and network configuration; Establish a physical connection between the OPC host computer and the hyperconverged server through fiber optic cables and network cables. The connection process passes through firewalls and switches. Configure IP addresses and network security policies. Step S32: Point table management; Download the point table from the OPC host computer, organize, classify and verify the point table, and then upload it to the data fusion platform to complete data identification and mapping; Step S33: Permission configuration; Enable telemetry and tele-signaling permissions on the OPC host computer side, forward data as a whole on the OPC host computer, configure forwarding permissions for newly added data points separately, and manage data access dynamically; Step S34: Data reading; The data fusion platform obtains DCS control data in real time through the OPC host computer, centrally accesses and processes the full dataset, and provides a data foundation for upper-level analysis, model calculation and control command generation.

10. A control data communication method based on OPC and Modbus for smart thermal power plants according to claim 7, characterized in that: Step S4 is specifically divided into the following steps. Step S41: Physical connection and network configuration; establish the write-back channel, the connection process passes through the firewall and switch, configure IP address and network security policies; Step S42: Master-slave configuration; Configure the master station as the communication card IP and the slave station as the data fusion platform IP on the controller, set the corresponding function codes, and realize the correct identification and transmission of control commands; Step S43: Data write-back; The data fusion platform sends control commands to the controller, and the controller receives the control commands.

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