An online hot standby redundancy method applied to a continuous casting secondary system

Abstract

The application discloses an online hot backup redundancy method applied to a continuous casting secondary system and belongs to the technical field of industrial automation control. The application adopts a dual-server structure of one for use and one for backup, the standby server monitors heartbeat variables of the main server in real time to judge the running state of the main server, and receives and caches all calculation data of the secondary model of the main server in real time during normal operation of the main server. When the heartbeat of the main server is monitored to be abnormal, the standby server automatically starts the secondary system, reads local cache data to recover the model calculation state and takes over the control right. The client automatically switches data interaction from the fault main server to the standby server by monitoring the heartbeat signal. The application adopts a common server to replace traditional special hot backup hardware, greatly reduces the cost, ensures the continuity of model calculation data through a data caching mechanism, avoids data loss caused by fault switching, realizes automatic seamless switching of the main server and the standby server, and effectively guarantees the stability and reliability of the continuous casting production process.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, specifically to an online hot standby redundancy method for a continuous casting secondary system, which is suitable for ensuring the high availability of the secondary model control system in the steel continuous casting production process. Background Technology

[0002] In the continuous casting process of steel, the secondary control system undertakes key functions such as process model calculation, production tracking, and process control. The secondary continuous casting model is the core hub connecting the primary basic automation and the tertiary production management system; its stable operation directly affects the quality of the cast billet and production efficiency. However, existing technologies have the following prominent problems in ensuring the reliability of the secondary continuous casting system: First, fault switching leads to data loss. When a fault occurs during the online operation of the secondary continuous casting model, production control will automatically switch to the primary system. This switching process results in the loss of process model tracking and calculation data and the withdrawal of dynamic control, which not only affects the quality of cast billets but also causes the loss of important production data, making subsequent quality analysis and process optimization difficult.

[0003] Secondly, traditional hot standby solutions are expensive. Traditional hot standby redundant server solutions typically use dedicated high-availability hardware, which often costs over 300,000 yuan. This puts a significant cost burden on small and medium-sized steel enterprises, making large-scale deployment difficult.

[0004] Third, data continuity cannot be guaranteed. Existing solutions cannot maintain the continuity of model calculation data after a main server failure, leading to secondary interruptions in the production process and gaps in process data, affecting the continuity of production scheduling and quality management.

[0005] Therefore, there is an urgent need for a low-cost, high-reliability hot standby redundancy solution to ensure that the continuous casting secondary model can continuously and stably control production and ensure the consistency of production tracking data. Summary of the Invention

[0006] This invention provides an online hot standby redundancy method for continuous casting secondary systems. By organically combining a dual-server architecture design, a heartbeat detection mechanism, a data synchronization and caching mechanism, and an automatic switching mechanism, the high availability of the continuous casting secondary system is ensured.

[0007] In a first aspect, the present invention provides an online hot standby redundancy method for a continuous casting secondary system, comprising: Deploy a dual-server architecture with one primary server and one backup server, where the primary server and the backup server run the same continuous casting secondary system and process configuration; The master server continuously generates and sends heartbeat variables that reflect its operating status; The backup server receives and monitors the heartbeat variables in real time, and automatically triggers a switchover process when it is determined that the primary server has failed based on the heartbeat variables. During the normal operation of the main server, the backup server receives and caches the calculation data of the secondary model of the main server in real time to form local cache data; The switching process includes: the backup server starting its secondary system and reading the local cached data to restore the model calculation state, thereby taking over control; By monitoring the heartbeat variable, the client automatically switches the data interaction object from the failed primary server to the backup server.

[0008] In some instances, the heartbeat variable is an integer variable that increments at preset time intervals and resets to zero after reaching a preset upper limit value to restart the loop. The backup server determines the operating status of the master server by comparing whether the value of the heartbeat variable received within a preset detection window has changed.

[0009] In some instances, the heart rate variable starts from zero and increments by 2 every 2 seconds, then resets to zero after reaching 2000 and restarts the cycle; the preset detection window is 10 seconds.

[0010] In some instances, the backup server receives and caches the computational data of the primary server's secondary model in real time, forming local cached data, including: The backup server writes the received computational data into a local cache file and updates the local cache file periodically according to a preset refresh frequency. Before each refresh, the current cached data is backed up to the historical database.

[0011] In some instances, the standby server initiates its secondary system and reads the local cached data to restore the model computation state, thereby taking over control, including: During the initialization process, the model of the backup server secondary system reads the latest model calculation data from the local cache data and starts the model to run calculations based on the read data.

[0012] In some instances, the client automatically switches the data interaction object from the failed primary server to the backup server by monitoring the heartbeat variable, including: The client receives heartbeat variables sent by the currently connected server in real time. When an abnormality is detected in the heartbeat variable, the IP address of the current server is blocked. The client attempts to connect to the IP address of the backup server and receive its heartbeat variables; If the heartbeat variable of the backup server is normal, the client will officially switch to the backup server for data interaction.

[0013] In some instances, if the heartbeat variable of the backup server is also abnormal, the client will maintain its current state and will not perform a switchover operation.

[0014] In some instances, the backup server is configured with the same network connectivity as the primary server, enabling it to communicate with the primary PLC system, other secondary systems, and the tertiary MES system, thus achieving seamless replacement after control is taken over.

[0015] In some instances, the backup server determines the operating status of the primary server by calling an identification function. The identification function performs multiple loop calculations on the received heartbeat variable within a preset detection window. If the heartbeat variable does not change or is empty within the detection window, the primary server is determined to have failed.

[0016] Secondly, the present invention provides a continuous casting secondary system that employs the online hot standby redundancy method described in any of the above-mentioned methods to achieve automatic fault switching between the primary server and the backup server.

[0017] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects: This invention employs a dual-server architecture, with one server in operation and one in standby. During normal operation of the primary server, the standby server receives and caches the calculation data of its secondary model in real time to form local cache data. Simultaneously, the primary server continuously sends heartbeat variables for monitoring by the standby server and the client. When the standby server determines that the primary server has failed based on the heartbeat variables, it automatically triggers a switchover process, starts its own secondary system, reads the local cache data, restores the model calculation state, and takes over control. The client also automatically switches its data interaction object simultaneously. This achieves seamless automatic takeover of the continuous casting secondary system in the event of a primary server failure, effectively ensuring the continuity and integrity of the process model calculation data, avoiding the data loss problem caused by fault switching in traditional solutions, and significantly improving the reliability and stability of continuous casting production process control. Attached Figure Description

[0018] 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.

[0019] Figure 1This is a schematic diagram of an online hot standby redundancy method for a continuous casting secondary system provided by an embodiment of the present invention. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the 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.

[0021] In the following description, specific embodiments of the invention will be illustrated with reference to steps and symbols performed by one or more computers, unless otherwise stated. Therefore, these steps and operations will be referred to several times as being performed by a computer, and computer execution as referred to herein includes operations by a computer processing unit representing electronic signals of data in a structured format. This operation transforms the data or maintains it at a location in the computer's memory system, which can be reconfigured or otherwise alter the operation of the computer in a manner well known to those skilled in the art. The data structure maintained by the data is the physical location of the memory, which has specific characteristics defined by the data format. However, the principles of the invention described above are not intended to be limiting, and those skilled in the art will understand that many of the following steps and operations can also be implemented in hardware.

[0022] The terms "module" or "unit" as used herein can be considered as software objects executing on the computing system. Different components, modules, engines, and services described herein can be considered as implementations on the computing system. The apparatus and methods described herein are preferably implemented in software, but can also be implemented in hardware, both of which are within the scope of this invention.

[0023] Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in this specification means the presence of features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. It should be understood that when we say an element is “connected” or “coupled” to another element, it can be directly connected or coupled to the other element, or there may be intermediate elements. Furthermore, “connected” or “coupled” as used herein can include wireless connections or wireless coupling. The term “and / or” as used herein includes all or any units and all combinations of one or more associated listed items.

[0024] This invention employs a dual-server architecture, with one server in operation and one in standby. The primary and standby servers are deployed with identical continuous casting secondary systems, including the same process model and configuration. Both servers maintain the same network connectivity. The primary server is responsible for receiving normal input parameters, receiving data from the tertiary MES and other systems, performing real-time calculations, and participating in online control. The standby server is configured with the same process model, maintains the same network connectivity as the primary server, and can perform network communication with the L1 PLC, other secondary systems, and the tertiary MES system, just like the primary server. It also maintains constant monitoring and data backup with the primary server, remaining in standby mode ready to take over control at any time. A detailed description follows.

[0025] In this embodiment of the invention, an online hot standby redundancy method for a continuous casting secondary system is provided, such as... Figure 1 As shown, it includes the following steps: S101: Deploy a dual-server architecture with one server in use and one in standby, where the primary server and the standby server run the same continuous casting secondary system and process configuration; S102: The master server continuously generates and sends heartbeat variables that reflect its operating status; S103: The backup server receives and monitors heartbeat variables in real time. When the heartbeat variables indicate that the primary server has failed, the switchover process is automatically triggered. S104: During the normal operation of the main server, the standby server receives and caches the calculation data of the secondary model of the main server in real time, forming local cache data; S105: The switchover process includes: the standby server starts its secondary system and reads local cached data to restore the model calculation state, thereby taking over control; S106: The client automatically switches the data interaction object from the failed primary server to the backup server by monitoring the heartbeat variable.

[0026] Specifically, for the heartbeat detection mechanism, this embodiment of the invention designs a dedicated heartbeat variable, Model_Watchdog. This variable is an integer that starts from zero and increments by 2 every 2 seconds. When it reaches 2000, it resets to zero and restarts the cycle. As long as the primary server's continuous casting secondary model is operating normally, this heartbeat variable will continuously cycle according to the above pattern. The backup server and each client receive the Model_Watchdog value sent by the primary server in real time to determine the primary server's operating status.

[0027] Specifically, for heartbeat recognition, this embodiment of the invention designs an identifier function `isRunning(int watchdog)` to determine the running status of the master server. This function receives the latest `Model_Watchdog` value sent by the master server in real time and performs multiple loop calculations within a 10-second detection window. If the `Model_Watchdog` value received within the detection window is the same as the previously sent value or is empty, it is determined that the master server system has crashed, and the function returns `false`; if the `Model_Watchdog` value continues to change normally, it is determined that the master server is running normally, and the function returns `true`.

[0028] The backup server monitors the master server's heartbeat and receives all computational data from the master server's secondary model in real time, forming a local system cache file named WisCC_catch.dat. By setting a reasonable refresh frequency, the backup server periodically updates the master server's system cache data, ensuring that it always holds the latest model computational data. Simultaneously, the cached data before each refresh is saved to a historical database, providing a backup function for historical data and supporting subsequent data traceability and analysis.

[0029] Specifically, when the standby server's monitoring heartbeat function `isRunning` returns false, it confirms that the primary server's secondary system has crashed, and the standby server's secondary system startup procedure will be automatically triggered. During the initialization process, the standby server's secondary model first reads the latest secondary model calculation data from the local cache file `WisCC_catch.dat`, and then starts the secondary model's calculations based on this cached data, thereby achieving a seamless replacement of the crashed primary server and ensuring the continuity of continuous casting production control.

[0030] In this system, data interaction between clients and servers is achieved by accessing the data port of a specified IP address. When a client detects an abnormal heartbeat from the currently connected server, it will automatically block the current server's IP address and begin accessing the IP address of a backup server. The client receives the heartbeat signal from the backup server. If the backup server's heartbeat is normal (returns true), the client officially switches to the backup server for data interaction; if the backup server's heartbeat is also abnormal (returns false), it indicates that the backup server is also faulty, and the system does not perform a switchover operation.

[0031] In another embodiment of the invention, two identical server hardware units are prepared, each costing approximately 20,000-30,000 yuan, a significant reduction compared to the over 300,000 yuan cost of traditional hot standby redundant servers. Identical continuous casting secondary systems are deployed on both servers, including identical process models, process configurations, and software environments, forming a one-for-one standby operational framework. The primary server receives normal input parameters, receives data from the tertiary MES and other systems, performs real-time calculations, and participates in online control. The standby server is configured with the same process model, maintains the same network connection as the primary server, and is in standby mode.

[0032] A heartbeat variable, Model_Watchdog, is set on the primary server, initialized to 0, and incremented by 2 every 2 seconds. Once it reaches 2000, it resets to zero and restarts the loop. The backup server and each client receive the Model_Watchdog value sent by the primary server in real time and call the isRunning function to check its status. If the received Model_Watchdog value remains unchanged or is empty within a 10-second detection window, the primary server is considered to have failed.

[0033] The backup server receives all calculation data from the primary server's secondary model in real time and writes the received data to the local cache file WisCC_catch.dat. The system updates the cached data periodically according to a set refresh frequency (which can be adjusted according to actual production needs). Before each refresh, the system backs up the current cached data to the historical database to ensure the traceability of production data and provide data support for subsequent quality analysis and process optimization.

[0034] When the heartbeat monitoring function of the standby server returns false, confirming that the primary server has failed, the system will automatically start the secondary system background model program on the standby server. During the initialization process, the secondary model on the standby server reads the latest secondary model calculation data from the local cache file WisCC_catch.dat, and starts the secondary model's calculation based on this cached data, achieving seamless replacement of the failed primary server and ensuring the continuity and stability of continuous casting production control.

[0035] The client continuously monitors the heartbeat status of the currently connected server. Upon detecting an abnormal heartbeat, it automatically blocks the current server's IP address. Subsequently, the client connects to the backup server's IP address and receives its heartbeat signal. If the backup server's heartbeat is normal (returns true), the client officially switches to the backup server for data interaction; if the backup server's heartbeat is also abnormal (returns false), it indicates that the backup server is also faulty, and the system maintains its current state without switching.

[0036] The embodiments of the present invention achieve the following significant technical effects through the above technical solutions: Cost advantage: Replacing traditional hot standby redundant servers (over 300,000 RMB) with ordinary servers (20,000-30,000 RMB / unit) significantly reduces hardware procurement costs, making high availability solutions affordable for small and medium-sized steel enterprises.

[0037] High reliability: It realizes an online one-to-one standby operation mode. When the main server fails, it can automatically and promptly switch to the standby server, which significantly improves the safety and stability of the secondary control of continuous casting production.

[0038] Data continuity: Through caching mechanisms and historical data backup functions, the continuity of production tracking data is ensured, effectively avoiding data loss due to server failures.

[0039] High adaptability: This solution adapts to the increasingly stringent requirements for process control in modern steel production, and can effectively ensure the continuity of the production process and the stability of product quality.

[0040] The above provides a detailed description of an online hot standby redundancy method for a continuous casting secondary system provided by the embodiments of the present invention. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An online hot standby redundancy method applied to a continuous casting secondary system, characterized in that, include: Deploy a dual-server architecture with one primary server and one backup server, where the primary server and the backup server run the same continuous casting secondary system and process configuration; The master server continuously generates and sends heartbeat variables that reflect its operating status; The backup server receives and monitors the heartbeat variables in real time, and automatically triggers a switchover process when it is determined that the primary server has failed based on the heartbeat variables. During the normal operation of the main server, the backup server receives and caches the calculation data of the secondary model of the main server in real time to form local cache data; The switching process includes: the backup server starting its secondary system and reading the local cached data to restore the model calculation state, thereby taking over control; By monitoring the heartbeat variable, the client automatically switches the data interaction object from the failed primary server to the backup server.

2. The method according to claim 1, characterized in that, The heartbeat variable is an integer variable that increments at preset time intervals and resets to zero after reaching a preset upper limit value to restart the loop. The backup server determines the operating status of the master server by comparing whether the value of the heartbeat variable received within a preset detection window has changed.

3. The method according to claim 2, characterized in that, The heart rate variable starts from zero and increments by 2 every 2 seconds. When it reaches 2000, it resets to zero and the cycle restarts. The preset detection window is 10 seconds.

4. The method according to claim 3, characterized in that, The backup server receives and caches the computational data of the primary server's secondary model in real time, forming local cached data, including: The backup server writes the received computational data into a local cache file and updates the local cache file periodically according to a preset refresh frequency. Before each refresh, the current cached data is backed up to the historical database.

5. The method according to claim 4, characterized in that, The backup server starts its secondary system and reads the local cached data to restore the model calculation state, thereby taking over control, including: During the initialization process, the model of the backup server secondary system reads the latest model calculation data from the local cache data and starts the model to run calculations based on the read data.

6. The method according to claim 5, characterized in that, The client automatically switches the data interaction object from the failed primary server to the backup server by monitoring the heartbeat variable, including: The client receives heartbeat variables sent by the currently connected server in real time. When an abnormality is detected in the heartbeat variable, the IP address of the current server is blocked. The client attempts to connect to the IP address of the backup server and receive its heartbeat variables; If the heartbeat variable of the backup server is normal, the client will officially switch to the backup server for data interaction.

7. The method according to claim 6, characterized in that, If the heartbeat variable of the backup server is also abnormal, the client will maintain its current state and will not perform a switchover operation.

8. The method according to claim 7, characterized in that, The backup server is configured with the same network connection status as the main server and can communicate with the primary PLC system, other secondary systems, and the tertiary MES system to achieve seamless replacement after taking over control.

9. The method according to claim 8, characterized in that, The backup server determines the operating status of the master server by calling an identification function. The identification function performs multiple loop calculations on the received heartbeat variable within a preset detection window. If the heartbeat variable does not change or is empty within the detection window, the master server is determined to have failed.

10. A continuous casting secondary system, employing the online hot standby redundancy method described in any one of claims 1 to 9, to achieve automatic fault switching between the primary server and the backup server.

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