A full-dimension redundancy stage system and its implementation method

Abstract

The application discloses a stage system with full-dimension redundancy and an implementation method thereof, which comprises a mechanical redundancy module, an electrical redundancy module, a software redundancy module, a control redundancy module, a use management module, a maintenance management module and a traceability module; the software redundancy module is developed by using a C# language; communication between the control redundancy module and each module adopts an EtherCAT and PROFINET double-bus redundancy architecture, wherein a main bus is a PROFINET bus, and a standby bus is an EtherCAT bus. The application adopts full-dimension redundancy design, covers four core modules of machinery, electricity, software and control, and is matched with use management, maintenance management and traceability modules, realizes double backup and collaborative work of each module, and improves the average failure-free time of the system to more than 100,000 hours, so that the defects that the prior art is limited to controller or single device redundancy and cannot realize full-system collaborative redundancy are overcome.

Description

Technical Field

[0001] This invention relates to the field of stage system technology, and in particular to a stage system with full-dimensional redundancy and its implementation method. Background Technology

[0002] With the rapid development of the cultural industry, the scale and complexity of stage performances are constantly increasing. Stage systems encompass multiple modules, including mechanical, electrical, software, and control systems, and their reliability and safety directly determine the performance effect and personnel safety. Existing stage systems often employ single-module designs or only provide simple redundancy in some key modules. Furthermore, software development languages ​​suffer from poor compatibility, low communication bus transmission rates, and insufficient real-time performance, exhibiting the following defects: Mechanical modules use a single drive mechanism and braking device; motor damage or transmission component failure can lead to jamming and loss of control of lifting platforms, hoists, etc.; Electrical modules use a single power supply circuit and signal transmission link; power outages or line faults can paralyze the system; Software and control modules use a single program and a single controller; program crashes or controller failures can render control commands unexecutable. Moreover, existing software is often developed using non-object-oriented languages, resulting in poor maintainability; communication often uses ordinary buses, leading to high transmission latency and insufficient stability; Standardized operating procedures and full-cycle maintenance mechanisms are lacking in usage and maintenance; human error and untimely maintenance can easily cause redundant modules to fail; A traceability system is missing, with operational and fault data from each module stored in a scattered manner or even not stored at all, making fault diagnosis and responsibility determination lack data support. While some existing solutions achieve heterogeneous redundancy at the controller level or redundant control of the top display device, none of them achieve full-dimensional collaborative redundancy across mechanical, electrical, software, control, usage, maintenance, and traceability aspects. Nor do they employ a C# language combined with a dual-bus redundancy architecture of EtherCAT and PROFINET to achieve high real-time communication, thus failing to fundamentally solve the reliability and safety issues of the stage system. Summary of the Invention

[0003] In order to overcome the shortcomings of existing technologies, the purpose of this invention is to provide a stage system with full-dimensional redundancy and its implementation method to solve the above-mentioned technical problems.

[0004] The technical solution adopted by this invention to solve the technical problem is as follows: According to one aspect of the present invention, a stage system with full-dimensional redundancy is designed, including a mechanical redundancy module, an electrical redundancy module, a software redundancy module, a control redundancy module, a usage management module, a maintenance management module, and a traceability module; the software redundancy module is developed using the C# language, and the communication between the control redundancy module and each module adopts a dual-bus redundancy architecture of EtherCAT and PROFINET, with the main bus being the PROFINET bus and the backup bus being the EtherCAT bus.

[0005] To better address the aforementioned technical deficiencies, the present invention also provides a more advanced technical solution: In some embodiments, the mechanical redundancy module includes a lifting platform, a boom, a rotary table, a main and auxiliary drive mechanism, a redundant braking device, and an emergency execution component; the main and auxiliary drive mechanisms adopt a synchronous linkage design, and the operating status is detected in real time by a position sensor and fed back to the control redundancy module. When the main drive mechanism fails, the auxiliary drive mechanism takes over within 500ms, and the operating accuracy error after taking over does not exceed ±0.5mm; the redundant braking device adopts a dual design of mechanical braking and electric braking, with a safety factor ≥10.

[0006] In some implementations, the electrical redundancy module includes a dual-circuit power supply system, a redundant power distribution unit, a redundant signal transmission link, and an emergency power supply component; the dual-circuit power supply system is connected to different mains power circuits and equipped with redundant UPS power supplies, with a switching time of ≤10ms; the redundant signal transmission link adopts a dual-link design of fiber optic link and copper cable link, monitors the link error rate in real time, and automatically switches; the redundant signal transmission link works in conjunction with the EtherCAT and PROFINET dual-bus redundancy architecture.

[0007] In some implementations, the software redundancy module includes a main program and a backup program developed in C#, dual data backup, and an automatic fault diagnosis and repair program. The main program and the backup program are independently deployed on different servers, and a hot backup synchronization mechanism is used to synchronize operation instructions, running parameters, and status data in real time. When the main program fails, the backup program automatically switches over with a switching time of ≤300ms. The software program interacts with the control redundancy module and each actuator through EtherCAT and PROFINET dual buses, with a data transmission delay of ≤50ms.

[0008] In some implementations, the control redundancy module adopts a dual-machine hot standby mode with a main controller and a backup controller, and uses a redundant communication link based on EtherCAT and PROFINET dual buses to achieve dual transmission of control commands and CRC32 verification; the main controller and the backup controller establish data synchronization through redundant connection of fiber optic cables, and the backup controller takes over within 200ms when the main controller fails; when the main bus fails in the communication bus, it automatically switches to the backup bus, and the switching time is ≤100ms.

[0009] In some implementations, the management module is used to standardize the operation process of the stage system, set up a three-level operation permission hierarchy of administrator, operator and maintenance permissions, and emergency operation procedures for faults; operation records are uploaded to the traceability module in real time via EtherCAT or PROFINET bus.

[0010] In some implementations, the maintenance management module is used to formulate a full-cycle maintenance plan that includes daily maintenance, periodic maintenance, and special maintenance, and to record maintenance data and fault handling status; the maintenance data is uploaded to the traceability module in real time via EtherCAT or PROFINET bus; the maintenance management module issues maintenance reminders and fault alarms based on the maintenance plan and the module's operating status.

[0011] In some implementations, the traceability module is used to collect and store the operating data, fault data, maintenance data, and operation data of each module of the stage system; the traceability module establishes data interaction with each module through EtherCAT and PROFINET dual buses, adopts a distributed storage architecture, and has a storage period of not less than 5 years; it supports querying, exporting, and analyzing data by time, module, and fault type.

[0012] In some implementations, in the EtherCAT and PROFINET dual-bus redundant architecture, the fiber optic link transmission rate is 1000 Mbps, the copper cable link transmission rate is 100 Mbps, and the link error rate switching threshold is ≥10⁻ 9 Bus transmission delay ≤40ms.

[0013] A method for implementing a stage system with full-dimensional redundancy includes the following steps: S1. Establish a mechanical redundancy architecture: Install the main and auxiliary drive mechanisms, redundant braking devices and emergency execution components, debug the synchronous operation accuracy of the main and auxiliary mechanisms, and set the fault triggering threshold and switching logic. S2. Establish an electrical redundancy architecture: Deploy a dual-circuit power supply system, redundant power distribution units, and fiber optic and copper cable dual-link signal transmission components; debug the power supply switching logic and signal transmission redundancy switching mechanism; and simultaneously deploy an EtherCAT and PROFINET dual-bus redundancy architecture. S3. Build a redundant software and control architecture: Develop the main program and backup program using C# and deploy them on different servers; debug the program synchronization mechanism; deploy the main controller and backup controller, adopting a dual-machine hot standby mode; debug the controller synchronization and switching logic; configure redundant communication links based on EtherCAT and PROFINET dual buses; set the CRC32 dual verification parameters for control commands; and install automatic fault diagnosis and repair programs. S4. Establish a usage and maintenance system: Develop a three-level operation permission classification standard and emergency operation procedure, and formulate a full-cycle maintenance plan; debug the connection between the usage management module and the maintenance management module and the dual bus; S5. Establish a traceability system: Deploy data acquisition equipment and debug its connection with the dual bus, establish a distributed traceability database, and realize real-time data storage and query; S6. System Debugging and Optimization: Simulate various fault scenarios, test the redundancy switching effect, dual-bus transmission stability and C# software operation reliability, optimize switching time and running accuracy, and improve fault diagnosis and tracing functions; during debugging, control mechanical redundancy switching ≤500ms, control redundancy switching ≤200ms, software redundancy switching ≤300ms, bus switching ≤100ms, and bus transmission delay ≤50ms.

[0014] The beneficial effects of this invention are as follows: This invention employs a full-dimensional redundancy design, covering four core modules: mechanical, electrical, software, and control, along with supporting management, maintenance, and traceability modules. This achieves dual backup and collaborative operation for each module, increasing the system's mean time between failures (MTBF) to over 100,000 hours. It overcomes the shortcomings of existing technologies that are limited to redundancy of controllers or single devices, failing to achieve full-system collaborative redundancy. The software is developed using C#, offering advantages such as object-oriented programming, strong maintainability, and good compatibility. Communication utilizes a dual-bus redundancy architecture of EtherCAT and PROFINET, with seamless switching between primary and backup buses and a transmission latency of no more than 50ms, effectively solving the problems of high communication latency and easy interruption in existing systems. The invention features rapid switching between redundant modules, with mechanical redundancy switching taking no more than 500ms, control redundancy switching no more than 200ms, software redundancy switching no more than 300ms, bus switching no more than 100ms, and electrical switching no more than 10ms. The switching is smooth and seamless, ensuring the continuity and safety of the performance. A three-level operation permission system and a full-cycle maintenance plan standardize the use and maintenance process, preventing redundancy failures due to human error or untimely maintenance. The traceability module collects full-process data in real time via dual buses, with a storage period of no less than 5 years, providing complete data support for fault diagnosis, responsibility identification, and system optimization. These features give the invention significant substantive characteristics and remarkable progress. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall architecture of the present invention; Figure 2 This is a schematic diagram of the electrical redundancy module architecture of the present invention; Figure 3 This is a schematic diagram of the software and control redundancy module architecture of the present invention; Figure 4 This is a schematic diagram of the usage and maintenance system + traceability system architecture of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0017] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0018] In the description of this invention, unless otherwise explicitly defined, terms such as setting, installing, connecting, and fixing should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0019] refer to Figures 1 to 4 As shown, this invention provides a fully redundant stage system, including a mechanical redundancy module 1, an electrical redundancy module 2, a software redundancy module 3, a control redundancy module 4, a usage management module 5, a maintenance management module 6, and a traceability module 7. The software redundancy module 3 is developed using C# language. The communication between the control redundancy module 4 and each module adopts a dual-bus redundancy architecture of EtherCAT and PROFINET, with the PROFINET bus as the primary bus and the EtherCAT bus as the backup bus. This invention employs a fully redundant design, covering four core modules: mechanical, electrical, software, and control, and is complemented by the usage management, maintenance management, and traceability modules 7. This achieves dual backup and collaborative operation of each module, overcoming the shortcomings of existing technologies that are limited to redundancy of controllers or single devices and cannot achieve full-system collaborative redundancy. The software is developed using C# language, which has the advantages of object-oriented design, strong maintainability, and good compatibility. The communication adopts a dual-bus redundancy architecture of EtherCAT and PROFINET, with seamless switching between the primary and backup buses, effectively solving the problems of high communication latency and easy interruption in existing systems.

[0020] In some embodiments, the mechanical redundancy module 1 includes main and auxiliary drive mechanisms for the lifting platform, boom, and turntable, redundant braking devices, and emergency execution components. The main and auxiliary drive mechanisms adopt a synchronous linkage design, and the operating status is detected in real time by position sensors and fed back to the control redundancy module 4. When the main drive mechanism fails, the auxiliary drive mechanism takes over within 500ms, and the operating accuracy error after takeover does not exceed ±0.5mm. The redundant braking device adopts a dual design of mechanical braking and electrical braking, with a safety factor ≥10. Through the synchronous linkage design of the main and auxiliary drive mechanisms and the real-time feedback from high-precision position sensors, when the main drive mechanism fails, the auxiliary drive mechanism can quickly take over within 500ms, and the operating accuracy error after takeover does not exceed ±0.5mm, ensuring uninterrupted operation and deviation-free movement of the stage machinery. The dual redundancy design of mechanical braking and electrical braking achieves a safety factor of over 10, and can be doubly locked in emergencies, fundamentally avoiding safety accidents caused by the falling or loss of control of core equipment such as the lifting platform and boom.

[0021] In some embodiments, the electrical redundancy module 2 includes a dual-circuit power supply system 8, a redundant power distribution unit 9, a redundant signal transmission link, and an emergency power supply component. The dual-circuit power supply system 8 is connected to different mains power circuits and equipped with a redundant UPS power supply 10, with a switching time ≤10ms. The redundant signal transmission link adopts a dual-link design of fiber optic link and copper cable link, monitors the link error rate in real time, and automatically switches. The redundant signal transmission link works in conjunction with the EtherCAT and PROFINET dual-bus redundancy architecture. By connecting the dual-circuit power supply system 8 to different mains power circuits and equipping it with a redundant UPS power supply 10, with a switching time of no more than 10ms, the core module is ensured to continue to be powered when the mains power is interrupted. The dual-link signal transmission design of fiber optic and copper cables, combined with the real-time error rate monitoring and automatic switching mechanism, and working in conjunction with the EtherCAT and PROFINET dual-bus redundancy architecture, achieves full-link dual protection for power supply and signal transmission, avoiding system paralysis caused by a single point of electrical failure.

[0022] In some implementations, the software redundancy module 3 includes a main program 11 and a backup program 12 developed in C#, dual data backup, and an automatic fault diagnosis and repair program. The main program 11 and the backup program 12 are independently deployed on different servers, employing a hot backup synchronization mechanism to synchronize operation commands, operating parameters, and status data in real time. When the main program 11 fails, the backup program 12 automatically switches over, with a switching time ≤300ms. The software program interacts with the control redundancy module 4 and various actuators via EtherCAT and PROFINET dual buses, with a data transmission delay ≤50ms. The main program 11 and the backup program 12, developed in C# and independently deployed on different servers, achieve real-time synchronization of operation commands, operating parameters, and status data through a hot backup synchronization mechanism. When the main program 11 fails, the backup program 12 automatically switches over with a switching time not exceeding 300ms, and the switching process is smooth without noticeable lag. The dual data backup and automatic fault diagnosis and repair program, combined with a data transmission delay of no more than 50ms, effectively prevent system interruptions caused by program crashes or data anomalies, improving the stability and maintainability of the software system.

[0023] In some implementations, the control redundancy module 4 adopts a dual-machine hot standby mode with a main controller 13 and a backup controller 14, coupled with a redundant communication link based on EtherCAT and PROFINET dual buses, to achieve dual transmission and CRC32 verification of control commands. The main controller 13 and the backup controller 14 establish data synchronization through redundant fiber optic cable connection. When the main controller 13 fails, the backup controller 14 takes over within 200ms. When the main bus fails in the communication bus, it automatically switches to the backup bus, with a switching time ≤100ms. The dual-machine hot standby mode with the main controller 13 and backup controller 14, and the data synchronization established through redundant fiber optic cable connection, ensure that control commands are not lost and the control link is not interrupted. The dual transmission and CRC32 verification mechanism for control commands, combined with the dual-bus redundancy design, ensures that the bus switching time does not exceed 100ms, fundamentally avoiding control failures caused by controller or communication bus failures.

[0024] In some implementations, the management module 5 is used to standardize the operation procedures of the stage system, setting up a three-tiered operation permission system (administrator, operator, and maintenance) and emergency operation procedures. Operation records are uploaded to the traceability module 7 in real time via EtherCAT or PROFINET bus. By setting up three-tiered operation permissions (administrator, operator, and maintenance personnel), human error caused by unauthorized operations is effectively avoided. The emergency operation procedures provide standardized handling procedures for various emergencies, guiding operators to respond quickly. The real-time upload of operation records to the traceability module 7 via the bus provides a complete chain of evidence for subsequent traceability of human error, ensuring the effectiveness of the redundancy system from a management perspective.

[0025] In some implementations, the maintenance management module 6 is used to formulate a full-cycle maintenance plan that includes daily maintenance, periodic maintenance, and special maintenance, and to record maintenance data and fault handling status. Maintenance data is uploaded to the traceability module 7 in real time via EtherCAT or PROFINET bus. The maintenance management module 6 issues maintenance reminders and fault alarms based on the maintenance plan and module operating status. By formulating a three-tiered full-cycle maintenance plan (daily, periodic, and special), the frequency, content, and standards of maintenance are clearly defined, ensuring that all redundant modules are always in normal working condition. The maintenance data is uploaded to the traceability module 7 in real time via the bus, and the maintenance reminder and fault alarm functions can notify maintenance personnel in advance for timely handling, avoiding redundant module failures due to untimely maintenance and effectively extending the overall service life of the system.

[0026] In some implementations, the traceability module 7 is used to collect and store operating data, fault data, maintenance data, and operational data of each module of the stage system. The traceability module 7 establishes data interaction with each module via a dual-bus architecture of EtherCAT and PROFINET, employing a distributed storage architecture with a storage period of no less than 5 years. It supports querying, exporting, and analyzing data by time, module, and fault type. By establishing real-time data interaction with each module through the dual-bus architecture of EtherCAT and PROFINET, and employing a distributed storage architecture to achieve long-term data storage of no less than 5 years, it comprehensively collects operating parameters, fault data, maintenance records, and operational logs of each module. It supports multi-dimensional querying, exporting, and analysis by time, module, fault type, etc., providing complete and reliable data support for rapid fault diagnosis, accurate responsibility identification, and continuous system optimization.

[0027] In some implementations, in the EtherCAT and PROFINET dual-bus redundant architecture, the fiber optic link transmission rate is 1000 Mbps, the copper cable link transmission rate is 100 Mbps, and the link error rate switching threshold is ≥10⁻ 9 Bus transmission delay ≤40ms.

[0028] A method for implementing a stage system with full-dimensional redundancy includes the following steps: S1. Establish a mechanical redundancy architecture: Install the main and auxiliary drive mechanisms, redundant braking devices and emergency execution components, debug the synchronous operation accuracy of the main and auxiliary mechanisms, and set the fault triggering threshold and switching logic. S2. Establish an electrical redundancy architecture: Deploy a dual-circuit power supply system 8, a redundant power distribution unit 9, and a dual-link signal transmission component consisting of fiber optic and copper cables. Debug the power supply switching logic and the signal transmission redundancy switching mechanism. Simultaneously deploy the EtherCAT and PROFINET dual-bus redundancy architecture. S3. Build a redundant software and control architecture: Develop the main program 11 and backup program 12 using C# and deploy them on different servers, and debug the program synchronization mechanism; deploy the main controller 13 and backup controller 14, adopting a dual-machine hot standby mode, debug the controller synchronization operation and switching logic, configure redundant communication links based on EtherCAT and PROFINET dual buses, set the control command CRC32 dual verification parameters; install automatic fault diagnosis and repair programs. S4. Establish a usage and maintenance system: Develop a three-level operation permission classification standard and emergency operation procedure, and formulate a full-cycle maintenance plan; debug the connection between the usage management module 5 and the maintenance management module 6 and the dual bus; S5. Establish a traceability system: Deploy data acquisition equipment and debug its connection with the dual bus, establish a distributed traceability database, and realize real-time data storage and query; S6. System Debugging and Optimization: Simulate various fault scenarios, test the redundancy switching effect, dual-bus transmission stability and C# software operation reliability, optimize switching time and running accuracy, and improve fault diagnosis and tracing functions; during debugging, control mechanical redundancy switching ≤500ms, control redundancy switching ≤200ms, software redundancy switching ≤300ms, bus switching ≤100ms, and bus transmission delay ≤50ms.

[0029] This invention forms a complete, standardized, and replicable method for constructing a multi-dimensional redundant stage system through six steps: building a mechanical redundancy architecture, an electrical redundancy architecture, a software and control redundancy architecture, establishing a usage and maintenance system, building a traceability system, and system debugging and optimization. This method quantitatively controls the switching time and bus transmission delay of each redundant module—mechanical redundancy switching no more than 500ms, control redundancy switching no more than 200ms, software redundancy switching no more than 300ms, bus switching no more than 100ms, and bus transmission delay no more than 50ms—ensuring that the system meets the high real-time and high reliability requirements of large-scale performances and is suitable for the construction and upgrading of various theaters, studios, and large performance venues.

[0030] Example 1 This embodiment provides a fully redundant stage system for use in large theater stages. The theater stage includes 4 main lifting platforms, 6 auxiliary lifting platforms, 30 electric hoists, and 2 rotating platforms.

[0031] In mechanical redundancy module 1, the lifting platform is driven by dual motors. Both the main motor and the auxiliary motor are SEW R-series helical gear reducers with a power of 15kW, equipped with absolute encoders (model: HEIDENHAIN ECN113, accuracy ±0.02mm) to detect the position and speed of the lifting platform in real time. The main motor and the auxiliary motor receive control commands via EtherCAT bus, adopting a master-slave follow control strategy. The auxiliary motor follows the speed and torque output of the main motor in real time. When the main motor current exceeds 120% of the rated value or the encoder feedback position deviation exceeds 1mm, the control redundancy module 4 determines that the main motor is faulty and switches to independent drive of the auxiliary motor within 350ms. After the switch, the operating accuracy error of the lifting platform is ±0.3mm. The boom is driven by dual winches with a winch wire rope diameter of 10mm and a safety factor of 12. The redundant braking device has two sets of independent brakes on both the lifting platform and the boom, and the braking torque of each set of brakes is 1.5 times the rated load.

[0032] In electrical redundancy module 2, the dual-circuit power supply is drawn from two independent transformers (10kV / 380V, capacity 800kVA) in the theater's power distribution room. The UPS power supply consists of two Huawei UPS5000-E series modular UPS units (capacity 60kVA, online double conversion mode) with a switching time of 6ms. The signal transmission fiber optic link uses single-mode dual-core fiber (model: G.652D) with a transmission rate of 1000Mbps, while the copper cable link uses Category 6a shielded twisted-pair cable (model: CAT6A) with a transmission rate of 100Mbps. Both the fiber optic and copper cable links are connected to an industrial Ethernet switch (model: MOXA EDS-518A). The switch is configured with link aggregation and redundancy protocols, and the bit error rate monitoring period is 100ms. If the bit error rate of the fiber optic link exceeds 10⁻ for three consecutive samples, the error rate will be recorded. 9 At that time, the switch will switch the data stream to the copper cable link within 50ms.

[0033] In software redundancy module 3, the main program 11 and backup program 12 are developed using C# based on the .NET 6.0 framework. They run on two Inspur NF5280M6 industrial servers (Intel Xeon Gold 6330 processor, 64GB memory, 1TB SSD RAID1 disk array) with Windows Server 2022 operating system. The main and backup programs use a RabbitMQ message queue to achieve real-time synchronization of operation commands, with a synchronization cycle of 50ms. Synchronized data includes the target position, running speed, acceleration curve, and preset parameters of each mechanical module. When the main program 11 process crashes or the CPU utilization rate continuously exceeds 95% for 3 seconds, the automatic fault diagnosis program determines that the main program 11 is faulty, triggering the backup program 12 to switch over, with a switching time of 220ms. Local backups are stored on the server RAID disk array, and cloud backups use Tencent Cloud Object Storage (COS) service, with automatic incremental backups performed daily at 2 AM.

[0034] In the control redundancy module 4, both the main controller 13 and the backup controller 14 use Siemens S7-1518HF series safety-type PLCs. A master-slave synchronous connection is established via the PROFINET bus, with a data synchronization cycle of 10ms. The main controller 13 communicates with the frequency converters and servo drives of each actuator via the PROFINET bus (master bus). The backup controller 14 synchronously receives all control commands from the main controller 13 in monitoring mode via the EtherCAT bus (backup bus) and performs CRC32 verification. When the command sent by the main controller 13 is inconsistent with the local verification result of the backup controller 14, the backup controller 14 resends the correctly verified command via the EtherCAT bus. If the main controller 13 experiences a hardware watchdog timeout or a PROFINET bus disconnection, the backup controller 14 takes over control within 150ms and simultaneously switches all slave stations on the PROFINET bus to the EtherCAT bus for communication, with a bus switching time of 60ms.

[0035] Management module 5 is deployed on a management terminal, using a B / S architecture web management interface. Administrators have the authority to modify system parameters, add or delete operator accounts, and view all traceability data; operators only have the authority to call performance scene programs and control the operation of the lifting platform and boom; maintenance only has the authority to view maintenance reminders and enter maintenance records. All operations record the operator ID, operation time, operation content, and operation result.

[0036] In Maintenance Management Module 6, routine maintenance is performed one hour before each performance, including checking the temperature of each drive motor (≤70℃), brake clearance (0.3-0.5mm), and bus communication status (packet loss rate ≤0.01%). Regular maintenance is performed on the first Monday of each month, including tightening mechanical connection bolts (torque wrench verification), cleaning electrical cabinet filters, and testing UPS battery internal resistance. Specialized maintenance is performed in the last week of each quarter, including conducting actual tests and verifications of each redundancy switching function, code review and vulnerability scanning of C# programs, and latency testing of the dual-bus network.

[0037] Traceability module 7 uses the TiDB distributed database (3-node cluster), with a storage period of 5 years, a daily data volume of approximately 2GB, and a total storage capacity designed to be 5TB. Data from each module is collected in real time via dual buses, with sampling frequencies of 100Hz for mechanical position data and 1Hz for electrical parameters. Operation logs are recorded based on event triggers. Traceability module 7 provides a web-based query interface, supporting queries based on multiple conditions such as time range, module name, fault code, and operator. Query results can be exported to Excel or JSON format.

[0038] Tests showed that the fully redundant stage system in this embodiment operated without interruption in single fault scenarios, including main motor stall, single-circuit power outage, abnormal exit of main program 11, offline operation of main controller 13, and disconnection of PROFINET bus. The system's mean time between failures (MTBF) reached 120,000 hours.

[0039] Example 2 This embodiment provides a fully redundant stage system for use in a television studio. The stage includes two lifting platforms, one rotating platform, ten lighting rigging rods, and four sets of LED screen lifting mechanisms. Unlike Embodiment 1, this embodiment focuses on demonstrating the specific implementation process of the system and the differentiated configurations for small and medium-sized stages.

[0040] In step S1, when building the mechanical redundancy architecture, due to the limited stage space in the studio, the main and auxiliary drive mechanisms adopt an integrated design. The main motor and auxiliary motor are coaxially installed in the same base, sharing a single frequency converter but equipped with independent contactors for switching. The position sensor uses a magnetic scale (model: SIKO MS500, accuracy ±0.05mm), installed on the side of the lifting platform guide rail. During commissioning, the overload threshold was set to 110% of the rated load (rated load 5t), and the abnormal speed threshold was set to ±15% of the set speed. The main and auxiliary motors were calibrated for synchronous operation accuracy using servo commissioning software, ensuring that the positional deviation was controlled within ±0.3mm and the speed deviation within ±1r / min. The fault switching logic was set as follows: when the positional deviation continuously exceeds 1mm for 200ms or the motor driver reports a fault, the control redundancy module 4 automatically disconnects the main motor contactor and simultaneously closes the auxiliary motor contactor. The measured switching time was 420ms.

[0041] In step S2, when setting up the electrical redundancy architecture, the dual-circuit power supply is connected to two different low-voltage busbars in the studio's power distribution room (sharing a single 10kV incoming line split by two transformers). The UPS power supply uses two SANTAK 3C3 PRO30kVA online UPS units, with a battery backup time of 15 minutes and a switching time of 8ms. In the dual-link system of fiber optic and copper cables, the fiber optic cable is laid in the low-voltage cable tray, and the copper cable is laid along the cable management rack at the rear of the equipment cabinet. The two links are physically separated to avoid simultaneous damage. The bit error rate switching threshold is set to 10⁻. 9 The link bit error rate is calculated in real time using an FPGA board. When the bit error rate exceeds the standard, the link is switched by a hardware trigger signal. The actual switching time is 45ms.

[0042] In step S3, when building the software and control redundancy architecture, the C# main program 11 and the backup program 12 are developed based on the .NET 8.0 framework, adopting an MVVM architecture. The interface layer uses WPF, and the business logic layer is encapsulated as an independent class library. Both servers are Dell PowerEdge T550 tower servers (Xeon Silver 4310 processor, 32GB memory, 512GB SSD), with Windows Server 2022 operating system. Program synchronization is achieved through SQL Server Always On high availability group to realize real-time database-level synchronization, synchronizing the stage equipment status table, scene parameter table, and operation log table. The main controller 13 and the backup controller 14 use Beckhoff CX5140 embedded PCs, connected to each actuator via EtherCAT terminal modules. The main controller 13 runs TwinCAT 3 Runtime, and the backup controller 14 runs in hot standby mode. Control command verification uses the CRC32 algorithm, with the checksum appended to the end of each EtherCAT frame. The backup controller 14 completes the verification within 50μs after receiving the frame and compares it with the verification result of the main controller 13.

[0043] In step S4, when establishing the usage and maintenance system, a "live broadcast backup mode" is added to the emergency operation procedure to address the special characteristics of live broadcasts in the studio: when the system detects any redundant module switching, it automatically reduces the speed of the lifting platform and rotating platform to 50% of their rated speed to minimize the impact of the switching process. Simultaneously, it sends a synchronization signal to the lighting and sound systems, triggering pre-programmed backup lighting effects and background music. The three-level operation permissions are centrally managed by the studio's technical manager, and operator accounts are linked to fingerprint readers, requiring fingerprint verification for each operation.

[0044] In step S5, when establishing the traceability system, the data acquisition equipment includes an NI cDAQ-9189 data acquisition chassis and supporting voltage input modules, thermocouple input modules, and digital input modules. The acquired signals include the three-phase current of each motor, winding temperature, brake status contact signals, and bus link status. The data acquisition equipment is connected to the dual bus via an EtherCAT slave terminal module to ensure that the acquired data is synchronized with the control system data timestamps, with a time synchronization accuracy ≤1ms. The traceability database uses a hybrid storage method combining InfluxDB time-series database and MySQL relational database. Time-series data (operating parameters) is stored in InfluxDB, and relational data (operation records, maintenance records) is stored in MySQL. Queries are performed using timestamp association.

[0045] In step S6, the system debugging and optimization phase, a total of 27 fault scenarios were simulated, including sequential interruption of dual mains power, program dead loop of main controller 13, disconnection of PROFINET bus cable, EtherCAT bus slave disconnection, 110% overload of lifting platform, and 120% overspeed of hoist. Testing showed that all redundancy switching indicators met design requirements. During the one-month trial operation, the system accumulated 432 hours of operation, with 15 simulated fault switching events. Performances were not interrupted. High-speed camera playback analysis of the switching process showed no significant pauses or jitters in stage movements, meeting the technical requirements for live broadcasts in the studio.

[0046] Example 3 This embodiment provides a fully redundant stage system for use in large outdoor performance venues (converted stadium stages). The stage includes 8 large lifting platforms (each with a load capacity of 20 tons), 4 sets of wire harness systems, and 6 sets of giant LED screen lifting mechanisms. Unlike embodiments 1 and 2, this embodiment focuses on the reliability verification of the dual-bus redundant architecture under harsh environments (high temperature, high humidity, strong electromagnetic interference) and the practical performance of emergency execution components.

[0047] In mechanical redundancy module 1, considering the high safety requirements of outdoor performances, the redundant braking device, based on the dual design of mechanical and electrical braking in embodiment 1, adds a third pure mechanical centrifugal brake. When the descent speed of the lifting platform exceeds 130% of the rated speed, the centrifugal brake automatically locks the drive shaft using mechanical centrifugal force, forming triple braking protection with a safety factor of 15. The emergency execution component is configured as a battery-powered hydraulic manual pump. When both the electrical and control modules fail, the operator can lower the lifting platform to the ground within 5 minutes using the hydraulic manual pump. The hydraulic manual pump is equipped with a pressure gauge and a pressure relief valve to prevent overspeed descent during manual operation.

[0048] In electrical redundancy module 2, due to limited power supply conditions for outdoor performances, the second circuit of the dual-circuit power supply is replaced by a mobile diesel generator set (500kVA, two units operating in parallel) to replace the mains power circuit, and works with the UPS power supply to form a three-level power supply guarantee of "mains power + diesel generator + UPS". The UPS backup time is extended to 30 minutes to ensure uninterrupted power supply to the core module during the start-up and grid connection of the diesel generator. For signal transmission, the fiber optic link uses armored outdoor optical cable (model: GYTA53-12B1), and the copper cable uses outdoor waterproof shielded cable (model: JWPA-SFTP-CAT6). The two links are laid along both sides of the stage, with an interval of no less than 10 meters to avoid simultaneous failure of both links due to accidental damage on one side.

[0049] In software redundancy module 3, to address potential network latency fluctuations during outdoor performances, the data synchronization mechanism between the primary and backup programs incorporates a triple safeguard: heartbeat, incremental synchronization, and full verification. Under normal circumstances, a heartbeat packet is sent every 100ms to confirm the primary program's (11) viability. Operation commands are transmitted in real-time using incremental synchronization, and a full data verification is performed every 5 minutes to ensure consistency between the primary and backup data. When network latency exceeds 200ms, the system automatically switches to full verification mode to prevent data asynchrony.

[0050] In the control redundancy module 4, due to the possibility of overheating and frequency reduction during long-term operation of the PLC in high outdoor temperatures, both the main controller 13 and the backup controller 14 are installed in a control cabinet with air conditioning cooling, and the cabinet temperature is controlled at 25±2℃. At the same time, when the temperature of a single controller exceeds 65℃, even if the controller does not report a fault, a preventive switch is triggered, transferring control to the backup controller 14 with a lower temperature, to avoid unexpected controller shutdown due to high temperature.

[0051] This embodiment underwent a 72-hour continuous full-load operation test in a summer outdoor environment (ambient temperature 38℃, relative humidity 85%), simulating fault scenarios such as main motor overload, mains power interruption (switching to diesel generator), main program 11 malfunction, main controller 13 high temperature warning, and fiber optic link breakage due to stage equipment collision. All redundancy switching was successfully completed. In the emergency execution component (hydraulic manual pump) simulation test, the operator manually and smoothly lowered the 20t lifting platform from a height of 2 meters to the ground, which took 4 minutes and 20 seconds. The descent speed was uniform and controllable, verifying the practicality of the emergency execution component under extreme conditions.

[0052] Example 4 This embodiment provides a fully redundant stage system for a centralized stage system applied to a multi-hall theater (including a main theater, an experimental theater, and a multi-functional hall). The three halls share a set of back-end server resources and a traceability database, and each hall independently deploys on-site level mechanical, electrical, and control redundancy modules.

[0053] In this embodiment, the main program 11 and backup program 12 of the software redundancy module 3 are deployed on a hyperconverged cluster composed of three physical servers using virtualization technology. The three servers simultaneously run virtual machine instances of the main program 11 and backup program 12. If any server fails, the program instance on it automatically migrates to another server, achieving N+1 redundancy at the program level. The database adopts a MySQL Group Replication multi-master mode, with one database node deployed in each of the three performance halls. The failure of any node does not affect data writing and querying.

[0054] In the control redundancy module 4, each performance hall is independently equipped with a main and backup PLC controller. The controllers of the three performance halls are interconnected through a fiber optic ring network. When the main and backup controllers of one performance hall fail simultaneously (in an extreme case), the backup controller 14 of the adjacent performance hall can temporarily take over the control, realizing cross-hall-level control redundancy. For example, if both the main and backup controllers of the main theater are damaged by lightning, the main controller 13 of the experimental theater can temporarily take over the control of the main theater's lifting platform through the fiber optic ring network, ensuring that the performance can continue that evening.

[0055] In terms of the traceability module 7, the data from the three performance halls are uniformly aggregated into the central traceability database. In addition to storing the operation data and fault data of each hall, it also adds a cross-hall comparative analysis function, which can compare the failure rate, maintenance frequency and redundancy switching success rate of the same equipment in different performance halls, providing decision support for the equipment management of the entire theater.

[0056] During six months of continuous operation in a multi-screen theater, this embodiment recorded a total of 132 redundant switching operations, including 89 software-level switching operations (including planned switching during program version upgrades), 28 electrical-level switching operations, 10 mechanical-level switching operations, and 5 control-level switching operations. Cross-screen takeover was not actually triggered, but three simulation exercises were conducted, verifying its feasibility. The takeover time was approximately 350ms, meeting the requirements for performance continuity. This embodiment fully demonstrates the scalability and adaptability of the present invention's technical solution under different scales and application scenarios.

[0057] The above descriptions are merely some embodiments of the present invention. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A stage system with full-dimensional redundancy, characterized in that, It includes a mechanical redundancy module, an electrical redundancy module, a software redundancy module, a control redundancy module, a usage management module, a maintenance management module, and a traceability module; the software redundancy module is developed using the C# language, and the communication between the control redundancy module and each module adopts a dual-bus redundancy architecture of EtherCAT and PROFINET, with the main bus being the PROFINET bus and the backup bus being the EtherCAT bus.

2. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The mechanical redundancy module includes the main and auxiliary drive mechanisms of the lifting platform, boom, and rotary table, a redundant braking device, and an emergency execution component. The main and auxiliary drive mechanisms adopt a synchronous linkage design, and the operating status is detected in real time by position sensors and fed back to the control redundancy module. When the main drive mechanism fails, the auxiliary drive mechanism takes over within 500ms, and the operating accuracy error after takeover does not exceed ±0.5mm. The redundant braking device adopts a dual design of mechanical braking and electric braking, with a safety factor ≥10.

3. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The electrical redundancy module includes a dual-circuit power supply system, a redundant power distribution unit, a redundant signal transmission link, and an emergency power supply component. The dual-circuit power supply system is connected to different mains power circuits and equipped with redundant UPS power supplies, with a switching time of ≤10ms. The redundant signal transmission link adopts a dual-link design of fiber optic link and copper cable link, monitors the link error rate in real time, and automatically switches. The redundant signal transmission link works in conjunction with the EtherCAT and PROFINET dual-bus redundancy architecture.

4. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The software redundancy module includes a main program and a backup program developed in C#, dual data backup, and an automatic fault diagnosis and repair program. The main program and the backup program are independently deployed on different servers and use a hot backup synchronization mechanism to synchronize operation instructions, running parameters, and status data in real time. When the main program fails, the backup program automatically switches over with a switching time of ≤300ms. The software program interacts with the control redundancy module and each actuator through EtherCAT and PROFINET dual buses, with a data transmission delay of ≤50ms.

5. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The control redundancy module adopts a dual-machine hot standby mode with a main controller and a backup controller, and uses a redundant communication link based on EtherCAT and PROFINET dual buses to realize dual transmission of control commands and CRC32 verification. The main controller and the backup controller establish data synchronization through redundant connection of fiber optic cable. When the main controller fails, the backup controller takes over within 200ms. When the main bus fails in the communication bus, it automatically switches to the backup bus, and the switching time is ≤100ms.

6. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The usage management module is used to standardize the operation process of the stage system, set up a three-level operation permission hierarchy of administrator, operator and maintenance permissions, and emergency operation procedures for faults; operation records are uploaded to the traceability module in real time via EtherCAT or PROFINET bus.

7. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The maintenance management module is used to formulate a full-cycle maintenance plan that includes daily maintenance, periodic maintenance, and special maintenance, and to record maintenance data and fault handling status. Maintenance data is uploaded to the traceability module in real time via EtherCAT or PROFINET bus. The maintenance management module issues maintenance reminders and fault alarms based on the maintenance plan and the module's operating status.

8. The stage system with full-dimensional redundancy according to claim 1, characterized in that, The traceability module is used to collect and store the operating data, fault data, maintenance data and operation data of each module of the stage system. The traceability module establishes data interaction with each module through EtherCAT and PROFINET dual buses, adopts a distributed storage architecture, and has a storage period of not less than 5 years. It supports querying, exporting and analyzing data by time, module and fault type.

9. The stage system with full-dimensional redundancy according to claim 1, characterized in that, In the EtherCAT and PROFINET dual-bus redundant architecture, the fiber optic link transmission rate is 1000Mbps, the copper cable link transmission rate is 100Mbps, and the link error rate switching threshold is ≥10⁻. 9 Bus transmission delay ≤40ms.

10. A method for implementing a stage system with full-dimensional redundancy as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. Establish a mechanical redundancy architecture: Install the main and auxiliary drive mechanisms, redundant braking devices and emergency execution components, debug the synchronous operation accuracy of the main and auxiliary mechanisms, and set the fault triggering threshold and switching logic. S2. Establish an electrical redundancy architecture: Deploy a dual-circuit power supply system, redundant power distribution units, and fiber optic and copper cable dual-link signal transmission components; debug the power supply switching logic and signal transmission redundancy switching mechanism; and simultaneously deploy an EtherCAT and PROFINET dual-bus redundancy architecture. S3. Build a redundant software and control architecture: Develop the main program and backup program using C# and deploy them on different servers, and debug the program synchronization mechanism; deploy the main controller and backup controller, adopt a dual-machine hot standby mode, debug the controller synchronization operation and switching logic, configure redundant communication links based on EtherCAT and PROFINET dual buses, and set the CRC32 dual verification parameters for control commands. Install automatic fault diagnosis and repair programs; S4. Establish a usage and maintenance system: Develop three-level operation authority classification standards and emergency operation procedures, and develop a full-cycle maintenance plan; Debug and use the management module and maintenance management module to interface with the dual bus; S5. Establish a traceability system: Deploy data acquisition equipment and debug its connection with the dual bus, establish a distributed traceability database, and realize real-time data storage and query; S6. System Debugging and Optimization: Simulate various fault scenarios, test the redundancy switching effect, dual-bus transmission stability and C# software operation reliability, optimize switching time and running accuracy, and improve fault diagnosis and tracing functions; during debugging, control mechanical redundancy switching ≤500ms, control redundancy switching ≤200ms, software redundancy switching ≤300ms, bus switching ≤100ms, and bus transmission delay ≤50ms.

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