CN118885338A - Controller cold backup control method - Google Patents

Abstract

The present application discloses a controller cold backup control method, which constructs standard sample data based on all task instructions that need to be executed by the controller; if the main controller fails to execute the task instruction, the current task output process data is compared with the standard sample data, if the data is inconsistent, the main controller re-executes the task instruction, if the data is consistent, the current task execution mechanism process data is compared with the standard sample data, if the data is inconsistent, the main controller switches to the backup controller, if the data is consistent, it is determined that the task instruction is successfully executed; the backup controller continues to execute the task instruction that the main controller failed to execute. During normal operation, one and only one of the main and backup controllers is in operation. Without increasing the operating power of the equipment, the present application enhances the reliability and fault tolerance of the control system, improves the stability of the controller operation, and avoids the decision-making problem of multi-controller signal conflicts.

Description

Controller cold backup control method

Technical Field

The present application relates to the field of electrical control technology, and more specifically, to a controller cold backup control method.

Background Art

In the control system, the controller is a task-based control unit. First, the background sends the task instruction to the controller, and the controller receives and executes the task instruction. During the actual task execution process, when the controller fails, it will cause the task instruction to fail to execute smoothly.

In order to ensure the reliable execution of tasks, a multi-controller redundancy solution is generally adopted. The hot backup in the prior art is to enable multiple controllers at the same time, receive data input, perform logical operations, and output at the same time. In addition, there is a direct coupling between the input signal and the output signal of the same channel of the main and standby controllers. When the signals conflict, complex data decisions need to be made to determine which controller's data is accurate. Therefore, this mode of operation consumes a large amount of computing power and operating power, and is also prone to errors, making it difficult to ensure the reliability and stability of the control system.

Summary of the invention

In response to at least one defect or improvement need in the prior art, the present application provides a controller cold backup control method to enhance the reliability and fault tolerance of the control system, improve the stability of controller operation, and avoid decision-making problems caused by multi-controller signal conflicts without increasing the operating power of the equipment.

To achieve the above object, the present application provides a controller cold backup control method, comprising:

Based on all the task instructions that need to be executed by the controller, standard sample data is constructed through waveform acquisition and feature extraction operations;

The main controller receives the task instruction and generates the current task output process data and the current task execution mechanism process data;

If the main controller fails to execute the task instruction, the first judgment process is entered to compare the current task output process data with the standard sample data. If the data are inconsistent, the main controller re-executes the task instruction. If the data are consistent, the second judgment process is entered;

Entering the second judgment process, comparing the process data of the current task execution mechanism with the standard sample data, if the data are inconsistent, the main controller is switched to the standby controller, if the data are consistent, it is determined that the task instruction is executed successfully;

The standby controller continues to execute the task instruction that failed to be executed by the active controller;

During normal operation, only one of the main controller and the standby controller is in operation.

Furthermore, the construction of standard sample data based on all the task instructions to be executed by the controller through waveform acquisition and feature extraction operations includes:

Count all the task instructions that need to be executed by the controller, combine the outputs used when each task instruction is executed normally in an orderly manner, and build an output process data sample set;

The controller drives the motor to rotate after output, collects the current waveform when the motor rotates, extracts the characteristic quantity, and constructs the actuator process data sample set;

The output process data sample set and the actuator process data sample set constitute the standard sample data.

Furthermore, the output data time series set of a single task is the output process data, and the actuator data time series set of a single task is the actuator process data;

The output process data of multiple tasks constitute the output process data sample set, and the actuator process data of multiple tasks constitute the actuator process data sample set;

The data types included in the data timing set include one or more of signal type, signal quantity, signal occurrence sequence, signal time interval, signal duration, and waveform data of the actuator.

Furthermore, during normal operation, the implementation method in which only one of the active controller and the standby controller is in operation includes:

The main controller and the standby controller adopt an interlocking circuit.

Furthermore, the output process data of the current task is compared with the standard sample data. If the data are inconsistent, it is determined to be a software execution failure, and the main controller re-executes the task instruction.

Furthermore, the second judgment process is entered to compare the process data of the current task execution mechanism with the standard sample data. If the data are inconsistent, it is judged as a controller hardware failure, and the main controller is switched to the backup controller.

Furthermore, the standby controller continues to execute the task instruction that failed to be executed by the active controller, including:

The standby controller requests and executes the latest task instruction in the first cycle of power-on to achieve the execution effect of the task instruction that failed to be executed by the main controller.

Furthermore, the operation mode of the interlocking circuit includes:

The main controller drives the first actuator, and the normally closed contact of the first actuator controls the power input of the standby controller; the standby controller drives the second actuator, and the normally closed contact of the second actuator controls the power input of the main controller;

When the system starts normally, the main and standby controllers are powered on and run at the same time. After a preset time, the main controller drives the first actuator, the first actuator acts, its normally closed contact is disconnected, and the standby controller is powered off and shut down.

When the main and standby controllers switch, the main controller resets the first actuator, its normally closed contact resets, the standby controller is powered on and runs, the standby controller drives the second actuator, the second actuator acts, its normally closed contact opens, the main controller is powered off and shuts down, and the standby controller runs alone.

Furthermore, the comparison of the current task output process data with the standard sample data is specifically as follows:

The output process data of the current task is compared with the output process data sample set in the standard sample data.

Furthermore, the comparison of the current task execution mechanism process data with the standard sample data is specifically as follows:

The current task execution mechanism process data is compared with the execution mechanism process data sample set in the standard sample data.

In general, the above technical solutions conceived by the present application can achieve the following beneficial effects compared with the prior art:

(1) The present application discloses a controller cold backup control method, which constructs standard sample data based on all task instructions that need to be executed by the controller; if the main controller fails to execute the task instruction, the current task output process data is compared with the standard sample data. If the data is inconsistent, the main controller re-executes the task instruction. If the data is consistent, the current task execution mechanism process data is compared with the standard sample data. If the data is inconsistent, the main controller switches to the backup controller. If the data is consistent, it is determined that the task instruction is successfully executed; the backup controller continues to execute the task instruction that the main controller failed to execute. During normal operation, one and only one of the main and backup controllers is in operation. Without increasing the operating power of the equipment, the present application enhances the reliability and fault tolerance of the control system, improves the stability of the controller operation, and avoids the decision-making problem of multi-controller signal conflicts.

(2) The present application compares the current task output process data with the standard sample data. If the data are inconsistent, it is judged as a software execution failure, and the main controller re-executes the task instruction. The current task execution mechanism process data is compared with the standard sample data. If the data are inconsistent, it is judged as a controller hardware failure, and the main controller is switched to the backup controller. The method of the present application includes a fault judgment and positioning based on sample data and an exception handling mechanism, which can accurately locate the cause of the fault and perform corresponding exception handling, thereby improving the controllability and fault tolerance of the control system.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

FIG1 is a core flow chart of a task-based controller cold backup control method provided in an embodiment of the present application;

FIG2 is a schematic diagram of the electrical interlocking structure of the main standby controller provided in an embodiment of the present application;

FIG3 is a schematic diagram of establishing a sample data set provided in an embodiment of the present application;

FIG4 is a flowchart of an exception handling method provided in an embodiment of the present application;

FIG5 is a schematic diagram of the structure of the interlocking circuit provided in an embodiment of the present application.

DETAILED DESCRIPTION

In order to make the purpose, technical solutions and advantages of the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application. In addition, the technical features involved in each embodiment of the present application described below can be combined with each other as long as they do not conflict with each other.

The terms "first", "second" or "nth" in the specification, claims or the above-mentioned drawings of this application are used to distinguish different objects, rather than to describe a specific order. In addition, the terms "including" or "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units that are not listed, or may optionally include other steps or units inherent to these processes, methods, products or devices.

As mentioned in the background technology section of the specification, the hot backup in the prior art is to enable multiple controllers at the same time, receive data input, perform logical operations, and output at the same time. In addition, there is a direct coupling between the input signal and the output signal of the same channel of the main and standby controllers. When the signals conflict, complex data decisions need to be made to determine which controller data is accurate. Therefore, the operation mode of the hot backup redundancy scheme in the prior art requires a large amount of computing power and operating power, and it is also easy to make mistakes, making it difficult to ensure the reliability and stability of the control system. In view of this technical status, the present application proposes a task-based controller cold backup control method, which can enhance the reliability and fault tolerance of the control system without increasing the operating power of the equipment, improve the stability of the controller operation, and avoid the decision-making problem of multi-controller signal conflicts.

With reference to FIG. 1 to FIG. 5 , an embodiment of the present application proposes a task-based controller cold backup control method, which may include the following steps.

Step 1: Based on all the task instructions that need to be executed by the controller, standard sample data is constructed through waveform acquisition and feature extraction operations.

In one embodiment, specifically, all task instructions that need to be executed by the controller are counted, and the outputs used when each task instruction is normally executed are combined in order to construct an output process data sample set.

After the controller outputs, it will drive the motor to rotate, collect the current waveform of each motor when it rotates, and extract the characteristic quantity as the actuator process data sample set.

The output process data sample set and the actuator process data sample set constitute the standard sample data. The standard sample data will be written into the controller program as a part of the controller program.

Referring to Figure 3, the controller program can be considered as a task-based function block. Each task includes task instructions, namely input data, output data and actuator data, etc. The establishment of standard sample data is based on the input data, output data and/or actuator data of the controller. Input data includes input digital data, input analog data and/or input communication data, etc. The ordered combination of input data for normal execution of a single task is called a task input process data sample, and the set of input process data samples of all tasks is called an input process data sample set. Similarly, the ordered combination of all output data of all tasks is called an output process data sample set; the ordered combination of actuator data corresponding to all tasks forms an actuator process data sample set. The output process data sample set and the actuator process data sample set form a total set, which is called standard sample data.

It can also be said that the input data time series set of a single task is the input process data, the output data time series set is the output process data, and the actuator data time series set is the actuator process data. The input process data, output process data, and actuator process data set of multiple tasks are sample data sets. The data types contained in the data time series set include one or more of the signal type, signal quantity, signal occurrence order, signal time interval, signal duration, and waveform data of the actuator.

When a task is executed, the ordered combination of the input data of the current task is called the task input process data; the ordered combination of the output data of the current task is called the task output process data; and the execution mechanism data of the current task is called the task execution mechanism process data.

The main and standby controllers use a power-on and power-off interlocking control method to ensure that only one controller is in operation. The main controller starts running first, and when it is determined that the main controller task execution fails, the standby controller automatically powers on and starts, and the main controller automatically powers off and stops running.

2 , the interlocking circuit includes a power module, a main controller, a backup controller, an actuator 1 (the actuator may be a component such as a relay) and an actuator 2.

The main controller drives actuator 1, and the normally closed contact of actuator 1 controls the power input of the standby controller; the standby controller drives actuator 2, and the normally closed contact of actuator 2 controls the power input of the main controller. When the interlock circuit starts normally, the main and standby controllers are powered on and run at the same time. After a period of time, the main controller drives actuator 1, actuator 1 acts, its normally closed contact is disconnected, and the standby controller is powered off and shut down. When the main and standby controllers are switched, the main controller resets actuator 1, its normally closed contact is reset, and the standby controller is powered on and runs. The standby controller drives actuator 2, actuator 2 acts, its normally closed contact is disconnected, the main controller is powered off and shut down, and the standby controller runs alone.

More specifically, referring to Figure 5, during the power-on startup phase of the interlock circuit, the power module U starts working, and the power output terminals (+ and -) provide control power to controllers A1 and A2 through the normally closed contacts of K1 and K2. The two controllers are powered on at the same time and enter the power-on startup phase.

After the two controllers are powered on at the same time and enter the power-on startup phase, after time T1, the main controller A1 controls the output q1 to be set (output high level), the relay K1 is activated, its normally closed contact is disconnected, and the standby controller A2 loses power and shuts down. The interlock circuit enters the normal operation state, at which time, the main controller A1 operates alone.

Step 2: The main controller receives the task instruction and generates the current task output process data and the current task execution mechanism process data.

In one embodiment, after receiving the task instruction, the main controller starts to record input data, output data and actuator data, and generates current task output process data and current task actuator process data.

Step 3: If the main controller fails to execute the task instruction, it enters the first judgment process and compares the current task output process data with the standard sample data. If the data are inconsistent, the main controller re-executes the task instruction. If the data are consistent, it enters the second judgment process.

Referring to FIG4 , in one embodiment, when the main controller receives a task instruction (when the main controller is running, the standby controller cannot receive the latest task instruction because the standby controller is in a power-off shutdown state.) and the task execution is unsuccessful, the fault type is first determined. Enter the first judgment process, compare the output process data of the current task with the output process data sample set in the standard sample data written by the controller program inside the main controller. When the data is inconsistent, it can be determined that a software execution failure has occurred. At this time, the main controller re-executes the current task instruction. When the data is consistent, enter the second judgment process.

Step 4, enter the second judgment process, compare the current task execution mechanism process data with the standard sample data, if the data are inconsistent, the main controller switches to the backup controller, if the data are consistent, it is determined that the task instruction is executed successfully.

Referring to Figure 4, in one embodiment, the second judgment process is entered to compare the current task execution mechanism process data with the execution mechanism process data sample set in the standard sample data. When the data are inconsistent, it can be determined that a controller hardware failure has occurred. At this time, the main controller is immediately switched to the backup controller; when the data are consistent, it can be considered that the task execution is successful and the controller input data is normal.

The method of the present application includes a fault judgment and location based on sample data and an exception handling mechanism, which can accurately locate the cause of the fault and perform corresponding exception handling, thereby improving the controllability and fault tolerance of the control system.

Step 5: The standby controller continues to execute the task instruction that failed to be executed by the active controller.

In one embodiment, after the switch between the primary and standby controllers is completed, within the first cycle of the standby controller startup, the standby controller requests the latest task instruction from the background, and re-executes the task instruction after receiving the task instruction issued by the background to continue executing the task instruction that failed to be executed by the primary controller in the previous round.

Without increasing the operating power of the equipment, the present application enhances the reliability and fault tolerance of the control system, improves the stability of the controller operation, and avoids the decision-making problem of multi-controller signal conflicts.

The flowchart and/or block diagram in the accompanying drawings illustrate the possible architecture, functions and operations of the system, method or computer program product according to various embodiments of the present application. In this regard, each box in the flowchart and/or block diagram can represent a part of a module, program segment or code, and a part of the above-mentioned module, program segment or code includes one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order from that marked in the accompanying drawings. It should also be noted that each box in the block diagram or flowchart, and the combination of the boxes in the block diagram or flowchart can be implemented with a dedicated hardware-based system that performs a specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

Those skilled in the art will appreciate that the features described in the various embodiments and/or claims of the present application may be combined and/or combined in a variety of ways, even if such combinations and/or combinations are not explicitly described in the present application. In particular, without departing from the spirit and teachings of the present application, the technical features described in the various embodiments and/or claims of the present application may be combined and/or combined in a variety of ways, and all of these combinations and/or combinations fall within the scope of the present application.

Although the present application has been shown and described with reference to specific exemplary embodiments of the present application, it should be understood by those skilled in the art that various changes in form and details may be made to the present application without departing from the spirit and scope of the present application as defined by the appended claims and their equivalents. Therefore, the scope of the present application should not be limited to the above-mentioned embodiments, but should be determined not only by the appended claims, but also by the equivalents of the appended claims.

Claims (10)

1. A controller cold backup control method, characterized by comprising: Based on all the task instructions that need to be executed by the controller, standard sample data is constructed through waveform acquisition and feature extraction operations; The main controller receives the task instruction and generates the current task output process data and the current task execution mechanism process data; If the main controller fails to execute the task instruction, the first judgment process is entered to compare the current task output process data with the standard sample data. If the data are inconsistent, the main controller re-executes the task instruction. If the data are consistent, the second judgment process is entered; Entering the second judgment process, comparing the process data of the current task execution mechanism with the standard sample data, if the data are inconsistent, the main controller is switched to the standby controller, if the data are consistent, it is determined that the task instruction is executed successfully; The standby controller continues to execute the task instruction that failed to be executed by the active controller; During normal operation, only one of the main controller and the standby controller is in operation. 2. The controller cold backup control method according to claim 1, characterized in that the step of constructing standard sample data based on all task instructions to be executed by the controller through waveform acquisition and feature extraction operations comprises: Count all the task instructions that need to be executed by the controller, combine the outputs used when each task instruction is executed normally in an orderly manner, and build an output process data sample set; The controller drives the motor to rotate after output, collects the current waveform when the motor rotates, extracts the characteristic quantity, and constructs the actuator process data sample set; The output process data sample set and the actuator process data sample set constitute the standard sample data. 3. The controller cold backup control method according to claim 2, characterized in that: The output data time series set of a single task is the output process data, and the actuator data time series set of a single task is the actuator process data; The output process data of multiple tasks constitute the output process data sample set, and the actuator process data of multiple tasks constitute the actuator process data sample set; The data types included in the data timing set include one or more of signal type, signal quantity, signal occurrence sequence, signal time interval, signal duration, and waveform data of the actuator. 4. The controller cold backup control method according to claim 1, characterized in that during normal operation, the implementation method of the active controller and the standby controller having only one in operation state includes: The main controller and the standby controller adopt an interlocking circuit. 5. The controller cold backup control method as described in claim 2 is characterized in that the current task output process data is compared with the standard sample data. If the data are inconsistent, it is judged as a software execution failure, and the main controller re-executes the task instruction. 6. The controller cold backup control method as described in claim 2 is characterized in that the second judgment process is entered, the process data of the current task execution mechanism is compared with the standard sample data, and if the data are inconsistent, it is judged as a controller hardware failure, and the main controller is switched to the backup controller. 7. The controller cold backup control method according to claim 1, wherein the standby controller continues to execute the task instruction that failed to be executed by the active controller, comprising: The standby controller requests and executes the latest task instruction in the first cycle of power-on to achieve the execution effect of the task instruction that failed to be executed by the main controller. 8. The controller cold backup control method according to claim 4, characterized in that the operation mode of the interlocking circuit includes: The main controller drives the first actuator, and the normally closed contact of the first actuator controls the power input of the standby controller; the standby controller drives the second actuator, and the normally closed contact of the second actuator controls the power input of the main controller; When the system starts normally, the main and standby controllers are powered on and run at the same time. After a preset time, the main controller drives the first actuator, the first actuator acts, its normally closed contact is disconnected, and the standby controller is powered off and shut down. When the main and standby controllers switch, the main controller resets the first actuator, its normally closed contact resets, the standby controller is powered on and runs, the standby controller drives the second actuator, the second actuator acts, its normally closed contact opens, the main controller is powered off and shuts down, and the standby controller runs alone. 9. The controller cold backup control method according to claim 2 or 5, characterized in that the step of comparing the current task output process data with the standard sample data is as follows: The output process data of the current task is compared with the output process data sample set in the standard sample data. 10. The controller cold backup control method according to claim 2 or 6, characterized in that the step of comparing the current task execution mechanism process data with the standard sample data is as follows: The current task execution mechanism process data is compared with the execution mechanism process data sample set in the standard sample data.