RU2279117C2 - Complex of software-hardware means for automation of control over technological processes - Google Patents

Abstract

FIELD: engineering of controlling and adjusting systems for controlling technological processes.

SUBSTANCE: complex contains workstations and servers based on personal electronic computer machines, connected as a local area Ethernet network, and also controllers and functional modules. Programmable logical integral circuits, built into each functional module, support programming of practically any algorithms for processing signals and control, adequate for tasks, assigned by engineer to current module. Three variants of system engineering are possible on basis of means included in complex: centralized control, local control, distributed control. In all three variants central microprocessor module controlled by software performs primary configuring of functional modules, information exchange, control and diagnostics of software and hardware means.

EFFECT: expanded functional capabilities, increased reliability, improved maintainability.

14 cl, 19 dwg

Description

Technical field

This technical solution relates to control and regulatory systems of general purpose, and in particular to means for controlling technological processes (for example, in nuclear energy).

State of the art

Known complexes of software and hardware for automation of process control (see, for example, CONTROL, PROTECTION AND SIGNALING UNITS OF THE COMPRESSOR FILLING MODULE (patent for invention RU 2211471 C1, 12/28/2000, IPK7 G 05 V 15/02, G 07 F 15/00), designed for automatic control, alarm and protection of the compressor refueling module.The disadvantage of this analogue is its low functionality, lack of reliability, non-seismic design.

Another analogue of the claimed technical solution is a COMPLEX of AUTOMATION GAS-PISTON ELECTRIC UNIT (patent for invention RU 2218587 C1, 06/18/2001, IPC 7 G 05 B 19/02, H 02 P 9/00), designed for automatic control and monitoring of gas piston power unit during the pre-start check, start-up, frequency control, start-up and load operation, normal and emergency stop, as well as to detect emergency and threatening situations in all operating modes of the unit and respond to these situations. The basic computing element is a programmable controller. The disadvantages of this analogue are limited functionality in terms of the number of controlled and controllable parameters and low reliability.

The NEW EDXC LINE TERMINATING ELEPTED AND TERMINATED WITH TERMINATED AND TERMINATED WITH TERMINATED AND TERMINATED WITH INTEGRATED TELESTER (TEXT) AND UNIVERSAL TEST CONSOLE is known. EDXC prospectus “The circuit switching system for text and data networks” from SIEMENS from the exhibition Communication, 05.24.1991, p. 9 (for further information about UTC see brochure A30930 No. 2470-P4-1-7629).

The disadvantage of this analogue is the constant and limited set of modules with insufficient functionality.

The closest analogue of the claimed technical solution (prototype) is the TPTS51 COMPLEX OF SOFTWARE AND TECHNICAL EQUIPMENT for automated process control systems (ACS TP) of reconstructed and constructed nuclear and thermal power plants (see the prospectus of the All-Russian Research Institute of Automatics, 1997).

The disadvantages of the prototype are:

a constant and limited set of functional modules, determined by the structure of the complex and not allowing the flexibility to rebuild and increase the number of monitored and controlled parameters;

outdated elemental base and structural decisions determined by it;

the complexity of the design base, which determines the appropriate manufacturability, reduced reliability and high cost;

the use of closed applicable interfaces and protocols that comply with in-house standards and do not allow the use of products from other manufacturers;

the use of licensed software, for which source codes are not available, which does not allow a comprehensive analysis of its correctness and thereby increase the safety of its use;

the presence of a group galvanic isolation of input / output channels, which reduces reliability and leads to a common cause failure of several input / output channels.

The essence of the technical solution

The well-known complex of software and hardware for process control automation includes Ethernet workstations and servers based on personal electronic computers (PCs) integrated via a local area network (LAN) Ethernet, as well as controllers connected to each other and to a PC via an Ethernet local area network workstations and servers connected through a local area network (LAN) Ethernet via personal electronic computers (PCs), as well as controllers connected via es Ethernet local area network with each other and with the PC.

The aim of this invention is to expand the functionality by creating a wide range of modules with a programmable structure, increasing reliability, improving maintainability, reducing cost characteristics.

To obtain this technical result, each controller contains a central processor module (MCP), designed to control functional modules and actuators, and functional modules (MF) with a configurable structure, designed to process signals from sensors and generate control signals of actuators, connected through a system VME-bus, moreover, the functional MF module with a configurable structure contains a VME-bus interface circuit, input mezzanines and output mezzanines variable number and structure are connected through a first set of connectors with the signal processing circuit and the control, and through a second group of connectors to external inputs and outputs of the functional module, respectively, for connecting external sensors and actuators.

In the configuration for operation in centralized control mode (for example, an atomic energy facility), the complex contains a central processing unit module for controlling functional modules and actuators, and functional modules with a configurable structure for processing signals from sensors and generating executive control signals mechanisms connected via the VME-bus system bus, functional modules contain VME-bus interface circuits, input mezzanines and mezzanines Displayed connected to the interface circuit VME-bus through a first set of outputs and inputs, and through connectors and a second group of inputs and outputs to the group inputs and outputs of functional unit for connection respectively external sensors and actuators.

In the local control configuration (for example, an atomic energy facility), a functional module with a configurable structure, designed to process signals from sensors and generate actuator control signals, contains a VME-bus interface circuit, a logical control circuit interconnected, input mezzanines and output mezzanines connected through the first group of outputs and inputs, respectively, with a logic control circuit, and through the second group of inputs and outputs with a group of inputs and outputs of the module optional for connecting external sensors and actuators, respectively.

In the configuration of distributed control (for example, an atomic energy facility), the complex contains a central processor module (MCP) designed to control functional modules and actuators, and functional modules (MF) with a configurable structure designed to process signals from sensors and generate executive control signals mechanisms connected via the VME-bus system bus, and each functional module contains a VME-bus interface circuit connected to a logical circuit control inputs, input mezzanines and output mezzanines connected through the first groups of outputs and inputs to the inputs and outputs of the logic control circuit, and through the second group of inputs and outputs, respectively, with the group of inputs of the functional module for connecting external sensors and a group of outputs for connecting actuators.

The central processor module contains a SINGLE-PC COMPUTER PC / 104 FORMAT, having COM-inputs (RS-232C), KEYB (keyboard), VGA (monitor) and ETHERNET (LAN), Xilink FPGA PC / 104 V INTERFACE CONVERTER having external VME, which has external discrete input, OK output (open collector) and input / output to the VME interface bus and connected via the second input-output to the control bus of the PC / 104 FORMAT COMPUTER, non-volatile memory (ENZU) connected to the Xilink FPGA on the third input-output PC / 104 INTERFACE CONVERTER TO VME INTERFACE.

The analog input mezzanine (MVA) contains programmable amplifiers, the inputs of the first two are the U (I) input of the mezzanine, a voltage / frequency converter connected by the inputs of V1 and V4 to the outputs of the third and fourth operational amplifiers, an opto-galvanic isolation element connected by the input to the mezzanine control input and on the output with the control input of the voltage / frequency converter, the output transistor stage connected to the voltage / frequency converter output, the second opto-isolation element connected entry of the output stage transistor, and an output with the digital output mezzanine reference voltage source connected to the operational amplifiers and the transducer voltage / frequency.

The analog output mezzanine (MVVA) contains a digital-to-analog D / A converter, the two inputs of which are connected respectively to the data input, and the clock frequency F is a mezzanine, an op-amp operational amplifier, the input of which is connected to the DAC output, and an output stage, the input of which is connected to the output of the op-amp operational amplifier, and the output is the output for connecting the load to the mezzanine.

Digital Input Mezzanine (IEC) contains an input bridge rectifier circuit. a signal converter from digital to analog form, connected to the input of the mezzanine color input circuit, a smoothing RC filter, an opto-isolation element connected to the output of the converter rectifier bridge circuit, and an output inverter connected at the input to the output of the opto-isolation element, and the output to the mezzanine TTL output .

Digital output mezzanine (MVVC, MVVC RELE1, MVVC RELE2) contains an input inverter, the input of which is connected to the TTL input of the mezzanine, a matching transistor connected to the output of the input inverter, a relay circuit with a damping diode connected to the output of the matching transistor, smoothing the output stage, connected to the contacts of the relay circuit and through the fuse to the output of the mezzanine.

Digital output mezzanine (MVVC 24 V) contains an input amplifier, the input of which is connected to the TTL input of the mezzanine, an optical key, the input of which is connected to the output of the input amplifier, a 5 V / 24 V voltage converter, whose input is connected to the output of the optical key, and the output with an output of 24 V of the mezzanine, and protective diodes connected to the output of the 5 V / 24 V voltage converter and the output of the mezzanine.

Digital pulse input mezzanine (MCCI) contains an input limiting diode circuit connected to the input Uc of the mezzanine, an optocoupler isolation element connected to the output of the limiting diode circuit, and an output inverter whose input is connected to the output of the optocoupler isolation element, and the output with the TTL output of the mezzanine .

The positioning mezzanine (Mpos) contains two input circuits for converting digital signals to analog, connected respectively to two inputs of the U input mezzanine, two opto-isolation elements connected to the corresponding outputs of the input conversion circuits, two output inverters connected by inputs to the outputs of the opto-isolation components, respectively, and outputs with TTL outputs of the mezzanine, a third inverter connected to the TTL input of the mezzanine, a transistor conversion cascade connected to the output of the third and inverter, an optical key, the input of which is connected to the output of the transistor conversion stage, a limiting output circuit, the input of which is connected to the output of the optical key, and the output with the third output of the mezzanine.

MIL-STD 1553B Serial Interface Mezzanine (MMPI) contains a CODER connected to a mezzanine TTL input, a DECODER connected to a mezzanine TTL output, a TRANSMITTER connected to a CODER output and a DECODER input, a matching transformer connected to a TRANSMISSION TRANSMITTER mezzanine.

The open collector / emitter output mezzanine (MVOK) contains an inverter connected to the TTL input, a matching transistor stage, the input of which is connected to the inverter output, an opto-isolation element, the input of which is connected to the output of the matching transistor stage, and output key circuits connected by the input with the collector and emitter of the transistor element of the opto-galvanic isolation, and the output through the safety and restrictive elements with the exit of the mezzanine.

The software tools of the complex additionally contain system-wide software tools (643.05749271.00002) and computer-aided design tools (643.05749271.00003).

List of drawings

Figure 1 shows a generalized block diagram of an automated control system based on a complex of software and hardware automation process control "PASSAT".

Figure 2 shows the structural diagram of a complex of software and hardware automation process control "PASSAT" (fragment with a controller).

Figure 3 shows the structural diagram of the functional module (MF).

Figure 4 shows the structural diagram of the connection of a set of software and hardware for automation of technological process control "PASSAT" in the centralized control mode (for example, the nuclear power facility).

Figure 5 shows the structural diagram of the configuration of a set of software and hardware for automation of process control "PASSAT" in the local control mode (for example, an atomic energy facility).

Figure 6 shows the structural diagram of the configuration of the functional module and the connection of the complex software and hardware automation of technological process control "PASSAT" in distributed control mode (for example, an atomic energy facility).

Figure 7 shows the structural diagram of the module of the Central processor.

On Fig is a structural diagram of the mezzanine input analog (MVA).

Figure 9 shows the structural diagram of the mezzanine output analog (MVVA).

Figure 10 shows the structural diagram of the mezzanine input digital (IEC).

Figure 11 shows the structural diagram of the digital mezzanine output (IECC; IECC RELAY1; IECC RELAY 2).

On Fig shows a structural diagram of a mezzanine output digital (MVVC 24 V).

On Fig shows a structural diagram of a mezzanine input digital pulse (MCCI).

On Fig shows a structural diagram of the mezzanine positioning (Mpos).

On Fig shows a structural diagram of a mezzanine serial interface (MMMP) MILL STD 1553B.

On Fig shows a structural diagram of the mezzanine output digital with an open collector / emitter (MVVOKZ).

On Fig shows a list of standards used in the development of the complex PASSAT.

On Fig shows the composition of the complex PASSAT.

On Fig shows a structural diagram of the software complex PASSAT.

An example embodiment of the invention.

An automated control system based on a complex of software and hardware for automation of technological process control "PASSAT" (Fig. 1) in the general case represents a top-level block system (SVBU) containing personal electronic computers (PCs) 1, complexes of automation tools for technological processes "PASSAT", located in cabinets 2 with installed controllers and connected to PC 1 SVBU via Ethernet 4 local area network (LAN), the sensors and sensors are connected to the cabinets tional mechanisms 3.

The complex of software and hardware for automation of technological process control (fragment) (Fig. 2) 5 contains controllers 6 connected through a local area network Ethernet 4 to each other and to personal electronic computers 1 of the control system, each controller 6 consists of a central processor module (MCP) ) 7 and functional modules (MFs) 8 connected via VME-bus interface (Versabus Module Europe-bus) 9.

A functional module with a configurable structure 8 (Fig. 3) contains a VME-bus 10 interface circuit, a signal processing and control circuit 11, and input / output mezzanines 12 connected through connectors 13 to a signal processing and control circuit 11 and through connectors 14 with connection circuits sensors and actuators.

4-6 additionally designated mezzanines INPUT 15 and OUTPUT 16, as well as input circuits from SENSORS 17 and output circuits to EXECUTIVE MECHANISMS 18.

The central processor module 7 (Fig. 7) contains a PC / 104 19 SINGLE-COMPUTER COMPUTER having COM-inputs (RS-232C), KEYB (keyboard), VGA (monitor) and Etherner (LAN), programmable logic integrated circuit FPGA Xilinx PC / 104 TO INTERFACE CONVERTER VME 20, connected at the input-output with a SINGLE-PC COMPUTER PC / 104 FORMAT and having an external digital input, output with an open collector (OK) and input-output to the VME 9 interface bus and connected to the second input -exit with the bus of the SINGLE-PLATED COMPUTER FORMAT RS / 104, non-volatile Ignition device (ENZU) 21 connected via the third input-output to the Xilinx FPGA of the RS / 104 TO INTERFACE VME INTERFACE CONVERTER.

An analog input mezzanine (MVA) (Fig. 8) contains operational amplifiers 22, opto-isolation elements 23 connected respectively to a control input and a digital output, a voltage / frequency converter 24, an output transistor stage 25, and a reference voltage source 26.

Analog output mezzanine (MVVA) (Fig. 9) contains a digital-to-analog converter DAC 27 connected to a data input and a clock frequency input Fact, an op-amp operational amplifier 28 and an output stage 29 with an output to the load.

Digital input mezzanine (MVC) (Fig. 10) contains an input bridge circuit of a rectifier for converting a signal from digital to analog form 30, an opto-galvanic isolation element 31, and an output inverter 32 for converting internal signals to TTL levels.

Digital output mezzanine (MVVC, MVVC RELAY1, MVVC RELAY2) (Fig. 11) contains an input inverter 32 for converting TTL level signals to internal signals, a relay 33 with a damping diode, a matching transistor 34, and an output stage 35 with a fuse.

The digital output mezzanine (MVVC 24 V) (Fig. 12) contains an input amplifier 37, an optical key 38, a voltage converter 5 V / 24 V 39 and protective diodes 40 at the output to the load.

Digital pulse input mezzanine (MCCI) (Fig. 13) contains an input limiting diode circuit 41, an opto-isolation element 23 and an output inverter 32 for converting internal signals to TTL levels.

The positioning mezzanine (Mpos) (Fig. 14) contains input circuits for converting digital signals to analog 30, opto-isolation elements 23 and output inverters 32, input inverter 32, transistor conversion stage 42, optical key 38, and output limiting circuit 43.

The MIL-STD 1553B serial interface mezzanine (MMMI) (Fig. 15) contains a CODER 44 connected to a TTL input, a DECODER 45 connected to a TTL output, a TRANSMITTER 46 connected to an output of a CODER 44 and a DECODER 45 input, a matching transformer 47 connected with TRANSMITTER 46 and access to the MANCHESTER bus.

The digital output mezzanine with an open collector / emitter (MVVOKZ) (Fig. 16) contains an input inverter 32, a matching stage 48, an opto-isolation element 32, and output keys connected to the output through a fuse.

PURPOSE

The complex "PASSAT" KSPD.420141.001 is designed to build automated process control systems (ACS TP) at nuclear power plants and other industrial facilities.

It is a set of unified software and hardware tools from which custom systems of various architectures and levels of complexity can be assembled.

The composition, functions and purpose of a custom-made system are determined by its design.

Design-composable means of the PASSAT complex are:

- layout cabinets in which a variable (project-dependent) number of controllers, power supplies and switching devices is installed;

- controllers in which various (depending on the project) functional modules (MF) and project-oriented software tools are installed in terms of quantity and nomenclature;

- functional modules, each of which consists of a basic module (MB), determined by the project of a set of input / output mezzanines of signals and configuration data of a programmable logic integrated circuit (FPGA) that defines the interaction of mezzanines in the MF.

The last level of project orientation - modular - distinguishes the PASSAT complex from similar complexes of automation equipment. The modern technologies used to create the complex allow project-oriented composition of functional modules with an accuracy of one or two information channels (or control channels). Built-in FPGAs on each module support “suturing” of almost any signal processing and control algorithms that are adequate to the tasks that the designer assigns to this module. This provides an opportunity for practically redundant design of systems based on complex facilities. At the same time, the complex includes the necessary redundancy management tools that allow you to create systems with two-, three- and four-fold redundancy and majority control.

A custom system consists of one or more layout cabinets, each of which has a project-defined number of controllers, power supplies, switching devices, etc. Arranged cabinets in accordance with the project can be combined using the network facilities of the complex.

Custom system software (target software) is created on the basis of system-wide software tools (ISPS) using computer-aided design (CAD) tools or in another way.

The complex is based on the idea of a “designer” for building an automated process control system, in which the designer (system integrator) can find everything necessary to create complete systems for various purposes and complexity with high requirements for reliability, speed, survivability and accuracy.

The technical policy of the developers of the complex, focused on open standards and specifications, allows the designer, when creating a custom system, to easily combine the tools of the PASSAT complex with automation tools of other manufacturers, provides conceptual unity of the project, allows you to create interacting automation systems based on common basic principles and tools.

The list of standards used in the development of the complex "PASSAT" is shown in Fig.17.

DISTINCTIVE FEATURES

- A high degree of adaptation to a specific system project through the use of modern mezzanine and FPGA technologies;

- Ease of expanding the composition and adaptation of hardware and software through the use of open international standards;

- Production of all hardware at Russian enterprises;

- Licensed cleanliness of software and hardware;

- High level of information security through the use of open source software;

- Ability to work in harsh operating conditions;

- Ability to build systems with two-, three- and four-fold redundancy of the functions performed.

OPERATING CHARACTERISTICS

- When using the complex for nuclear power plants, it relates to the third class in terms of safety impact, in accordance with PNAE G-01-011-97 (OPB88 / 97).

- By the type of climatic modification it belongs to the UHL group, according to its location - to category 4 in accordance with GOST 15150-69.

- Power is supplied by two independent feeders from one of the networks of the following type:

a) alternating current voltage from 187 V to 242 V with a frequency of (50 ± 1) Hz;

b) DC voltage from 187 V to 242 V;

c) direct current voltage (24 ± 2) V.

- The power consumed by each layout cabinet, W, not more than:

a) when installing 2 controllers in a cabinet - 300;

b) when installing the 1st controller -150 in the cabinet.

By resistance to seismic effects, it belongs to category I (NP-031-01).

- In accordance with RD 25 818-87 at the installation site it belongs to group A, according to its functional purpose - to version I.

- According to electromagnetic compatibility, it corresponds to performance group III, criterion A according to GOST R 50746-2000.

- Resistant to earthquakes with an intensity of 8 points at around 20 m on the MSK-64 scale.

- In terms of environmental protection, it meets the requirements of IP30 group according to GOST 14254-96.

- The mean time between failures when operating in the duplication mode of controllers is at least 100,000 hours.

- The average recovery time is not more than 1 hour

- The average service life under the condition of restoration of failed funds is at least 30 years.

- The average shelf life without conservation of at least 5 years.

FUNCTIONS TO BE FULFILLED

- Collection (measurement) of analog and discrete signals from sensors about the state of the technological control object (TOU).

- Receiving information from external systems via digital communication channels.

- Indication of parameters, indicators and presentation of information to the operator.

- Identification and indication of deviations of analog parameters from the set values.

- Identification and indication of the inconsistency of the state of the mechanisms issued to the protection teams, locks and functional group control (FGU).

- Monitoring the work of the Federal State Institution.

- Registration of measured and calculated parameters, events, sequence of protection, locks, state of mechanisms, actions of operators.

- Recognition and registration of pre-emergency, emergency events and situations, identification of the root causes of accidents and the operation of protections.

- Technological alarm.

- Calculation of complex parameters and indicators.

- Protection of technological equipment.

- Management of security systems (protective, localizing, providing).

- Automatic control (blocking, FSI).

- Remote control.

- Automatic regulation.

- Diagnostics of the condition of equipment using special tools.

- Diagnostics of hardware and software automation status.

- Centralized testing of protections and interlocks.

- Carrying out diagnostics of the system's operability at startup and maintenance.

- Self-diagnosis and mutual diagnostics of the complex in the process of functioning.

- Localization of the detected malfunction to the level of the plug-in module.

STRUCTURE

The structure of the complex reflects its basic concept and consists of the elements shown in Fig. 18:

- hardware for signal processing and control (controllers, functional modules);

- System integration tools (cabinets, switching devices, network tools);

- power supplies (line voltage converters, power supply units);

- means of the system of the upper block level (SVBU) (workstations, servers, software);

- system-wide software tools;

- computer aided design tools.

The structure of the complex reflects its basic concept of the LEGO designer for the creation of industrial control systems. The technical policy focused on open standards and specifications allows the designer, when creating a custom system, to easily combine the tools of the PASSAT complex with automation tools of other manufacturers. For example, the use of the Ethernet network protocol and the TCP / IP protocol stack for the interaction of signal processing and control tools (the middle level of the automatic process control system) with the SVBU tools (the upper level) allows practically any upper-level tools to be used in the system based on the PASSAT complex .

CONTROLLER

The KSPD.421457.002 controller is a system-forming component of the complex. It is a crate of the open standard Euromechanics IEC 297 (19 ", 6U), which provides a high degree of mechanical strength and makes it possible to operate VME devices in harsh conditions (vibration, shock, etc.).

The design of the rack provides good ventilation, reliable operation in a wide temperature range.

The highly reliable and efficient asynchronous VME communication protocol enables hard real-time operation.

High degree of modularity (up to 17 functional modules in a crate).

Are installed in the controller

- central processor module (MCP) KSPD.467449.001;

- module serial interface (MPI) KSPD. 426477.001;

- power supply unit BP-24 KSPD.436537.001 or BPS KSPD.436618.001;

- the required number of functional modules (MF).

The controller provides connection of up to 544 discrete signals, up to 272 analog signals or an arbitrary combination of discrete and analog signals. In the latter case, when calculating the total number of signals, the following should be considered:

- each controller allows you to place up to 17 MF;

- each MF allows you to place up to 16 mezzanines;

- each mezzanine provides reception (output) of one analog signal or two discrete signals of the same type.

For example, it is possible to implement a controller that provides work with 400 signals, 144 of which are analog, 256 are discrete.

Signal cables are connected from the back of the controller through two types of connectors that are installed on the transition modules (MP). It is possible to connect signals through a switching device (CC), which, if necessary, can be placed in a cross-cabinet.

Two types of transition modules provide connection of sensors and actuators to the controller

- directly using Wago connectors;

- using cables through the switching device.

CENTRAL PROCESSOR MODULE

The central processor module KSPD.467449.001 is made on the basis of a single-board computer of the PC / 104 standard installed on the carrier module. The carrier module converts PC / 104 interface signals to VME bus signals (IEC 821).

This technical solution allows the manufacture of central processor modules with a wide range of computing power, operating in the industrial and industrial temperature range.

It has two RS 232/485 interfaces, one or two (depending on the type of single-board computer) of the IEEE 802.3u Ethernet network controller. Ability to connect a monitor, keyboard and mouse.

MCP software is stored in non-volatile memory (on a flash-disk), where it is placed with the help of technological equipment. The amount of memory is also scalable.

The module has 4 discrete inputs of the "dry contact" type (used to provide control of unauthorized access) and two discrete outputs of the type "open collector".

Using the protected processor operating mode provides failure detection of software, processor, and RAM.

FUNCTIONAL MODULES

Each functional module is composed of the base module (MB) KSPD.426439.001 and the set of mezzanines defined by the project. Thus, the functional module of the PASSAT complex is design-composable. Up to 16 mezzanines can be installed on each base module, representing either one analog channel or two discrete in any combination.

This enables the user to have up to 16 analog or up to 32 discrete channels on one functional module.

The digital circuit of the base module provides interfacing of channel circuits located on mezzanines with the VME interface.

The insulation module between the 1000 V channels, between the channels and the digital part of the base module 1500 V is provided on the functional module.

Each MF is design-composable and consists of MB (mezzanine carrier) and a set of mezzanines determined by the project. MFs provide processing of signals from sensors and the formation of control signals by actuators (MI) of a technological object. Possible options for the design layout of the MF, providing for the same type and different types of input / output channels.

Thanks to the applied FPGA technology in the Ministry of Finance, it is provided in accordance with the project

- "flashing" of signal processing and control algorithms;

- adjustment to specific values of settings and boundary parameters;

- monitoring the functioning of the remote control;

- priority execution of control commands.

The sensors of the “dry contact” type are powered from both external and internal power sources at the MF.

The nomenclature of metrological characteristics of the MF is determined by its composition.

Information about the health / malfunction of a particular MF is indicated by LED indicators on the front panel of the MF and can be transmitted to the upper level and to other controllers via the LAN.

MFs are installed in the controller along the rails and are fastened with captive screws; they have means that provide a “hot” replacement of modules (without turning off the power).

The structure of the functional module provides three levels of monitoring and diagnostics.

At the first level, the data exposed by the electronic module to the VME bus is controlled. One hundred percent duplication of data (direct and inverse value) provides dynamic control (in each reading cycle) of the data.

At the second level, it is possible to diagnose the health of the electronic module by simulating changes in the input signals inside the FPGA.

At the third level, it is possible to fully diagnose the health of the electronic module to an external connector.

MESONS

The mezzanine technology used in the construction of hardware for signal processing and control makes it possible to design-oriented layout of functional modules with an accuracy of one or two information channels (or control channels).

Using mezzanines of various channels in any combination, you can configure a custom system without hardware redundancy on the channels.

Each mezzanine is a functionally complete device that provides the interface module functional (MF) with a technological control object that processes or generates a specific type of signal. Depending on the type of signal, the mezzanines are divided into analog (single-channel) and digital (two-channel).

Mezzanines pre-process signals and convert them to digital form. The converted signal through the mezzanine connector is transmitted to the MB logic circuit of the corresponding MF implemented on the FPGA.

The input mezzanines provide reception of the following unified signals from sensors of physical quantities: discrete; analogue; converters of thermoelectric types ТХК, ТХА and ТПП; thermal resistance converters TSP and TSM standard graduations.

Output mezzanines provide the formation of discrete and analog control signals.

Provides power for sensors such as "dry contact", "Sapphire", thermal resistance.

Galvanic separation of input / output channels between themselves and between channels and the digital part provides high noise immunity and non-proliferation of failures.

The PASSAT complex includes mezzanines of 30 options.

ANALOGUE INPUT MESONIN (MBA)

Execution options

MVA (0-5 mA) KSPD. 426431.001

MVA (0 / 4-20 mA) KSPD. 426431.001-01

MVA (0-100 mV) KSPD. 426431.001-02

MVA (0-1 V) KSPD. 426431.001-03

MVA (0-10 V) KSPD. 426431.001-04

MVA (± 20 mV) KSPD. 426431.001-05

MVA (± 50 mV) KSPD. 426431.001-06

MVA (± 5 V) KSPD. 426431.001-07

Number of channels 1

Input impedance (voltage) not less than 1 megohm

Input resistance (current): (0-5 mA) no more than 200 Ohms, (4-20 mA) no more than 50 Ohms

Internal voltage source 24 V 40 mA for powering sapphire sensors

Input of signals from thermocouples (based on input mezzanines of 20 mV, 50 mV):

Types of thermocouples - THK (L), THA (K), TPP (R), TPP (S)

Permissible voltage overload 35 V

The limits of the permissible basic reduced error of not more than ± 0.1%

50 Hz frequency interference mitigation: general view at least 90 dB, normal view at least 100 dB

Insulation resistance 1500 V from the digital circuit

ANALOGUE INPUT MESONIN (MBA)

Execution options

MVA (50P) KSPD. 426431.002

MVA (50M) KSPD. 426431.002-01

MVA (100P) KSPD. 426431.002-02

MVA (100M) KSPD. 426431.002-03

Number of channels 1

Types of thermal converters - 50P, 100P, 50M, 100M

4-wire connection

Permissible voltage overload 35 V

The limits of the permissible basic reduced error of not more than ± 0.1%

50 Hz frequency interference mitigation: general view at least 90 dB, normal view at least 100 dB

Insulation resistance 1500 V from the digital circuit

ANALOGUE OUTPUT MEZONIN (MVVA)

Execution options

MVVA (0-5 mA) KSPD. 426435.001

MVVA (0-20 mA) KSPD. 426435.001-01

MVVA (0-10 V) KSPD. 426435.001-02

Number of channels 1

Load resistance:

and not less than 2 kOhm for (2-10 V);

no more than 2 kOhm for (0-5 mA);

no more than 500 Ohms for (4-20 mA).

The limits of the permissible basic reduced error of not more than ± 0.1%

Insulation resistance 1500 V from the digital circuit

DIGITAL INPUT MEZONIN (IEC)

Execution options

IEC (0-5 V) KSPD. 426433.001

IEC (0-12V) KSPD. 426433.001-01

IEC (0-24 V) KSPD. 426433.001-02

IEC (0-48 V) KSPD. 426433.001-03

IEC (0 ~ 220 V) KSPD. 426433.001-04

IEC (0-220 V) KSPD. 426433.001-05

IEC (SC) KSPD. 426433.001-06

Number of channels 2

Power supply of the dry contact sensor 24 V / 40 mA

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

DIGITAL OUTPUT MEZONIN (IECC)

Execution options

MVVC OK1 KSPD. 426436.001

MVVC OK2 KSPD. 426436.001-01

MVVC OK3 KSPD. 426436.004

Number of channels 2

Maximum Switching Voltage / Current:

OK1-220 V / 0.25 A; OK2 - 48 V / 1 A;

OK3-24 V / 1 A (with 500 Hz modulation).

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

DIGITAL OUTPUT MEZONIN (IECC)

IECC RELAY1 KSPD. 426436.002

Number of channels 2

Maximum switching voltage / current: 220 V / 1 A

Sparking chains

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

DIGITAL OUTPUT MEZONIN (IECC)

IECC RELE2 KSPD. 426436.005

Number of channels 2

Maximum switching voltage / current: 220 V / 1 A

Sparking chains

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

DIGITAL OUTPUT MEZONIN (IECC)

MVVC 24V KSPD. 426436.003

Number of channels 2

Output voltage 24V, current up to 40 mA.

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

DIGITAL PULSE INPUT MESONIN (MVTS)

MVTSI KSPD. 426433.002

Number of channels 2

Input Voltage (0-5V)

Maximum input frequency 300 kHz

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

MESONIN POSITIONING (Mpos)

MPOS KSPD. 426437.001

Number of channels 2

Input Voltage (0-5V)

Open Collector Output 48 B / I A

Insulation resistance 1500 V from the digital circuit

Channel-to-channel insulation strength 1000 V

SERIAL INTERFACE MESONIN (ММПИ) MIL- STD 1553В ММПИ КСПД.426439.004

The number of channels of the serial interface 2 (primary and backup)

Connection to the main channel according to the scheme without matching transformer

Differential output voltage of the transmitter in the trunk channel (8 ± 0.5) V

The output characteristics of the receiver correspond to GOST 26765.52-87

DC supply voltage 5V ± 5% and 12V ± 5%

OUTPUT DIGITAL MEZONIN WITH AN OPEN COLLECTOR / EMITTER

(MVVOKZ) KSPD. 426436.004

Number of channels 2

Maximum switching current 1 A

Insulation resistance 1500 V from the digital circuit

500 Hz modulation capability

POWER SUPPLIES

The PASSAT complex is powered by two independent feeders of one of the networks:

- voltage 220 V AC with a frequency of 50 Hz;

- DC voltage 220 V;

- DC voltage 24 V.

Power supply from a 220 V network is carried out through a network voltage converter (PSN) KSPD.464479.001, which provides the conversion of 220 V AC / DC voltage to 24 V DC.

The loss of power on either of the two feeders causes the ACFAIL signal to appear on the controller's VME bus.

The power supply units control the deviation of the output voltage with an indication on the front panel of the unit.

In order to meet the requirements of GOST R 50746-2000 by EMC, power supply facilities have line filters and protection devices against high-voltage impulses at the input.

Parameter BP220 KSPD. 436618.002 BP24 KSPD.436537.001 BPS KSPD. 436618.001 Input voltage 187 to 242 V (24 ± 2) V 187 to 242 V Output voltage 24V / 12A 5V / 30A, ± 12V / 2A 5V / 30A, ± 12V / 2A Remote start Yes No No

NETWORK MEANS

Network tools provide information interaction between the means of the PASSAT complex and consist of the following components:

- module serial interface (MPI) KSPD. 4,264,777.001;

- means of information transfer MCP.

MPI provides information exchange in accordance with GOST 26765.52-87 (MIL-STD 1553В) through 4 channels.

MCP network tools provide information exchange on the following interfaces:

- Ethernet 100 Mbps IEEE 802.3 u;

- RS-232C / RS-485.

Interaction between controllers in systems with multiple redundancy is carried out according to the interface GOST 26765.52-87 (MIL-STD 1553В).

Interaction between controllers within the same cabinet and interfacing with diagnostic equipment is carried out via the RS-232C (RS-485) interface.

The interaction between the controllers and the control system is carried out via Ethernet IEEE-802.3u (10/100 Mb / s) over the physical medium of transmission "twisted pair".

CUPBOARD

The cabinet is made in accordance with GOST 28601.2-90 (analogue of the Euromechanics standard).

Provides installation of block frames with a width of 482.6 mm (19 ").

- Overall dimensions of the cabinet no more than 1954 × 600 × 600 mm.

- Weight no more than 150 kg.

The switching device (CC) provides the supply of signals from sensors to controllers and signals from controllers to actuators and other technological equipment.

SOFTWARE

Created on the basis of open source software (FOSS) using the technology of object-oriented programming (OOP) and the principle of software reuse (software reuse), taking into account the requirements of international standards.

Include:

- system-wide software included in the controller;

- SVBU software.

System-wide software tools provide

- launch and control of the application;

- programmatic access to interfaces RS-232, RS-485, LPT;

- software access to Ethernet LAN;

- programmatic access to the stacks of network protocols TCP / IP and UDP / IP;

- programmatic access to the VME bus controller;

- interaction with the hardware resources of the MCP,

SSBU software is built on the basis of the SUOK (Management and Operational Control Systems) platform developed by VNIIIAES and allows implementing standard SSBU functions:

- registration, archiving, logging;

- import / export of data;

- Operator interface with display and display control functions;

- connection of applied tasks;

- monitoring;

- analysis of events;

- calculations;

- issuing commands.

Computer aided design (CAD) tools of the complex provide computer support for the work of the designer. A wide range of types of signals received from sensors and issued to actuators covers the needs of most automation systems for process control.

The composition of the software is shown in the structural diagram (Fig.19).

OPTIONS FOR THE WORK ORGANIZATION OF THE PASSAT COMPLEX

The PASSAT complex provides the designer with the opportunity to use three types of controller architectures that differ in the degree of "intelligence" that the functional modules are endowed with and the role; which is played by custom system software (target software).

When using the centralized control architecture controller, the data from the MF is transmitted via the VME bus to the MCP, where it is processed by the target software using the ISPS. Depending on the algorithm of the system’s functioning, the following actions are possible:

- transfer of the measured value of the technological parameter for display on the workstation SVBU via LAN type Ethernet;

- the formation of the control action (command) for the actuator (MI) in accordance with the control logic and the specified settings;

- transfer of the control action to the corresponding MF associated with the desired MI via the VME bus.

Having received the control action, the MF sends the data to the mezzanine connected through the MF (CC) with the desired IM through the MB logic circuit. The mezzanine converts the digital command code into a signal perceived by the MI. The generated signal through MP, UK and cable is transmitted to the IM. Calculation of unmeasured technological parameters, their storage and transfer to the SSDS is also performed by the MCP under the control of the target software.

When using the controller of the local control architecture, the signal processing and control functions are implemented by “hard logic” implemented by the FPGA located on the MF. The following options are possible: the mezzanine, which received the signal from the sensor, and the mezzanine, which forms the control signal, are placed in one MF; the mezzanine, which received the signal from the sensor, and the mezzanine, which forms the control signal, are located in different MFs.

In the first case, the processing of the adopted value of the technological parameter and the decision to issue the appropriate command to the MI is adopted by the logic circuit (“hard logic”) implemented by the FPGA of this MF. Signal transmission between MFs does not occur. If necessary (if it is stipulated by the system functioning algorithm), the value of the measured technological parameter and / or information about the issued control action is transmitted from the MF via the VME bus to the MCP, where it is perceived by the target software.

In the second case, regardless of which MF decides to issue a command — the one in which the input signal is received, or the one in which the output signal is issued — interaction between the MF is necessary. When using the local control architecture, the interaction is realized by connecting the signal inputs / outputs of the MF through the transition module (MP) and CC, or bypassing the CC through the MP.

In the first and second cases, the MCP under the control of the target software performs the initial configuration of the MF, the exchange of information with the SSDS, and the monitoring and diagnostics of software and hardware.

When using the controller of the distributed control architecture, as in the case of local control, the signal processing and control functions are implemented by “hard logic” implemented by the FPGA located on the MF. The difference is that if MF interaction is necessary, it is implemented by exchanging data via the VME bus with the participation of the MCP and the corresponding software.

If necessary, it is possible to use controllers with different architectures in one product.

MAIN ADVANTAGES OF THE PASSAT COMPLEX

Summing up, we briefly formulate the main advantages of the PASSAT complex.

- The unified software and hardware platform provides a conceptual project unity, allows you to create interacting automation systems for a technological facility on common basic principles and tools, which improves their reliability and ease of use.

- The design-composable composition of functional modules (accurate to one or two input / output channels) provides flexible optimal design of systems based on complex facilities. In addition, each channel has an individual galvanic isolation, which reduces the likelihood of failures for a common reason.

- The applied interfaces, protocols and constructs comply with open international standards, which allows, firstly, to avoid dependence on a specific manufacturer, and secondly, to use the technical and software solutions developed at the world level.

- Software with open source codes allows you to conduct a comprehensive analysis of their correctness (verification) and thereby increase the security of their use in systems.

- The applied modern elemental base provides effective technical solutions and facilitates the maintainability problem.

- The double-sided printed circuit boards used in electronic modules are more reliable, simple and cheap to manufacture, maintainable compared to multi-layer ones.

The main technical and software solutions are protected by the following certificates and patents of the Russian Federation:

1. System-wide software tools (643.05749271.00002)

Certificate of official registration of the computer program No. 2003612612 of December 1, 2003.

Rightholder NPP COMPLEXES AND SYSTEMS LLC, Penza

2. Computer-aided design tools (643.05749271.00003)

Certificate of official registration of the computer program No. 2003612611 of December 1, 2003

Rightholder NPP COMPLEXES AND SYSTEMS LLC, Penza

3. A set of software and hardware for automation of process control.

Patent for an industrial design (application 2003502504 (034581) of November 3, 2003, the decision to grant a patent of May 20, 2004)

Rightholder NPP COMPLEXES AND SYSTEMS LLC, Penza

4. The complex of hardware and software automation of technological process control "PASSAT".

Utility Model Patent No. 35902 of October 21, 2003, IPC7 G 05 B 15/02.

Rightholder NPP COMPLEXES AND SYSTEMS LLC, Penza

Thus, the PASSAT complex is a reasonable alternative to existing complexes of automation equipment and is ready for industrial use.

Industrial applicability

This technical solution is industrially feasible, has wider functionality, increased reliability due to the continuous diagnostics of the operation of the managed facility.

A prototype complex was manufactured. The complex "PASSAT" passed acceptance tests, which confirmed the claimed characteristics. Specifications agreed and approved in the prescribed manner. Documentation assigned letter O ₁ .

Claims (14)

1. A set of software and hardware tools for automating technological processes, containing workstations and servers integrated via a local area network (LAN) Ethernet and personal computer computers (PCs), as well as controllers connected to each other and to an Ethernet local area network PC, characterized in that each controller contains a central processor module (MCP), designed to control functional modules and actuators, and function modules Ionic (MF) with a configurable structure, designed to process signals from sensors and generate control signals of actuators, connected via the VME-bus system bus, moreover, a functional MF module with a configurable structure contains a VME-bus interface circuit, input mezzanines and output mezzanines of variable quantity and structures connected through the first group of connectors to the signal processing and control circuit, and through the second group of connectors with external inputs and outputs of the functional module, respectively GOVERNMENTAL, for connecting external sensors and actuators. 2. The complex of software and hardware for automation of control according to claim 1, characterized in that in the configuration for operating in centralized control mode, for example, an atomic energy facility, the complex contains a central processing unit module for controlling the functional modules and actuators, and modules functional MFs with a configurable structure, designed to process signals from sensors and generate control signals of actuators, connected through a system VME-bus, functional modules contain VME-bus interface circuits, input mezzanines and output mezzanines connected to the VME-bus interface circuit through the first group of outputs and inputs, and through connectors and the second group of inputs and outputs with a group of module inputs and outputs functional for connecting external sensors and actuators, respectively. 3. The complex of software and hardware for automation of control according to claim 1, characterized in that in the local control configuration, for example, an atomic energy facility, a functional module with a configurable structure for processing signals from sensors and generating control signals for actuators, contains an interface circuit VME-bus, logic control circuitry, interconnected, input mezzanines and output mezzanines, connected through the first group of outputs and inputs respectively to the log scheme eskogo control, and via second group of inputs and outputs, - a group of inputs and outputs of functional unit for connection respectively external sensors and actuators. 4. The complex of software and hardware automation control according to claim 1, characterized in that in the configuration of distributed control, for example, an atomic energy facility, the complex contains a central processor module (MCP) designed to control functional modules and actuators, and functional modules ( MF) with a configurable structure, designed to process signals from sensors and generate control signals for actuators, connected via the VME-bus system bus, m each functional module contains a VME-bus interface circuit connected to a logic control circuit, input mezzanines and output mezzanines connected through the first groups of outputs and inputs to the inputs and outputs of the logical control circuit, and through the second groups of inputs and outputs, respectively, with a group of inputs functional module for connecting external sensors and a group of outputs for connecting actuators. 5. The complex of control automation software and hardware according to claim 1, characterized in that the central processor module contains a PC / 104 FORMAT SINGLE COMPUTER having COM-inputs (RS-232C), KEYB (keyboard), VGA (monitor) and ETHERNET (LAN), Xilink FPGA PC / 104 V INTERFACE CONVERTER VME, which has external digital input, OK output (open collector) and input-output to the VME interface bus and connected via the second input-output to the control board of the SINGLE-PC COMPUTER / FORMAT 104, non-volatile memory (ENZU), s connected to the third input-output from the FPGA Xilink PC / 104 INTERFACE CONVERTER TO VME INTERFACE. 6. The complex of control automation software and hardware according to claim 1, characterized in that the analog input mezzanine (MVA) contains programmable amplifiers, the inputs of the first two are the U (I) input of the mezzanine, a voltage / frequency converter connected by inputs V1 and V4 with the outputs of the third and fourth operational amplifiers, an opto-galvanic isolation element connected at the input to the mezzanine control input, and at the output to the voltage / frequency converter control input, the output transistor stage connected to the output m of the voltage / frequency converter, the second opto-isolation element connected at the input to the output transistor stage, and at the output to the digital mezzanine output, a reference voltage source connected to operational amplifiers and the voltage / frequency converter. 7. The complex of control automation software and hardware according to claim 1, characterized in that the analog output mezzanine (MVVA) contains a digital-to-analog D / A converter, the two inputs of which are connected respectively to the data and clock frequency input Ftak mezzanine, an op-amp operational amplifier, the input of which is connected with the output of the DAC, and the output stage, the input of which is connected to the output of the op-amp operational amplifier, and the output is the output for connecting the load to the mezzanine. 8. The complex of control automation software and hardware according to claim 1, characterized in that the digital input mezzanine (IEC) comprises an input bridge circuit of a rectifier of a signal converter from digital to analog form, connected to the input of the U input mezzanine, smoothing an RC filter, an opto-galvanic isolation element connected to the output of the bridge circuit of the converter rectifier, and the output inverter connected at the input to the output of the opto-galvanic isolation element, and the output to the mezzanine TTL output. 9. The complex of control automation software and hardware according to claim 1, characterized in that the digital output mezzanine (MVVC, MVVC RELE1, MVVC RELE2) contains an input inverter, the input of which is connected to the TTL input of the mezzanine, matching a transistor connected to the output of the input inverter, relay circuit with a damping diode connected to the output of the matching transistor, smoothing the output stage, connected to the contacts of the relay circuit and through the fuse to the output of the mezzanine. 10. The complex of software and hardware automation control according to claim 1, characterized in that the digital output mezzanine (MVVC 24 V) contains an input amplifier, the input of which is connected to the TTL input of the mezzanine, an optical key, the input of which is connected to the output of the input amplifier, a 5 V / 24 V voltage converter, the input of which is connected to the output of the optical key, and the output is connected to the 24 V output of the mezzanine, and protective diodes connected to the output of the 5 V / 24 V voltage converter and the mezzanine output. 11. The complex of control automation software and hardware according to claim 1, characterized in that the digital pulse input mezzanine (MCCI) contains an input limiting diode circuit connected to the input Uc of the mezzanine, an opto-isolation element connected to the output of the limiting diode circuit, and an output an inverter, the input of which is connected to the output of the optovoltaic isolation element, and the output to the mezzanine TTL output. 12. The complex of software and hardware control automation according to claim 1, characterized in that the positioning mezzanine (Mpos) contains two input circuits for converting digital signals to analog, respectively connected to two inputs of the Uin mezzanine, two opto-isolation elements connected to the corresponding outputs input conversion circuits, two output inverters connected by inputs respectively to outputs of opto-isolation elements, and outputs - with TTL-outputs of a mezzanine, third inverter, connected connected to the TTL input of the mezzanine, a transistor conversion cascade connected to the output of the third inverter, an optical key whose input is connected to the output of the transistor conversion cascade, a limiting output circuit, the input of which is connected to the output of the optical key, and the output to the third output of the mezzanine. 13. The complex of control automation software and hardware according to claim 1, characterized in that the MIL-STD 1553B serial interface mezzanine (MMPI) contains a CODER connected to a mezzanine TTL input, a DECODER connected to a mezzanine TTL output, a TRANSMITTER connected with the output of the CODER and the input of the DECODER, a matching transformer connected to the TRANSMITTER and the output to the MANCHESTER bus of the mezzanine. 14. The complex of control automation software and hardware according to claim 1, characterized in that the open-collector / emitter output mezzanine (MVOK) comprises an inverter connected to the TTL input, matching a transistor stage, the input of which is connected to the inverter output, an opto-galvanic element isolation, the input of which is connected to the output of the matching transistor cascade, and output key circuits connected at the input to the collector and emitter of the transistor element of the opto-galvanic isolation, and at the output through a fuse ny and restrictive elements - with the exit of the mezzanine.

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