数控系统功能安全关键技术的研究
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摘要
高档数控系统已成为新兴高新技术产业和尖端工业的使能技术和最基本装备。针对高档数控系统中高速、高精、复合化、网络化和多轴联动等发展方向对安全性的特殊需求,本文对数控系统功能安全展开了深入的研究。
功能安全涉及到安全相关的机电控制系统、安全相关技术和其它风险降低策略,其目的是保证安全功能的正确执行。根据相关国际标准,功能安全的具体实现包括风险评估和风险降低两个过程,其所涉及的核心技术主要包括风险评估方法和风险降低策略。基于此,本文重点解决相对应的风险评估方法、总线安全通信技术以及系统安全监控方法等关键技术。
本文主要工作及研究成果包括：
1.提出了一种递阶式风险评估方法。
为有效识别风险因素,评估系统安全性能,本文提出了一种递阶式风险评估方法。首先给出了递阶式层次结构模型将复杂系统逐级分解简化,构建了评估序列集矩阵以融合各层级专家经验,并且设计出序列集模糊映射方法将专家经验进行量化,从而获取各层级中因素权重；然后针对所获取递阶式层次结构模型,从顶层开始将各层级因素权重进行逐层传播扩散直至底层,从而定位关键风险因素：同时辅以水平分片法,与安全等级匹配规则集相结合,确定数控系统风险程度等级；最后采用实际案例对所提出方法和有向图矩阵法进行性能对比,结果证明该方法能够有效减少评估结果相似度,降低评估时间,适合于数控系统风险评估过程的应用,具有很好的应用前景。
2.提出了一种基于双环现场总线的安全通信方法。
针对数控系统中安全信息对传输安全性及实时性的需求,本文提出一种在数控系统双环现场总线上对所传输消息进行环形编码的消息安全通信方法。该方法充分利用了两条通信环路,其中一条环路用于传输各从站点的原始消息,另一条环路采用环形编码算法生成了用于从站点进行自我修复的关联消息,在增强信息冗余度的同时,保证了主站点对应答消息的及时获取。论文中还给出了数控双环现场总线安全报文结构,并设计出相应的数据恢复算法,最后采用数学手段及实验测试对所提出方法与传统的双通道通信方法进行性能比较,证明所提安全通信方法在未增加报文长度和算法复杂度的前提下,能够有效增强冗余性,降低重传概率,同时满足通信实时性要求,结果表明该方法适合于数控现场总线消息安全通信的应用,具有很好的应用前景。
3.提出了一种基于离散事件系统的安全监控系统建模方法。
数控系统是一类典型的离散事件系统,因此在离散事件系统基础上研究安全监控系统的建模方法,能够有效增强数控系统中安全控制功能的健壮性。本文首先总结了离散事件系统中已有的安全监控系统建模过程,并在此基础上,针对可能发生的事件可视性丢失问题,以及事件可视性突发丢失后的后继修复问题,提出了新的安全监控系统模型；重新定义了新模型中各元组的含义及内部原理,同时提出一种步进融合算法,给出了相应的伪代码和算法描述；最后,采用数学手段及实验验证对所提出方法与已有方法进行性能比较,证明该方法能够在保证安全监控目的的同时,获取更高的语言演化自由度,以及更低的模型复杂度,和更少的模型生成时间。
The high-end Computer Numerical Control (CNC) System is the enabling technology and basic equipment of developing new and hi-tech industry and advanced industrial science and technology. To meet the high-end CNC demands of safety, which is proposed by the performance of high velocity, high accuracy, composition, networking development trends and multiple channels, this dissertation focuses on the research of the functional safety of CNC system and related key technologies.
Functional safety is part of the safety of the machine and the machine control system which depends on the correct functioning of the safety-related electrical control system, other technology safety-related systems and external risk reduction facilities. In accordance with related international standards, the implementation of functional safety includes two procedures, the first one is the risk assessment procedure, and the other one is the risk reduction procedure. Therefore, this dissertation focuses on solving related risk assessment method, safety communication method and safe supervisory control method.
The main contributions of the dissertation are described as following:
1. We present a hierarchical risk assessment method for CNC system.
To identify risk factors and estimate the safety level of CNC system effectively, a hierarchical risk assessment method was presented. First of all, a hierarchical model of CNC system was proposed to disintegrate and simplify the complex CNC system, and an assessment sequences set matrix was deeply researched with the corresponding fuzzy mapping algorithm to mix the expert experience together and to quantize the expert experience. Secondly, a layered diffusion method of factor weights was proposed to locate key risk factors, and a horizontal fragmentation method was adopted to calculate the risk degree of CNC system. Finally, case studies were adopted to compare the performance between the digraph and matrix method and the new mechanism. The results proved that the new mechanism could decrease the similarity performance, reduce the execution time, and be more suitable for the application of risk assessment process in CNC systems.
2. We present a safety communication method based on CNC Dual Ring Fieldbus.
To meet the requirements of safety signals in transmission security and real-time performance of CNC system, a message safety communication method which adopting ring coding based on CNC Dual Ring Fieldbus was presented. Corresponding to the proposed method for safety communication, one ring field bus is used to transmit original messages, and the other one is used to transmit selfreparing messages which can be caculated to achieve original messages. The structure of CNC Dual Ring Fieldbus safety message was proposed, and safety communication mechanism based on Dual Ring and related algorithms were deeply researched. And then mathematic method and experiment tests were adopted to compare the performance between the new and traditional mechanisms. The results proved that the new mechanism could enhance the redundancy performance, reduce the retransmission probability, meet the real-time performance, and be more suitable for the application of message safety-critical communication in CNC Fieldbus.
3. We present a safe supervisory control method under observability failure for Discrete Event System (DES).
CNC system is a typical DES, so the robustness of safe control function of CNC system can be enhanced by the research of safe supervisory control methods based on the DES. Firstly, we summarized and described traditional modeling methods in detail for DES. Moreover, to solve the problem of safe supervisory control under possible loss of observability and repair of observability failure for DES, a step-fusion algorithm was proposed. Based on the step-fusion algorithm, a new safe supervisory control model was presented. And then mathematic method and case study were adopted to compare the performance between the new and traditional mechanisms. The results proved that the new mechanism could obtain a safe controller that avoids disaster states, and be more permissive than the traditional supervisor.
功能安全涉及到安全相关的机电控制系统、安全相关技术和其它风险降低策略,其目的是保证安全功能的正确执行。根据相关国际标准,功能安全的具体实现包括风险评估和风险降低两个过程,其所涉及的核心技术主要包括风险评估方法和风险降低策略。基于此,本文重点解决相对应的风险评估方法、总线安全通信技术以及系统安全监控方法等关键技术。
本文主要工作及研究成果包括：
1.提出了一种递阶式风险评估方法。
为有效识别风险因素,评估系统安全性能,本文提出了一种递阶式风险评估方法。首先给出了递阶式层次结构模型将复杂系统逐级分解简化,构建了评估序列集矩阵以融合各层级专家经验,并且设计出序列集模糊映射方法将专家经验进行量化,从而获取各层级中因素权重；然后针对所获取递阶式层次结构模型,从顶层开始将各层级因素权重进行逐层传播扩散直至底层,从而定位关键风险因素：同时辅以水平分片法,与安全等级匹配规则集相结合,确定数控系统风险程度等级；最后采用实际案例对所提出方法和有向图矩阵法进行性能对比,结果证明该方法能够有效减少评估结果相似度,降低评估时间,适合于数控系统风险评估过程的应用,具有很好的应用前景。
2.提出了一种基于双环现场总线的安全通信方法。
针对数控系统中安全信息对传输安全性及实时性的需求,本文提出一种在数控系统双环现场总线上对所传输消息进行环形编码的消息安全通信方法。该方法充分利用了两条通信环路,其中一条环路用于传输各从站点的原始消息,另一条环路采用环形编码算法生成了用于从站点进行自我修复的关联消息,在增强信息冗余度的同时,保证了主站点对应答消息的及时获取。论文中还给出了数控双环现场总线安全报文结构,并设计出相应的数据恢复算法,最后采用数学手段及实验测试对所提出方法与传统的双通道通信方法进行性能比较,证明所提安全通信方法在未增加报文长度和算法复杂度的前提下,能够有效增强冗余性,降低重传概率,同时满足通信实时性要求,结果表明该方法适合于数控现场总线消息安全通信的应用,具有很好的应用前景。
3.提出了一种基于离散事件系统的安全监控系统建模方法。
数控系统是一类典型的离散事件系统,因此在离散事件系统基础上研究安全监控系统的建模方法,能够有效增强数控系统中安全控制功能的健壮性。本文首先总结了离散事件系统中已有的安全监控系统建模过程,并在此基础上,针对可能发生的事件可视性丢失问题,以及事件可视性突发丢失后的后继修复问题,提出了新的安全监控系统模型；重新定义了新模型中各元组的含义及内部原理,同时提出一种步进融合算法,给出了相应的伪代码和算法描述；最后,采用数学手段及实验验证对所提出方法与已有方法进行性能比较,证明该方法能够在保证安全监控目的的同时,获取更高的语言演化自由度,以及更低的模型复杂度,和更少的模型生成时间。
The high-end Computer Numerical Control (CNC) System is the enabling technology and basic equipment of developing new and hi-tech industry and advanced industrial science and technology. To meet the high-end CNC demands of safety, which is proposed by the performance of high velocity, high accuracy, composition, networking development trends and multiple channels, this dissertation focuses on the research of the functional safety of CNC system and related key technologies.
Functional safety is part of the safety of the machine and the machine control system which depends on the correct functioning of the safety-related electrical control system, other technology safety-related systems and external risk reduction facilities. In accordance with related international standards, the implementation of functional safety includes two procedures, the first one is the risk assessment procedure, and the other one is the risk reduction procedure. Therefore, this dissertation focuses on solving related risk assessment method, safety communication method and safe supervisory control method.
The main contributions of the dissertation are described as following:
1. We present a hierarchical risk assessment method for CNC system.
To identify risk factors and estimate the safety level of CNC system effectively, a hierarchical risk assessment method was presented. First of all, a hierarchical model of CNC system was proposed to disintegrate and simplify the complex CNC system, and an assessment sequences set matrix was deeply researched with the corresponding fuzzy mapping algorithm to mix the expert experience together and to quantize the expert experience. Secondly, a layered diffusion method of factor weights was proposed to locate key risk factors, and a horizontal fragmentation method was adopted to calculate the risk degree of CNC system. Finally, case studies were adopted to compare the performance between the digraph and matrix method and the new mechanism. The results proved that the new mechanism could decrease the similarity performance, reduce the execution time, and be more suitable for the application of risk assessment process in CNC systems.
2. We present a safety communication method based on CNC Dual Ring Fieldbus.
To meet the requirements of safety signals in transmission security and real-time performance of CNC system, a message safety communication method which adopting ring coding based on CNC Dual Ring Fieldbus was presented. Corresponding to the proposed method for safety communication, one ring field bus is used to transmit original messages, and the other one is used to transmit selfreparing messages which can be caculated to achieve original messages. The structure of CNC Dual Ring Fieldbus safety message was proposed, and safety communication mechanism based on Dual Ring and related algorithms were deeply researched. And then mathematic method and experiment tests were adopted to compare the performance between the new and traditional mechanisms. The results proved that the new mechanism could enhance the redundancy performance, reduce the retransmission probability, meet the real-time performance, and be more suitable for the application of message safety-critical communication in CNC Fieldbus.
3. We present a safe supervisory control method under observability failure for Discrete Event System (DES).
CNC system is a typical DES, so the robustness of safe control function of CNC system can be enhanced by the research of safe supervisory control methods based on the DES. Firstly, we summarized and described traditional modeling methods in detail for DES. Moreover, to solve the problem of safe supervisory control under possible loss of observability and repair of observability failure for DES, a step-fusion algorithm was proposed. Based on the step-fusion algorithm, a new safe supervisory control model was presented. And then mathematic method and case study were adopted to compare the performance between the new and traditional mechanisms. The results proved that the new mechanism could obtain a safe controller that avoids disaster states, and be more permissive than the traditional supervisor.
引文
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