Research And Development Of High-performance Embedded Industrial Controller Based On PowerPC

The core of the DCS(Distributed Control System)—the main controller, which is responsible for the data processing and data communication, has strong effects over the real-time performance and reliability performance of the entire system.Domestic DCS controller can hardly safisfy the needs of large process industry due to the shortcomings in aspects of computation performance,communication efficiency and data protection under power failure. In view of these problems, this dissertation designs and develops a high-performance embedded industrial controller combined with the DCS researches.The main works of the dissertation as follows:1.As to the issue of computation performance, PowerPC Processor and high-speed DDR2 SDRAM are used, so the shortcomings of low computation performance of processor, low communication speed of main storage of SDRAM, low reliability are overcome. Based on the profound research of key technologies of PowerPC Processor, high-speed storage, key modules which affect the computation performance are optimally designed to improve the computation performance of the controller.2.As to the issue of communication efficiency, redundant Gbit ethernet are used to improve communication efficiency between controller and upper system net, and redundant high-speed ethernet are designed to improve communication efficiency between controller and field controll net. As to the issue of communication efficiency between redundant controllers, the design of high-speed PCI-Express bus which is used to solve the present problem of low communication efficiency of serial interface greatly improve the communication efficiency. The hardware and software of the system which are designed and developed based on the profund researches of above communication technologies, greatly improve the communication efficiency of the entire controller.3.As to the issue of data protection under power failure, the Farad Capacitor Power-saving design is proposed, in which the farad capacitor is charged when the controller works well, and provides the electricity when the power fails. High-speed reliable non-volatile NAND Flash is used to store the data under power failure, which solves the problem of the SRAM design in which most CPU resource are taken and long time for data protection under power failure is achieved, and system reliability is improved.4.Prototype machine of controller is developed. Tests of the functions, performances of the controller and tests for the Farad Capacitor Power-saving design are done on the machine. The results indicate that the controller has made evident improvements compared with the counterpart of the main stream domestic DCS controller, and the new controller demonstrates excellent computation performance, high communication efficiency, and high memory reliability.