CN101122793A - Industrial production line embedded type main control system - Google Patents
Industrial production line embedded type main control system Download PDFInfo
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- CN101122793A CN101122793A CNA2006100528501A CN200610052850A CN101122793A CN 101122793 A CN101122793 A CN 101122793A CN A2006100528501 A CNA2006100528501 A CN A2006100528501A CN 200610052850 A CN200610052850 A CN 200610052850A CN 101122793 A CN101122793 A CN 101122793A
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Abstract
The invention relates to an embedded main-control system of industrial production line. And embedded data serve controls operation of the whole system. A flash storage pattern, a high-speed memory pattern, an electronic drives, a touch screen, a system fault self recovery pattern, a high-speed collection module, an Ethernet interface, radio frequency module, and an industrial bus pattern are connected by an internal bus on a core main control panel of the system.. The paralleled industrial bus pattern are connected with the production line technology hardware coupling pattern and then connected with an actuator device, a sensor and a meter. The high-speed collection module is connected with a field apparatus state pattern by the production line technology hardware coupling pattern. The Ethernet interface is connected with a parent server and Internet. The system has the embedded data server at the core, which is provided with features of high-precision, interference resistance, networking and good freshness, thereby improving responsive efficiency of industrial field data, quality of products and technical specifications. A universal interface platform of the system makes the system able to be applicable to various lines.
Description
Technical field
The present invention relates to a kind of industrial production line embedded type main control system; Be specifically related to parameters such as a kind of various electric currents that are used for industry spot monitoring and control field, voltage, environmental parameters such as temperature, humidity, cigarette sense, pressure, image, sound, various solids, liquid, gas, and the various processing parameters of production run 1) monitoring sampling in real time 2) utilize associated production technology Calculation formula that sampled data is carried out real-time analysis and calculated 3) result of calculation is fed back in real time, finish the misarrangement of production run and the real-time control of tuning.
Background technology
The industrial production line process control is industrial important component part, also there is semi-automatic situation in some traditional industrial production lines, these production line control systems exist the production run opertaing device to separate, can't unify integrated management, can't realize that also production line comprehensive parameters real-time online detects and the function of FEEDBACK CONTROL, production efficiency also has much room for improvement, the production line of the no datat acquisition system of especially domestic independent research exists the shortcoming of can not online detection and correcting mistakes, and detects by checkout equipment after product must be produced by the time and finish again and could determine that product is qualified in to deny.The production line that has a data acquisition system (DAS) for major part also exists the shortcoming that can only online detection can not On-line Control corrects mistakes, exist when general data acquisition system (DAS) is applied to industry spot at present and can only gather but out of contior weakness, exist and to find mistake and can not solve the problem that mistake depends on artificial solution automatically, and these data acquisition system (DAS) data acquisition rates are not high, do not reach the technical grade requirement, can't adapt to the requirement of industry spot high-speed data acquisition and control.The all basic control system that realizes with slave computer and host computer combination of most of production line control, this is that the host computer slave computer control model of core exists the improved place of many needs with the industrial computer, and many traditional production lines can't be realized the control of telecommunication networkization.All be that control system is separated with management information system mostly simultaneously, and for flourishing now WEB technology, these systems can't use these technology aspect collection and the control, and control system internal microprocessor employing general procedure mechanism, and operational efficiency is not high.
Summary of the invention
The present invention be directed to exist in the above-mentioned general data acquisition system (DAS) and can only gather but can not control, data acquisition rate is not high, do not reach the technical grade requirement, can't adapt to the present situation that industry spot requires, a kind of intellectuality of designing and developing, networking, high-precision production line control system, this control system can realize that by inner high speed acquisition module and feedback coupling link monitoring, Treatment Analysis and the FEEDBACK CONTROL to the scene regulated in one.Technical grade Performance Characteristics advantage by this control system, can make this control system be satisfied with other monitoring real-time data acquisition fields, the advantage that while proofreaies and correct in conjunction with real-time Treatment Analysis, FEEDBACK CONTROL, the adjusting of this control system, can greatly remedy the other field data acquisition system (DAS) and can only gather and to realize the defective controlled, and increase the intelligent level in other monitoring fields.
This control system is by the work of embedded data server controls total system, the high-performance processor of server internal core master control borad connects by internal bus, the Flash memory module, internal memory, electronic hard disc, the system failure is from recovering module, the high speed acquisition communication module, Ethernet interface, radio-frequency module, the industrial bus module, articulate production-line technique coupling hardware module by the industrial bus module, production-line technique coupling hardware module connects the intelligence sensor in the production line respectively, instrument and high precision actuator, thereby the real-time sync response of the multiple-contact data in the realization production line, Treatment Analysis, and realize online detection production technology and the actuator equipment of controlling in the production line by the coupling algorithm Control Software under the embedded real time operating system software in the master control borad, thereby improve the production line key process parameter.
Technical solution of the present invention: system carries coupling algorithm Control Software, production-line technique coupling hardware module, signal isolator, industrial bus module, intelligence sensor unit, touch-screen, high precision actuator by embedded data server, plate and forms.In the embedded data server, the embedded real-time oss of embedded master control borad of the core plate of unifying carries the coupling algorithm Control Software, connect the high speed acquisition communication module by the master control borad internal bus, the inner acquisition channel of high speed acquisition communication module is by production-line technique coupling hardware module field equipment connecting state cell, and master control borad industrial bus module connects intelligence sensor, instrument and actuator equipment by production-line technique coupling hardware module.
The embedded data server is a core with embedded master control borad, inner 32 bit processors of master control borad articulate the system failure from recovering module, electronic hard disc, Ethernet interface, radio-frequency module, high speed acquisition communication module etc. by inner 32 high-speed buses, and each circuit and interface is all by inner real-time embedded operating system management of process, can realize that each interface module efficiently moves.Master control borad is gathered apparatus for production line state and failure message by the high speed acquisition communication module Real-time and Dynamic that internal bus connects, store important field data and fault recovery historical record by electronic hard disc, connect upper system and Internet by Ethernet interface, realization remotely logs on to system and realizes monitoring in real time of real-time fabrication line process and management, and the system failure is from the functions such as filtering, constant pressure and flow, power supply anti-jitter and system reset of recovering module feasible system power supply.
High speed acquisition communication module RS232, RS485 and USB2.0 interface, interface adopt operating system interrupt response acquisition management, and frequency acquisition is the highest at 108kHZ.
Radio-frequency module adopts FSK modulation system, carrier frequency frequency 433MHZ, received current＜20mA, transmitter current＜500mA.Module work has low-power consumption.
The system failure is core with MAX706 in conjunction with controller from recovering module, adopt system failure timer-controlled self-inspection design, the abnormal state of related apparatus for production line simultaneously can realize that on-the-spot gross mistake, product technological parameter deviation are excessively and realize the fielded system emergency processing during system exception and reset.
The novelty that needle set of the present invention has:
1, exist high-speed data acquisition for the on-the-spot field of commercial production, the high-speed data computing, the technical grade requirement of result of calculation high-speed feedback control, general data acquisition system (DAS) exists can only gather but out of contior weakness (for example i) Chinese patent, the number of applying for a patent: the 03133458.X applying date: 2003.06.17 title: intelligent high-speed real time data sampling device is 98248745.2 applying date of the number of applying for a patent 1998.11.27 title ii): a kind of general data collector), so on-the-spot field of these data acquisition system (DAS)s and inapplicable commercial production, and the index of these data acquisition system (DAS) image data does not reach the requirement of technical grade yet, i for example) the maximum sampling rate of intelligent high-speed real time data sampling device is 600 times/second, and the maximum sampling rate of the present invention reaches more than the 100KHz (100000 times/second).The present invention not only can gather the various information in production scene, and can error be proofreaied and correct according to associated production industrial analysis collection result, will proofread and correct the result and feed back to production line and control correction.If catastrophic failure (for example the production line parts burn) appears in production line, then the production line that will move stops to report to the police simultaneously automatically, and to avoid more fault and loss, will make mistakes simultaneously position and correlation parameter show is convenient to artificial maintenance.
2, the present invention can realize the information acquisition correction and control of the real-time online of industry spot production run.Domestic independent research do not exist the shortcoming of can not online detection and correcting mistakes with the production line of data acquisition system (DAS), detect by checkout equipment again after product must be produced by the time and finish and could determine that product is qualified in to deny.Can only gather but out of contior weakness owing to exist when at present general data acquisition system (DAS) is applied to industry spot, so the production line that has a data acquisition system (DAS) for major part exists the shortcoming that can only online detection can not On-line Control corrects mistakes.The present invention carries out real-time sampling by each the road technology to production line, the fuzzy structure algorithm of multilayer that carries by plate carries out the calculating of related process computing formula to the different technologies parameter of gathering, the discovery error exceeds standard, the FEEDBACK CONTROL production line is revised in real time immediately, realize detecting in real time in process of production online correcting mistakes, thereby can avoid the defective waste of product, improve production technology and product quality, save and produce and labor cost.
3, the present invention has the advantage of using and expanding to other on-the-spot fields (fields such as for example environment on-site supervision, road on-site supervision, forest fire protection monitoring), these on-the-spot fields generally require the rank height not as the industry spot field to information acquisition and control, real-time response feedback speed etc., the present invention has good extendability, bus in the system and module interface all are to design according to the general module interface platform, the butt joint corresponding peripheral device just can satisfy the Detection ﹠ Controling in these on-the-spot fields, has wide upgrading to expand space.
4, the embedded master control veneer among the present invention is a core with 32 high-performance embedded processors and embedded real-time operating system, and universal industrial level bus that master control borad is inner integrated and inner universal high speed zone bus have very strong compatibility.Mainboard adopts anti-interference regional bus design, can realize that the high speed of plate upper module and processor is stablized communication, and each module adopts the embedded OS mechanism management simultaneously, can realize the efficient real time execution of module interface.And integrated ethernet module on the plate is supported the all-network ICP/IP protocol, can realize that the user remotely logs on to this master control borad and realizes the real-time dynamic monitoring management.
5, adopt signal coupling unit and production-line technique coupling hardware module, can realize the quick conversion and the amplification of acquired signal, remove the noise of on-the-spot sophisticated signal simultaneously fast by the filter unit in the signal coupling unit, production technology coupling hardware module can realize that the quick coupling of the drive unit of master control borad Control and Feedback information and actuating equipment loads, thereby shortens controller response time and efficient.
6, by the ICP/IP protocol in network interface and the master control borad, can realize that master control borad becomes network node, not only can make the information of master control borad collection collect upper system and remote server by Ethernet, and can move to the monitoring realization link on the master control borad by Ethernet, land by telecommunication network and directly to make the long-distance user log on master control borad, the ruuning situation and the information of each module on the real-time monitoring master control borad.
7, professional industrial bus module is connected to processor by internal bus, can improve the response efficiency and the stability of industrial bus.LonWorks industrial bus in the specialty industrial bus module has plurality of advantages, embody a concentrated reflection of: i) system has opening and interoperability: the LonWorks network is interconnected by the LonTalk agreement by intelligent node, form " Peerto Peer " peer-to-peer network, the developer only need be with main energy flower at the system applies design aspect, and does not need to go specially to realize and test transmission line and communication system.Ii) distributed no center control: network node is near spot sensor and topworks, each node can both be finished control and communication function, the part of nodes fault can not cause systemic breakdown, monitoring station can arbitrarily be installed in any position of network, and the position is conversion at any time also, function is reciprocity fully between the monitoring station, also can be defined as different stage.These characteristics all have great significance to debugging, maintenance and the stability of system.Iii) flexible, construction cycle of system configuration is short, to use medium in extensive range: adopts dissimilar transceivers, system can utilize multiple medium such as twisted-pair feeder, optical cable, concentric cable, line of electric force, wireless, infrared ray to carry out signal to transmit; Structures such as free topological structure or bus-type are formed in specific requirements such as distance, transmission speed and field apparatus according to transmission range, and these bring great convenience all for system design and maintenance upgrade transformation.
Description of drawings
The hardware structure diagram of Fig. 1 industrial production line embedded type main control system of the present invention
Fig. 2 internal system plate of the present invention loading system Control Software workflow diagram
Fig. 3 master control borad Flash of the present invention and main memory circuit connection layout
Fig. 4 electronic hard disc of the present invention, CAN bus circuit connection layout
Fig. 5 LonWorks modular circuit of the present invention connection layout
Embodiment
As Fig. 1 high-performance data server is a kind of professional application expansion bus and interface of having, simultaneously the central control system of integrated universal interface platform.It is the core CPU (central processing unit) that internal system adopts the embedded real-time operating system with high performance 32 flush bonding processors and multi-process parallel processing.Integrated non-volatile Flash storer and high-speed internal memory unit on the master control borad, as Fig. 3, the startup configuration information of low capacity Flash storage system, the real time operating system of jumbo Flash storage system association, integrated coupling algorithm control system software realizes that each plate carries module under the operating system simultaneously, be implemented in optimization management of process and control under the real time operating system, and the fuzzy structure algorithm of multilayer by software inhouse, at different production-line techniques, realize carrying out the composite technology algorithm process by the real time data of online acquisition.
The industrial bus module is by the interior zone high-speed bus, integrated universal industrial control bus system and professional application industrial-controlled general line system.
Be connected to processor as Fig. 4, Fig. 5 specialty industrial bus module by internal bus, can improve the response efficiency and the stability of industrial bus.Wherein the LonWorks industrial bus has advantages such as system has opening and interoperability, distributed no center control, system configuration is flexible, the construction cycle is short, the application medium are in extensive range.
1) at the professional application Industry Control, system is according to different industrial bus interface and protocol specification, designed corresponding professional industrial bus interface module, by internal bus direct connection processing device unit and professional industrial bus module, the parallel production-line technique coupling hardware module that inserts of specialty industrial bus, connect intelligence sensor, instrument and actuator equipment with this, realize the collection and the distributed couplings control of real-time device state parameter.Production-line technique coupling hardware module inside comprises that filtering circuit, photoelectric coupled circuit, PID regulate coupling unit, A/D change-over circuit, signal amplification change-over circuit, difference anti-jamming circuit, high-speed signal connector; the winding that photoelectric coupled circuit adopts H11D1 and H11L1 to form is isolated; and adopt the design of difference filter noise cancellation circuit, accurate device and efficient coupled transfer signal in can holding circuit.PID regulates coupling unit, the employing self-adaptation is regulated, controller is introduced in non-linear control, and adopt the anticipatory analysis control mode, it is the conversion control circuit of core in conjunction with microcontroller that the A/D change-over circuit adopts with MSC1211A/D and D/A converter, inside comprises instrument amplifier, programmable gain amplifier, multicircuit switch, digital filtering, signal calibration circuit, can provide and carry the high precision normal voltage, precision is 0.2%, drift is for 5ppm/ ℃, can save space and device cost, also exportable this voltage standard or external voltage standard.Thereby can gather 0 ~ 300mV micro-signal of external sensor output, controller software is realized the elimination of zero-error, correction, channel gain, drift correction and the nonlinear compensation of reference voltage simultaneously.High-speed signal connector adopts the ERmet2 type, and pin is counted 2-308, IEC 61076-4-101 standard, data transmission rate: 1GBit/s.
Directly in articulating internal bus, avoided conversion links and delay with the versabus signal by industrial bus, this specialty bus is gathered communication speed and is reached as high as 1.2M/s.
2) at the universal industrial bus standard, system by the interior zone bus integrated the PC/104 bus unit.Versatility expansion by this bus inserts the on-the-spot expansion equipment of standards such as on-the-spot image collection card, industrial analysis instrument, has improved the commercial Application extendability of master control system.
The high speed acquisition communication module is connected with processor by master control borad interior zone bus, module adopts leads to RS232, RS485, USB2.0 universal serial bus more, and each bus run adopts the exception response relational structure, unusual and real time operating system response abnormality is related by each serial bus module Hardware Response Delay, realizes the operating system grade response processing of passage real time data.RS232, RS485 gather baud rate at 57600bps/s, and the USB communication speed reaches as high as 1.25M/s.
As Fig. 4, the electronic hard disc unit adopts standard DOS file system, on-the-spot real-time change data and the apparatus for production line failure logging of main storage.
The system failure is core with MAX706 in conjunction with controller from recovering module, adopt system failure timer-controlled self-inspection design, the abnormal state of related apparatus for production line simultaneously can realize that on-the-spot gross mistake, product technological parameter deviation are excessively and realize the fielded system emergency processing during system exception and reset.
Radio-frequency module is by the direct connection processing device of internal bus and realize stablizing at a high speed communication, and module adopts the FSK modulation system, carrier frequency frequency 433MHZ, and receiver module is provided with antenna, can increase the wireless collection distance.
Ethernet interface has complete ICP/IP protocol by operating system, have the complete network service, the real time and on line monitoring that this master control system realizes each module interface can be realized remotely logging on to, and on-the-spot technological parameter data and the real time record of recollecting data can be realized.And at the complex environment at scene, the Ethernet interface end has adopted anti-voltage transient, anti-high pressure and strong electrostatic protection design, system's Ethernet interface directly can be inserted site environment.
Fig. 2 carries the workflow diagram of Control Software for plate in the invention, implementation is: the start-up control program, set processing parameter, by the intelligence sensor data in interruption and the real-time acquisition channel of repeating query dual mode, by image data check and correction and Error processing, then deviate and treatment for correcting are sent to actuator unit, realize the manufacturing parameter correction, feed back by measuring with fixed at the synchronous acquisition sensor values simultaneously.And real time data is made form and formation curve analysis, and each equipment operation situation of synchronous scanning, be recorded as form.Above data are sent simultaneously and are recorded in electronic hard disc and top service device database.
The present invention can be used as a kind of general-purpose interface platform butt joint corresponding peripheral device and is applied to nearly all industrial production automation field.
This invention at present is mainly used in the cable production industry: most cable production lines of present domestic independent research mainly are divided three classes: the artificial experience that 1) also rests on the dependence workman in the production run on the cables production critical processes such as cable diameter, temperature, expansion rate, backguy motor speed is judged, not only personnel cost height, regularly cause waste because of cable is defective, the cable of these production lines generally rests on the non-standard cable line and produces.2) semi-automatic cable production line though cable productions such as infrared caliper umbilical cable linear diameter, temperature, expansion rate, backguy motor speed are arranged, still needs labor management.Because it is just defective that cable of problem appears in a certain points in aspect such as cable diameter, temperature, foaming, (producing the whole situation that goes wrong of machine seldom has so the in a single day some links of production machine go wrong, but local minor issue is frequent appearance) this semi-automatic production line can't stop or report to the police, artificial discovery such as have only, so the defective waste that causes of cable is just inevitable.So artificial control can't reach accuracy and the precision that technical parameter is regulated, and also can't in time reflect for the variation of field data, more can't in time realize the feedback regulation of standard, causes unnecessary waste.3) have the cable production line of data acquisition system (DAS), but existing, can only gather but out of contior weakness the information acquisition system on these production lines, after the various information of production line are gathered, can not proofread and correct error, can only carry out artificially production line being controlled correction, often cause more fault and loss because artificial reflection is untimely.3 class cable production lines also exist the cable electrical characteristic and must wait until that to detect the electric property that could determine cable by checkout equipment again after cable production is finished qualified in denying simultaneously, can not online detection and the shortcoming that corrects mistakes.At top 3 class cable production lines, advantage of the present invention mainly contains: the opertaing device of in process of production cables such as cable diameter, temperature, expansion rate, backguy motor speed being produced critical process becomes artificial quality control and is automated quality control.Produce some links production line that goes wrong and to stop and to report to the police and show the position of makeing mistakes, can regulate and reflect the improvement of on-the-spot aspects such as data, realize the automatic assembly line of unattended duty.Carry out real-time sampling by each road technology to cable production, the fuzzy structure algorithm of multilayer that carries by plate carries out the crucial calculating such as spectrum analysis of fast fourier transform to the different technologies parameter of gathering, the discovery error exceeds standard, the FEEDBACK CONTROL production line is revised (response time is in 1 microsecond) in real time immediately, realization detects the production technology electric property value and online the correcting mistakes of the cable of per unit length in process of production in real time, thereby can avoid the defective waste of product, improved production technology and product quality, saved and produce and labor cost.
Should invention use simultaneously: electricity-saving lamp production industry, plastics-production industry, water pollution monitoring industry, electrical production industry, mechanical processing industry in a plurality of applications.
Claims (10)
1. industrial production line embedded type main control system, comprise that (wherein the embedded data server is a core with embedded master control borad to the embedded data server, comprises on the master control borad: 32 high-performance processors, the Flash memory module, internal memory, electronic hard disc, the system failure is from recovering module, the high speed acquisition communication module, Ethernet interface, radio-frequency module, the industrial bus module), plate carries the coupling algorithm Control Software, production-line technique coupling hardware module, the industrial bus module, the PC/104 bus interface, the intelligence sensor unit, instrument, parts such as high precision actuator equipment.It is characterized in that: the operation of embedded data server controls total system, Flash memory module on the embedded data server core master control borad, memory modules, electronic hard disc, the high speed acquisition communication module, the system failure is from recovering module, Ethernet interface, the industrial bus module is by internal bus connection processing device, master control borad directly connects touch-screen by internal bus, the coupling algorithm Control Software is loaded in plate and carries in the real-time embedded operating system, the industrial bus module is parallel to connect intelligence sensor by production-line technique coupling hardware module, instrument and high precision actuator equipment, the high speed acquisition communication module is by production-line technique coupling hardware module field equipment connecting state cell, and Ethernet interface directly inserts among top service device and the Internet.
2. industrial production line embedded type main control system according to claim 1, it is characterized in that embedded master control borad carries start-up routine loading real-time embedded operating system and coupling algorithm Control Software among the Flash by plate, by each module on the coupling algorithm Control Software control panel.
3. according to claim 1,2 described industrial production line embedded type main control systems, it is characterized in that described plate carries control program and the data analysis that the coupling algorithm Control Software comprises each interface module and handles, comprise that simultaneously the production-line technique multilayer blurs the structure algorithm program.
4. industrial production line embedded type main control system according to claim 1 is characterized in that described production-line technique coupling hardware module regulates coupling unit, A/D change-over circuit, signal by filtering circuit, photoelectric coupled circuit, PID and amplify change-over circuit, difference anti-jamming circuit, high speed connector and form.
5. according to claim 1,4 described industrial production line embedded type main control systems, it is characterized in that described production-line technique coupling hardware module is programmable signal converter, conversion delaing time＜=0.1us, the hardware module of production-line technique coupling is simultaneously sent field equipment state parameter and failure message in real time.
6. industrial production line embedded type main control system according to claim 1, it is characterized in that described touch-screen passes through the coupling algorithm Control Software in real time at existing production run state and device parameter, and record shows abort situation when the system failure, is convenient to maintenance of equipment.
7. industrial production line embedded type main control system according to claim 1, it is characterized in that, the high speed acquisition communication module is by production-line technique coupling hardware module field equipment connecting state cell, real-time collection site equipment status parameter and failure message, high speed acquisition communication module passage adopts USB (universal serial bus), and the communication speed extreme value is at 1.25Mbps/s.
Processor connects the coupling algorithm software analysis processing control information that production-line technique coupling hardware module is gathered real-time running data and passed through master control borad inside by the industrial bus module, then feedback control information is sent into actuator unit by bus and production-line technique coupling hardware module.
8. industrial production line embedded type main control system according to claim 1 is characterized in that described radio-frequency module adopts FSK modulation system, carrier frequency frequency 433MHZ, received current＜20mA, transmitter current＜500mA.Module work has low-power consumption.
9. according to claim 1,3 described industrial production line embedded type main control systems, it is characterized in that the described fuzzy structure algorithm of multilayer that utilizes similarity realizes that the processing parameter of gathering analyzes formula by the various related process of internal system and calculate the product performance index value.
10. according to claim 1,7 described industrial production line embedded type main control systems, it is characterized in that, system is by interrupt mechanism real-time response collection site device fabrication technological parameter, equipment status parameter and failure message, realize the analyzing and processing and the correction of online production technological parameter of data then by the coupling algorithm Control Software, feedback control information is sent into actuator by the shaping of production-line technique coupling hardware module, conversion and PID adjusting, regulate the apparatus for production line operation by the driver of actuator, realize the online in real time misarrangement and the tuning of processing parameter.
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