CN103455018A - Resistance welding machine control management system based on heterogeneous network technique - Google Patents
Resistance welding machine control management system based on heterogeneous network technique Download PDFInfo
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- CN103455018A CN103455018A CN2013104281955A CN201310428195A CN103455018A CN 103455018 A CN103455018 A CN 103455018A CN 2013104281955 A CN2013104281955 A CN 2013104281955A CN 201310428195 A CN201310428195 A CN 201310428195A CN 103455018 A CN103455018 A CN 103455018A
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Abstract
The invention relates to the field of resistance welding machine networking control, in particular to a resistance welding machine control management system based on a heterogeneous network technique. The resistance welding machine control management system adopts a mode of three layers of structures and two layers of networks. According to the three layers of the structures, the lower layer is a resistance welding machine, the middle layer is a power grid balance control unit, and the upper layer is an upper computer monitoring system. According to the two layers of the networks, the power grid balance control unit in the middle layer is connected with the resistance welding machine on the lower layer through a CAN bus network, and the power grid balance control unit in the middle layer is connected with the upper computer monitoring system on the upper layer in an industrial Ethernet mode. The resistance welding machine control management system has the advantages that three-phase power balance and network system management and control are integrated, power grid balanced load current calculation can be completed in a cyclic wave, working states and welding results of all welding machines can be displayed in real time, and automation and management levels of workshops are greatly improved.
Description
Technical field
The invention relates to resistance welder networking control field, especially a kind of resistance welder control and management system based on heterogeneous network technologies.
Background technology
Often need tens on the welding production line in weld car workshop to hundreds of resistance welders, these resistance welders need to be in the synchronization concurrent working of switching on simultaneously, this has proposed very high requirement with regard to the power supply capacity of giving factory, tend to make the power plant overload, cause the normal production of outage impact, in addition, resistance welder on existing auto vendor welding production line is all generally independent control, can't carry out centralized control to the use of resistance welder, welding quality can't be analyzed timely and monitor, because managerial personnel can't see various operational factors in time, also just can't analyze the problem existed in welding technology.
At present, though some resistance welder control and management systems being arranged domestic, is substantially all grid balance and welding machine monitoring management to be divided into to two cover systems control separately.Grid balance is controlled mostly and is realized by PLC or IPC, and adopt Star Network to open up the benefit structure and carry out the cable connection, because the layout of welding machine in workshop has very large dispersiveness, therefore the wiring amount is large, wiring distance, poor reliability; And the function such as monitoring, programming, data base administration that will simultaneously complete welding machine must configure the bus systems such as other CAN or RS-485 again, not only equipment is numerous and diverse, further increased again system cost and maintenance difficulties, still be difficult to meet the needs of actual production simultaneously.
Summary of the invention
The problem that the invention will solve is to overcome the prior art deficiency, a kind of resistance welder control and management system based on heterogeneous network technologies is provided, " grid balance " and " monitoring in real time " all realized by the bus communication mode, the heterogeneous network system that adopts CAN bus and switched industrial ethernet to form, realize controlling three-phase power balance and network system control integration.
For solving the problems of the technologies described above, the technical scheme that the invention adopts is: a kind of resistance welder control and management system based on heterogeneous network technologies, and described resistance welder control and management system adopts three-decker two-tier network pattern;
Described three-decker, lower floor is resistance welder, and middle layer is the grid balance control module, and upper strata is Monitor Computer Control System;
Described two-tier network, middle layer grid balance control module adopts the CAN bus network to be connected with the lower resistors welding machine, and middle layer grid balance control module adopts the Industrial Ethernet mode to be connected with the upper strata Monitor Computer Control System;
Described CAN bus network is a plurality of, and the station layout according to resistance welder in workshop is divided into different CAN bus network by it;
Described resistance welder arranges the CAN communication control circuit, and described CAN communication control circuit is for being connected to the CAN bus network to resistance welder;
Described grid balance control module arranges CANOpen fieldbus module and Ethernet interface, and described grid balance control module is for CAN bus network and Industrial Ethernet conversion;
Described Monitor Computer Control System is provided with Ethernet switch;
The CAN communication control circuit of described CAN bus network one end contact resistance welding machine, the other end connects the CANOpen fieldbus module of grid balance control module, form many host computer control LAN (Local Area Network), the Ethernet interface of described grid balance control module carries out data transmission communication by the Ethernet switch of Industrial Ethernet and Monitor Computer Control System;
Described grid balance control module adopts the built-in PC control system, duty operation grid balance is controlled software, comprise built-in PC control device, display system, CANopen fieldbus module, power measurement module, power isolation module, described built-in PC control device carries Ethernet interface, can realize and the master system communication, described CANopen fieldbus module, power measurement module, power isolation module adopt E-Bus bus mode and built-in PC control system to carry out communication; Described built-in PC control system has Industrial PC and hardware PLC dual-use function;
Described Monitor Computer Control System is responsible for the duty of real-time monitoring site welding machine, comprise PC management system, monitor, printer, UPS uninterrupted power source, Ethernet switch, described monitor, printer, UPS uninterrupted power source, Ethernet switch connect the PC management system, and described PC management system comprises PC main frame, Windows operating system, real-time dataBase system, PLC real-time core system and host computer management software.Monitor Computer Control System is mainly realized the database management function of Real-time Collection, welder fault Real-Time Monitoring, welding condition remote programmable, welding parameter and the failure message of welding parameter;
Described Monitor Computer Control System is realized and the connection of factory management system by Industrial Ethernet;
Described each CAN bus network, maximum communication distance is 1000 meters, can control at most 64 welding machines.
Advantage and good effect that the invention has are:
1, by the combination to CAN bus and switched industrial ethernet heterogeneous network system, grid balance and monitoring are in real time all realized by the bus communication mode, realize controlling three-phase power balance and network system control integration, simple in structure, safe and reliable.
2, under the support of communication network, the real-time processing of data is protected, and not only the grid balance load current calculates and can complete in a cycle, and the duty of all welding machines and welding result can show in real time.
3, monitoring in real time, remote programmable, data management and grid balance are controlled and can be realized in a cover system, and abundant software function greatly improves job-shop automation and management level.
4, cancel a large amount of cable connection of grid balance part of hub-and-spoke configuration, truly by the bus communication mode, realize networking and limited capacity function.Resistance welder can work in networking mode, also can work in unit (off line) mode.When system breaks down or shuts down, resistance welder can enter the off-line working state automatically.
The accompanying drawing explanation
Fig. 1 is system architecture theory diagram of the present invention
Fig. 2 is grid balance control module theory diagram
Fig. 3 is resistance welder control panel theory diagram
The theory diagram that Fig. 4 is Managing system of above position machine
Embodiment
As shown in Figure 1, the present invention includes many resistance welders, grid balance control module, Monitor Computer Control System and factory management system; Resistance welder forms CAN bus LAN by the CAN communication control circuit on its inner welding machine control panel circuit; Station layout according to resistance welder in workshop is divided into different CAN bus network by it, and each CAN bus network can be controlled at most 64 resistance welders; One end of CAN bus network connects 120 ohm of bus characteristics resistance welders, and the CANOpen fieldbus module on the other end and grid balance control module, form many host computer control LAN (Local Area Network); The grid balance control module is responsible for moving grid balance and is controlled software, and the while is as the terminal of master system and resistance welder communication data; What grid balance control module and Monitor Computer Control System adopted is that Industrial Ethernet ADS mode is carried out the data transmission, by grid balance control module conversion equipment, CAN bus and Industrial Ethernet are realized to seamless, the efficient connection, fast by the Industrial Ethernet traffic rate, contain much information, real-time monitoring that the advantage such as networking flexibility realizes butt welding machine; Monitor Computer Control System is realized the data sharing with factory management system by Ethernet.
As shown in Figure 2, grid balance control module control section mainly is comprised of built-in PC control system, display system, polylith CANopen fieldbus module, power isolation module and highly sensitive power measurement module, the built-in PC control device carries Ethernet interface, between these modules, adopts the E-Bus bus mode to carry out communication, the built-in PC device has Industrial PC and hardware PLC dual-use function, and independent operating 4 overlaps the PLC tasks simultaneously, and its extension element function is very perfect, can complete as required the control task of various complexity, the CANopen fieldbus module is connected and designs with the CAN bus network for realizing built-in PC, by it, realizes the CAN Data Communication in Computer Networks that grid balance control module and resistance welder form, the power measurement module can be measured all relevant three-phase alternating current electrical quantitys, and the line voltage of resistance welder supply transformer can directly be measured, and power network current is measured by simple current transformer, contributes to carry out comprehensive electrical network analysis and energy management, the low work characteristics according to the resistance welder cyclic duration factor, we use and adopt the timesharing control strategy electrical network, control the quantity of the welding machine of energising welding simultaneously on each phase line of supply transformer, can effectively stablize line voltage, realizing grid balance for the boot sequence of controlling resistance welding machine controls, need in resistance welder control panel software, increase by two control signals: welding application signal and welding answer signal, every welding machine sends welding application signal at the previous cycle of energising welding to the grid balance control system, after the grid balance control system receives the welding application, according to current line voltage and application situation, the welding machine that proposes the welding application is ranked, determine the welding machine that can switch on according to factors such as the order of queuing up and welding machine station right of priority, thereby realize the interlocked control management of energising welding process
As shown in Figure 3, the resistance welder master control borad mainly is comprised of synchro control master control borad, current/voltage feedback circuit, phase-locking and control circuit, output control circuit, input control circuit, welding signal control circuit, CAN communication control circuit, switching power supply, RS485 communication control circuit; The synchro control master control borad is Single Chip Microcomputer (SCM) system, comprises data-carrier store RAM, program storage, expansion I/O interface, serial port, CAN bus interface, PWM, and it completes the control of full machine; The RS485 communication control circuit is the programmable device communication interface circuit, can complete the communication with the monitor of programming, and the information such as parameter, network numbering, limited capacity mode, right of priority of resistance welder is set; The CAN communication control circuit, for resistance welder is connected to the CAN bus network, is realized the both-way communication with the grid balance control module; Output control circuit, comprise the signals such as fault, welding end of a period, clamping, air valve output; Input control circuit, comprise startup, reset, monotroded point, clamping etc., through photoelectric isolating circuit etc., enters CPU; Switching power supply, provide full machine required+24V, ± 15V ,+5V ,+the 9V power supply, phase-locking and control circuit are by pulse shaping circuit.
As shown in Figure 4, Managing system of above position machine mainly is comprised of PC management system, monitor, printer, UPS uninterrupted power source, Ethernet switch; The PC management system is the control core of whole master system, and the PC management system mainly comprises PC main frame, Windows operating system, real-time dataBase system, PLC real-time core system and host computer management software.Managing system of above position machine is mainly realized the functions such as data base administration of Real-time Collection, resistance welder fault Real-Time Monitoring, welding condition remote programmable, welding parameter and the failure message of welding parameter.The PC management system realizes and grid balance control module and factory management system by Industrial Ethernet.
Used on-line synchronous and dynamic adjustment to wait advanced algorithm, the energising request of each welding machine in network has all been calculated to judgement, provided the response that allows energising or forbid energising in a cycle (20ms); According to transformer capacity, the welding current summation that restriction is worked simultaneously; According to the three-phase equilibrium degree, limit alternate maximum current difference; Each resistance welder importance difference, but weighting is treated.
Duty shows in real time, comprises the real-time demonstration of welded condition, waiting status, idle condition, malfunction, off-line state; Welding parameter shows in real time, comprises specification number, work item, welding current, weld interval, pilot angle, conduction angle, solder joint number; Failure message shows in real time, comprises weldering plane No., work item, fault number, failure cause, solution.
Unified programming, can be indoor to any welding machine programming in centralized control, and different welding machine programming datas can copy mutually, simultaneously, can arbitrarily call in the programming data of any welding machine.Data base administration, provide the methods such as inquiry to parameters, modification, deletion, can form the Excel statistical report form, and print.Information sharing, can be integrated with workshop level information management system (ERP), by network, shares information.
Above one embodiment of the present of invention are had been described in detail, but described content is only preferred embodiment of the present invention, can not be considered to for limiting practical range of the present invention.All equalization variations of doing according to the present patent application scope and improvement etc., within all should still belonging to patent covering scope of the present invention.
Claims (5)
1. the resistance welder control and management system based on heterogeneous network technologies, is characterized in that: described resistance welder control and management system employing three-decker two-tier network pattern;
Described three-decker, lower floor is resistance welder, and middle layer is the grid balance control module, and upper strata is Monitor Computer Control System;
Described two-tier network, middle layer grid balance control module adopts the CAN bus network to be connected with the lower resistors welding machine, and middle layer grid balance control module adopts the Industrial Ethernet mode to be connected with the upper strata Monitor Computer Control System;
Described CAN bus network is a plurality of, and the station layout according to resistance welder in workshop is divided into different CAN bus network by it;
Described resistance welder arranges the CAN communication control circuit, and described CAN communication control circuit is for being connected to the CAN bus network to resistance welder;
Described grid balance control module arranges CANOpen fieldbus module and Ethernet interface, and described grid balance control module is for CAN bus network and Industrial Ethernet conversion;
Described Monitor Computer Control System is provided with Ethernet switch;
The CAN communication control circuit of described CAN bus network one end contact resistance welding machine, the other end connects the CANOpen fieldbus module of grid balance control module, form many host computer control LAN (Local Area Network), the Ethernet interface of described grid balance control module carries out data transmission communication by the Ethernet switch of Industrial Ethernet and Monitor Computer Control System.
2. a kind of resistance welder control and management system based on heterogeneous network technologies according to claim 1, it is characterized in that: described grid balance control module adopts the built-in PC control system, be responsible for the operation grid balance and control software, comprise the built-in PC control device, display system, the CANopen fieldbus module, the power measurement module, power isolation module, described built-in PC control device carries Ethernet interface, can realize and the master system communication, described CANopen fieldbus module, the power measurement module, power isolation module adopts E-Bus bus mode and built-in PC control system to carry out communication, described built-in PC control system has Industrial PC and hardware PLC dual-use function.
3. a kind of resistance welder control and management system based on heterogeneous network technologies according to claim 1, it is characterized in that: described Monitor Computer Control System is responsible for the duty of real-time monitoring site welding machine, comprise PC management system, monitor, printer, UPS uninterrupted power source, Ethernet switch, described monitor, printer, UPS uninterrupted power source, Ethernet switch connect the PC management system, and described PC management system comprises PC main frame, Windows operating system, real-time dataBase system, PLC real-time core system and host computer management software.Monitor Computer Control System is mainly realized the database management function of Real-time Collection, welder fault Real-Time Monitoring, welding condition remote programmable, welding parameter and the failure message of welding parameter.
4. a kind of resistance welder control and management system based on heterogeneous network technologies according to claim 1 is characterized in that: described Monitor Computer Control System is realized by Industrial Ethernet and the connection of factory management system.
5. according to the described a kind of resistance welder control and management system based on heterogeneous network technologies of claim 1-4 any one, it is characterized in that: described each CAN bus network, maximum communication distance is 1000 meters, can control at most 64 welding machines.
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| CN2013104281955A CN103455018A (en) | 2013-09-17 | 2013-09-17 | Resistance welding machine control management system based on heterogeneous network technique |
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Cited By (7)
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| CN104281086A (en) * | 2014-10-22 | 2015-01-14 | 郑州斯倍思机电有限公司 | Soft PLC control system based on EtherCAT communication protocol and applied to automatic argon-welding device |
| CN105388873A (en) * | 2015-12-10 | 2016-03-09 | 天津七所高科技有限公司 | Universal wireless spot welding machine distributed control system |
| CN105945944A (en) * | 2016-05-18 | 2016-09-21 | 华东理工大学 | Remote real-time monitoring system for welding robot system |
| CN106181007A (en) * | 2016-08-26 | 2016-12-07 | 天津七所高科技有限公司 | A kind of spot-welded standard parameter automatic switchover system |
| CN107272583A (en) * | 2017-06-29 | 2017-10-20 | 中车株洲电机有限公司 | A kind of motor welds networked system |
| CN107803579A (en) * | 2017-10-31 | 2018-03-16 | 天津七所高科技有限公司 | A kind of dual processors electric resistance welding control device with interface of internet of things |
| CN110703677A (en) * | 2019-09-29 | 2020-01-17 | 四川中曼电气工程技术有限公司 | PLC control system integrated on industrial personal computer |
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104281086A (en) * | 2014-10-22 | 2015-01-14 | 郑州斯倍思机电有限公司 | Soft PLC control system based on EtherCAT communication protocol and applied to automatic argon-welding device |
| CN105388873A (en) * | 2015-12-10 | 2016-03-09 | 天津七所高科技有限公司 | Universal wireless spot welding machine distributed control system |
| CN105945944A (en) * | 2016-05-18 | 2016-09-21 | 华东理工大学 | Remote real-time monitoring system for welding robot system |
| CN105945944B (en) * | 2016-05-18 | 2019-10-11 | 华东理工大学 | A kind of remote real-time monitoring system for welding robot system |
| CN106181007A (en) * | 2016-08-26 | 2016-12-07 | 天津七所高科技有限公司 | A kind of spot-welded standard parameter automatic switchover system |
| CN107272583A (en) * | 2017-06-29 | 2017-10-20 | 中车株洲电机有限公司 | A kind of motor welds networked system |
| CN107803579A (en) * | 2017-10-31 | 2018-03-16 | 天津七所高科技有限公司 | A kind of dual processors electric resistance welding control device with interface of internet of things |
| CN110703677A (en) * | 2019-09-29 | 2020-01-17 | 四川中曼电气工程技术有限公司 | PLC control system integrated on industrial personal computer |
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Application publication date: 20131218 |