CN104865915A - Polycarboxylate superplasticizer automatic production line intelligent controller - Google Patents
Polycarboxylate superplasticizer automatic production line intelligent controller Download PDFInfo
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- CN104865915A CN104865915A CN201510121140.9A CN201510121140A CN104865915A CN 104865915 A CN104865915 A CN 104865915A CN 201510121140 A CN201510121140 A CN 201510121140A CN 104865915 A CN104865915 A CN 104865915A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 33
- 229920005646 polycarboxylate Polymers 0.000 title claims abstract description 23
- 239000008030 superplasticizer Substances 0.000 title abstract 2
- 238000004891 communication Methods 0.000 claims abstract description 27
- 230000006870 function Effects 0.000 claims abstract description 16
- 230000010354 integration Effects 0.000 claims abstract description 7
- 239000003638 chemical reducing agent Substances 0.000 claims description 21
- 238000000034 method Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 8
- 239000000872 buffer Substances 0.000 claims description 5
- 230000008878 coupling Effects 0.000 claims description 5
- 238000010168 coupling process Methods 0.000 claims description 5
- 238000005859 coupling reaction Methods 0.000 claims description 5
- 230000008901 benefit Effects 0.000 claims description 4
- 238000013461 design Methods 0.000 claims description 4
- 230000009471 action Effects 0.000 claims description 3
- 230000002093 peripheral effect Effects 0.000 claims description 3
- 230000005540 biological transmission Effects 0.000 claims description 2
- 230000000903 blocking effect Effects 0.000 claims description 2
- 238000002474 experimental method Methods 0.000 claims description 2
- BTCSSZJGUNDROE-UHFFFAOYSA-N gamma-aminobutyric acid Chemical compound NCCCC(O)=O BTCSSZJGUNDROE-UHFFFAOYSA-N 0.000 claims description 2
- 239000012464 large buffer Substances 0.000 claims description 2
- 230000001681 protective effect Effects 0.000 claims description 2
- 238000001514 detection method Methods 0.000 abstract description 5
- 238000005516 engineering process Methods 0.000 description 12
- 238000010586 diagram Methods 0.000 description 6
- 230000018109 developmental process Effects 0.000 description 4
- 238000002955 isolation Methods 0.000 description 4
- 238000011161 development Methods 0.000 description 3
- 238000012544 monitoring process Methods 0.000 description 3
- 238000004886 process control Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000003745 diagnosis Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000012407 engineering method Methods 0.000 description 1
- 210000004744 fore-foot Anatomy 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 230000006855 networking Effects 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Control By Computers (AREA)
- Feedback Control In General (AREA)
Abstract
The invention relates to a polycarboxylate superplasticizer automatic production line intelligent controller. The controller includes a hardware part and a software part; a feedback relationship is established between switching quantity input and switching quantity output; an adjustment relationship is established between analog quantity output and second serial communication; a data transfer relationship is established between a first serial port and a second serial port; switching quantity input and output interfaces are connected with the input and state feedback end of a corresponding switching valve respectively; a first serial communication interface is connected with an upper computer so as to complete instruction receiving and communication function detection; a second serial communication interface is connected with various kinds of sensors; received sensor data are processed by a processor; an analog quantity output port is connected with a dropwise adding valve so as to be used for controlling the opening degree of the valve and dropwise adding flow rate; abstraction integration is performed on an equipment object to be controlled by the software part; the equipment object is abstracted to a structural body on a program through C language and by using structural bodies, and therefore, related data of the equipment object can be packaged.
Description
Technical field
The present invention relates to a kind of polycarboxylate water-reducer automatic production line intelligent controller, belong to automatic industrial manufacturing line technical field.
Background technology
The feature of industrial automation technology generates by the middle of concept, and so-called industrial automation refers to the participation of nobody and carries out Industry Control automatically and carry out commercial production, and it can regulate the parameter, technical indicator, the qualified degree of product etc. of industry automatically; Production equipment carries out the production run of automatic control operation according to relevant certain procedures and instruction.Industrial automation technology mainly comprises: hardware technology, software engineering and systems technology three part.At present, industrial automation system divides 5 grades usually: business administration level, production manager level, process control level, equipment controlled stage and detection driving stage.Front two-level management level relates generally to the software of computing machine, network technology and infotech; Process control level relates to intelligent control technology and engineering method; Device level and detection driving stage relate to EIC integration technology, field bus technique and new unit ac digital speed adjusting technique.Control integration in another development trend of industrial automation, so-called control integration is exactly set up information platform that is fully integrated, open, the comprehensive automation of full factory, enterprise's lateral communications are closely connected together with longitudinally communicating, by the overall treatment to information such as business decision, management, plan, scheduling, process optimization, fault diagnosis, field controls, form meaning system ensemble widely.Industry and general enterprises network are roughly divided into 3 layers, i.e. enterprise management level, process monitoring layer and field control layer.
Therefore, under the overall background of industrial automation technology development trend, the industrial automation of polycarboxylate water-reducer automatic production line, relates generally to process monitoring layer and field control layer, wherein applies the most outstanding and is apparent that intelligent control technology and field bus technique.
Existing polycarboxylate water-reducer production line often runs into a lot of difficulty at process control level and detection driving stage, this is mainly because the traditional manual type of the many employings of control mode and circuit design, intellectualized reconstruction for production line needs a long-term process, and the input of manpower and financial resources can increase gradually.In addition, too high to the use cost of most of medium and small sized enterprises PLC, available resources waste is serious.
Therefore for the intellectualized reconstruction of polycarboxylate water-reducer automatic production line, propose by fieldbus, adopt MCU controller to form the control framework with digital technology and communication capacity with same traditional measure and control instrument of being inserted by CPU.At present, fieldbus both domestic and external has kind more than 60, due to commercial interest, result in and work out the Great War of fieldbus national standard in recent years, under the cry of the unified international standard of market and technology development need, International Electrotechnical Commission's amended IEC61158.3 ~ 6 standard passes on January 4th, the most 1.But the domestic application to field bus technique is also slower at present, one is the establishment expecting single fieldbus international standard, but objective fact is IEC have passed 8 kinds of bus standards, estimates to be difficult at short notice change; Two is that fieldbus has difficulties in the system integration, and condition is also immature, there is the identification of bus product interoperability and the problem of reliability aspect in addition.
During existing polycarboxylate water-reducer production line is produced, how to reach regulator instrument relevant to scene to realize together from main regulation, thus realize the thorough dispersion of control, be regulate more timely, remove too much artificial production to participate in, improve production Product Precision not high, and the reliability improving whole system is all the objective problem existed.
Summary of the invention
Polycarboxylate water-reducer automatic production line intelligent controller adopts the ARM kernel control chip of main flow as main controller core, utilizes MODBus standard for Fieldbus, realizes the industrial networking of RS485/MODBus bus network.By the dropping of controller function module, switch and feedback, and serial ports or CAN communication mode, coordinate the digital instrument etc. adding CPU, solve the intelligentized control method on polycarboxylate water-reducer automatic production line from hardware.Fire the software adding modular software programming idea and PID, the reinforced algorithm of intelligence, achieve production testing, improve Product Precision, Intelligent adjustment and intelligence drip reinforced function.
The technical solution used in the present invention is a kind of polycarboxylate water-reducer automatic production line intelligent controller, and this controller comprises hardware components and software section; Specifically hardware components comprises two-way communication, one group of On-off signal, one group of output switch parameter, one group of analog quantity (DAC) export, and on Current hardware basis, defines corresponding driver, Software Development Platform.Controller is specifically made up of main processor core district, On-off signal output module, analog output (DAC) module, first serial communication module (CAN or RS232), second serial communication module (RS485).In current application, between On-off signal and output switch parameter, establish feedback relationship.Export in analog quantity (D/A) and establish adjustment relation between second serial communication.Data transitive relation is established between first serial and second serial.On-off signal output interface connects input and the feedback of status end of respective switch valve respectively.First serial communication interface is connected with host computer, completes the communication function such as command reception, detection.Second serial communication interface is connected with various sensor, is processed the sensing data received by processor.Analog output port is connected with dropping valve, for controlling opening of valve, controls to drip flow velocity.
In addition, industry spot disturbing factor is many, no exception in the polycarboxylate water-reducer environment of plant, there is various interference source, needs effective measures to reduce their interference to signal, ensures that signal transmits accurately and reliably.The signal of processor input and output, by high speed photo coupling and magnetic coupling quarantine measures, is connected with each functional module, processor is exported or receives the signal of several module, carrying out mutually stable communication, play anti-interference protective effect.
The device object that software section will control carries out abstract integration, utilizes structure by C language, the structure in device object abstract program, reaches the related data of sealed in unit object.By C language Function Modules blocking, the operational motion of device object is carried out programming realization, and be finally incorporated into inside engineering structure in an independent equipment sources file, the data realizing equipment become to be integrated with action, specify function and the control mode of equipment, form a functional unit.Such as: test tank equipment abstract, define test tank data structure, comprise its related data, as quality.Use function to realize to its attached action, comprise quantitative dosage, constant speed drips, quantitative discharging, forms a dropping unit on the whole.
After software equipment integrates each functional unit of abstract, carry out the integrally-built design of software, by on hardware, peripheral hardware has oneself data register, arranges a large buffer zone, buffer zone is divided into several area of space in software configuration, distribute to functional unit respectively, make these regions become the data register of functional unit, the data of hold function unit, functional unit can directly read one's own data area by power function.As the data register that functional unit has oneself.
In SFU software functional unit, drip unit and adopt pid algorithm to carry out flow control, according to PI dominated formulate,
control the aperture (because it is larger to drip valve opening, speed is larger, and mass change is larger) dripping valve, reach the target of coutroi velocity.
P and I coefficient is all the adjusted value recorded by many experiments.I quality of regulation error, before dropping starts, by obtaining velocity amplitude and the time for adding of user's input inside host computer, controller calculates the quality needing to drip, use the current reactor quality of sensor transmissions to alleviate dropping quality, calculate quality after desirable dropping, after being added dropwise to complete, the qualitative data of read sensor, deducts difference that desirable dropping quality obtains and takes advantage of and carry out quality adjustment in adjustment factor I.P governing speed error, during dropping, record drips front and back system time, use before and after dropping process of poor quality divided by drawing present speed during this period of time, the difference that user inputs speed and present speed is taken advantage of and is carried out speed adjustment in P, finally add that current control valve opening draws last control valve opening, reach and regulate dropping flow velocity object.
This modularization programming of software can also carry out the expansion of module, only has hardware to meet the demands, Requirement Increases, can satisfy the demands.
Beneficial outcomes of the present invention: polycarboxylate water-reducer automatic production line intelligent controller utilizes the theory of industry 4.0, achieves production line intelligent regeneration, thoroughly solves unstable product quality problem removes manual operation in conscientiously producing.Achieve raising Product Precision, promote intelligentized object.
Accompanying drawing explanation
Fig. 1: polycarboxylate water-reducer automatic production line intelligent controller structure block diagram.
Fig. 2: intelligent controller software architecture diagram.
Fig. 3: polycarboxylate water-reducer automatic production line intelligent controller onsite application figure.
Fig. 4: intelligent controller process flow diagram.
Embodiment
Composition graphs 1, to Fig. 4 part, is being described in detail these diagrams with lower part:
Polycarboxylate water-reducer automatic production line intelligent controller structure block diagram (as shown in accompanying drawing Fig. 1), mainly contain each hardware module composition of practical function, mainly include primary processor MCU chip, RS485 communication module, CAN or serial communication modular, switch control rule and feedback module, dropping control module, provide the power module of three kinds of voltages, use power isolation module that GND is separately defined MCU core space and peripherals district.Because industry spot interference is huge, isolated from power and signal isolation (high speed photo coupling isolation, electromagnetic isolation) also account for the larger part of hardware.
Intelligent controller software structure design (as shown in accompanying drawing Fig. 2), the project organization of Fig. 2 is have employed in order to the flexible expansion of later controller and the independence of controller function, intermediate buffer (intermediate variable) can define larger (when RAM capacity allows again), be defined as sharing body, the access of byte (8bits) individual word (16bits) can be carried out to intermediate variable, accelerate data reading speed, improve treatment effeciency.In order to access conveniently, the most forefoot area of intermediate variable to the content assignment after instructions parse, to each abstract functional unit out can flexible allocation in the data field of intermediate buffer.Now abstract functional unit has switch and feedback unit, dropping control module, RS485 communication unit, CAN or serial communication unit.
Polycarboxylate water-reducer automatic production line intelligent controller onsite application arrangenent diagram (as shown in accompanying drawing Fig. 3), show on the whole controller polycarboxylate water-reducer automatic production line position everywhere, user operation host computer industrial computer sends instruction to controller by CAN or serial bus, after instruction resolved by controller, perform instruction, by-pass valve control instrument coordinates intelligent work, and reaching is whole device systems work and status monitoring feedback.
Intelligent controller performs flow process (as shown in accompanying drawing Fig. 4), this is when not having embedded real-time operating system, the main flow that software performs, and initialization is so after equipment (functional module on controller hardware), receive instruction by interrupt mode, and verify.Instructions parse unit starts the content after resolving instruction storing and resolving and understands its data field of intermediate buffer.Unit and the dropping control module of switch and feedback perform in succession, read data finish the work from their data field.And then this process that circulates from instructions parse.
Comprehensive above description, polycarboxylate water-reducer automatic production line intelligent controller has well played good effect in the polycarboxylate water-reducer production environment of complexity, improves the quality of product, ensure that constant product quality.The crucial dropping control being just the accuracy that its intelligence is fed in raw material and using pid algorithm.Can be good at the production requirement completing user.
Claims (3)
1. polycarboxylate water-reducer automatic production line intelligent controller, is characterized in that: this controller comprises hardware components and software section; Specifically hardware components comprises two-way communication, one group of On-off signal, one group of output switch parameter, one group of analog output, and on Current hardware basis, define corresponding driver, Software Development Platform; Controller is specifically made up of main processor core district, On-off signal output module, analog output module, first serial communication module, second serial communication module; In current application, between On-off signal and output switch parameter, establish feedback relationship; Adjustment relation is established between analog output and second serial communication; Data transitive relation is established between first serial and second serial; On-off signal output interface connects input and the feedback of status end of respective switch valve respectively; First serial communication interface is connected with host computer, completes command reception, detects communication function; Second serial communication interface is connected with various sensor, is processed the sensing data received by processor; Analog output port is connected with dropping valve, for controlling opening of valve, controls to drip flow velocity;
The device object that software section will control carries out abstract integration, utilizes structure by C language, the structure in device object abstract program, reaches the related data of sealed in unit object; By C language Function Modules blocking, the operational motion of device object is carried out programming realization, and be finally incorporated into inside engineering structure in an independent equipment sources file, the data realizing equipment become to be integrated with action, specify function and the control mode of equipment, form a functional unit;
After software equipment integrates each functional unit of abstract, carry out the integrally-built design of software, by on hardware, peripheral hardware has oneself data register, arranges a large buffer zone, buffer zone is divided into several area of space in software configuration, distribute to functional unit respectively, make these regions become the data register of functional unit, the data of hold function unit, functional unit can directly read one's own data area by power function.
2. polycarboxylate water-reducer automatic production line intelligent controller according to claim 1; it is characterized in that: the signal of processor input and output is by high speed photo coupling and magnetic coupling quarantine measures; be connected with each functional module; processor is exported or receives the signal of several module; carry out mutually stable communication, play anti-interference protective effect.
3. polycarboxylate water-reducer automatic production line intelligent controller according to claim 1, is characterized in that: adopt pid algorithm to carry out flow control in described software section, according to PI dominated formulate,
control the aperture dripping valve, reach the target of coutroi velocity;
P and I coefficient is all the adjusted value recorded by many experiments; I quality of regulation error, before dropping starts, by obtaining velocity amplitude and the time for adding of user's input inside host computer, controller calculates the quality needing to drip, use the current reactor quality of sensor transmissions to alleviate dropping quality, calculate quality after desirable dropping, after being added dropwise to complete, the qualitative data of read sensor, deducts difference that desirable dropping quality obtains and takes advantage of and carry out quality adjustment in adjustment factor I; P governing speed error, during dropping, record drips front and back system time, use before and after dropping process of poor quality divided by drawing present speed during this period of time, the difference that user inputs speed and present speed is taken advantage of and is carried out speed adjustment in P, finally add that current control valve opening draws last control valve opening, reach and regulate dropping flow velocity object.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201510121140.9A CN104865915A (en) | 2015-03-19 | 2015-03-19 | Polycarboxylate superplasticizer automatic production line intelligent controller |
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| CN201510121140.9A CN104865915A (en) | 2015-03-19 | 2015-03-19 | Polycarboxylate superplasticizer automatic production line intelligent controller |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106094763A (en) * | 2016-08-01 | 2016-11-09 | 北京工业大学 | A kind of restructural polycarboxylate water-reducer automated production controller based on FPGA |
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Application publication date: 20150826 |