CN105988445A - Continuous casting electro hydraulic servo system signal acquisition monitoring system and signal acquisition monitoring method - Google Patents
Continuous casting electro hydraulic servo system signal acquisition monitoring system and signal acquisition monitoring method Download PDFInfo
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- 230000033228 biological regulation Effects 0.000 description 3
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Abstract
The present invention provides a continuous casting electro hydraulic servo system signal acquisition monitoring system and a signal acquisition monitoring method. Each electro hydraulic servo device is connected and provided with a signal acquisition monitoring system which is configured to collect data of the electro hydraulic servo device, and the signal acquisition monitoring system is connected with an industrial Ethernet which is provided with a data acquisition module and a diagnosis monitoring module and transmits the obtained signal data to the data acquisition module and the diagnosis monitoring module through the industrial Ethernet and then transmits the signal data to a following electro hydraulic servo control system. The continuous casting electro hydraulic servo system signal acquisition monitoring system and the signal acquisition monitoring method can collect signal states of a plurality of electro hydraulic servo systems in high speed at the same time, can improve long-term data record storage, trend analysis and automatic alarm diagnosis functions, improve the data acquisition speed and access efficiency, improve the validity and speedability of fault diagnosis of a continuous casting electro hydraulic servo system, reduce the probability of faults failing to report and decrease the down time caused by faults of the device.
Description
Technical field
The present invention relates to the monitoring technology of equipment state signal, particularly relate to a kind of steel-making continuous casting that is applied to and produce the high-speed signal acquisition monitoring system and method for line electrohydraulic servo system.
Background technology
At present, steel-making continuous casting each steel production enterprise produces in line, some response speeds require that control object high, that control process is complicated often uses high speed electrohydraulic servosystem realize regulation and control, such as Hydraulic Oscillation of The Continuous Casting Mould and continuous cast mold Liquid Steel Level Control etc..And control accuracy is generally required the highest by these the most complicated control processes, once electrohydraulic servo system performance or state deteriorate, and are easy for causing precision to exceed standard or out of control, cause continuous casting to produce and interrupt or produce billet quality defect.
And owing to continuous casting process is irreversible process, the fault in-situ having no progeny in production is difficult to reproduce and retain, the data storage of control system itself and analyzing and diagnosing ability are the most weak, therefore, applying wider way under prior art is the monitoring system using one referred to as HMI (Human Machine Interface) on automatic production line, i.e. man machine interface monitoring system, to on-the-spot various equipment states with production process is monitored and record, such as the WINCC system of SIEMENS company exploitation, the Intouch system etc. of Wonderware company exploitation.
But, through the most on-the-spot practical operation and application feedback, the signal sampling period of this HMI monitoring system is very limited, and the sampling period typically can only achieve 250ms, can only meet the monitoring requirement of middle low speed control object.And for the vibration of continuous cast mold high-frequency hydraulic, Mold Steel Level control this kind of object needing regulation at a high speed, the signal sampling period of existing HMI monitoring system is difficult to meet state analysis required resolution requirement, the semaphore loss in detail gathered is serious, causes that DATA REASONING analysis is inaccurate, transient fault rate of failing to report is higher.Additionally, existing monitoring system is not enough to the condition monitoring capabilities of continuous casting high speed electrohydraulic servosystem, some performance state change of continuous casting electrohydraulic servo system cannot be reflected, it is difficult to some early stages, hiding exception and state deterioration are identified and are reported to the police, the analyzing and diagnosing effectiveness comparison making system is poor, once electrohydraulic servo system breaks down, and its troubleshooting is longer for recovery time, and the loss that fault causes is bigger.
Although, the most have developed the signal acquiring system towards high speed performance requirement, pda system such as IBA company of Germany, but this kind of system price is expensive, resource overhead is big, and system compatibility is the strongest, bottom data interface does not opens, it is difficult to be efficiently used for condition monitoring and the fault analysis and diagnosis of continuous casting high speed electrohydraulic servosystem.
The Chinese patent of Application No. CN201220372524.X discloses " the dress joint sealing device data acquisition system of a kind of SIEMENS PLC control system ", shouldUtility modelPropose the data collecting system of the compositions such as a kind of execute-in-place terminal, I/O server, monitoring server.
This patent is high to hardware requirement, and does not describes the method realizing data high-speed acquisition and recording.
The Chinese patent of Application No. CN201120257116.5 discloses " a kind of plc data logging modle ", shouldUtility modelPropose a kind of microcontroller, RS232 drive circuit, expansion bus interface and the data recordin module of power supply composition.
This patent can only carry out man-to-man data acquisition, it is difficult to realizes long-time mass data collection, the analyzing and processing inconvenience of data sharing and data；
The Chinese patent of Application No. 200910103626.4 discloses " method and system of a kind of industrial process data high speed acquisition ", and this invention proposes sets up acquisition system with existing network, data acquisition server and controller.
Although what this patent proposed this system uses step substantially, but for how reaching the high-speed data acquisition of Millisecond, the method how realizing high speed data access, lack and specifically describe.
In sum, signals collecting monitoring method under prior art or be difficult to the object of regulation at a high speed is carried out effective signal monitoring, cause that DATA REASONING analysis is inaccurate, transient fault rate of failing to report is higher, or some performance state change that cannot reflect continuous casting electrohydraulic servo system is caused owing to condition monitoring capabilities is not enough, being difficult to some early stages, hiding exception and state deterioration are identified and are reported to the police, the analyzing and diagnosing effectiveness comparison making system is poor.
Summary of the invention
The high speed signal that continuous casting produces line electrohydraulic servo system in order to solve to exist under prior art is difficult to accurate acquisition, the problem monitored, analyze, diagnose, the invention provides continuous casting electrohydraulic servo system signals collecting monitoring system and signals collecting monitoring method, the monitoring-controlling system signal sampling period length under prior art, fault rate of failing to report height can be efficiently solved, the problem that condition monitoring capabilities is not enough, the present invention's is described in detail below:
Continuous casting electrohydraulic servo system signals collecting monitoring system, continuous casting electrohydraulic servo system and EPA including each electrohydraulic servo device composition, wherein, electrohydraulic servo device is made up of the actuator such as servo valve, oil cylinder and electrohydraulic servo-controlling system, it is characterised in that:
Each described electrohydraulic servo device is connected with a signals collecting monitoring system respectively, and cylinder rod chamber, oil cylinder rodless cavity, valve core of servo valve and the servo valve current/voltage signal of electrohydraulic servo device are monitored, sample, store and data communication by this signals collecting monitoring system；
Described each signals collecting monitoring system is all connected with EPA, and EPA is connected with data acquisition module and diagnostic monitoring module, the signal data obtained is transmitted to data acquisition module and diagnostic monitoring module by signals collecting monitoring system by EPA, is re-fed into follow-up electrohydraulic servo-controlling system.
nullContinuous casting electrohydraulic servo system signals collecting monitoring system according to the present invention，It is characterized in that，Described signals collecting monitoring system includes the detection module that sequential signal connects，Signal high-speed sampling module，Data cache module and Communication processing module，Wherein detection module and servo valve、The operator signals such as oil cylinder connect，By servo valve、Every detection signal of telecommunication of the actuators such as oil cylinder sends into the signal high-speed sampling module of follow-up connection，Signal high-speed sampling module is connected with electrohydraulic servo-controlling system signal，The signal simulation amount that the detection signal of telecommunication sent here by detection module and electrohydraulic servo-controlling system are sent here/digital quantity conversion and high speed fixed cycle are sampled，And be converted into and can send into follow-up data cache module by the data that digital quantity represents，This data cache module by signal high-speed sampling module samples to each data volume concentrate be packaged into packet，Then packet is saved in predetermined spatial cache，Data cache module is connected to EPA by Communication processing module，Data cache module and data acquisition module are carried out data communication.
Continuous casting electrohydraulic servo system signals collecting monitoring system according to the present invention, it is characterized in that, described detection module includes oil cylinder displacement detector, cylinder rod chamber pressure detector, oil cylinder rodless cavity pressure detector, valve core of servo valve displacement detector and servo valve current/voltage signal detector, these detectors are respectively to servo valve, the all parts of the actuators such as oil cylinder detects, it is specially, the travel displacement change of oil cylinder displacement detector detection cylinder piston rod, the oil pressure of cylinder rod chamber pressure detector detection cylinder rod chamber, the oil pressure of oil cylinder rodless cavity pressure detector detection oil cylinder rodless cavity, valve core of servo valve displacement detector is for detecting the change of valve core of servo valve displacement, servo valve current/voltage signal detector then detects the curtage signal that electrohydraulic servo-controlling system is delivered on servo valve.
Continuous casting electrohydraulic servo system signals collecting monitoring system according to the present invention, it is characterized in that, described data acquisition module includes gathering sub module stored and time complexity curve submodule, wherein, gather the data of the spatial cache of the sub module stored each data cache module of communication interface batch capture by EPA, and be saved in gathering the data come in storage medium with document form data, time complexity curve submodule then for being modified data acquisition time, eliminates the data acquisition time error between each data cache module.
Continuous casting electrohydraulic servo system signals collecting monitoring system according to the present invention, it is characterized in that, described diagnostic monitoring module is circulated calculating to the file data of storage in data acquisition module and analyzes, when finding data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system simultaneously.
A kind of continuous casting electrohydraulic servo system signals collecting monitoring method based on above-mentioned continuous casting electrohydraulic servo system signals collecting monitoring system, it comprises the following steps that described:
1) detection module that signals collecting is monitored system is connected in the actuators such as the servo valve of each electrohydraulic servo device existing, oil cylinder, detects the traveled distance change in displacement of cylinder piston rod, the oil pressure change of cylinder rod chamber, oil pressure change, the change of valve core of servo valve displacement and the curtage Setting signal of servo valve of oil cylinder rodless cavity respectively；
2) control signal of signal detected by detection module and electrohydraulic servo-controlling system together sends into signal high-speed sampling module, by signal high-speed sampling module according to the sampling period set, high speed timer interrupt mode is used to carry out the synchronized sampling of signal, i.e., high speed fixed cycle is sampled, and each semaphore is changed by simulation amount/digital quantity, it is converted into the data that can represent with digital quantity；
3) data cache module is in step 2) in the middle each sampling period set, each data volume sampled is concentrated and is packaged into packet, then packet is saved in predetermined data buffer storage space；
4) Communication processing module is connected to EPA data cache module, data cache module and data acquisition module are carried out data communication, and this data communication is to carry out by the way of setting up data acquisition channel between data cache module and the data acquisition module of each signals collecting monitoring system.
5) data of each data cache module spatial cache of data acquisition module batch capture, and gathering the data of coming, through data compression and acquisition time correction, be saved in storage medium with the form of data file；
null6) step 5) in be acquired time complexity curve process and completed by the time complexity curve submodule of data acquisition module gathering the data come，It is specially，Every time when gathering sub module stored and performing batch capture data block task，Time complexity curve submodule calculates once the time difference Δ T between the data sampling time of this data block and data acquisition module present system time automatically，Every certain correction cycle，Go to update the time complexity curve amount of corresponding acquisition channel with current time difference Δ T，And every time when data block write data file，Automatically according to time complexity curve amount, the data block acquisition time of write data file is modified，Wherein，Revised data block gathers the data sampling time-time complexity curve amount of end time=data block，And revised data block gathers time started=revised data block and gathers the data packet group number * data sampling period that end time-data block gathers；
7) diagnostic monitoring module is circulated calculating to the file data of storage in data acquisition module and analyzes, when being diagnosed to be data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system simultaneously.
Continuous casting electrohydraulic servo system signals collecting monitoring method according to the present invention, it is characterized in that, described step 3) in data buffer storage space be made up of the data block that two structures are identical, each data block includes head and two parts of entity, wherein, timed interrupt cycle in data block header, signal sampling period, data packet group number, often group number of words is to preset quantitatively, the current data sample time of data block, current group number and to be filled with mark be quantity of state, and the entity of data block is made up of packet, the group number of packet keeps consistent with often group data number of words with the set amount of data block header.
Continuous casting electrohydraulic servo system signals collecting monitoring method according to the present invention, it is characterised in that described step 3) in the process of data buffer storage of data cache module as follows:
1) pre-set signal sampling period, timed interrupt cycle, the group number of packet and often organize number of words, wherein signal sampling period should be not less than timed interrupt cycle, and is the integral multiple of timed interrupt cycle；
2) within each sampling period, data cache module, each data sampled, loads a packet the most continuously；
3) within each sampling period, packaged packet is alternately stored in two data blocks；
4) after first data block is filled with, second data block of restoring；After second data block is filled with, first data block of restoring, such circulation constantly realizes the caching of data.
nullContinuous casting electrohydraulic servo system signals collecting monitoring method according to the present invention，It is characterized in that，Described step 5) in data acquisition module the batch capture of data and storage are completed by gathering sub module stored，Gather the state that sub module stored monitors two data blocks of each data cache module on acquisition channel continuously，When any one data block sends and is filled with signal，In this data block batch capture to the data file of data acquisition module，And data file is by file header、Each acquisition channel defines、The data label definition of each acquisition channel、Gather respectively organizes data block、The data block index composition of each acquisition channel，Data file is through data compression，Preserve on a storage medium，And gather sub module stored before data block write data file，In large-capacity storage media, continuous print memory space has been allocated in advance for data file；
nullContinuous casting electrohydraulic servo system signals collecting monitoring method according to the present invention，It is characterized in that，Described data file has allocated continuous print memory space in large-capacity storage media in advance，The process of this predistribution memory space is specially，First according to the deposit cycle of individual data file、Sampling period、Gather data volume，Automatically determine data file and take the greatest length of memory space，This greatest length=file header length+all acquisition channel length+all data label length+in the deposit cycle, data block total length+in the deposit cycle, data block indexes total length，Then according to the deposit cycle of individual data file，Automatically create data file on a storage medium，Finally before data write file，The greatest length of memory space is taken according to data file，In advance file read-write pointer is moved to end of file，And automatically perform closedown and the opening operation of a file，Continuous print memory space is allocated on a storage medium in advance for data file.
The continuous casting electrohydraulic servo system signals collecting monitoring system and the signals collecting monitoring method that use the present invention obtain following beneficial effect:
1) the continuous casting electrohydraulic servo system signals collecting monitoring system of the present invention and signals collecting monitoring method simultaneously high speed acquisition can monitor the signal condition of multiple electrohydraulic servo systems, and are provided that the storage of long term data record, trend analysis and automatic alarm diagnostic function；
2) continuous casting electrohydraulic servo system signals collecting monitoring system and the signals collecting monitoring method of the present invention eliminates Systems for routine surveillance for people restriction on data sampling period and monitoring, diagnosing ability and deficiency; substantially increase acquisition speed and access efficiency; thus significantly improve the effectiveness to continuous casting high speed electrohydraulic servosystem fault diagnosis and rapidity; reduce fault and fail to report probability, decrease Stop-Time of Device Failure.
Accompanying drawing explanation
Figure1 is the continuous casting electrohydraulic servo system signals collecting monitoring system structure signal of the present inventionFigure；
Figure2 is the flow process of the continuous casting electrohydraulic servo system signals collecting monitoring method of the present inventionFigure；
Figure3 is the block data structure of the data cache module of the present inventionFigure；
Figure4 is the data buffer storage control flow of the data cache module of the present inventionFigure；
Figure5 is the data file structure of the data acquisition module of the present inventionFigure；
Figure6 is the memory space predistribution control flow of the data file of the present inventionFigure；
Figure7 is the Correction and Control flow process of the data acquisition time of the present inventionFigure。
FigureIn: 1-electrohydraulic servo device, the actuators such as 1a-servo valve, oil cylinder, 1b-electrohydraulic servo-controlling system, 2-EPA, 3-data acquisition module, 4-diagnostic monitoring module, 5-A-signals collecting monitoring system, A1-detection module, A2-signal high-speed sampling module, A3-data cache module, A4-Communication processing module.
Detailed description of the invention
Below in conjunction with attachedFigureWith embodiment, continuous casting electrohydraulic servo system signals collecting monitoring system and the signals collecting monitoring method of invention are further described.
AsFigureShown in 1, continuous casting electrohydraulic servo system signals collecting monitoring system, including continuous casting electrohydraulic servo system and the EPA 2 of each electrohydraulic servo device 1 composition, wherein, electrohydraulic servo device is made up of the actuator 1a such as servo valve, oil cylinder and electrohydraulic servo-controlling system 1b.
Each electrohydraulic servo device 1 is connected with signals collecting monitoring system A respectively, and cylinder rod chamber, oil cylinder rodless cavity, valve core of servo valve and the servo valve current/voltage signal of electrohydraulic servo device 1 are monitored, sample, store and data communication by this signals collecting monitoring system；
Each signals collecting monitoring system A is all connected with EPA 2, and EPA is connected with data acquisition module 3 and diagnostic monitoring module 4, the signal data obtained is transmitted to data acquisition module and diagnostic monitoring module by signals collecting monitoring system by EPA, is re-fed into follow-up electrohydraulic servo-controlling system 5.
nullSignals collecting monitoring system A includes the detection module A1 that sequential signal connects，Signal high-speed sampling modules A 2，Data cache module A3 and Communication processing modules A 4，Wherein detection module and servo valve、The actuator 1a signals such as oil cylinder connect，By servo valve、Every detection signal of telecommunication of the actuators such as oil cylinder sends into the signal high-speed sampling module of follow-up connection，Signal high-speed sampling module is connected with electrohydraulic servo-controlling system 1b signal，The signal simulation amount that the detection signal of telecommunication sent here by detection module and electrohydraulic servo-controlling system are sent here/digital quantity conversion and high speed fixed cycle are sampled，And be converted into and can send into follow-up data cache module by the data that digital quantity represents，This data cache module by signal high-speed sampling module samples to each data volume concentrate be packaged into packet，Then packet is saved in predetermined spatial cache，Data cache module is connected to EPA 2 by Communication processing module，Data cache module and data acquisition module 3 are carried out data communication.
Detection module A1 includes oil cylinder displacement detector, cylinder rod chamber pressure detector, oil cylinder rodless cavity pressure detector, valve core of servo valve displacement detector and servo valve current/voltage signal detector, these detectors are respectively to servo valve, the all parts of the actuator 1a such as oil cylinder detects, it is specially, the travel displacement change of oil cylinder displacement detector detection cylinder piston rod, the oil pressure of cylinder rod chamber pressure detector detection cylinder rod chamber, the oil pressure of oil cylinder rodless cavity pressure detector detection oil cylinder rodless cavity, valve core of servo valve displacement detector is for detecting the change of valve core of servo valve displacement, servo valve current/voltage signal detector then detects the curtage signal that electrohydraulic servo-controlling system 1b delivers on servo valve.
Data acquisition module 3 includes gathering sub module stored and time complexity curve submodule, wherein, gather the data of the spatial cache of the sub module stored each data cache module A3 of communication interface batch capture by EPA 2, and be saved in gathering the data come in storage medium with document form data, time complexity curve submodule then for being modified data acquisition time, eliminates the data acquisition time error between each data cache module.
Diagnostic monitoring module 4 is circulated calculating to the file data of storage in data acquisition module 3 and analyzes, when finding data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system 5 simultaneously.
Based on continuous casting electrohydraulic servo system signals collecting monitoring system continuous casting electrohydraulic servo system signals collecting monitoring method, referenceFigure1 HeFigureShown in 2, it comprises the following steps that described:
1) the detection module A1 that signals collecting is monitored system A is connected on the actuator 1a such as the servo valve of each electrohydraulic servo device 1 existing, oil cylinder, detects the traveled distance change in displacement of cylinder piston rod, the oil pressure change of cylinder rod chamber, oil pressure change, the change of valve core of servo valve displacement and the curtage Setting signal of servo valve of oil cylinder rodless cavity respectively；
2) control signal of signal detected by detection module A1 and electrohydraulic servo-controlling system 1b together sends into signal high-speed sampling modules A 2, by signal high-speed sampling module according to the sampling period set, high speed timer interrupt mode is used to carry out the synchronized sampling of signal, i.e., high speed fixed cycle is sampled, and each semaphore is changed by simulation amount/digital quantity, it is converted into the data that can represent with digital quantity；
3) data cache module A3 is in step 2) in the middle each sampling period set, each data volume sampled is concentrated and is packaged into packet, then packet is saved in predetermined data buffer storage space；
4) 4 data cache module A3 of Communication processing modules A are connected to EPA 2, data cache module and data acquisition module 3 are carried out data communication, this data communication is to carry out by the way of setting up data acquisition channel between data cache module and the data acquisition module of each signals collecting monitoring system A, wherein, the structure of each data acquisition channel see asUnder Table 1:
Table 1The structure of each data acquisition channel
5) data of each data cache module A3 spatial cache of data acquisition module 3 batch capture, and gathering the data of coming, through data compression and acquisition time correction, be saved in storage medium with the form of data file；
6) step 5) in be acquired time complexity curve process and completed by the time complexity curve submodule of data acquisition module 3 gathering the data come, referenceFigureShown in 7, it is specially, every time when gathering sub module stored and performing batch capture data block task, time complexity curve submodule calculates once the time difference Δ T between the data sampling time of this data block and data acquisition module present system time automatically, every certain correction cycle, go to update the time complexity curve amount of corresponding acquisition channel with current time difference Δ T, and every time when data block write data file, automatically according to time complexity curve amount, the data block acquisition time of write data file is modified, wherein, revised data block gathers the data sampling time-time complexity curve amount of end time=data block, and revised data block gathers time started=revised data block and gathers the data packet group number * data sampling period that end time-data block gathers；
7) diagnostic monitoring module 4 is circulated calculating to the file data of storage in data acquisition module 3 and analyzes, when being diagnosed to be data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system 5 simultaneously.
AsFigureShown in 3, above-mentioned step 3) in data buffer storage space be made up of the data block that two structures are identical, each data block includes head and two parts of entity, wherein the structure of data block header see asFollowing table 2:
Table 2The structure of data block header
Timed interrupt cycle in data block header, signal sampling period, data packet group number, often group number of words are to preset quantitatively, the current data sample time of data block, current group number and to be filled with mark be quantity of state, and the entity of data block is made up of packet, the group number of packet keeps consistent with often group data number of words with the set amount of data block header.
AsFigureShown in 4, above-mentioned step 3) in the process of data buffer storage of data cache module A3 as follows:
1) pre-set signal sampling period, timed interrupt cycle, the group number of packet and often organize number of words, wherein signal sampling period should be not less than timed interrupt cycle, and is the integral multiple of timed interrupt cycle；
2) within each sampling period, data cache module, each data sampled, loads a packet the most continuously, and packet structure is such asFollowing table 3:
Table 3The structure of packet
3) within each sampling period, packaged packet is alternately stored in two data blocks；
4) after first data block is filled with, second data block of restoring；After second data block is filled with, first data block of restoring, such circulation constantly realizes the caching of data.
Above-mentioned step 5) in data acquisition module the batch capture of data and storage are completed by gathering sub module stored, gather the state that sub module stored monitors two data blocks of each data cache module on acquisition channel continuously, when any one data block sends and is filled with signal, in this data block batch capture to the data file of data acquisition module, asFigureShown in 5, data file is defined by file header, each acquisition channel, the data label of each acquisition channel defines, gather respectively organize data block, each acquisition channel data block index form, data file is through data compression, preserve on a storage medium, and gather sub module stored data block write data file before, in large-capacity storage media, allocated continuous print memory space in advance for data file；
Above-mentioned data file has allocated continuous print memory space in large-capacity storage media in advance, and the process of this predistribution memory space is specifically, such asFigureShown in 6, first according to the deposit cycle of individual data file, sampling period, gather data volume, automatically determine data file and take the greatest length of memory space, this greatest length=file header length+all acquisition channel length+all data label length+in the deposit cycle, data block total length+in the deposit cycle, data block indexes total length, then according to the deposit cycle of individual data file, automatically create data file on a storage medium, finally before data write file, the greatest length of memory space is taken according to data file, in advance file read-write pointer is moved to end of file, and automatically perform closedown and the opening operation of a file, continuous print memory space is allocated on a storage medium in advance for data file.
Embodiment
The continuous casting electrohydraulic servo system signals collecting of the present invention is monitored system and signals collecting monitoring method is applied on six stream circle billet continuous casting tundish slide plate electrohydraulic servo systems.The tundish slide plate electro-hydraulic servo system of the present embodimentAltogether6 sets, often stream 1 set, often set slide plate electrohydraulic servo system is made up of critical pieces such as control system (S7-300 controller), servo valve, skateboard tanks.
(refer toFigure1), the detection module A1 that signals collecting is monitored system A is connected to the servo valve of each electrohydraulic servo device 1 existing, on the actuator 1a such as oil cylinder, detect the traveled distance change in displacement of cylinder piston rod respectively, the oil pressure change of cylinder rod chamber, the oil pressure change of oil cylinder rodless cavity, the change of valve core of servo valve displacement and the curtage Setting signal of servo valve, in the present embodiment, skateboard tank displacement detector uses built-in magnetostriction type displacement transducer, oil cylinder stroke scope 80mm, output signal of telecommunication 4-20mA, for detecting the traveled distance displacement of skateboard tank.Cylinder rod chamber pressure detector and rodless cavity pressure detector, use the oil pressure sensor of two-wire system 4-20mA, measures scope 0-400Bar, is respectively used to detect oil pressure and the oil pressure of rodless cavity of cylinder rod chamber.Valve core of servo valve displacement detector uses built-in displacement sensor, and output signal 4-20mA, for detecting the change of valve core of servo valve displacement.The Setting signal of the servo valve of the present embodiment is voltage signal, uses voltage signal detector to deliver to the voltage Setting signal on servo valve for detecting and controlling system, and range of signal is ± 10V.
In the present embodiment, signal high-speed sampling modules A 2 includes the processor of high-speed a/d input card and band high speed interrupt, for the detection signal of telecommunication that detection module A1 is sent here, the signal sent here with electrohydraulic servo system 7, simulation amount/digital quantity conversion, sample with high speed fixed cycle, be converted into the data that can represent with digital quantity；
In the present embodiment, data cache module A3 includes processor and internal memory, and each data volume that signal high-speed sampling modules A 2 is sampled by processor is concentrated and is packaged into packet, then packet is saved in spatial cache predetermined on internal memory；
In the present embodiment, Communication processing modules A 4 have employed ethernet communication interface module and Ethernet switch, for the data cache module of each electrohydraulic servo system is connected to EPA, carries out data communication with data acquisition module；
In the present embodiment, data acquisition module 3 includes gathering sub module stored and time complexity curve submodule.Gather sub module stored use Ethernet card as communication interface, and with big capacity hard disk memorizer；By ethernet communication interface, the data of the spatial cache of each data cache module A3 of batch capture, and be saved in the form of a file in large-capacity storage media gathering the data come；Time complexity curve submodule, for being modified data acquisition time, eliminates the data acquisition time error between each data cache module；
In the present embodiment, diagnostic monitoring module 4 is a data analysis monitoring terminal, for the file data of storage in data acquisition module 3 being circulated calculating and analyzing, when finding data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to electrohydraulic servo-controlling system 5 simultaneously.
Continuous casting electrohydraulic servo system signals collecting monitoring method, referenceFigure1 HeFigureShown in 2, for the high speed signal of six stream circle billet continuous casting tundish slide plate electrohydraulic servo systems is acquired monitoring in the present embodiment, comprise the following steps:
Step 1: detection module A1 is connected on existing slide plate electrohydraulic servo system, detect the traveled distance change in displacement (i.e. the actual aperture of skateboard tank) of skateboard tank piston rod respectively, the oil pressure change of cylinder rod chamber, the oil pressure change of oil cylinder rodless cavity, the change (i.e. the actual aperture of servo valve) of valve core of servo valve displacement, the curtage Setting signal (i.e. the setting aperture of servo valve) of servo valve；
Step 2: signal and the control signal of slide plate electrohydraulic servo system itself that detection module A1 detects together send into signal high-speed sampling modules A 2, by signal high-speed sampling module according to the sampling period set, use high speed timer interrupt mode to carry out the synchronized sampling of signal, and each semaphore is converted into the data that can represent with digital quantity；
Using the high speed Interruption in 10ms cycle to carry out signal sampling in the present embodiment, the sampling period keeps Tong Bu, to guarantee that all signal processing details are not omitted with the process cycle of slide plate electrohydraulic servo-controlling system；
In the present embodiment, signal high-speed sampling modules A 2 is in addition to receiving the signal that detection module is sent here, also receive the setting aperture of the skateboard tank sent here from electrohydraulic servo-controlling system, crystallizer sets molten steel liquid level, the actual molten steel liquid level of crystallizer, and casting machine pulling rate signal etc.；
Step 3: each data volume sampled, within each sampling period, is concentrated and is packaged into packet, then packet is saved in predetermined data buffer storage space by data cache module A3；
In the present embodiment, data buffer storage space is made up of the data block that two structures are identical, is DB1 and DB2 respectively, and each data block includes that head and two parts of entity (refer toFigure3), the structure of data block header see asFollowing table 4
Table 4The structure of embodiment data block header
Data block header includes 4 set amounts, is timed interrupt cycle, signal sampling period, data packet group number respectively, often organizes number of words.Data block header also includes 3 quantity of states, is the current data sample time of data block, current group number respectively and is filled with mark；The entity of data block is made up of 200 groups of packets, and the group number of packet is consistent with the set amount of data block header with often group data number of words.
Data cache module carries out the control process of data buffer storage and (refers toFigure4), including:
(1) pre-set signal sampling period, timed interrupt cycle, the group number of packet and often organize number of words；Wherein signal sampling period should be not less than timed interrupt cycle, and is the integral multiple of timed interrupt cycle；
Signal sampling period and timed interrupt cycle in the present embodiment are 10ms, and the data packet group number of each data block is 200 groups, and often group number of words is 10 words；
(2) within each sampling period, data cache module each data sampled, load the most continuously the structure of a packet packet see asFollowing table 5
| Symbol | Data name (label) | Data type |
| Data_1 | The actual aperture of skateboard tank | WORD |
| Data_2 | The oil pressure of skateboard tank rod chamber | WORD |
| Data_3 | The oil pressure of skateboard tank rodless cavity | WORD |
| Data_4 | Valve core of servo valve displacement | WORD |
| Data_5 | The voltage Setting signal of servo valve | WORD |
| Data_6 | The setting aperture of skateboard tank | WORD |
| Data_7 | Crystallizer sets molten steel liquid level | WORD |
| Data_8 | The actual molten steel liquid level of crystallizer | WORD |
| Data_9 | Casting machine Actual Casting Speed | WORD |
| Data_10 | Other control signal | WORD |
Table 5The structure of embodiment packet
(3) within each sampling period, packaged packet is alternately stored in two data blocks DB1 and DB2；
(4) after first data block DB1 is filled with, second data block DB2 of restoring；After second data block DB2 is filled with, first data block DB1 of restoring, such circulation constantly realizes the alternately caching of data；
Step 4: 4 data cache module A3 of Communication processing modules A are connected to EPA 2, carries out data communication by data cache module and data acquisition module 3；
Above-mentioned data communication is to carry out by the way of setting up data acquisition channel between each data cache module and data acquisition module.Data communication in the present embodiment uses TCP/IP communications protocol, vertical 6 acquisition channels of building together, and the data cache module of the most corresponding 6 streams, the structure of each data acquisition channel is such asFollowing table 6；
Table 6The structure of each data acquisition channel of embodiment
Step 6: the data of data acquisition module 3 batch capture each data cache module spatial cache, and gathering the data of coming, through data compression and acquisition time correction, be saved in large-capacity storage media with the form of data file；
Batch capture and the storage of data are completed by data acquisition module by gathering sub module stored；
Gather sub module stored and on acquisition channel, monitor two data blocks DB1 and the state of DB2 of each data cache module continuously, when any one data block sends and is filled with signal, in this data block batch capture to the data file of data acquisition module；
Data file (refers toFigure5), file header, each acquisition channel define, the data label of each acquisition channel defines, gather respectively organize data block, each acquisition channel data block index form, data file, through data compression, is saved on big capacity hard disk memorizer；
Gather sub module stored before data block write data file, on big capacity hard disk memorizer, continuous print memory space has been allocated in advance for data file, to accelerate the data access speed of data acquisition module, it is to avoid the impact on data access speed of the disk file fragment.
Gather the process that sub module stored is data file predistribution memory space, (refer toFigure6), including:
The first deposit cycle according to individual data file, sampling period, collection data volume, automatically determine data file and take the greatest length of memory space, this greatest length=file header length+all acquisition channel length+all data label length+in the deposit cycle, data block total length+in the deposit cycle, data block indexes total length, the deposit cycle that sets of the present embodiment was as 2 hours, therefore, each data file can preserve the data of 2 hours of all acquisition channels.
Then according to the deposit cycle of individual data file, creating data file the most on a storage medium, the deposit cycle that sets of the present embodiment, as 2 hours, therefore, creates a data file in every 2 hours automatically on harddisk memory.
Finally before data write file, the greatest length of memory space is taken according to data file, in advance file read-write pointer is moved to end of file, and automatically performs closedown and the opening operation of a file, allocate continuous print memory space for data file on a storage medium in advance.
The makeover process of data acquisition time is completed by described data acquisition module by time complexity curve submodule, revises step and (refers toFigure7), it is specially, every time when gathering sub module stored and performing batch capture data block task, time complexity curve submodule calculates once the time difference Δ T between the data sampling time of this data block and data acquisition module present system time automatically, every certain correction cycle (such as 24 hours), go to update the time complexity curve amount of corresponding acquisition channel with current time difference Δ T, and every time when data block write data file, automatically according to time complexity curve amount, the data block acquisition time of write data file is modified, wherein, revised data block gathers the data sampling time-time complexity curve amount of end time=data block, and revised data block gathers time started=revised data block and gathers the data packet group number * data sampling period that end time-data block gathers；
Step 7: diagnostic monitoring module 4 is circulated calculating to the file data of storage in data acquisition module 3 and analyzes, when being diagnosed to be data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system 5 simultaneously.
In the present embodiment, when diagnostic monitoring module is by carrying out computational analysis to the signal data of the fluent plate electrohydraulic servo system in data file, find that the actual aperture of stream servo valve starts to become big with the difference set between aperture, exceed alarming value, on monitoring terminal, then show the big warning of valve core of servo valve deviation immediately, and provide the prompting and tutorial message how to process, send the signal of correction of deviation to fluent plate electrohydraulic servo system simultaneously.
The continuous casting electrohydraulic servo system signals collecting monitoring system of the present invention and signals collecting monitoring method simultaneously high speed acquisition can monitor the signal condition of multiple electrohydraulic servo systems, and are provided that the storage of long term data record, trend analysis and automatic alarm diagnostic function.And the continuous casting electrohydraulic servo system signals collecting monitoring system of the present invention and signals collecting monitoring method eliminate Systems for routine surveillance for people restriction on data sampling period and monitoring, diagnosing ability and deficiency; substantially increase acquisition speed and access efficiency; thus significantly improve the effectiveness to continuous casting high speed electrohydraulic servosystem fault diagnosis and rapidity; reduce fault and fail to report probability, decrease Stop-Time of Device Failure.
The continuous casting electrohydraulic servo system signals collecting monitoring system of the present invention and signals collecting monitoring method are applicable to various steel-making continuous casting and produce the signals collecting monitoring field of line electrohydraulic servo system.
Claims (10)
1. continuous casting electrohydraulic servo system signals collecting monitoring system, the continuous casting electrohydraulic servo system formed including each electrohydraulic servo device (1) and EPA (2), wherein, electrohydraulic servo device is made up of the actuator such as servo valve, oil cylinder (1a) and electrohydraulic servo-controlling system (1b), it is characterised in that:
Described each electrohydraulic servo device (1) is connected with signals collecting monitoring system (A) respectively, and cylinder rod chamber, oil cylinder rodless cavity, valve core of servo valve and the servo valve current/voltage signal of electrohydraulic servo device (1) are monitored, sample, store and data communication by this signals collecting monitoring system；
Described each signals collecting monitoring system (A) is all connected with EPA (2), and EPA is connected with data acquisition module (3) and diagnostic monitoring module (4), the signal data obtained is transmitted to data acquisition module and diagnostic monitoring module by signals collecting monitoring system by EPA, is re-fed into follow-up electrohydraulic servo-controlling system (5).
null2. continuous casting electrohydraulic servo system signals collecting monitoring system as claimed in claim 1，It is characterized in that，Described signals collecting monitoring system (A) includes the detection module (A1) that sequential signal connects，Signal high-speed sampling module (A2)，Data cache module (A3) and Communication processing module (A4)，Wherein detection module and servo valve、The actuators such as oil cylinder (1a) signal connects，By servo valve、Every detection signal of telecommunication of the actuators such as oil cylinder sends into the signal high-speed sampling module of follow-up connection，Signal high-speed sampling module is connected with electrohydraulic servo-controlling system (1b) signal，The signal simulation amount that the detection signal of telecommunication sent here by detection module and electrohydraulic servo-controlling system are sent here/digital quantity conversion and high speed fixed cycle are sampled，And be converted into and can send into follow-up data cache module by the data that digital quantity represents，This data cache module by signal high-speed sampling module samples to each data volume concentrate be packaged into packet，Then packet is saved in predetermined spatial cache，Data cache module is connected to EPA (2) by Communication processing module，Data cache module and data acquisition module (3) are carried out data communication.
null3. continuous casting electrohydraulic servo system signals collecting monitoring system as claimed in claim 2，It is characterized in that，Described detection module (A1) includes oil cylinder displacement detector、Cylinder rod chamber pressure detector、Oil cylinder rodless cavity pressure detector、Valve core of servo valve displacement detector and servo valve current/voltage signal detector，These detectors are respectively to servo valve、The all parts of the actuators such as oil cylinder (1a) detects，It is specially，The travel displacement change of oil cylinder displacement detector detection cylinder piston rod，The oil pressure of cylinder rod chamber pressure detector detection cylinder rod chamber，The oil pressure of oil cylinder rodless cavity pressure detector detection oil cylinder rodless cavity，Valve core of servo valve displacement detector is for detecting the change of valve core of servo valve displacement，Servo valve current/voltage signal detector then detects the curtage signal that electrohydraulic servo-controlling system (1b) is delivered on servo valve.
4. continuous casting electrohydraulic servo system signals collecting monitoring system as claimed in claim 1, it is characterized in that, described data acquisition module (3) includes gathering sub module stored and time complexity curve submodule, wherein, gather the data of the spatial cache of the sub module stored each data cache module of the communication interface batch capture (A3) by EPA (2), and be saved in gathering the data come in storage medium with document form data, time complexity curve submodule is then for being modified data acquisition time, eliminate the data acquisition time error between each data cache module.
5. continuous casting electrohydraulic servo system signals collecting monitoring system as claimed in claim 1, it is characterized in that, described diagnostic monitoring module (4) is circulated calculating to the file data of storage in data acquisition module (3) and analyzes, when finding data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system (5) simultaneously.
6. a continuous casting electrohydraulic servo system signals collecting monitoring method for continuous casting electrohydraulic servo system signals collecting based on the claims 1 to claim 4 monitoring system, it comprises the following steps that described:
1) detection module (A1) that signals collecting is monitored system (A) is connected in the actuators (1a) such as the servo valve of existing each electrohydraulic servo device (1), oil cylinder, detects the traveled distance change in displacement of cylinder piston rod, the oil pressure change of cylinder rod chamber, oil pressure change, the change of valve core of servo valve displacement and the curtage Setting signal of servo valve of oil cylinder rodless cavity respectively；
2) control signal of signal detected by detection module (A1) and electrohydraulic servo-controlling system (1b) together sends into signal high-speed sampling module (A2), by signal high-speed sampling module according to the sampling period set, high speed timer interrupt mode is used to carry out the synchronized sampling of signal, i.e., high speed fixed cycle is sampled, and each semaphore is changed by simulation amount/digital quantity, it is converted into the data that can represent with digital quantity；
3) data cache module (A3) is in step 2) in the middle each sampling period set, each data volume sampled is concentrated and is packaged into packet, then packet is saved in predetermined data buffer storage space；
4) Communication processing module (A4) is connected to EPA (2) data cache module (A3), data cache module and data acquisition module (3) are carried out data communication, and this data communication is to carry out by the way of setting up data acquisition channel between data cache module and the data acquisition module of each signals collecting monitoring system (A).
5) data of data acquisition module (3) batch capture each data cache module (A3) spatial cache, and gathering the data of coming, through data compression and acquisition time correction, be saved in storage medium with the form of data file；
null6) step 5) in be acquired time complexity curve process and completed by the time complexity curve submodule of data acquisition module (3) gathering the data come，It is specially，Every time when gathering sub module stored and performing batch capture data block task，Time complexity curve submodule calculates once the time difference Δ T between the data sampling time of this data block and data acquisition module present system time automatically，Every certain correction cycle，Go to update the time complexity curve amount of corresponding acquisition channel with current time difference Δ T，And every time when data block write data file，Automatically according to time complexity curve amount, the data block acquisition time of write data file is modified，Wherein，Revised data block gathers the data sampling time-time complexity curve amount of end time=data block，And revised data block gathers time started=revised data block and gathers the data packet group number * data sampling period that end time-data block gathers；
7) diagnostic monitoring module (4) is circulated calculating to the file data of storage in data acquisition module (3) and analyzes, when being diagnosed to be data exception, display alarm and diagnostic message on monitoring terminal, prompting and guides Operation and Maintenance personnel to carry out abnormal disposal in time, sends interlocking and correction signal to follow-up electrohydraulic servo-controlling system (5) simultaneously.
7. continuous casting electrohydraulic servo system signals collecting monitoring method as claimed in claim 6, it is characterized in that, described step 3) in data buffer storage space be made up of the data block that two structures are identical, each data block includes head and two parts of entity, wherein, timed interrupt cycle in data block header, signal sampling period, data packet group number, often group number of words is to preset quantitatively, the current data sample time of data block, current group number and to be filled with mark be quantity of state, and the entity of data block is made up of packet, the group number of packet keeps consistent with often group data number of words with the set amount of data block header.
8. continuous casting electrohydraulic servo system signals collecting monitoring method as claimed in claim 6, it is characterised in that described step 3) in the process of data buffer storage of data cache module (A3) as follows:
1) pre-set signal sampling period, timed interrupt cycle, the group number of packet and often organize number of words, wherein signal sampling period should be not less than timed interrupt cycle, and is the integral multiple of timed interrupt cycle；
2) within each sampling period, data cache module, each data sampled, loads a packet the most continuously；
3) within each sampling period, packaged packet is alternately stored in two data blocks；
4) after first data block is filled with, second data block of restoring；After second data block is filled with, first data block of restoring, such circulation constantly realizes the caching of data.
null9. continuous casting electrohydraulic servo system signals collecting monitoring method as claimed in claim 6，It is characterized in that，Described step 5) in data acquisition module the batch capture of data and storage are completed by gathering sub module stored，Gather the state that sub module stored monitors two data blocks of each data cache module on acquisition channel continuously，When any one data block sends and is filled with signal，In this data block batch capture to the data file of data acquisition module，And data file is by file header、Each acquisition channel defines、The data label definition of each acquisition channel、Gather respectively organizes data block、The data block index composition of each acquisition channel，Data file is through data compression，Preserve on a storage medium，And gather sub module stored before data block write data file，In large-capacity storage media, continuous print memory space has been allocated in advance for data file.
null10. continuous casting electrohydraulic servo system signals collecting monitoring method as claimed in claim 9，It is characterized in that，Described data file has allocated continuous print memory space in large-capacity storage media in advance，The process of this predistribution memory space is specially，First according to the deposit cycle of individual data file、Sampling period、Gather data volume，Automatically determine data file and take the greatest length of memory space，This greatest length=file header length+all acquisition channel length+all data label length+in the deposit cycle, data block total length+in the deposit cycle, data block indexes total length，Then according to the deposit cycle of individual data file，Automatically create data file on a storage medium，Finally before data write file，The greatest length of memory space is taken according to data file，In advance file read-write pointer is moved to end of file，And automatically perform closedown and the opening operation of a file，Continuous print memory space is allocated on a storage medium in advance for data file.
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