CN107229248B - A wireless remote monitoring system and method for a powder metallurgy forming process machine - Google Patents

Abstract

The invention discloses a wireless remote monitoring system and method for a powder metallurgy forming process machine. The system includes an upper PC monitoring machine located at a remote monitoring point, a transfer station PLC, a transfer station PLC located in a powder metallurgy production workshop, and real-time data monitoring. Module and PLC, by using PLC as the control module, the information collected by the 485BD module on the PLC is first transmitted to the PLC of the transfer station through the RS485 protocol, and the PLC of the transfer station is then transmitted to the PLC of the transfer station of the remote monitoring point using the 433M communication module. The station PLC then interacts with the configuration kingview of the upper PC monitoring machine. Through the cooperation of wired and wireless, this system can monitor powder metallurgy molding production parameters in real time, database storage, real-time alarm, remote control start and stop of mobile phone terminals, and read Excel data reports, so as to realize real-time guidance of on-site production and reduce the number of on-site workers. Labor intensity.

Description

A wireless remote monitoring system and method for a powder metallurgy forming process machine

technical field

The invention relates to the technical field of powder metallurgy forming remote detection and industrial communication, in particular to a wireless remote monitoring system and method for powder metallurgy forming process machines.

Background technique

The traditional powder metallurgy production site is limited to the current business operation mode or the traditional mode. The collection of production information mainly relies on manual records, manual forms, email communication, etc. The statistical methods are backward, the information collection is lagging, the information processing is not timely, and the batch arrangement is not Reasonable, the inventory turnover efficiency is low, and the equipment usage efficiency is not high; at the same time, the visibility of the powder metallurgy manufacturing process is poor, the current production status cannot be reflected in time, and the responsible personnel cannot deal with it immediately. The information of various system departments cannot be effectively integrated, the interaction between various systems is still at a relatively preliminary level, and the communication efficiency is relatively low, which causes a waste of resource costs and time costs. Therefore, it is of great significance to design a remote monitoring system for powder metallurgy forming process.

The monitoring system software developed by Kingview is a new type of industrial automatic control system, which replaces the traditional closed system with an integrated system composed of standard industrial computer software and hardware platforms. Kingview6.55 is a set of products developed by Yakong Technology according to the current development trend of automation technology, facing the low-end automation market and applications, and aiming at realizing enterprise integration. The product aims to build a strategic industrial application service platform, integrates the support of the industrial real-time database (KingHistorian) independently developed by Yakong Technology, and can provide enterprises with an effective platform for data collection, analysis and management of the entire production process , so that enterprises can obtain information in a timely and effective manner, and respond in a timely manner to obtain optimal results, making remote monitoring of great significance in applications.

Contents of the invention

Aiming at the backwardness of current powder metallurgy molding production monitoring methods and the respective limitations of wired and wireless modes, the present invention proposes a wireless remote monitoring system and method for powder metallurgy molding process machines. The wired and wireless interconnected monitoring system provides A programmable logic controller PLC (Mitsubishi PLC FX-2N) is used as a control module, and at the same time as a data transmission and reception transfer station, a 433M communication module and a 485BD module (FX2N-485-BD) are used as a wireless and wired data transmission module. Kingview is used as the monitoring system of the upper PC monitoring machine. The system does not need a fixed IP, is farther than wired transmission distance, and is not controlled by terrain. It can realize real-time alarm, real-time monitoring, production data storage and input, remote control of mobile terminal, remote PLC programming, and real-time guidance during the production process of molding machines. Powder metallurgy molding production can avoid risks, greatly reduce the powder metallurgy scrap rate, reduce powder metallurgy production costs, increase production profits, reduce the labor intensity of front-line workers, and facilitate the management of supervisors, which has great practical value.

According to the disclosed embodiments, the first aspect of the present invention discloses a wireless remote monitoring system for powder metallurgy forming process machines, the system includes an upper PC monitoring machine located at the remote monitoring point, a transfer station PLC, and a computer located in the powder metallurgy production workshop Transfer station PLC, n data real-time monitoring modules, n PLCs, n 485BD modules, n is an integer greater than 1; among them, the transfer station PLC of the remote monitoring point and the transfer station PLC of the powder metallurgy production workshop are connected through respective 433M communication module for wireless data communication;

In the powder metallurgy production workshop, each data real-time monitoring module is connected to a PLC respectively, and each PLC is wired to the transfer station PLC of the powder metallurgy production workshop through a 485BD module, wherein, the data real-time monitoring module consists of several Composed of machine sensors, responsible for the collection and transmission of the production parameters of the machine in the powder metallurgy forming process; the PLC controls the operation of the machine in the powder metallurgy forming process, and at the same time receives the production parameters of the machine in the powder metallurgy forming process;

The upper PC monitoring machine is connected with the transfer station PLC of the remote monitoring point, and the upper PC monitoring machine performs configuration monitoring through KingView, and transfers each process machine collected by the transfer station PLC of the remote monitoring point. The on-site data of different stations on the platform are displayed and recorded in the configuration screen, and at the same time, it is interconnected with the Excel data report to generate an Excel report in real time, read the identity of the on-site personnel, production batch number, and shift time in Excel, and display it on the configuration screen show.

Further, the transfer station PLC of the remote monitoring point and the transfer station PLC of the powder metallurgy production workshop use GPRS network technology to perform wireless data communication through their respective connected 433M communication modules.

Further, the 485BD module uses the RS485 protocol to realize short-distance wired data transmission between PLCs.

Further, the PLC, the transfer station PLC of the remote monitoring point, and the transfer station PLC of the powder metallurgy production workshop are all Mitsubishi FX-2N, which are used for centralized data collection.

Further, the host PC monitoring machine and the transfer station PLC of the remote monitoring point are interconnected in a master-slave question-and-answer manner.

According to the disclosed embodiment, the second aspect of the present invention discloses a method for wireless remote monitoring of a powder metallurgy forming process machine, the method includes the following steps:

The data real-time monitoring module collects raw data through the machine sensors installed in different positions of the powder metallurgy forming process machine;

The PLC collects raw data through the data real-time monitoring module and transforms it into the required production data value;

The PLC uses the 485BD communication module to open the RS485 protocol, and collects the production data values of each powder metallurgy forming process machine into a transfer station PLC located in the powder metallurgy production workshop through the form of N:N network;

The transfer station PLC of the powder metallurgy production workshop and the transfer station PLC of the remote monitoring point realize wireless remote transmission through the 433M communication module, and the transfer station PLC of the remote monitoring point receives information to realize a large-scale wireless data concentration;

The upper PC monitoring machine of the remote monitoring point is connected with the centralized data transfer PLC through the programming port. The configuration king and the PLC realize real-time reading or rewriting of the data in the PLC through the one-to-one correspondence of variables. Through the 433M communication module, the variable is used to One-to-one correspondence to realize the function of remote control of powder metallurgy forming process machines;

The upper PC monitoring machine of the remote monitoring point is configured through KingView software, and the on-site data of different stations on each process machine collected by the transfer station PLC of the remote monitoring point is called to display and record in the configuration screen. At the same time, it is interconnected with Excel data reports, generates Excel reports in real time, reads the identities of on-site personnel, production batch numbers, shift hours, etc., and displays them on the configuration screen.

Further, the method also includes the following steps:

Use the mobile terminal to remotely control the variables in the PLC through the 433M communication module to realize the function of remotely controlling the powder metallurgy forming process machine.

Further, the production data value includes molding pressure, rotational speed, product weight, quantity of qualified and unqualified products, and machine utilization rate.

Compared with the prior art, the present invention has the following advantages and effects:

1) Through the configuration monitoring of the upper computer, the on-site production status can be grasped in an all-round way, including production personnel information, production batch information, production quantity information, pass rate, machine utilization rate, etc.

2) Using wireless and wired cooperation can realize wireless remote monitoring and make the overall network more stable than the overall wireless, saving monitoring costs.

3) Remote control using mobile terminals can enable production personnel to solve on-site failures in a timely manner and reduce labor intensity.

4) With PLC as the field control module and data storage module, it can adapt to various environments and is stable and reliable.

5) Use the Kingview professional industrial control software to collect and read the transfer station PLC, realize the link with Excel data, facilitate external data input, and facilitate the realization of docking with order data.

Description of drawings

Fig. 1 is a structural schematic diagram of a wireless remote monitoring system of a powder metallurgy forming process machine disclosed by the present invention;

Fig. 2 is a flow chart of a wireless remote monitoring method for powder metallurgy forming process machines disclosed by the present invention.

Detailed ways

In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments It is a part of embodiments of the present invention, but not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.

Embodiment one

As shown in Figure 1, this embodiment discloses a wireless remote monitoring system for powder metallurgy forming process machines. Station PLC, n data real-time monitoring modules, n PLCs, n 485BD modules, n is an integer greater than 1; among them, the transfer station PLC of the remote monitoring point and the transfer station PLC of the powder metallurgy production workshop are connected through respective The 433M communication module performs wireless data communication; the wireless data communication adopts GPRS network technology, where the GPRS network technology is only an exemplary enumeration of technologies in wireless data communication, and the GPRS wireless data communication technology does not constitute a limitation to the technical solution of the present invention.

In the powder metallurgy production workshop, each data real-time monitoring module is respectively connected with a PLC, and the data real-time monitoring module is mainly composed of machine sensors, responsible for the collection and transmission of the production parameters of the powder metallurgy forming process machine; the PLC Control the operation of the powder metallurgy forming machine and receive the production parameters of the powder metallurgy forming process machine at the same time; n PLCs are wired to connect with the transfer station PLC of the powder metallurgy production workshop through n 485BD modules.

The upper PC monitoring machine is connected with the transfer station PLC of the remote monitoring point, and the upper PC monitoring machine is configured through KingView software, and transfers each process machine collected by the transfer station PLC of the remote monitoring point. The on-site data of different stations on the platform are displayed and recorded in the configuration screen, and at the same time, it is interconnected with the Excel data report to generate an Excel report in real time, and the on-site personnel identity, production batch number, shift time, etc. are read in Excel and displayed on the configuration screen. on display.

The monitoring personnel can program the PLC control program through the upper PC monitoring machine, and finally the powder metallurgy production workshop and the 433M communication module of the remote monitoring point realize wireless remote transmission. In addition, the remote control of the equipment can also be realized through the mobile terminal.

The wireless remote monitoring system of a powder metallurgy forming process machine disclosed in this embodiment includes a 433M communication module and a 485BD module, wherein the 433M communication module is connected with the transfer station PLC of the remote monitoring point and the transfer station PLC of the powder metallurgy production workshop respectively Connected, using GPRS network technology for data communication between powder metallurgy production workshops and remote monitoring points. The 485BD module is used for short-distance wired data transmission between PLCs. The system centralizes the data transmission in the remote monitoring point through the combination of wired and wireless, and performs wireless remote monitoring with the upper PC monitoring machine configuration king.

The PLC, the transfer station PLC of the remote monitoring point, and the transfer station PLC of the powder metallurgy production workshop are all Mitsubishi FX-2N, which are used for centralized data collection. The upper PC monitoring machine and the transfer station PLC of the remote monitoring point are interconnected in a master-slave question and answer mode.

In summary, the wireless remote monitoring system disclosed in this embodiment adopts PLC as the control module, and the 485BD module transmits the information collected by the PLC to the PLC terminal of the transfer station through the RS485 protocol, and the PLC of the transfer station uses the 433M communication module to transmit to In the transfer station PLC of the remote monitoring point, the transfer station PLC performs information interaction with the configuration king in the upper PC monitoring machine. Through the cooperation of wired and wireless, this system greatly reduces the cost, and at the same time, it can give full play to the advantages of wired and solve the problems caused by the environment. It can monitor the production parameters of powder metallurgy forming remotely in real time, database storage, real-time alarm, mobile terminal Remote control start and stop, Excel data report reading. Real-time guidance of on-site production, avoiding risks, bringing high profits to powder metallurgy production, while reducing the labor intensity of on-site workers, has great practical value.

Embodiment two

As shown in Figure 2, this embodiment discloses a wireless remote monitoring method for a powder metallurgy forming process machine, and the specific steps include the following:

Step S1, the data real-time monitoring module collects raw data through the machine sensors installed at different positions of the machine in the powder metallurgy forming process;

Step S2, the PLC collects raw data through the data real-time monitoring module and converts them into required production data values, including molding pressure, rotational speed, product weight, qualified and unqualified product quantity, and machine utilization rate;

Step S3, the PLC uses the 485BD communication module to open the RS485 protocol, and collects the production data values of each powder metallurgy forming process machine into a transfer station PLC located in the powder metallurgy production workshop through the form of N:N network;

Step S4, the transfer station PLC of the powder metallurgy production workshop and the transfer station PLC of the remote monitoring point realize wireless remote transmission through the 433M wireless communication module, and receive information at the transfer station PLC of the remote monitoring point, thereby realizing large-scale range of wireless data sets;

Step S5, the upper PC monitoring machine of the remote monitoring point is connected with the centralized data transfer PLC through the programming port, and the configuration king and the PLC realize real-time reading or rewriting of the data in the PLC through the one-to-one correspondence of variables, and through the 433M communication module , using the method of one-to-one correspondence of variables to realize the function of remote control of powder metallurgy forming process machines;

Step S6, the upper PC monitoring machine of the remote monitoring point is configured through KingView software, and the on-site data of different stations on each process machine collected by the transfer station PLC of the remote monitoring point is called in the configuration screen Display records, and interconnect with Excel data reports at the same time, generate Excel reports in real time, read the identity of on-site personnel, production batch numbers, shift hours, etc. in Excel, and display them on the configuration screen;

Step S7, the mobile terminal remotely controls the variables in the PLC through the 433M communication module, realizing the function of remotely controlling the powder metallurgy forming process machine.

The wireless remote monitoring method for the above-mentioned powder metallurgy forming process machine is based on the technical solution for realizing wireless remote monitoring of the wireless remote monitoring system for the powder metallurgical forming process machine disclosed in Embodiment 1. In the powder metallurgy production workshop, the data real-time monitoring module mainly Composed of machine sensors, it is responsible for the collection and transmission of the production parameters of the machine in the powder metallurgy forming process; the PLC controls the operation of the powder metallurgy forming machine, and at the same time the above data is collected to the PLC, and the PLCs of different stations in each process are centralized through the 485BD module Transfer station PLC, and then the parameters are sent to the 433M communication module to realize GPRS network technology for wireless remote transmission. In the remote monitoring point, another 433M communication module receives the wireless remote signal from the powder metallurgy production workshop, configures it through the Kingview software in the upper PC monitoring machine, retrieves the data collected in the PLC of the transfer station, and sends The on-site data in the production process of the powder metallurgy forming process machine is displayed and recorded in the configuration screen, and at the same time, it is interconnected with the Excel data report to generate an Excel report in real time, and Excel reads the identity of the on-site personnel, production batch number, shift time, etc., and Displayed on the configuration screen. The monitoring personnel can program the PLC control program through the upper PC monitoring machine, and finally the powder metallurgy production workshop and the 433M communication module of the remote monitoring point realize wireless remote transmission. In addition, the remote control of the equipment can also be realized through the mobile terminal. The present invention monitors the configuration of the upper PC monitoring unit, and can grasp the on-site production status in an all-round way, including production personnel information, production batch information, production quantity information, pass rate, machine utilization rate, etc., and can use wireless and wired cooperation The realization of wireless remote monitoring can also save monitoring costs, and the use of mobile terminals for remote control can enable production personnel to solve on-site failures in a timely manner and reduce labor intensity.

The above-mentioned embodiment is a preferred embodiment of the present invention, but the embodiment of the present invention is not limited by the above-mentioned embodiment, and any other changes, modifications, substitutions, combinations, Simplifications should be equivalent replacement methods, and all are included in the protection scope of the present invention.

Claims (6)

1. A wireless remote monitoring system for a powder metallurgy molding process machine, characterized in that the system includes an upper PC monitoring machine positioned at a remote monitoring point, a transfer station PLC and a transfer station PLC located in a powder metallurgy production workshop, n data Real-time monitoring module, n PLCs, n 485BD modules, n is an integer greater than 1; among them, the transfer station PLC of the remote monitoring point and the transfer station PLC of the powder metallurgy production workshop communicate wirelessly through the respective connected 433M communication modules communication; In the powder metallurgy production workshop, each data real-time monitoring module is connected to a PLC respectively, and each PLC is wired to the transfer station PLC of the powder metallurgy production workshop through a 485BD module, wherein, the data real-time monitoring module consists of several Composed of machine sensors, responsible for the collection and transmission of the production parameters of the machine in the powder metallurgy forming process; the PLC controls the operation of the machine in the powder metallurgy forming process, and at the same time receives the production parameters of the machine in the powder metallurgy forming process; The upper PC monitoring machine is connected with the transfer station PLC of the remote monitoring point, and the upper PC monitoring machine performs configuration monitoring through KingView, and transfers each process machine collected by the transfer station PLC of the remote monitoring point. The on-site data of different stations on the platform are displayed and recorded in the configuration screen, and at the same time, it is interconnected with the Excel data report to generate an Excel report in real time, read the identity of the on-site personnel, production batch number and shift time in Excel, and display it on the configuration screen show; Wherein, the transfer station PLC of the remote monitoring point and the transfer station PLC of the powder metallurgy production workshop use GPRS network technology to perform wireless data communication through the 433M communication modules connected respectively; Wherein, the 485BD module adopts the RS485 protocol to realize short-distance wired data transmission and communication between PLCs. 2. The wireless remote monitoring system of a powder metallurgy forming process machine according to claim 1, characterized in that, The PLC, the transfer station PLC of the remote monitoring point, and the transfer station PLC of the powder metallurgy production workshop are all Mitsubishi FX-2N, which are used for centralized data collection. 3. A wireless remote monitoring system for powder metallurgy forming process machines according to claim 1, characterized in that the upper PC monitoring machine and the transfer station PLC of the remote monitoring point are interconnected in a master-slave question-and-answer manner. 4. A wireless remote monitoring method of the wireless remote monitoring system of the powder metallurgy forming process machine according to any one of claims 1 to 3, characterized in that the method comprises the following steps: The data real-time monitoring module collects raw data through the machine sensors installed in different positions of the powder metallurgy forming process machine; The PLC collects raw data through the data real-time monitoring module and transforms it into the required production data value; The PLC uses the 485BD communication module to open the RS485 protocol, and collects the production data values of each powder metallurgy forming process machine into a transfer station PLC located in the powder metallurgy production workshop through the form of N:N network; The transfer station PLC of the powder metallurgy production workshop and the transfer station PLC of the remote monitoring point realize wireless remote transmission through the 433M communication module, and the transfer station PLC of the remote monitoring point receives information to realize a large-scale wireless data concentration; The upper PC monitoring machine of the remote monitoring point is connected with the centralized data transfer PLC through the programming port. The configuration king and the PLC realize real-time reading or rewriting of the data in the PLC through the one-to-one correspondence of variables. Through the 433M communication module, the variable is used to One-to-one correspondence to realize the function of remote control of powder metallurgy forming process machines; The upper PC monitoring machine of the remote monitoring point is configured through KingView software, and the on-site data of different stations on each process machine collected by the transfer station PLC of the remote monitoring point is called to display and record in the configuration screen. At the same time, it is interconnected with Excel data reports, generates Excel reports in real time, reads the identities of on-site personnel, production batch numbers and shift hours in Excel, and displays them on the configuration screen. 5. The wireless remote monitoring method of a powder metallurgy forming process machine according to claim 4, characterized in that the method further comprises the following steps: Use the mobile terminal to remotely control the variables in the PLC through the 433M communication module to realize the function of remotely controlling the powder metallurgy forming process machine. 6. The wireless remote monitoring method of a powder metallurgy forming process machine according to claim 4, wherein the production data value includes forming pressure, rotating speed, product weight, qualified and unqualified product quantity and machine Utilization rate.

Images