CN107678393B - Intelligent spraying control system and method based on soft PLC - Google Patents

Abstract

The invention relates to an intelligent spraying control system and method based on soft PLC, wherein the system comprises a soft PLC development module, a soft PLC operation module, an FPGA data processing module, an IO interface module and a sensor module; the soft PLC operation module is respectively connected with the soft PLC development module, the sensor module and the FPGA data processing module, and is used for receiving and interpreting an instruction list sent by the soft PLC development module, reading or writing data of a register in the sensor module and sending the data to the FPGA data processing module; the FPGA data processing module is connected with external equipment through an IO interface module, and outputs a control instruction to the external equipment after processing data to control the switching value of the external equipment. The invention has the advantages of relatively low price, strong openness, high compatibility, capability of meeting different process requirements, good expansibility, high running speed, high working efficiency and the like.

Description

Intelligent spraying control system and method based on soft PLC

Technical Field

The invention relates to the technical field of industrial control, in particular to an intelligent spraying control system and method based on a soft PLC.

Background

With the continuous development of the industry, the PLC has been widely used in the field of automatic control due to its programmable and universal, modular, reusable programming language.

At present, most of spraying robots adopt a robot controller, a traditional PLC (programmable logic controller) to control the robot and surrounding automation equipment to work cooperatively. However, the traditional PLC is expensive, the PLCs of different manufacturers are incompatible, the customizability is poor, the operating speed is low, the working efficiency is low, and the healthy development of the intelligent spraying industry is not facilitated.

How to reduce the cost of spraying equipment, improve PLC's compatibility, improve functioning speed and work efficiency has become the problem that the spraying trade needs a urgent need to solve.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provide the intelligent spraying control system based on the soft PLC, which has the advantages of relatively low price, strong openness, high compatibility, capability of meeting different process requirements, good expansibility, high running speed and high working efficiency.

In order to achieve the purpose, the technical scheme provided by the invention is as follows: an intelligent spraying control system based on soft PLC comprises a soft PLC development module, a soft PLC operation module, an FPGA data processing module, an IO interface module and a sensor module; the soft PLC operation module is respectively connected with the soft PLC development module, the sensor module and the FPGA data processing module, and is used for receiving and interpreting an instruction list sent by the soft PLC development module, reading or writing data of a register in the sensor module and sending the data to the FPGA data processing module; the FPGA data processing module is connected with external equipment through an IO interface module, and outputs a control instruction to the external equipment after processing data to control the switching value of the external equipment.

Further, the system also comprises an IO expansion module, and the IO expansion module is connected with the FPGA data processing module.

Further, the sensor module comprises a resin pressure sensor, a curing agent pressure sensor and an air pressure sensor, and the three are respectively connected with the soft PLC operation module.

Further, the soft PLC development module comprises a PLC ladder diagram searching and editing unit, a ladder diagram checking unit, a conversion unit, a communication unit and a monitoring template database; the PLC ladder diagram searching and editing unit, the ladder diagram checking unit, the conversion unit and the communication unit are sequentially connected; the monitoring template database is connected with the PLC ladder diagram searching and editing unit; the soft PLC development module is connected with the soft PLC operation module through the communication unit;

the monitoring template database is used for storing monitoring standard modules commonly used in the spraying industry;

the PLC ladder diagram searching and editing unit searches relevant PLC ladder diagram templates from the monitoring template database and compiles a PLC ladder diagram;

the ladder diagram checking unit is used for carrying out semantic and logic checking on the obtained ladder diagram;

the conversion unit converts the compiled ladder diagram into an instruction list through diagram search and a binary tree algorithm;

and the communication unit sends the instruction list to the soft PLC operation module.

In order to achieve the above object, the present invention further provides an intelligent spraying control method based on soft PLC, comprising the steps of:

s1, inputting the name of the equipment to be controlled and the sensor generating the input signal in the PLC ladder diagram searching and editing unit by the user, and searching the relevant PLC ladder diagram template from the monitoring template database;

s2, the PLC ladder diagram searching and editing unit sorts the searched relevant PLC ladder diagram templates from high to low according to the similarity and the use heat;

s3, the user selects the PLC ladder diagram template, and edits and modifies the PLC ladder diagram template according to the actual application requirement if necessary, and directly calls the PLC ladder diagram template if not necessary;

s4, the ladder diagram checking unit carries out semantic and logic checking on the obtained ladder diagram;

s5, the conversion unit converts the compiled ladder diagram into an instruction list through diagram search and a binary tree algorithm;

s6, the soft PLC operation module receives and interprets the instruction list sent by the soft PLC development module through the communication unit, reads or writes data of a register in the sensor module, and sends the data to the FPGA data processing module;

and S7, the FPGA data processing module processes the data and outputs a control instruction to external equipment to control the switching value of the external equipment, so that intelligent spraying is realized.

Further, the step S5 of converting the written ladder diagram into the instruction list by the graph search and binary tree algorithm includes the specific steps of:

s51, scanning from left to right, if a first primitive is scanned and the primitive is normally open, creating an LD node, then creating a left node, and recording the attribute of the primitive; if the primitive is normally closed, an LDI node is created, a left node is created in the same way, and the attribute of the primitive is recorded; if the scanned primitive is not the first primitive AND the primitive is normally open, an AND node is created, then a left node is created, AND the attribute of the primitive is recorded; if the scanned primitive is not the first primitive and the primitive is normally closed, an ANI node is created, a left node is created in the same way, and the attribute of the primitive is recorded;

s52, continuing to scan to the right, if the primitive is scanned, creating a right node, and recording the attribute of the primitive; if the underlines are scanned, judging the left underline and the right underline; if the underline is left, turning to the upper line, and scanning from left to right; if the underline is the right underline, recording the coordinate A (i, j) of the underline and switching to the next line for scanning; if the underline is not scanned, continuing to scan to the right;

s53, after the next row is switched to, judging whether a node exists and whether the pnode [ i +1] [ j ] type is larger than 0; if the node and the pnode [ i +1] [ j ] type are larger than 0, turning to the previous row, and scanning from right to left; if underlines are scanned in the scanning process, turning to the next line and scanning from left to right; if the underline is not scanned, go to the previous line and continue to scan from right to left.

Further, in step S6, the soft PLC operating module adopts a stack method to interpret the instruction list, which includes the following steps: scanning IO state, executing a PLC (programmable logic controller) interpretation program, outputting refreshing, judging whether to stop scanning and stop working;

when the PLC interpreter interprets a branch block, the next two results are reserved; the value of the branch point at the beginning of the branch block is kept in the Stack, and the value of the branch block is kept in the variable result;

after the PLC interpreter interprets a branch block, if the PLC interpreter finds an ANB instruction immediately, the branch block is indicated to be connected with other normally-open and normally-closed contacts or a branch block in series, at the moment, the uppermost value of the Stack is popped up, the value and result are subjected to logical AND operation, and the result is stored in result;

when an OUT instruction is found, carrying OUT logical addition operation on the uppermost values of the result and the Stack, storing the result in the result, and clearing the Stack;

when the END command is found, the ON/OFF state of the image register for outputting Y is output as the actual output, and then a new scanning cycle is started.

Compared with the prior art, the principle and the advantages of the scheme are as follows:

1. software is adopted to replace hardware PLC, the openness is strong, and a special spraying control system can be customized according to different process requirements.

2. The system is simplified, unnecessary functions are removed, and the cost is greatly reduced.

3. The system has the advantages of having an IO expansion module, having better expandability and increasing functions according to requirements.

4. Scanning from left to right when the ladder diagram is converted into an instruction list, creating an LD node when a first primitive is scanned, creating a left node again, and recording the attribute of the primitive; continuing to scan to the right, if the graphic element is scanned, creating a right node, and recording the attribute of the graphic element; if the underlines are scanned, judging the left underline and the right underline; if the underline is left, turning to the upper line, and scanning from left to right; if the right underline, go to the next line scan. The method can avoid the condition of scanning when underlines are encountered, reduce the scanning times and improve the efficiency of the scanning algorithm.

5. The stack method is adopted to deal with complex instruction list interpretation, so that the memory can be quickly released, and the operation efficiency is improved.

Drawings

FIG. 1 is a schematic structural diagram of an intelligent spraying control system based on a soft PLC according to the present invention;

FIG. 2 is a schematic structural diagram of a soft PLC development module in the intelligent spraying control system based on soft PLC according to the present invention;

FIG. 3 is a flow chart of an intelligent spray control method based on soft PLC according to the present invention;

fig. 4 is a flowchart of converting a ladder diagram into an instruction list in the intelligent spraying control method based on the soft PLC of the present invention.

Detailed Description

The invention will be further illustrated with reference to specific examples:

referring to fig. 1-2, the intelligent spraying control system based on soft PLC according to this embodiment includes a soft PLC development module 1, a soft PLC operation module 2, an FPGA data processing module 3, an IO interface module 4, a sensor module 5, and an IO extension module 6; the soft PLC operation module 2 is respectively connected with the soft PLC development module 1, the sensor module 5 and the FPGA data processing module 3, and is used for receiving and interpreting an instruction list sent by the soft PLC development module 1, reading or writing data of a register in the sensor module 5 and sending the data to the FPGA data processing module 3; the FPGA data processing module 3 is connected with an external device 7 through an IO interface module 4; the external equipment 7 comprises a fiber spraying valve, a resin circulating valve, a curing agent circulating valve and switches for scram, operation, pause and the like.

And the IO expansion module 6 is connected with the FPGA data processing module 3 and is used for accessing more switches which are actually needed.

The soft PLC development module 1 comprises a PLC ladder diagram searching and editing unit 1-1, a ladder diagram checking unit 1-2, a conversion unit 1-3, a communication unit 1-4 and a monitoring template database 1-5; the PLC ladder diagram searching and editing unit 1-1, the ladder diagram checking unit 1-2, the conversion unit 1-3 and the communication unit 1-4 are sequentially connected; the monitoring template database 1-5 is connected with the PLC ladder diagram searching and editing unit 1-1; the soft PLC development module 1 is connected with the soft PLC operation module 2 through the communication units 1-4.

Corresponding to spraying external equipment, the sensor module 5 comprises a resin pressure sensor 5-1, a curing agent pressure sensor 5-2 and an air pressure sensor 5-3 which are respectively connected with the soft PLC operation module 2.

The intelligent spraying control principle is as follows:

s1, according to actual needs, when a user inputs the name of the equipment to be controlled and a sensor (such as a resin pressure sensor 5-1) generating an input signal in the PLC ladder diagram searching and editing unit 1-1, searching a relevant PLC ladder diagram template from the monitoring template database 1-5;

s2, the PLC ladder diagram searching and editing unit 1-1 sorts the searched relevant PLC ladder diagram templates from high to low according to the similarity and the use heat;

s3, the user selects the PLC ladder diagram template, and edits and modifies the PLC ladder diagram template according to the actual application requirement if necessary, and directly calls the PLC ladder diagram template if not necessary;

s4, the ladder diagram checking unit 1-2 carries out semantic and logic checking on the obtained ladder diagram;

s5, the conversion unit 1-3 converts the written ladder diagram into an instruction list through diagram search and binary tree algorithm, and the specific steps are as follows:

s51, scanning from left to right, if a first primitive is scanned and the primitive is normally open, creating an LD node, then creating a left node, and recording the attribute of the primitive; if the primitive is normally closed, an LDI node is created, a left node is created in the same way, and the attribute of the primitive is recorded; if the scanned primitive is not the first primitive AND the primitive is normally open, an AND node is created, then a left node is created, AND the attribute of the primitive is recorded; if the scanned primitive is not the first primitive and the primitive is normally closed, an ANI node is created, a left node is created in the same way, and the attribute of the primitive is recorded;

s52, continuing to scan to the right, if the primitive is scanned, creating a right node, and recording the attribute of the primitive; if the underlines are scanned, judging the left underline and the right underline; if the underline is left, turning to the upper line, and scanning from left to right; if the underline is the right underline, recording the coordinate A (i, j) of the underline and switching to the next line for scanning; if the underline is not scanned, continuing to scan to the right;

s53, after the next row is switched to, judging whether a node exists and whether the pnode [ i +1] [ j ] type is larger than 0; if the node and the pnode [ i +1] [ j ] type are larger than 0, turning to the previous row, and scanning from right to left; if underlines are scanned in the scanning process, turning to the next line and scanning from left to right; if the underline is not scanned, go to the previous line and continue to scan from right to left.

S6, the soft PLC operation module 2 receives and interprets the instruction list sent by the soft PLC development module 1 through the communication units 1-4, reads or writes data of a register in the sensor module 5, and sends the data to the FPGA data processing module 3; the soft PLC operation module 2 adopts a stack method to explain an instruction list, and comprises the following steps: scanning IO state, executing a PLC (programmable logic controller) interpretation program, outputting refreshing, judging whether to stop scanning and stop working;

when the PLC interpreter interprets a branch block, the next two results are reserved; the value of the branch point at the beginning of the branch block is kept in the Stack, and the value of the branch block is kept in the variable result; after the PLC interpreter interprets a branch block, if the PLC interpreter finds an ANB instruction immediately, the branch block is indicated to be connected with other normally-open and normally-closed contacts or a branch block in series, at the moment, the uppermost value of the Stack is popped up, the value and result are subjected to logical AND operation, and the result is stored in result; when an OUT instruction is found, carrying OUT logical addition operation on the uppermost values of the result and the Stack, storing the result in the result, and clearing the Stack; when the END command is found, the ON/OFF state of the image register for outputting Y is output as the actual output, and then a new scanning cycle is started.

And S7, the FPGA data processing module 3 outputs a control instruction to external equipment (a resin circulating valve) after processing the data, controls the switching value of the external equipment and realizes intelligent spraying.

The above-mentioned embodiments are merely preferred embodiments of the present invention, and the scope of the present invention is not limited thereto, so that variations based on the shape and principle of the present invention should be covered within the scope of the present invention.

Claims (1)

1. The utility model provides an intelligence spraying control system based on soft PLC which characterized in that: the system comprises a soft PLC development module (1), a soft PLC operation module (2), an FPGA data processing module (3), an IO interface module (4) and a sensor module (5);

the soft PLC operation module (2) is respectively connected with the soft PLC development module (1), the sensor module (5) and the FPGA data processing module (3) and is used for receiving and interpreting an instruction list sent by the soft PLC development module (1), reading or writing data of a register in the sensor module (5) and sending the data to the FPGA data processing module (3); the FPGA data processing module (3) is connected with external equipment through an IO interface module (4), and outputs a control instruction to the external equipment after processing data to control the switching value of the external equipment;

the FPGA data processing system also comprises an IO expansion module (6), wherein the IO expansion module (6) is connected with the FPGA data processing module (3);

the sensor module (5) comprises a resin pressure sensor (5-1), a curing agent pressure sensor (5-2) and an air pressure sensor (5-3), and the three are respectively connected with the soft PLC operation module (2);

the soft PLC development module (1) comprises a PLC ladder diagram searching and editing unit (1-1), a ladder diagram checking unit (1-2), a conversion unit (1-3), a communication unit (1-4) and a monitoring template database (1-5); the PLC ladder diagram searching and editing unit (1-1), the ladder diagram checking unit (1-2), the conversion unit (1-3) and the communication unit (1-4) are sequentially connected; the monitoring template database (1-5) is connected with the PLC ladder diagram searching and editing unit (1-1); the soft PLC development module (1) is connected with the soft PLC operation module (2) through the communication units (1-4);

the monitoring template database (1-5) is used for storing monitoring standard modules commonly used in the spraying industry;

the PLC ladder diagram searching and editing unit (1-1) searches relevant PLC ladder diagram templates from the monitoring template database (1-5) and compiles a PLC ladder diagram;

the ladder diagram checking unit (1-2) is used for carrying out semantic and logic checking on the obtained ladder diagram;

the conversion unit (1-3) converts the written ladder diagram into an instruction list through diagram search and a binary tree algorithm;

the communication unit (1-4) sends the instruction list to the soft PLC operation module (2);

the method comprises the following steps:

s1, when a user inputs the name of the equipment to be controlled and the sensor generating an input signal in the PLC ladder diagram searching and editing unit (1-1), searching a relevant PLC ladder diagram template from the monitoring template database (1-5);

s2, the PLC ladder diagram searching and editing unit (1-1) sorts the searched relevant PLC ladder diagram templates from high to low according to the similarity and the use heat;

s3, the user selects the PLC ladder diagram template, and edits and modifies the PLC ladder diagram template according to the actual application requirement if necessary, and directly calls the PLC ladder diagram template if not necessary;

s4, the ladder diagram checking unit (1-2) carries out semantic and logic check on the obtained ladder diagram;

s5, the conversion unit (1-3) converts the compiled ladder diagram into an instruction list through diagram search and binary tree algorithm;

s6, the soft PLC operation module (2) receives and interprets the instruction list sent by the soft PLC development module (1) through the communication unit (1-4), reads or writes data of a register in the sensor module (5), and sends the data to the FPGA data processing module (3);

s7, the FPGA data processing module (3) processes the data and outputs a control instruction to external equipment to control the switching value of the external equipment, so that intelligent spraying is realized;

the step S5 converting unit (1-3) converts the written ladder diagram into the instruction list by the diagram search and binary tree algorithm, which includes the following specific steps:

s51, scanning from left to right, if a first primitive is scanned and the primitive is normally open, creating an LD node, then creating a left node, and recording the attribute of the primitive; if the primitive is normally closed, an LDI node is created, a left node is created in the same way, and the attribute of the primitive is recorded; if the scanned primitive is not the first primitive AND the primitive is normally open, an AND node is created, then a left node is created, AND the attribute of the primitive is recorded; if the scanned primitive is not the first primitive and the primitive is normally closed, an ANI node is created, a left node is created in the same way, and the attribute of the primitive is recorded;

s52, continuing to scan to the right, if the primitive is scanned, creating a right node, and recording the attribute of the primitive; if the underlines are scanned, judging the left underline and the right underline; if the underline is left, turning to the upper line, and scanning from left to right; if the underline is the right underline, recording the coordinate A (i, j) of the underline and switching to the next line for scanning; if the underline is not scanned, continuing to scan to the right;

s53, after the next row is switched to, judging whether a node exists and whether the pnode [ i +1] [ j ] type is larger than 0; if the node and the pnode [ i +1] [ j ] type are larger than 0, turning to the previous row, and scanning from right to left; if underlines are scanned in the scanning process, turning to the next line and scanning from left to right; if the underline cannot be scanned, turning to the previous line to continue scanning from right to left;

in the step S6, the soft PLC operating module (2) interprets the instruction list by using a stack method, and includes the following steps: scanning IO state, executing a PLC (programmable logic controller) interpretation program, outputting refreshing, judging whether to stop scanning and stop working;

when the PLC interpreter interprets a branch block, the next two results are reserved; the value of the branch point at the beginning of the branch block is kept in the Stack, and the value of the branch block is kept in the variable result;

after the PLC interpreter interprets a branch block, if the PLC interpreter finds an ANB instruction immediately, the branch block is indicated to be connected with other normally-open and normally-closed contacts or a branch block in series, at the moment, the uppermost value of the Stack is popped up, the value and result are subjected to logical AND operation, and the result is stored in result;

when an OUT instruction is found, carrying OUT logical addition operation on the result and the uppermost value of the Stack, storing the result in the result, and clearing the Stack;

when the END command is found, the ON/OFF state of the image register for outputting Y is output as the actual output, and then a new scanning cycle is started.

Images