CN110844161B - Control system of cigarette packet packaging unit - Google Patents

Abstract

The invention discloses a control system of a tobacco bale packing unit, which comprises a control component based on IPC, a field monitoring platform, a field control platform and a data acquisition networking device; the control assembly comprises a master station control module arranged in the master electric control cabinet, a first I/O slave station module communicated with the master station control module, a second I/O slave station module and an analog input module which are respectively communicated with the master station control module in the sub electric control cabinet; the on-site monitoring and on-site control platform with the visual man-machine interaction interface and the data acquisition networking device are respectively communicated with the master station control module; and the data acquisition networking device is used for transmitting the packaging unit data to an external data server and/or a wireless terminal. The invention abandons the traditional key technology held by foreign equipment suppliers, and integrates a set of new generation electric control scheme which can realize low-cost maintenance and flexible upgrading and expansion for the domestic tobacco enterprises on the basis of retaining the mechanical structure, station function and the like of the foreign equipment.

Description

Control system of cigarette packet packaging unit

Technical Field

The invention relates to the technical field of cigarette making, in particular to a control system of a cigarette packet packaging machine set.

Background

In the current domestic cigarette making field, the commonly adopted cigarette pack packing machine set is a cigarette packing device introduced from abroad in the beginning of the 90 th century, and the packing speed of the device is 400 packs/min, and the machine set performance is mature, so that the machine set is widely applied to cigarette enterprises.

Taking a GDX2 type packaging machine set as an example, the whole production line of the machine set comprises a hard box packaging machine, a CH box outer transparent paper packaging machine, a CT hard strip packaging machine, a CV strip outer transparent paper packaging machine, a machine set electric control system and the like. The adopted electric control system is a special control system 'MICRO II' of foreign equipment suppliers, and the 'MICRO II' type control system is a traditional local area network industrial control mode taking a PLC as a core, and the set of electric control system at least comprises three aspects of defects from the aspect of current development of a cigarette enterprise:

Firstly, because the core components of the packaging machine are special accessories produced by foreign equipment suppliers, domestic tobacco enterprises have higher purchase cost and longer purchase period for the electric spare parts of the packaging machine set, and the comprehensive cost for maintaining the set of electric control system is high.

Secondly, the development platform of the traditional electric control system is a system platform specially made by foreign equipment suppliers for products, and a special programming language is adopted, so that the difficulty of mastering the system by domestic tobacco enterprise technicians is greatly increased.

Thirdly, especially, the core control mode of the system is poor in openness, and along with the progress of the times and the development of electronic information technology, the old and closed properties of the original electric control system bring about little hindrance to the requirements of personalized upgrading, informatization reconstruction and the like which are required by domestic tobacco enterprises with rapid development.

Disclosure of Invention

The invention aims to provide a brand-new cigarette packet packaging unit control system with advantages of independent research, design, expansion and the like by combining the mechanical structure, layout and basic functions of each station of the original packaging unit, so that domestic cigarette enterprises solve the problems of blocked technical excavation, compatibility, innovation, expansion and the like brought by traditional foreign equipment, and the constraint and technical monopoly of foreign equipment suppliers on the innovation of the cigarette making industry in China are eliminated and terminated.

The technical scheme adopted by the invention is as follows:

A pack wrapper unit control system comprising:

IPC (also known as industrial personal computer, industrial computer or industrial computer in the field habit) based control component, on-site monitoring platform, on-site management and control platform and data acquisition networking device. That is, in order to ensure that the newly designed system operates stably and has enough system resources to ensure the detection and control precision of the system, the control system of the cigarette packet packaging unit adopted by the invention adopts the following independent four-layer frame design thought: the IPC control layer, the intelligent monitoring layer, the upper management and control layer and the data acquisition edge calculation layer.

The control assembly comprises a master station control module arranged in a master electric control cabinet, a first I/O slave station module communicated with the master station control module, a second I/O slave station module and an analog input module in a sub electric control cabinet communicated with the master station control module respectively through a switch; the plurality of sub electric control cabinets are arranged at the machine body of each corresponding station on the packaging machine set in a scattered manner. In other words, on the basis of the framework, the specific conception is a mode of distributed acquisition and centralized management, and communication is established between each distributed I/O slave station and the embedded PC controller master station, so that high speed, stability and reliability of data transmission are ensured. Specifically, one network can be realized through an Ethernet bus, protocol processing can directly reach each I/O layer without any lower sub-bus and gateway delay, a single bus system can cover all equipment stations, the task of high-speed control of equipment can be completed in the most simplified topological structure in actual operation, and the stability and the high efficiency of the whole system are ensured.

The field monitoring platform, the field management and control platform and the data acquisition networking device are respectively communicated with the master station control module; the data acquisition networking device is used for transmitting the unit data to an external data server and/or a wireless terminal; the field monitoring platform and the field control platform are provided with visual human-computer interaction interfaces. Through the design, complicated and redundant measuring instruments are not needed, and each monitoring signal state, gating phase and detection curve can be effectively monitored and controlled in real time through a visual human-computer interaction interface, so that the field application of operators is greatly facilitated. Specifically, different expression forms can be adopted to embody different detection and rejection conditions, real-time data can be associated with 3D visual simulation, and a fault expert diagnosis library can be configured on the management and control platform to assist operators in quickly searching and solving the electrical faults of the system.

In one possible implementation, the method comprises:

The control assembly is communicated with the interior through an EtherCAT protocol. As described above, when a specific implementation manner of communication between the master and slave is constructed, the EtherCAT bus can be used to realize communication connection in the control layer, and the Ethernet bus has good expansibility, can accommodate 65532 stations at most, and can completely cover and meet the requirements of sites and applications.

And the master station control module is communicated with the on-site monitoring platform, the on-site control platform and the data acquisition networking device through an ADS protocol. In order to make the data acquisition and transmission and man-machine interaction efficient and stable, the communication between the IPC control layer and the man-machine interaction platform (i.e. the monitoring layer and the upper layer) can adopt an ADS communication protocol based on TCP/IP, and the communication protocol can complete one communication in a very short time (10 ms), so that the high efficiency and the real-time performance of data information monitoring can be ensured. The data acquisition networking device communicates with an external data server through a TCP/IP protocol, that is, the data acquisition networking device can exchange with sites outside the system by utilizing a stable and reliable mature network protocol during implementation, and the design has the advantage of being convenient for providing good and various external expansibility for the system.

In one possible implementation, the method comprises:

the master station control module is respectively communicated with the field monitoring platform, the field management and control platform and the data acquisition networking device through an ADS protocol through a switch. By combining the layout and the equipment structure of an actual tobacco enterprise workshop, the switch ensures the efficiency and the stability of network bus transmission.

In one possible implementation, the method comprises:

The encoder of the main machine station of the tobacco bale packing unit, the encoder of the auxiliary machine CH station of the tobacco bale packing unit and the encoder shared by the auxiliary machine CT station and the CV station of the tobacco bale packing unit are respectively and directly communicated with the main station control module through an EtherCAT bus. In other words, the system can realize the control requirement of the traditional foreign system by means of the structure framework of master-slave network communication and the standardized industrial control product in a software programming mode, greatly saves special hardware adopted in the foreign existing control system, and can send the collected motion signals of key components to a master station control module directly through an Ethernet for processing and feeding back action instructions, for example, through each I/O slave station, the design concept can enable most of the signals to be processed through a prefabricated program algorithm, so that faults caused by hardware processing are reduced, and the operation speed is further improved.

In one possible implementation, the method comprises:

The data acquisition networking device is specifically used for acquiring the operation parameters and the bottom data of the master station control module in real time according to a preset strategy and transmitting the operation parameters and the bottom data to an external data server and/or a wireless terminal in one way. In order to ensure external expansibility and reduce invasion and influence of external equipment on the system, the data acquisition networking device can receive and transmit related data outwards from the inside of the system, but the data acquisition networking device does not send data to the bottom layer of the IPC control layer, so that the data acquisition networking device is used as a unidirectional data isolation device, and the safety of the bottom layer data of the system is ensured.

In one possible implementation, the method comprises:

the data acquisition networking device is also provided with a plurality of communication interfaces which are in butt joint with external auxiliary equipment, wherein the auxiliary equipment comprises one or more of the following: MES system, comprehensive test bench and logistics system. As mentioned above, the outward expansion performance is also considered in the design framework of the system, so that in combination with the actual requirement of the tobacco package packaging operation, the data can be docked to the auxiliary device related to the tobacco package packaging by means of the data acquisition networking device.

In one possible implementation, the method comprises:

The control assembly further comprises a safety controller which is arranged in the main electric control cabinet and is electrically connected with the main station control module, and the safety controller is provided with multiple paths of I/O channels. Aiming at the safety control requirement of the control system of the cigarette packet packaging unit, the implementation can adopt a safety controller such as TwinSAFE to realize the safety operation control related to equipment, so that the system integrates the automatic control, the servo control (each station execution end) and the safety control, the reliability and the compatibility of the system are integrally improved, and the error of the packaging unit in continuous production can be less than one thousandth.

In one possible implementation, the method comprises:

The control component compatibility includes an ST structural text programming language based on the IEC61131-3 standard. As mentioned above, the foreign equipment suppliers write programs by adopting special software language, which greatly hinders deep grasp and technical iteration of the native technicians, so the invention proposes that the native technicians can write corresponding control processes for their own actual demands quickly and efficiently by adopting a simple and modularized standard structure.

In one possible implementation, the method comprises:

the control component is configured with a TwainCAT software system. Based on the implementation manner, the invention further provides a mature and easy-to-use software system reference at present, and the TwainCAT system is provided with a multi-core multi-thread processing technology, can process twenty thousands of data points per second, has better high compatibility and supplements the design of the invention.

In one possible implementation, the method comprises:

The data acquisition networking device comprises a Ceres machine bank. As the data acquisition networking device of the edge calculation layer, the existing intelligent hardware-Ceres machine can be adopted to realize the actual operation, the functions of data acquisition, data analysis, data classification, data access, data transmission, data interface management and interaction and the like can be realized in an integrated mode, and meanwhile, the machine integrates advanced communication technologies such as Internet+ and mobile interaction and the like, so that the integration and data interaction with a tobacco enterprise management system can be effectively enhanced.

Drawings

For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described with reference to the accompanying drawings, in which:

FIG. 1 is an electrical block diagram of an embodiment of a pack wrapper unit control system provided by the present invention;

Fig. 2 is an electrical schematic diagram of a preferred embodiment of a control system for a pack wrapping unit according to the present invention.

Detailed Description

Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the invention.

Aiming at the problem that the electronic control technology of the existing tobacco bale packing unit is monopolized by foreign equipment suppliers to cause the realization of digital and intelligent transformation upgrading in the tobacco manufacturing industry in China, the invention needs to further point out that the invention aims at protecting independent devices, equipment, instruments and technologies, and provides a solution idea for organically integrating the current advanced technology in the industrial control field with the traditional tobacco bale packing equipment in consideration of the technical iteration and the like of the current tobacco enterprise, thereby discarding the key electronic control technology held by foreign equipment suppliers, and integrating and forming a complete technical scheme capable of realizing low-cost maintenance and flexible upgrading expansion for the tobacco enterprise in China on the basis of keeping the traditional advantages of the foreign equipment mechanical structure, station function and the like. In other words, the present invention contributes to the field: on the premise of fully utilizing the structure of the existing unit equipment, a heuristic instruction is provided for the skilled person to get rid of foreign technical blockade and realize autonomous research and development innovation.

Returning to the implementation mode of the application, the application is based on the advanced design of an automatic control technology, adopts an industrial PC (personal computer) as a data processing platform, adopts an IPC technology to replace the traditional PLC technology introduced in the background as a control core, adopts an efficient industrial Ethernet to realize the communication control mode of each secondary station and a master station, and realizes the technical consistency and advancement of an electric control system of cigarette packaging equipment. Specifically, the IPC intelligent control system based on the PC control technology and the high-speed bus technology EtherCAT can meet the requirements of high-speed process control and real-time data acquisition and intelligent diagnosis of a packaging machine, can meet the control requirements of the traditional PLC, has excellent data processing capacity, high-speed communication capacity and high compatibility, meets the technical development expectations of the current smoke machine machinery in China, and can also meet the actual requirements of the tobacco enterprises in China for function and service expansion in the aspect of informatization upgrading and transformation in the future.

Based on the foregoing, the present invention provides an embodiment of a control system for a tobacco packet packing unit, as shown in fig. 1, the system may include:

IPC (also known as industrial personal computer, industrial computer or industrial computer in the field habit) based control component, on-site monitoring platform, on-site management and control platform and data acquisition networking device. The control assembly comprises a master station control module (such as an embedded PC (personal computer) controller and a CPU (central processing unit) module) arranged in a master electric control cabinet, a first I/O (input/output) slave station module communicated with the master station control module, a second I/O slave station module and an analog input module, wherein the second I/O slave station module and the analog input module are respectively communicated with the master station control module in a sub electric control cabinet through a switch (the switch in the master electric control cabinet in FIG. 1 is only schematic and does not limit the setting position of the switch); the master station control module, the I/O slave station module and the analog input module are correspondingly provided with accessories such as a power supply configuration module in practice, but the power supply configuration module is not an important point of the invention and is not excessively limited; the sub-electric control cabinet is combined with the layout of the stations of the main machine and the auxiliary machine of the packaging machine set, and can be, but not limited to, a plurality of independent small electric cabinets which are distributed and arranged at the machine body of the corresponding stations of the packaging machine set, and only one sub-electric control cabinet is shown by a dotted line frame in fig. 1. As can be seen from the foregoing, in this embodiment, the control mode of the packaging unit is designed into a distributed I/O topology structure, and a single bus system, such as EtherCAT protocol communication, is established between each distributed I/O slave station (including an analog input module having only an input function) and the master station control module, so as to achieve a network-to-network, without any underlying sub-bus and without gateway delay, and cover each station of the host and the auxiliary machine.

The specific structural design thought of the distributed I/O can refer to the GDX2 model, namely 2X101, 2X401, 2X501, 2X751, 2X595, 3X101, 3X151, 3X451, 3X501, 3X901, 3X931, 3X721, 3X595, 3X599 and other connectors and bridge cables in an electric control cabinet matched with original foreign equipment can be canceled, and related detection signals, output control signals, safety protection and the like can be realized by redesigning corresponding electric boxes and mounting brackets.

Continuing the previous, the on-site monitoring platform, the on-site control platform and the data acquisition networking device are respectively communicated with the master station control module; the data acquisition networking device is used for transmitting the unit data to an external data server and/or a wireless terminal (the external electric connection relationship is indicated by a dotted line in fig. 1), wherein the unit data can be data from a master station control module, 7 can also be data from a field monitoring platform and a field management platform, and certainly can also be both the data and the data; the field monitoring platform and the field control platform are provided with visual human-computer interaction interfaces. Through the design, complicated and redundant measuring instruments are not needed, and each monitoring signal state, gating phase and detection curve can be effectively monitored and controlled in real time through a visual human-computer interaction interface, so that the field application of operators is greatly facilitated. Specifically, different expression forms can be adopted to embody different detection and rejection conditions, real-time data can be associated with 3D visual simulation, and a fault expert diagnosis library can be configured on the management and control platform to assist operators in quickly searching and solving the electrical faults of the system. For example, operators and maintenance personnel can easily realize visual online monitoring on detection and rejection conditions through a '3D shift chain monitoring' interface of a visual OPC man-machine interface, so that intervention measures can be timely taken, and equipment maintenance can be conveniently guided. Meanwhile, in order to be more convenient for equipment maintainers to monitor fault reasons, the monitoring platform can also have functions of historical data simulation tracing and data simulation speed regulation and control, so that the maintainers can more accurately and rapidly find fault points.

In summary, in order to ensure that the newly designed control system of the cigarette packet packaging machine set operates stably and has enough system resources to ensure the detection and control precision of the system, the above embodiment adopts an independent four-layer frame design idea: the IPC control layer, the intelligent monitoring layer, the upper management and control layer and the data acquisition edge calculation layer. Based on the framework, the specific conception is a mode of distributed acquisition and centralized management, so that high-speed, stable and reliable system data transmission can be ensured.

With respect to the specific communication modes of the foregoing components, and with reference to fig. 2, the present invention provides the following implementation references:

(1) The control assembly is internally communicated through an EtherCAT protocol, namely, the communication of each distributed I/O of the automatic bottom layer and the servo-driven communication are realized by adopting the EtherCAT industrial Ethernet bus technology, one EtherCAT network is realized to the bottom, protocol processing directly reaches the I/O layer, any lower sub-bus is not needed, no gateway delay exists, and the single bus system can cover all devices, so that the complex and high-speed control task of the devices is completed by the simplest network structure.

With regard to EtherCAT bus technology, etherCAT (ethernet control automation technology) is an open architecture, ethernet-based fieldbus system, the name CAT of which is an acronym for control automation technology (Control Automation Technology). EtherCAT has reached a new level in network performance. The refresh period of 1000 distributed I/O data is only 30 mus, including the terminal cycle time. Up to 1486 bytes of process data may be exchanged over an ethernet frame, almost equivalent to 12000 digital I/O. And this data volume is transferred only for 300 mus. Communication with 100 servo axes requires only 100 mus. During this time, settings and control data may be provided to all axes and their actual positions and states reported. The distributed clock technique ensures that the synchronization time offset between these axes is less than 1 microsecond.

By utilizing the excellent performance of the EtherCAT technology, a control method which cannot be realized by the traditional field bus system can be realized. In this way, the ultra-high speed control loop can be formed by the bus. The functions that traditional electronic control systems require local dedicated hardware support can now be mapped in software, and the vast bandwidth resources enable the parallel transmission of state data with any data. EtherCAT technology enables communication technology to be matched with modern high-performance IPC, a bus system is no longer a bottleneck of a control concept, and data transmission of distributed I/O exceeds performance which can only be achieved by a local I/O interface.

Such network performance advantages are evident in small controllers with relatively moderate computing power. The high-speed cycle of EtherCAT can be completed between two control cycles. Thus, the controller always has the latest input data available, with minimal delay in output addressing. The response behavior of the controller is significantly improved without enhancing the computational power itself.

(2) And the master station control module is communicated with the on-site monitoring platform, the on-site management and control platform and the data acquisition networking device through an ADS protocol to realize data acquisition, uploading, writing, issuing and monitoring. In order to make data acquisition and transmission and man-machine interaction efficient and stable, the communication between the IPC control layer and the man-machine interaction platform (namely the monitoring layer and the upper layer) can adopt an ADS communication protocol based on TCP/IP; the ADS communication protocol (automation device specification) of Beckhoff, which is developed for data exchange between different software modules, such as communication between NC and PLC, acts as a transport layer of the system. The protocol provides a way to communicate with any variable of the control software program using other means, for example, requiring communication with another PC or device, ADS protocol is used on top of TCP/IP, which means that all data is available from the desired location in the communication network, and the communication protocol can complete one communication in a very short time (< 10 ms), thus sufficient to ensure the efficiency and real-time of data information monitoring. In addition, in one possible implementation manner, in combination with the actual layout and the equipment structure of the tobacco enterprise workshop, the master station control module can respectively communicate with the on-site monitoring platform, the on-site management and control platform and the data acquisition networking device through an ADS protocol through a switch, so that the efficiency and the stability of network bus transmission are ensured.

(3) The data acquisition networking device communicates with an external data server through a TCP/IP protocol, namely, the data acquisition networking device can exchange with sites outside the system by utilizing a stable and reliable mature network protocol when in implementation, and the design has the advantage of being convenient for providing good and various external expansibility for the system.

(4) The data acquisition networking device can also interact data with an external remote terminal through mainstream wireless communication technologies such as 4G, 5G, WIFI, GPS and the like, and in the remote interaction process, external equipment reads unit related parameter data in a machine bank, such as but not limited to material consumption, quality alarm, equipment shutdown alarm, production data, machine speed, parameter adjustment of a quality detection system, production typesetting data, comprehensive test board real-time data and the like, so that operators can see the production conditions at a glance. For example, the purposes of remote monitoring, diagnosis and the like are realized by pushing package production line state, equipment fault information and the like through APP in mobile intelligent terminals of operators and management personnel.

With respect to the aforementioned data acquisition networking device, the specific function may be to acquire, in real time, relevant information such as the operation parameters of the master station control module (which may also include the two monitoring platforms) and the underlying data according to a preset policy, and send the relevant information to an external data server and/or a wireless terminal in a unidirectional manner. As mentioned above, the outward expansion performance is also considered in the design framework of the system, so that in combination with the actual requirement of the tobacco package packaging operation, the data can be docked to the auxiliary device related to the tobacco package packaging by means of the data acquisition networking device.

Specifically, the data acquisition networking device is also provided with a plurality of communication interfaces which are in butt joint with external auxiliary connection equipment, and the system and an external system are interconnected and intercommunicated by utilizing the TCP/IP protocol. Wherein the secondary device comprises one or more of the following: an MES system (Manufacturing Execution System ), a comprehensive test bench, and a logistics system. And the system is in butt joint with an MES system, and related information such as quality information, rejection information, equipment alarm information, consumption information and the like of the stand-alone equipment are directly uploaded to the MSE system and then are processed by the MES system and then are sent to related personnel terminals. And the device is connected with the comprehensive test bench, an operator only needs to put the cigarettes into the test bench, the test bench automatically measures the cigarettes, measurement data (index data such as the weight, the length, the circumference and the suction resistance of the cigarettes) can be transmitted to the intelligent management platform in real time, and the operator can adjust the device according to the data in time so as to meet production requirements. With commodity circulation butt joint, operating personnel accessible this intelligent system, real-time to the former auxiliary material of commodity circulation calling, after calling, the automatic warehouse system of commodity circulation is automatic to be dispatched AGV pay-off dolly, retrieves the empty auxiliary material tray of unit, then sends the former auxiliary material tray of commodity circulation distribution dish to call auxiliary material unit to realize the automatic dispatch of former auxiliary material.

The unidirectional data acquisition networking device is used for reducing the invasion and influence of external equipment on the system while ensuring the external expansibility, and can receive and transmit related data outwards from the inside of the system, but the data acquisition networking device does not send data to the bottom layer of the IPC control layer, so that the data acquisition networking device is used as a unidirectional data isolation device, and the safety of the bottom layer data of the system is ensured.

Based on the above concepts, in a preferred implementation, the data acquisition networking device may include a Ceres robot. As the data acquisition networking device of the edge calculation layer, the existing intelligent hardware-Ceres machine can be adopted to realize the actual operation, the functions of data acquisition, data analysis, data classification, data access, data transmission, data interface management and interaction and the like can be realized in an integrated mode, and meanwhile, the machine integrates advanced communication technologies such as Internet+ and mobile interaction and the like, so that the integration and data interaction with a tobacco enterprise management system can be effectively enhanced. That is, the main function of the machine bank is to serve as a bridge for data collection and equipment bottom layer data exchange, through program writing, protocol matching and parameter setting, IPC bottom layer data can be sent into the machine bank in real time according to user requirements, and a data processor, an MES and the like can continuously refresh the data from the machine bank.

In addition, in view of the safety control requirement of the control system of the cigarette packet packaging machine set provided by the invention, in a preferred embodiment, the control assembly can further comprise a safety controller which is arranged in the main electric control cabinet and is electrically connected with the main station control module, and the safety controller is provided with multiple paths of I/O channels. Therefore, the system integrates automatic control, servo control (each station execution end) and safety control, so that the reliability and compatibility of the system are integrally improved, and the error of the packaging machine set in continuous production can be reduced to be very small. In actual operation, a safety controller such as TwinSAFE can be adopted to realize the safety operation control related to the equipment; moreover, for the same purpose, it is also considered that all the terminal modules of the main electric control cabinet and the sub electric control cabinet can have a self-diagnosis function, so that the safety and maintainability of the system can be further improved.

As mentioned above, the foreign equipment suppliers adopt special software language to write programs, which greatly prevents the deep grasp and technical iteration of the technicians in the country, so the invention proposes in a preferred implementation manner that the control component can be compatible with various general programming languages, which can include ST structure text programming languages based on IEC61131-3 standard, that is, the control software of the invention can adopt simple and modularized standard structure, so that the technicians in the country can write corresponding control process for their own actual demands quickly and efficiently. In response thereto, the invention further provides a more mature and easy to use software system reference today, i.e. the control component can be configured with the TwainCAT software system. The TwainCAT system has the multi-core multi-thread processing technology, can process two tens of thousands of data points per second, has better high-compatibility characteristic, and is complementary with the design of the invention.

In summary, the distributed I/O design with one network to the bottom and the control software system mentioned above, the present invention proposes that the software algorithm can replace the special components of the traditional MICRO II type electric control system, so as to reduce the system cost, improve the system stability, and realize the rapid update iteration of part of key functions. The encoder arranged at the main machine station of the tobacco package packaging unit, the encoder arranged at the auxiliary machine CH station of the tobacco package packaging unit and the encoder shared by the auxiliary machine CT station and the CV station of the tobacco package packaging unit can be respectively and directly communicated with the master station control module through the EtherCAT bus.

In other words, the system can realize the control requirement of the traditional foreign system by means of the structure framework of master-slave network communication and the standardized industrial control product in a software programming mode, greatly saves special hardware adopted in the foreign existing control system, and can send the collected motion signals of key components to a master station control module directly through an Ethernet for processing and feeding back action instructions, for example, through each I/O slave station, the design concept can enable most of the signals to be processed through a prefabricated program algorithm, so that faults caused by hardware processing are reduced, and the operation speed is further improved.

The machine unit adopts three absolute value encoders to determine the phase of the machine by combining with the actual components of the existing packaging machine unit, so that the accurate error-free matching between the mechanical phase and the electrical phase of the machine is realized, the control precision and the performance of the machine are improved to the maximum extent, and the accurate completion of all quality detection of the machine is ensured. The absolute value encoder has higher precision, and after the measured binary code is converted into an angle, the precision is higher (the error of each circle is one thousandth), so that the error between the main motor and the rest motor is lower, the precision of each station link mechanism is ensured, the precision of the rotating speed between the motors is ensured, and the precision of the conveying and cutting length of the original auxiliary materials is ensured. Therefore, the absolute encoder is used for driving the main motor of the machine to follow the speed measurement in real time, so that the most reasonable matching between the electromechanics is ensured.

However, in the conventional electronic control system, the binary code acquired by the encoder needs to be transmitted to a special encoder board provided by a foreign equipment provider, and then is converted into an angle and speed signal through hardware processing of the encoder board, and then is sent to a Central Processing Unit (CPU) to control the movement of key components of the equipment. For example, the existing MICRO II may be implemented by using a special board card and a driver of the g.d company in terms of operation processing, step motor control, and servo motor control of an encoder, and by using the g.d encoder board card, step motor board card, and tri-axis dc brushless motor board card, and by using a special step motor driver, dc brushless motor driver, and a special power supply, it is possible to implement the related control application, and these special components are not only expensive, but also inconvenient to maintain.

In one implementation mode of the invention, the acquired binary codes can be transmitted to the input module of the secondary station by the three encoders, signals are directly transmitted to the CPU of the primary station through the EtherCAT bus, the input signals are converted into functions and Gray codes through a software algorithm built in the CPU, and then the functions and Gray codes are converted into required phase signals, so that the rotation angle and the like of the acquisition equipment in a fixed period can be calculated.

Finally, taking the original GDX2 model as an example, combining with the EtherCAT bus technology and the ADS protocol, the invention can specifically adopt BECKHOFF embedded industrial personal computer control modules to be matched with corresponding high-performance I/O modules in the implementation process, and simultaneously, auxiliary TwinSAFE safety controllers, an AX5000 type servo driver, a variable frequency driver, an intelligent controller and the like of BECKHOFF are adopted to finish the execution of actions such as detection, action control, drive control, safety control, temperature control and the like of a GDX2 packaging unit and real-time data acquisition, and further verifies that the data detection precision of the improved GDX2 electric control system can reach the improvement of more than twenty percent, and the real-time performance of remote information interaction is ensured by virtue of the data transmission speed of 100M.

That is, the brand new control system of the cigarette packet packaging machine set provided by the invention cancels special fittings of foreign equipment suppliers as much as possible, adopts industry standard parts or domestic general parts to upgrade and reform the electric control circuit, thereby realizing the point-to-point accurate acquisition of various detection signals, safety signals and the like, further simplifying the safety circuit of the original electric control system, reducing the fault shutdown caused by circuit joints, improving the stability and safety of equipment operation, and simultaneously greatly reducing the maintenance cost of the control system of the cigarette packet packaging machine set. The Ethernet bus is adopted on the communication protocol to realize the communication connection of the automation layer of the control system, the design idea of distributed I/O is adopted, the electric hardware layout and management of the electric control system are simplified, and the reliability of the system is effectively improved. Meanwhile, an advanced data acquisition technology, a 3D visualization technology and an expert fault diagnosis technology can be configured, so that the newly designed control system of the cigarette packet packaging unit has an intelligent and visual fault alarm diagnosis function, and the technical difficulty of a customer in equipment maintenance and use is reduced.

The implementation mode of the invention has little change with the control process flow, operation habit, operation instruction position and the like of the traditional electric control system of the existing packaging machine set through field inspection, and can fully utilize the characteristics and functions of each station of the original equipment so as to ensure that all detection, control and the like are consistent with the original electric control system; the design concept of the invention closely surrounds the application flow and process links of the existing packaging unit equipment such as process control, safety control, quality detection, rejection, fault diagnosis, data acquisition, data interaction and the like, so the invention can be regarded as the re-creation of the foreign existing equipment unit on the electrical control level. The stability of the control system of the cigarette packet packaging machine set provided by the invention is tested to completely meet the continuous operation of 30 multiplied by 24 hours, and the control system fully meets the production and management expectations of domestic cigarette enterprises.

The construction, features and effects of the present invention have been described in detail with reference to the embodiments shown in the drawings, but the above description is only preferred embodiments of the present invention, and it should be understood that the technical features of the above embodiments and preferred modes thereof can be reasonably combined and matched into various equivalent schemes by those skilled in the art without departing from or changing the design concept and technical effects of the present invention; therefore, the invention is not limited to the embodiments shown in the drawings, but is intended to be within the scope of the invention as long as changes made in the concept of the invention or modifications to the equivalent embodiments do not depart from the spirit of the invention as covered by the specification and drawings.

Claims (7)

1. A pack wrapper unit control system, comprising:

The system comprises an IPC-based control assembly, a field monitoring platform, a field control platform and a data acquisition networking device;

the control assembly comprises a master station control module arranged in a master electric control cabinet, a first I/O slave station module communicated with the master station control module, a second I/O slave station module and an analog input module in a sub electric control cabinet communicated with the master station control module respectively through a switch; the plurality of sub electric control cabinets are distributed at the machine body of each corresponding station on the packaging machine set;

the field monitoring platform, the field management and control platform and the data acquisition networking device are respectively communicated with the master station control module; the data acquisition networking device is used for transmitting the unit data to an external data server and/or a wireless terminal;

the field monitoring platform and the field control platform are provided with visual human-computer interaction interfaces;

the data acquisition networking function is used as a unidirectional data isolation device, and the operation parameters and the bottom data of the master station control module, the on-site monitoring platform and the on-site management and control platform are acquired in real time according to a preset strategy and sent to an external data server and/or a wireless terminal in a unidirectional mode;

The data acquisition networking device is provided with a plurality of communication interfaces which are in butt joint with external auxiliary equipment, wherein the auxiliary equipment comprises one or more of the following: the system comprises an MES system, a comprehensive test bench and a logistics system;

The control assembly is communicated with the interior through an EtherCAT protocol;

the master station control module is communicated with the on-site monitoring platform, the on-site control platform and the data acquisition networking device through an ADS protocol;

the data acquisition networking device communicates with an external data server through a TCP/IP protocol.

2. The pack wrapper unit control system of claim 1, wherein:

The master station control module is respectively communicated with the field monitoring platform, the field management and control platform and the data acquisition networking device through an ADS protocol through a switch.

3. The pack wrapper unit control system of claim 1, the pack wrapper unit comprising a main machine and an auxiliary machine, wherein:

the encoder arranged at the main machine station, the encoder arranged at the auxiliary machine CH station and the encoder shared by the auxiliary machine CT station and the CV station are respectively and directly communicated with the master station control module through the EtherCAT bus.

4. The pack wrapper unit control system of claim 1, wherein:

the control assembly further comprises a safety controller which is arranged in the main electric control cabinet and is electrically connected with the main station control module, and the safety controller is provided with multiple paths of I/O channels.

5. The pack wrapper unit control system of claim 1, wherein:

The control component compatibility includes an ST structural text programming language based on the IEC61131-3 standard.

6. The pack wrapper unit control system of claim 5, wherein:

The control component is configured with a TwainCAT software system.

7. The pack wrapper unit control system of any one of claims 1-6, wherein:

The data acquisition networking device comprises a Ceres machine bank.