CN110865599A - PLC-based simulated intelligent processing equipment and method - Google Patents
PLC-based simulated intelligent processing equipment and method Download PDFInfo
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- CN110865599A CN110865599A CN201911144206.0A CN201911144206A CN110865599A CN 110865599 A CN110865599 A CN 110865599A CN 201911144206 A CN201911144206 A CN 201911144206A CN 110865599 A CN110865599 A CN 110865599A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/058—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
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- G05B2219/14006—Safety, monitoring in general
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Abstract
The invention relates to a simulation intelligent processing device and a method based on PLC, wherein the device is realized based on a PLC controller and comprises the following steps: the equipment buffer area is used for storing a workpiece queue to be processed, and workpieces in the workpiece queue are sorted based on a scheduling rule; the workpiece selection module is used for selecting a processing workpiece from the equipment buffer zone; the workpiece processing module is used for carrying out timer-based simulation processing on the processed workpiece according to set parameters; storing the workpiece queue in an array form in the equipment buffer area; the PLC is a PLC with an Ethernet communication interface and supporting a TCP/IP protocol and an OPC protocol. Compared with the prior art, the invention has the advantages of high simulation precision, low cost, convenient teaching practice and the like.
Description
Technical Field
The invention relates to the technical field of teaching and training devices, in particular to a PLC-based simulated intelligent processing device and method.
Background
The intelligent manufacturing is a strong national strategy advocated by governments of all countries all over the world, and the intelligent workshop is a foothold of an intelligent manufacturing concept. The operation management of the intelligent workshop is a hotspot of intelligent manufacturing research and is also an important link of intelligent manufacturing teaching practice, however, the cost for constructing the hardware environment is high, and the flexibility is poor. Although the simulation technology is an important means for researching the operation of the intelligent workshop, the simulation technology only simulates the intelligent workshop in a virtual environment and cannot truly reflect the details of the intelligent workshop, so that the deviation between the research result and the practical application is caused, and meanwhile, students are difficult to deeply understand in the teaching practice link. Therefore, in the intelligent manufacturing research and teaching practice process, a suitable experimental device is needed to replace the huge and expensive production equipment in the workshop.
And part of researchers combine actual production scenes and control the mechanical module through the PLC control panel, so that actual production equipment is simulated. The Chinese patent 'an intelligent manufacturing integrated application teaching and training device' (application number: 201721745216.6) takes an automatic assembly sorting system as a background, different automatic mechanical action processes are realized by controlling an automatic assembly sorting module and an automatic cutting module through a PLC control panel, and the automatic assembly sorting device is simulated. But the device belongs to special equipment and has no flexibility. The Chinese patent 'teaching training device based on PLC module' (application number: 201820571796.X) takes an electric heater, a purifier and a humidifier commonly used in modern families as control objects, takes the electric heater module, the purifier module and the humidifier module as input ends to be connected with the PLC module, and is respectively provided with corresponding indicator lamps as output ends. Specific household appliances are simulated through the temperature sensor, the PM2.5 sensor and the humidity sensor, so that the household appliance is close to life, and students can understand and learn PLC application knowledge better. Although the device can simulate various devices, a network is not formed among a plurality of devices, and the requirement of networked manufacturing is difficult to meet.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides PLC-based simulated intelligent processing equipment and method suitable for networked intelligent manufacturing teaching.
The purpose of the invention can be realized by the following technical scheme:
the utility model provides a simulation intelligence processing equipment based on PLC, this equipment is realized based on a PLC controller, includes:
the equipment buffer area is used for storing a workpiece queue to be processed, and workpieces in the workpiece queue are sorted based on a scheduling rule;
the workpiece selection module is used for selecting a processing workpiece from the equipment buffer zone;
the workpiece processing module is used for carrying out timer-based simulation processing on the processed workpiece according to set parameters;
storing the workpiece queue in an array form in the equipment buffer area;
the PLC is a PLC with an Ethernet communication interface and supporting a TCP/IP protocol and an OPC protocol.
Further, the apparatus further comprises:
and the fault triggering module is used for receiving fault parameters and simulating the equipment fault process based on the fault parameters.
Further, the fault parameters include a fault start time, a fault repair time, and a fault interval time.
Further, the equipment is connected with an upper computer through an OPC interface.
Further, the scheduling rules include first-in-first-out, earliest lead time, shortest remaining processing time, or minimum critical value.
Furthermore, a plurality of devices are connected into the same local area network through Ethernet, and each device is in communication connection with the device buffer area of other devices through an OPC protocol, so that the flow of workpieces among the devices is simulated.
Further, each device has a unique ID number, and when a workpiece flows between the devices, the previous device transfers workpiece process information into a device buffer of the next device corresponding to the ID number through an OPC protocol based on the workpiece process information.
The invention also provides a simulated intelligent processing method based on the equipment, which comprises the following steps:
1) acquiring the process information of workpieces, and transmitting each workpiece into an equipment buffer area of equipment with a corresponding ID number;
2) selecting a workpiece to be machined in the equipment buffer area, and simulating the production machining activity of the workpiece by a timer according to the process information of the workpiece;
3) and (3) judging whether the workpiece is in the last procedure or not, if so, finishing the processing, otherwise, transmitting the workpiece into an equipment buffer area of next equipment according to the workpiece process information, and returning to the step 2).
Compared with the prior art, the invention has the following beneficial effects:
1. the PLC equipment is used for simulating equipment in an intelligent workshop to simulate production and processing, and the processing process of the PLC equipment dynamically changes according to the process information of the workpiece, so that the PLC equipment has certain flexibility. Based on the configuration, the invention can realize the configuration of various intelligent workshop scenes and provide an experimental equipment basis for researching intelligent manufacturing technology for scientific research and teaching practice.
2. The invention realizes the simulated processing of the workpiece by adding the functional module in the PLC to simulate the intelligent processing equipment, and provides a physical environment for researching the intelligent manufacturing technology for scientific research and teaching practice.
3. The invention realizes the communication interconnection of a plurality of devices through the Ethernet and the OPC protocol, and can realize the production and processing activities under different production scenes such as a production line and the like.
4. The invention can be configured into different production scenes, and can provide a hardware experimental platform for the implementation of emerging technologies such as digital twin and information physical systems in intelligent manufacturing.
5. The invention can simulate the equipment fault by inputting fault parameters, interrupt the production process and better fit the actual production scene.
Drawings
FIG. 1 is a schematic diagram of a simulated intelligent processing apparatus of the present invention;
FIG. 2 is a diagram of an implementation of the present invention for simulating information transmission between intelligent process tools;
FIG. 3 is a real-time monitoring implementation of the simulated intelligent processing tool of the present invention;
FIG. 4 is a process flow diagram of the present invention for simulating an intelligent process tool;
FIG. 5 is a Gantt chart of a simulated intelligent processing tool in a fault-free scenario in an embodiment of the present disclosure;
FIG. 6 is a Gantt chart of simulated intelligent processing equipment in a fault scenario in an embodiment of the present invention;
fig. 7 is a gantt chart of a plurality of simulated intelligent processing devices in a fault-free scenario in an embodiment of the present invention.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments. The present embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation manner and a specific operation process are given, but the scope of the present invention is not limited to the following embodiments.
Example 1
As shown in fig. 1, the analog intelligent processing device based on PLC according to this embodiment is implemented based on a PLC controller, and includes a device buffer, a workpiece selection module, and a workpiece processing module, where the device buffer is used to store a workpiece queue to be processed, and workpieces in the workpiece queue are sorted based on a scheduling rule; the workpiece selection module is used for selecting a processing workpiece from the equipment buffer zone; and the workpiece processing module is used for performing timer-based simulation processing on the processed workpiece according to the set parameters. The workpiece queue is stored in the equipment buffer area in an array form, and the equipment buffer area can be arranged separately from the whole equipment. In this embodiment, the PLC controller is a PLC controller that supports a TCP/IP protocol and an OPC protocol and has a phoenix band ethernet communication interface.
The equipment buffer area is composed of an array, the elements of the array are workpiece objects, when a new workpiece arrives, the workpiece enters a buffer area workpiece queue for queuing, namely, an element is added in the array.
The scheduling rule is a commonly used heuristic scheduling rule, and comprises the following steps: first-in-first-out (FIFO), earliest lead time (EDD), Shortest Remaining Process Time (SRPT), or minimum critical value (CR). And sequencing the workpiece queues in the buffer area according to the selected scheduling rule, so that the processing equipment selects the workpieces according to the corresponding scheduling rule to simulate production and processing.
The simulation processing based on the timer specifically comprises the following steps: the processing time of the workpiece is obtained by reading the process information of the workpiece entering the processing equipment, and the simulated processing activity is realized by utilizing the timer.
In some embodiments, the device further comprises a fault triggering module for receiving fault parameters, and simulating a device fault process based on the fault parameters. The fault parameters comprise fault starting time, fault repairing time (MTTR) and fault interval time (MTBF), equipment faults are simulated, and the machining process is interrupted, so that the equipment is more consistent with actual production equipment.
In some embodiments, the device is connected to the upper computer through an OPC interface. The OPC interface can collect the equipment state information and upload the information to an upper computer for real-time monitoring.
As shown in fig. 2, in some embodiments, there are multiple devices, the multiple devices are connected to the same lan through ethernet, and each device is communicatively connected to a device buffer of another device through an OPC protocol, so as to simulate the flow of workpieces among the devices, thereby completing production and processing activities in different production scenarios, such as a pipeline. Each device has a unique ID number, and when a workpiece flows among the devices, the previous device transfers workpiece process information into a device buffer area of the next device corresponding to the ID number through an OPC protocol based on the workpiece process information.
The simulated intelligent processing method of the equipment comprises the following steps:
1) acquiring the process information of workpieces, and transmitting each workpiece into an equipment buffer area of equipment with a corresponding ID number;
2) selecting a workpiece to be machined in the equipment buffer area, and simulating the production machining activity of the workpiece by a timer according to the process information of the workpiece;
3) judging whether the workpiece is in the last procedure or not, if so, finishing the processing, otherwise, transmitting the workpiece into an equipment buffer area of next equipment according to the process information of the workpiece, and returning to the step 2);
in the process of the steps, each device can acquire device state information through an OPC interface and can upload the device state information to an upper computer for real-time monitoring.
In addition to the above steps, the apparatus may also simulate the occurrence of a fault based on the input fault parameters.
Example 2
In the embodiment, a PLC controller of the ILE 130ETH model provided by phoenix is used as an equipment base, each function module is packaged into classes by adopting an object-oriented idea, and a production plan is executed to realize production and processing activities of a workpiece on a simulated intelligent processing device, and an adopted design framework is shown in fig. 2. The workpiece refers to a product required to be processed in a production demand, the workpiece is a specific example object of each product, and member variables of the product include an ID, a name, a delivery date, a processing time of a current processing procedure, a current processing step, a processing technology and the like. The member variables of the buffer comprise equipment ID, name and work queue array, and the member method comprises entering the buffer and leaving the buffer. And when a new workpiece is put into the production system, selecting a buffer zone corresponding to the equipment ID according to the processing technology of the workpiece, and triggering the buffer zone to enter. The workpiece queue of the buffer area is composed of an array, and the component elements in the array are workpiece objects and are used for storing all workpieces waiting for processing by the processing equipment. And when the processing equipment is idle, triggering the method for leaving the buffer area, and selecting the workpiece to be processed from the buffer area to enter the processing equipment for processing according to a scheduling rule. The member variables of the processing equipment comprise equipment ID, name, equipment state, fault parameters, workpieces currently being processed, scheduling rules and the like, and the member method comprises the steps of reading process information of the workpieces, simulating a processing process, selecting a buffer area of the next processing equipment of the workpieces and setting the fault parameters. The process tool object is associated with its corresponding buffer object by a tool ID. And after the workpiece enters the processing equipment, reading the processing information of the workpiece, namely processing time, and simulating the processing process of the workpiece by using a timer. And after the machining is finished, if the next procedure exists, sending the workpiece into a buffer area of the next device, otherwise, finishing the machining. The equipment can cause the equipment fault to occur and be repaired by setting fault parameters; and information transmission and real-time monitoring are carried out through TCP/IP and OPC protocols. The information transmission and real-time monitoring process of the simulated intelligent processing equipment is realized as shown in fig. 3, a plurality of pieces of simulated intelligent processing equipment and a plurality of PCs are connected into the same local area network through IP (Internet protocol) setting, then workpiece information is transmitted among the plurality of pieces of equipment through an OPC (OLE for process control) protocol, and the PCs can display the state information of the equipment to realize the real-time monitoring of the equipment state.
The processing flow of the simulated intelligent processing equipment is shown in fig. 4, and the specific process is as follows:
step 1, setting a scheduling rule of the simulation intelligent processing equipment;
step 3, judging the production state of the intelligent processing equipment, if the equipment is in an idle state, namely no workpiece is processed, sequencing a workpiece queue in a buffer area according to a scheduling rule, taking out the first sequenced workpiece and placing the first sequenced workpiece into the processing equipment, and moving the position of the rest workpieces in the queue forward by one bit; if the equipment is in a busy state or a fault state, the equipment does not operate;
Experiment 1: two simulation intelligent processing devices based on PLC provided by the invention are adopted to simulate a production process experiment. The experimental setup was as follows: the production schedule is shown in table 1, each piece of the simulated intelligent processing equipment respectively processes 3 workpieces, and the processing time of the workpieces is the same. Setting that no fault occurs in the equipment 1 and a fault occurs in the equipment 2, wherein the fault parameters are as follows: the start time is 2s, the fault repair time (MTTR) is 1s, and the inter-fault time (MTBF) is 4 s. The processing start and stop times of the two simulated intelligent processing devices are recorded, and the results are respectively shown in fig. 5 and fig. 6.
TABLE 1 production schedule with or without failure
Experiment 2: two pieces of PLC-based simulation intelligent processing equipment provided by the invention are adopted to form a production line simulation production process experiment. The experimental setup was as follows: production schedule as shown in table 2, the workpiece was machined for 3s on the machine 1 and 4s on the machine 2. The processing start and stop times of the two simulated intelligent processing devices are recorded, and the result is shown in fig. 7.
Table 2 production schedule in scenario of multiple simulated intelligent processing devices
In conclusion, the PLC-based simulation intelligent processing equipment can operate independently and can also be used for collaboratively organizing different production modes, actual production equipment can be effectively replaced, and a physical environment is provided for operation research and teaching practice of an intelligent workshop.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concepts. Therefore, the technical solutions that can be obtained by a person skilled in the art through logic analysis, reasoning or limited experiments based on the prior art according to the concept of the present invention should be within the protection scope determined by the present invention.
Claims (8)
1. The utility model provides a simulation intelligence processing equipment based on PLC which characterized in that, this equipment is realized based on a PLC controller, includes:
the equipment buffer area is used for storing a workpiece queue to be processed, and workpieces in the workpiece queue are sorted based on a scheduling rule;
the workpiece selection module is used for selecting a processing workpiece from the equipment buffer zone;
the workpiece processing module is used for carrying out timer-based simulation processing on the processed workpiece according to set parameters;
storing the workpiece queue in an array form in the equipment buffer area;
the PLC is a PLC with an Ethernet communication interface and supporting a TCP/IP protocol and an OPC protocol.
2. The PLC-based analog smart process apparatus of claim 1, further comprising:
and the fault triggering module is used for receiving fault parameters and simulating the equipment fault process based on the fault parameters.
3. The PLC-based analog smart process tool of claim 2, wherein the fault parameters include a fault start time, a fault repair time, and a fault interval time.
4. The PLC-based simulated intelligent processing equipment as claimed in claim 1, wherein the equipment is connected with an upper computer through an OPC interface.
5. The PLC-based analog smart process facility of claim 1, wherein the scheduling rules include first-in-first-out, earliest lead time, shortest remaining process time, or minimum critical value.
6. The PLC-based simulated intelligent processing facility as claimed in claim 1, wherein a plurality of said facilities are connected to the same lan via ethernet, and each facility is communicatively connected to a facility buffer of another facility via OPC protocol to simulate the flow of workpieces between each facility.
7. The PLC-based analog smart process tool of claim 6, wherein each of the tools has a unique ID number, and when a workpiece flows between the tools, a previous tool transfers workpiece process information into a tool buffer of a next tool having a corresponding ID number through an OPC protocol based on the workpiece process information.
8. A simulated intelligent machining method based on the device as claimed in claim 6, characterized by comprising the following steps:
1) acquiring the process information of workpieces, and transmitting each workpiece into an equipment buffer area of equipment with a corresponding ID number;
2) selecting a workpiece to be machined in the equipment buffer area, and simulating the production machining activity of the workpiece by a timer according to the process information of the workpiece;
3) and (3) judging whether the workpiece is in the last procedure or not, if so, finishing the processing, otherwise, transmitting the workpiece into an equipment buffer area of next equipment according to the workpiece process information, and returning to the step 2).
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