CN110928232B - Mechanical digital twin control system of coke oven - Google Patents
Mechanical digital twin control system of coke oven Download PDFInfo
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- CN110928232B CN110928232B CN201911418570.1A CN201911418570A CN110928232B CN 110928232 B CN110928232 B CN 110928232B CN 201911418570 A CN201911418570 A CN 201911418570A CN 110928232 B CN110928232 B CN 110928232B
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Classifications
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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
- G05B19/054—Input/output
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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
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
Abstract
The application discloses a mechanical digital twin control system of a coke oven, which specifically comprises: comprising the following steps: the system comprises a data acquisition and analysis unit for acquiring real-time running state information of coke oven mechanical equipment, a server unit and a client unit for monitoring and operating by staff. Wherein the data acquisition analysis unit includes: the system breaks through the limitation of manual management equipment, and a manager of the coke oven vehicle can realize omnibearing and multidimensional control of the coke oven machinery through a digital environment, so that the real-time on-site state of the coke oven mechanical equipment can be truly and accurately reflected, and the control of the equipment is more facilitated.
Description
Technical Field
The application relates to the field of coke oven mechanical equipment control, in particular to a coke oven mechanical digital twin control system.
Background
In the traditional industrial automatic control system, the state monitoring of the equipment is realized by adopting configuration software, the visualization of the equipment is developed by a graphic picture editing function integrated by the configuration software, and a human-computer interface is planar, so that the system has great limitation and cannot completely and reliably display the actual state of the equipment. The traditional three-dimensional technology can only be used in demonstration propaganda, calculation simulation and product research and development stages, is limited by software functions, cannot provide convenience conditions for use and operation of equipment, and cannot meet the requirement of using PLC control equipment.
Disclosure of Invention
According to the problems existing in the prior art, the application discloses a mechanical digital twin control system of a coke oven, which comprises:
the system comprises a data acquisition and analysis unit for acquiring real-time running state information of coke oven mechanical equipment, a server unit and a client unit for monitoring and operating by staff;
the data acquisition and analysis unit analyzes historical data of faults of each operation device in the system by combining a transverse and longitudinal comparison mode with the technological process of the mechanical device of the coke oven, acquires information about the fault type, the fault device type, the fault frequency and the fault time of the device, and judges the service life of the device according to the life cycle of the device, the running time of the device and the state data of accessory parts;
the data acquisition and analysis unit creates a state data table, an alarm data table, a production plan data table, a life cycle management data table and an energy consumption management data table in an edge calculation server database according to different data function attributes, and stores the data into a database corresponding table for subsequent service;
the server unit maintains and controls the BOOM structure, the user roles, the authority allocation, the basic data maintenance and the fault diagnosis solution of the control system data;
and the client unit loads the real-time running state of the coke oven mechanical equipment into monitoring equipment of the coke pushing process in a data synchronization mode to integrally monitor the coke pushing process of the coke oven.
Further, the system comprises a plurality of coke oven mechanical four-cart PLC controllers for collecting field big data, a coke oven mechanical ground central control PLC controller for summarizing real-time data of each vehicle device on the field, and an edge calculation SERVER for receiving state data of the coke oven mechanical devices through OPC SERVER and analyzing and processing the real-time data;
the coke oven mechanical four-cart PLC controller collects state data of the operation process of the coke oven mechanical equipment, wherein the state data comprises running mechanism position data, coke pushing mechanism position data, coal leveling mechanism position data, door taking mechanism position, hydraulic pressure, hydraulic flow, motor current, motor rotating speed, mechanical mechanism deflection, speed reducer vibration data and auxiliary mechanism data, and the state data is sent to the coke oven mechanical ground central control PLC controller;
the edge calculation server collects state data of the coke oven machinery ground central control PLC controller through an OPC communication protocol, and screens, initializes, format changes, classifies and stores the collected original data of the coke oven machinery equipment in an edge calculation mode.
The system comprises a digital twins application server for deploying WebService service by running a three-dimensional engine, a digital twins data server for data storage service and a database management client for maintaining and managing system data.
The client unit includes: the system comprises a plurality of industrial large-screen background wall display devices which are deployed in a coke oven machine ground central control room and used for monitoring the central control room, webClient which is deployed in the coke oven machine ground central control room and used for controlling Web end devices, mobile end handheld devices which are used for remotely controlling the coke oven machine operation, and VR/AR Client which is used for controlling the working state of the coke oven machine devices.
The coke oven mechanical ground central control PLC controller of the equipment layer gathers data of a plurality of coke oven mechanical four-cart PLC controllers and central control data points;
the edge calculation server collects state data of a central control PLC controller on the mechanical ground of the coke oven, screens, initializes, format transforms, classifies, stores and analyzes the collected original data of mechanical equipment of the coke oven by adopting an edge calculation mode to generate basic business logic data and stores the basic business logic data into the edge calculation server;
the edge computing server generates a data collection of received data, wherein the data collection comprises real-time original acquired data and basic service logic data, a database of the edge computing server, a database of a digital twins application server for deploying WebService service and a database of a digital twins data server are synchronized in real time by adopting a data synchronization algorithm, and the synchronized data are transmitted to a client unit for binding and driving the three-dimensional animation model data.
The database management client forms a service data total set by configuring a BOM structure of the coke oven mechanical equipment and service data points, and the service data total set is classified into three types according to attributes of the service data total set, wherein the three types are real-time acquisition data acquired by binding the service data total set, constant data acquired from a database and service logic data generated by operation on the basis of the service data total set.
The database management client performs service analysis on the service data aggregate and feeds back analysis results to the client unit; the client unit reads alarm data points in the service data collection, performs early warning analysis on the change trend of the real-time running state of the coke oven equipment, writes early warning information into the early warning information collection, and synchronously broadcasts the early warning information to the client unit through data.
The edge computing server, the application server and the data server perform real-time synchronization of a database through a data synchronization algorithm, a data bidirectional link is opened, the control system is in millisecond-level delayed data docking with the PLC of the four-cart of the coke oven machinery, and a three-dimensional digital environment model is driven by adopting real-time data of the coke oven machinery mechanism.
The coke oven mechanical four-cart PLC controller is connected with the coke oven mechanical ground central control PLC controller in a wireless industrial Ethernet communication mode, the coke oven mechanical ground central control PLC controller is connected with the edge calculation server through an industrial Ethernet, the edge calculation server is connected with the digital twin data server through an Ethernet, the digital twin data server is connected with the digital twin application server and the database management Client through an Ethernet, the digital twin application server is connected with the large screen background wall display devices 1-N in a HDMI/DIV data interface mode, the digital twin application server is connected with the WebClient through an Ethernet, and the mobile terminal handheld device and the VR/AR Client (3.4) are connected with the digital twin application server through wireless communication.
According to the application, a physical model of the coke oven mechanical equipment is established through three-dimensional development software such as Solid edge/3D Max/Solid works/Maya, the physical model is imported into an application Server U3D/OSG/UE three-dimensional engine through an STL intermediate format, big data acquisition is carried out on all vehicle PLC controllers of the coke oven machinery, the data are transmitted to a coke oven machinery ground central control PLC controller for summarization, an edge computing Server obtains data of the coke oven machinery ground central control PLC controller through an OPC Server, processing analysis such as screening, transformation and initialization is carried out on the data, a database synchronization algorithm is established, a database Server, an edge computing Server and an application Server are used for data synchronization and storage, a WebService service is deployed in the application Server, the physical model in a three-dimensional engine is driven by combining data in the database Server, and a Client (comprising VR/AR Client, a mobile terminal APP and a large screen display device) carries out control on the coke oven mechanical equipment through communication with the application Server.
By adopting the technical scheme, the system provided by the application is based on various hardware structures, so that the real-time running state of the coke oven mechanical equipment is truly and accurately dynamically monitored in a three-dimensional mode, the production process of the digital three-dimensional model and the real equipment is kept consistent, the degree of the digital twin is achieved, the multidimensional management and control of the coke oven mechanical equipment is realized, and an important technical support function is played for unmanned operation of the coke oven machinery.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings that are required to be used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments described in the present application, and other drawings may be obtained according to the drawings without inventive effort to those skilled in the art.
FIG. 1 is a schematic diagram of the system of the present application.
Fig. 2 is a schematic diagram of the operation of the system of the present application.
FIG. 3 is a diagram of a data synchronization algorithm of the system of the present application.
Fig. 4 is a data flow diagram of the system of the present application.
Detailed Description
In order to make the technical scheme and advantages of the present application more clear, the technical scheme in the embodiment of the present application is clearly and completely described below with reference to the accompanying drawings in the embodiment of the present application:
the mechanical digital twin control system of the coke oven shown in fig. 1 and 2 specifically comprises: a mechanical digital twin control system for a coke oven, comprising: the system comprises a data acquisition and analysis unit 1 for acquiring real-time running state information of coke oven mechanical equipment, a server unit 2 and a client unit 3 for monitoring and operating staff.
Wherein the data acquisition and analysis unit 1 comprises: a plurality of coke oven machinery four-cart PLC controllers 1-N1.1 for carrying out on-site big data acquisition are arranged in each cart control room of the coke oven machinery. A coke oven machine ground central control PLC controller 1.2 for gathering real-time data of each vehicle device on site, wherein the devices are deployed in a coke oven machine ground central control distribution room. An edge computing server 1.3 for data OPC communication, data screening, transformation, initialization and the like for data processing analysis service is deployed on a coke oven machine ground center control distribution room server cabinet.
Further, the coke oven mechanical four-cart PLC controller 1.1 collects state data of the operation process of the coke oven mechanical equipment, and comprises running mechanism position data, coke pushing mechanism position data, coal leveling mechanism position data, door taking mechanism position, hydraulic pressure, hydraulic flow, motor current, motor rotating speed, mechanical mechanism deflection, speed reducer vibration data and auxiliary mechanism data, and the data are sent to the coke oven mechanical ground central control PLC controller 1.2.
Furthermore, the edge calculation Server 1.3 is configured with an OPC Server service, acquires state data of the coke oven machinery ground central control PLC controller 1.2 through an OPC communication protocol, and performs processing analysis such as screening, initializing, format conversion, classification, storage and the like on the acquired original data of the coke oven machinery equipment in an edge calculation mode, including: converting PLC Boolean data, WORD data, floating point data and integer data into WORD data required by a database, converting real-time state of a motor into motor running time for life cycle statistics, converting instantaneous liquid level value of a water tank into liquid level difference value for water resource consumption data for energy consumption management and the like.
Further, as shown in fig. 3 and fig. 4, the data acquisition and analysis unit 1 adopts a transverse and longitudinal comparison mode to combine with the mechanical equipment process of the coke oven to analyze the historical data of faults of each operation equipment in the system, obtain the fault type, the fault equipment type, the fault frequency and the fault time of the equipment, and judge the service life of the equipment according to the life cycle of the equipment, the running time of the equipment and the state data of the accessory parts.
Furthermore, the data acquisition and analysis unit 1 creates a state data table, an alarm data table, a production plan data table, a life cycle management data table and an energy consumption management data table in the edge computing server database according to different data function attributes, and stores the data into a database corresponding table for subsequent service.
Further, the server unit 2 includes: the system comprises a three-dimensional engine, a digital twin application server 2.1 for deploying WebService service, a digital twin data server 2.2 for data storage service and a database management client 2.3 for maintaining and managing system data.
Furthermore, the database management client 2.3 is a background of the control system database, and is used for managing and controlling the control system data BOOM structure, user roles, authority allocation, basic data maintenance and fault diagnosis solution maintenance.
Further, the client unit 3 includes: the system comprises a plurality of industrial large-screen background wall display devices 3.1 which are deployed in a coke oven machine ground central control room and used for monitoring the central control room, webClient3.2 which is deployed in the coke oven machine ground central control room and used for controlling Web end devices, mobile end handheld devices 3.3 which are used for remotely controlling the coke oven machine operation, and VR/AR Client 3.4 which is used for controlling the working state of the coke oven machine device.
Further, the coke oven mechanical ground central control PLC controller 1.2 in the data acquisition and analysis unit 1 gathers data of the plurality of coke oven mechanical four-cart PLC controllers 1.1 and central control data points. The server unit 2 acquires the data in the edge computing server 1.3, generates a data collection set, wherein the data collection set comprises real-time original acquired data and basic service logic data, and is directly broadcast to a client through data synchronization for binding and using the three-dimensional animation model data in the system client unit 3.
Further, the database management client 2.3 forms a service data total set by configuring a BOM structure of the mechanical equipment of the coke oven and service data points, wherein three data points of the service data total set are respectively real-time collected data, and the data points of the service data total set are realized by binding the data collection total set; obtaining data constant points from a database; one is a service logical point, which is generated by operation on the basis of a data aggregate. Wherein the service data aggregate support is stored in a database DB as historical data in different modes (triggered, periodic), frequency for later analysis. The database management client 2.3 performs service analysis on the service data aggregate and feeds back an analysis result to the client unit 3; the client unit 3 reads alarm data points in the service data total set, performs early warning analysis on the change trend of the real-time running state of the coke oven equipment, writes early warning information into the early warning information total set, and synchronously broadcasts the early warning information to the client unit 3 through data.
Further, the edge computing server 1.3, the digital twin application server 2.1 and the digital twin data server 2.2 perform database real-time synchronization through a data synchronization algorithm of the system, a data bidirectional link is opened, data butt joint of a control system and millisecond-level delay of a PLC (programmable logic controller) of the equipment is realized, and a three-dimensional digital environment model is driven by real-time data of a mechanical mechanism of a coke oven. And the client loads data into monitoring equipment of the coke pushing process in a data synchronization mode to integrally monitor the coke pushing process of the coke oven.
Further, the coke oven machinery four-cart PLC controllers 1-N1.1 are connected with the coke oven machinery ground central control PLC controller 1.2 in a communication mode of wireless industrial Ethernet, and the coke oven machinery ground central control PLC controller 1.2 is connected with the edge calculation server 1.3 through the industrial Ethernet. The edge computing server 1.3 is connected with the digital twin data server 2.2 through the Ethernet, and the digital twin data server 2.2 is connected with the digital twin application server 2.1 and the database management client 2.3 through the Ethernet. The digital twin application server 2.1 is connected with the large-screen background wall display devices 1-N3.1 through an HDMI/DIV data interface mode, the digital twin application server 2.1 is connected with the WebClient3.2 through Ethernet, and the mobile terminal handheld device 3.3 and the VR/AR Client 3.4 are connected with the digital twin application server 2.1 through wireless communication.
The specific working process of the system disclosed by the application can adopt the following procedures:
a digital physical model of the mechanical equipment of the coke oven is established through three-dimensional development software such as Solid edge/3D Max/Solid works, and rendering of model materials, textures, colors and shadows is carried out through Maya, so that each part of the digital model is ensured to be consistent with real equipment in terms of appearance and motion characteristics.
Creating a digital environment by using a Unity three-dimensional engine, building a simulated coke oven scene in the digital environment, importing a coke oven mechanical digital physical model into an application server U3D/OSG/UE three-dimensional engine through an STL intermediate format, and designing the mutual cooperation action association of the coke oven mechanical digital physical model. The real-time state mainly comprises:
and (3) coal charging process: the processes of opening the furnace hole, cleaning the furnace cover, cleaning the platform, guiding coal, loading coal and the like can be visually seen, and the four furnace holes and the furnace cover are visible.
And (3) coal leveling process: the small furnace door can be visually seen to be opened, the door frame and the small furnace door can be cleaned, the platform can be cleaned, and the coal leveling rod acts, forms and current flows.
Pushing coke: the two sides of the oven door can be visually seen to be opened, the door frame and the oven door can be cleaned, the platform can be cleaned, the coke guide gate can be moved, the coke pushing rod can be moved, the travel, the current, the red Jiao Donghua can be moved, the coke receiving animation can be moved, and the coke receiving tank can be moved.
The whole process comprises the following steps: comprises a furnace body and an accessory mechanism thereof, and the four trolleys are positioned relative to the furnace body and the furnace number, and the empty receiving tank of the electric locomotive is fully filled.
And (3) abnormal alarm: for the mechanism for giving out abnormal alarm, different colors of highlighting are presented according to the alarm level.
Process state prompting: for the key action node part, a literal state identifier is given.
The application discloses a coke oven machinery digital twin control system, which breaks through the limitation of manual management equipment, and a manager of a coke oven vehicle can realize omnibearing and multidimensional control of coke oven machinery through a digital environment, so that the on-site real-time state of coke oven machinery equipment can be truly and accurately reflected, and the control of the equipment is more facilitated.
The foregoing is only a preferred embodiment of the present application, but the scope of the present application is not limited thereto, and any person skilled in the art, who is within the scope of the present application, should make equivalent substitutions or modifications according to the technical scheme of the present application and the inventive concept thereof, and should be covered by the scope of the present application.
Claims (7)
1. A mechanical digital twin control system for a coke oven, comprising:
a data acquisition analysis unit (1) for acquiring real-time running state information of the coke oven mechanical equipment, a server unit (2) and a client unit (3) for monitoring and controlling by staff;
the data acquisition and analysis unit (1) adopts a transverse and longitudinal comparison mode to combine the technological process of the mechanical equipment of the coke oven, analyzes the historical data of faults of each operation equipment in the system, acquires information about the fault type, the fault equipment type, the fault frequency and the fault time of the equipment, and judges the service life of the equipment according to the life cycle of the equipment, the running time of the equipment and the state data of accessory parts;
the data acquisition and analysis unit (1) creates a state data table, an alarm data table, a production plan data table, a life cycle management data table and an energy consumption management data table in an edge calculation server database according to different data function attributes, and stores the data into a database corresponding table for subsequent service;
the server unit (2) maintains and controls the BOOM structure, the user roles, the authority allocation, the basic data maintenance and the fault diagnosis solution of the control system data;
the client unit (3) adopts a data synchronization mode to load the real-time running state of the coke oven mechanical equipment into monitoring equipment of the coke pushing process to integrally monitor the coke pushing process of the coke oven; wherein, the coke oven mechanical ground central control PLC controller (1.2) of the equipment layer gathers the data of a plurality of coke oven mechanical four-cart PLC controllers (1.1) and central control data points;
the edge calculation server (1.3) collects state data of the coke oven machinery ground central control PLC controller (1.2), and adopts an edge calculation mode to screen, initialize, transform format, classify, store and analyze the collected original data of the coke oven machinery equipment to generate basic service logic data and store the basic service logic data into the edge calculation server (1.3);
the method comprises the steps that an edge computing server (1.3) is obtained to generate a data collection set from received data, wherein the data collection set comprises real-time original acquired data and basic business logic data, a database of the edge computing server (1.3), a database of a digital twin application server (2.1) for deploying WebService service and a database of the digital twin data server (2.2) are subjected to real-time data synchronization by adopting a data synchronization algorithm, and the synchronized data are transmitted to a client unit (3) for binding and driving three-dimensional animation model data.
2. The system according to claim 1, wherein: the data acquisition and analysis unit (1) comprises: the system comprises a plurality of coke oven mechanical four-cart PLC controllers (1.1) for acquiring field big data, a coke oven mechanical ground central control PLC controller (1.2) for summarizing real-time data of each vehicle device on the field, and an edge calculation SERVER (1.3) for receiving state data of the coke oven mechanical devices through OPC SERVER and analyzing and processing the real-time data;
the coke oven mechanical four-cart PLC (1.1) collects state data of the operation process of the coke oven mechanical equipment, wherein the state data comprises running mechanism position data, coke pushing mechanism position data, coal leveling mechanism position data, door taking mechanism position, hydraulic pressure, hydraulic flow, motor current, motor rotating speed, mechanical mechanism deflection, speed reducer vibration data and auxiliary mechanism data, and the state data is sent to the coke oven mechanical ground central control PLC (1.2);
the edge calculation server (1.3) collects state data of the coke oven machinery ground central control PLC (1.2) through an OPC communication protocol, and screens, initializes, format changes, classifies and stores the collected original data of the coke oven machinery equipment in an edge calculation mode.
3. The system according to claim 1, wherein: the server unit (2) comprises: the system comprises a digital twin application server (2.1) for deploying WebService service by running a three-dimensional engine, a digital twin data server (2.2) for data storage service, and a database management client (2.3) for maintaining and managing system data.
4. The system according to claim 1, wherein: the client unit (3) comprises: the system comprises a plurality of industrial large-screen background wall display devices (3.1) which are deployed in a coke oven machine ground central control room and used for monitoring the central control room, webClient (3.2) which is deployed in the coke oven machine ground central control room and used for controlling Web end devices, mobile end handheld devices (3.3) which are used for remotely controlling the coke oven machine operation, and VR/AR Client (3.4) which is used for controlling the working state of the coke oven machine device.
5. A system according to claim 3, characterized in that: the database management client (2.3) forms a service data total set by configuring a BOM structure of the coke oven mechanical equipment and service data points, and classifies the service data total set into three types according to the attribute of the service data total set, wherein the three types are respectively real-time acquisition data acquired by binding the data total set, constant data acquired from a database and service logic data generated by operation on the basis of the data total set;
the database management client (2.3) performs service analysis on the service data aggregate and feeds back analysis results to the client unit (3); the client unit (3) reads alarm data points in the service data total set, performs early warning analysis on the change trend of the real-time running state of the coke oven equipment, writes early warning information into the early warning information total set, and synchronously broadcasts the early warning information to the client unit (3) through data.
6. The system of claim 4, further characterized by: the edge computing server (1.3), the application server (2.1) and the data server (2.2) perform database real-time synchronization through a data synchronization algorithm, a data bidirectional link is opened, a control system and a coke oven mechanical four-cart PLC (1.1) millisecond-level delayed data docking is realized, and a coke oven mechanical mechanism real-time data driving three-dimensional digital environment model is adopted.
7. The system of claim 1, further characterized by: the coke oven mechanical four-cart PLC (1.1) is connected with the coke oven mechanical ground central control PLC (1.2) in a wireless industrial Ethernet communication mode, the coke oven mechanical ground central control PLC (1.2) is connected with the edge computing server (1.3) through an industrial Ethernet, the edge computing server (1.3) is connected with the digital twin data server (2.2) through an Ethernet, the digital twin data server (2.2) is connected with the digital twin application server (2.1) and the database management Client (2.3) through an Ethernet, the digital twin application server (2.1) is connected with the large screen background wall display device (3.1) through an HDMI/DIV data interface mode, the digital twin application server (2.1) is connected with the WebContents (3.2) through an Ethernet, and the mobile terminal handheld device (3.3) and the VR/AR Client (3.4) are connected with the digital twin application server (2.1) through an HDMI/DIV data interface mode.
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| CN201911418570.1A CN110928232B (en) | 2019-12-31 | 2019-12-31 | Mechanical digital twin control system of coke oven |
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| CN201911418570.1A CN110928232B (en) | 2019-12-31 | 2019-12-31 | Mechanical digital twin control system of coke oven |
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| CN113467359A (en) * | 2020-03-31 | 2021-10-01 | 上海梅山钢铁股份有限公司 | Device and method for monitoring state of coke pusher equipment |
| CN113801666B (en) * | 2021-10-26 | 2024-04-05 | 大连华锐重工焦炉车辆设备有限公司 | Virtual-real combined large-scale coke oven mechanical equipment debugging system and debugging method |
| CN114266412A (en) * | 2021-12-29 | 2022-04-01 | 浙江中控技术股份有限公司 | Optimization method and device for coking production, electronic equipment and storage medium |
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