CN113801666A - Virtual-real combined debugging system and debugging method for large coke oven mechanical equipment - Google Patents
Virtual-real combined debugging system and debugging method for large coke oven mechanical equipment Download PDFInfo
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- 239000003245 coal Substances 0.000 claims abstract description 16
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B41/00—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B41/00—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
- C10B41/005—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke for charging coal
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B41/00—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke
- C10B41/02—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke for discharging coke
- C10B41/04—Safety devices, e.g. signalling or controlling devices for use in the discharge of coke for discharging coke by electrical means
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- 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
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- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention provides a virtual-real combined debugging system for large coke oven mechanical equipment, which comprises: the system comprises a PLC module in charge of running a coal charging car program, a PLC module in charge of running a coke pusher program, a PLC module in charge of running a coke guide program, a PLC module in charge of running an electric locomotive program, a PLC module in charge of running a ground coordination program, a computer for installing an OPC module compatible with a main flow controller hardware equipment interface system, a process virtual debugging platform and an Ethernet switch module for communication, wherein the PLC and the virtual debugging system are connected into a local area network under the same switch and an AC220V/DC24V power supply conversion module for supplying power to the PLC modules. The virtual debugging system is not based on a three-dimensional model, is simple in configuration, convenient to store and low in cost, and can realize the rapid debugging of the PLC program process logic of the coke oven machinery.
Description
Technical Field
The invention relates to the technical field of virtual debugging of PLC (programmable logic controller) programs, in particular to a debugging system and a debugging method of virtual and real combined large coke oven mechanical equipment.
Background
The large-scale coke oven mechanical equipment is influenced by factors such as the integral installation progress of a customer project and the like in the field debugging stage, and the field debugging time is long. When the electric tuning personnel debug on site, the time is spent to modify and perfect the program, and equipment can be damaged and even the safety of the personnel can be damaged in the debugging process. At present, most of virtual debugging software is developed based on a three-dimensional model, and coke oven mechanical equipment does not have the three-dimensional model during design, so that time and labor are wasted if a set of three-dimensional model is developed only for virtual debugging.
Disclosure of Invention
According to the technical problems that equipment can be damaged and even personnel safety can be endangered in the debugging process, the debugging system of the mechanical equipment of the large coke oven is provided and is combined virtually and practically.
The invention discloses a virtual-real combined debugging system for large coke oven mechanical equipment, which comprises: the system comprises a PLC module in charge of running a coal charging car program, a PLC module in charge of running a coke pusher program, a PLC module in charge of running a coke guide program, a PLC module in charge of running an electric locomotive program, a PLC module in charge of running a ground coordination program, a computer for installing an OPC module compatible with a main flow controller hardware equipment interface system, a process virtual debugging platform and an Ethernet switch module for communication, wherein the PLC and the virtual debugging system are connected into a local area network under the same switch and are connected with an AC220V/DC24V power supply conversion module for supplying power to the PLC modules;
the virtual debugging platform of said process includes: the device comprises a data acquisition module, a configuration module for configuring the actual peripheral equipment of the coke oven machinery, an interface display module for displaying the configuration and a Windows system file for storing the configuration file.
Further, the data acquisition module comprises: a data center and a component center.
Further, the data center further includes: external data and internal data; the external data is data transmitted from the PLC, and the internal data is logical operation of platform internal data;
the part center comprises two threads;
one of the threads comprises: virtual operation configuration of actual peripheral equipment of the coke oven machinery, namely error capture when a coke oven mechanical part library and a virtual platform have faults and operation fault information of an external PLC program; the other thread includes: the description of the mechanical process flow of the coke oven, namely a mechanism for judging execution through the color change of a flow tree.
Further, the input of the PLC program is used as the output of the process virtual debugging platform, and the output of the PLC program is used as the input of the process virtual debugging platform.
The invention also comprises a debugging method of the virtual-real combined large coke oven mechanical equipment, which comprises the following steps:
s1: the PLC program is downloaded to each PLC module through STEP7 software; the PLC module includes: the system comprises a coal charging car PLC module, a coke pushing car PLC module, a coke guide car PLC module, an electric locomotive PLC module and a ground central control PLC module;
s2: the ground central control PLC module is connected with the coal charging car PLC module, the coke pushing car PLC module, the coke guide PLC module and the electric locomotive PLC module through TCP/IP, and input and output signals of the coal charging car PLC module, the coke pushing car PLC module, the coke guide PLC module and the electric locomotive PLC module are collected into a central control PLC;
s3: the ground central control PLC module is connected with the process virtual debugging platform through OPC;
the OPC is Kepware; the Kepware reads the IP address, the mark name, the input/output address, the DB data block address and the data type of the PLC module and returns the result after the virtual platform is executed to the ground central control PLC to realize control;
s4: connecting the Kepware in the step S3 with a data center of the process virtual debugging platform; the data center sends the central control PLC data read by Kepware to the component center; the component center sends the data to a configuration module;
s5: the configuration module is used for realizing simulation and feedback of field actuators and sensors related to a control program;
s6: the configuration module transmits the actual peripheral equipment required by the PLC program to the component center after completing configuration;
s7: storing the configured components into WINDOWS system files in a exporting mode, and directly importing the components when debugging next time;
s8: the component center sends the configured components to a display interface for display; and the display interface sends a control command to the component center, and the feedback data is transmitted to the central control PLC module through the component center.
S9: and the central control PLC transmits the changed data to each vehicle PLC module to realize the closed-loop control of the field device mechanism.
More closely, the coal charging car PLC module, the coke pushing car PLC module, the coke guide car PLC module, the electric locomotive PLC module and the ground central control PLC module adopt SIMATIC S7-400, and the power supply of DC24V is provided by a guide rail type power supply.
Compared with the prior art, the invention has the following advantages:
the virtual debugging system is not based on a three-dimensional model, is simple in configuration, convenient to store and low in cost, and can realize the rapid debugging of the PLC program process logic of the coke oven machinery. The platform can simulate the functions of actuators such as a frequency converter, a brake, an oil cylinder, an electromagnet and the like on site and elements such as a limiting element, an encoder and a temperature detection element, and replaces an actual controlled physical object on site to assist the PLC control system to complete a control flow. The PLC module only needs a power supply, a CPU and a communication module, and all input and output modules do not need a real object. The digital quantity signal can be directly given through the platform; analog quantity signals can be given through the DB blocks, so that virtual simulation debugging of mechanical multi-vehicle linkage of the coke oven can be completed on site, the logic reliability of a control program is verified, and the debugging time of a project site is greatly shortened.
2. The virtual debugging platform is connected with the PLC module by using an OPC industrial communication protocol, and the communication protocol enables the type of the PLC not to be limited.
3. And the visual operation interface ensures that the man-machine interaction of the platform is simpler and more humanized.
4. The virtual debugging platform can also debug an upper computer connected with the PLC.
5. The industrial equipment component library established by the virtual platform is a universal component library and can also be expanded to virtual debugging of other heavy mechanical equipment.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a flow chart of the overall structure of the present invention.
Fig. 2 is a wiring diagram of the electrical system of the present invention.
FIG. 3 is a schematic flow chart of the method of the present invention.
Detailed Description
In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and claims of the present invention and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in sequences other than those illustrated or described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
As shown in figures 1-3, the invention provides a virtual-real combined debugging system for large-scale coke oven mechanical equipment, which is characterized in that an independently developed process virtual debugging platform reads data changes of internal variables of a PLC through OPC, detects a control instruction sent by a control system and simulates the action of an execution mechanism. When the mechanism acts, physical quantity changes such as stroke, position and the like corresponding to the correlation simulation cause changes of detection elements such as simulated sensors and the like, and then change information is read through the data acquisition module and written back to the PLC in real time, so that closed-loop control of the field device mechanism is realized.
The wiring diagram of the debugging system developed according to the method is shown in fig. 1, which includes: the system comprises a PLC module in charge of running a coal charging car program, a PLC module in charge of running a coke pusher program, a PLC module in charge of running a coke guide program, a PLC module in charge of running an electric locomotive program, a PLC module in charge of running a ground coordination program, a computer for installing an OPC module compatible with a main flow controller hardware equipment interface system, a process virtual debugging platform and an Ethernet switch module for communication, wherein the PLC and the virtual debugging system are connected into a local area network under the same switch and an AC220V/DC24V power supply conversion module for supplying power to the PLC modules.
The virtual debugging platform comprises: the system comprises a data acquisition module, a configuration module, an interface display module and a Windows system file.
The data acquisition module comprises a data center and a component center. The data center comprises external data and internal data, wherein the external data is data transmitted from the PLC, and the internal data is logical operation of the platform internal data.
The component center contains two threads, one thread containing: the virtual operation configuration of the actual peripheral equipment of the coke oven machinery, namely error capture when the coke oven mechanical component library and the virtual platform have faults and operation fault information of an external PLC program. The other thread is mainly used for describing the mechanical process flow of the coke oven, and the executing mechanism can be seen through the color change of the flow tree.
The configuration module is mainly used for configuring actual peripheral equipment of the coke oven machinery, such as: oil cylinder, motor, etc. The input of the PLC program is used as the output of the virtual debugging platform, and the output of the PLC program is used as the input of the virtual debugging platform.
The interface display module is used for displaying the configured components. It is to be understood that in the present application, the components may be dragged as desired according to personal preferences, as a preferred embodiment. The parts are displayed by characters and numbers, and some parts can be visually displayed by progress bars or color changes and the like. Such as: the stroke value of the oil cylinder can be displayed through the progress bar.
In the invention, the Windows system file is used for storing the configuration file, so that debugging personnel can conveniently copy in and copy out.
The invention also comprises a debugging method of virtual and real combined large coke oven mechanical equipment, which comprises the following steps:
step S1: the PLC program is downloaded to each PLC module through STEP7 software; the PLC module includes: the system comprises a coal charging car PLC module, a coke pushing car PLC module, a coke guide car PLC module, an electric locomotive PLC module and a ground central control PLC module;
step S2: the ground central control PLC module is connected with the coal charging car PLC module, the coke pushing car PLC module, the coke guide PLC module and the electric locomotive PLC module through TCP/IP, and input and output signals of the coal charging car PLC module, the coke pushing car PLC module, the coke guide PLC module and the electric locomotive PLC module are collected into a central control PLC;
step S3: the ground central control PLC module is connected with the process virtual debugging platform through OPC;
the OPC is Kepware; the Kepware reads the IP address, the mark name, the input/output address, the DB data block address and the data type of the PLC module and returns the result after the virtual platform is executed to the ground central control PLC to realize control; and the Kepware is used as a soft gateway, reads the IP address, the mark name, the input/output address, the DB data block address and the data type of the PLC module, and returns the result after the virtual platform is executed to the ground central control PLC to realize control.
Step S4: connecting the Kepware in the step S3 with a data center of the process virtual debugging platform; the data center sends the central control PLC data read by Kepware to the component center; the component center sends the data to a configuration module;
step S5: the configuration module is used for realizing simulation and feedback of field actuators and sensors related to a control program; the invention uses C # language to develop a industrial equipment parts library. The component library includes: control elements such as buttons, indicator lights, contactors, relays, and the like; the device comprises an oil pump, an oil cylinder, a motor, a limit switch, a proximity switch and other executing elements. The input information of the component is connected with the output information of the PLC module, and the output information of the component is connected with the input information of the PLC module.
Step S6: the configuration module transmits the actual peripheral equipment required by the PLC program to the component center after completing configuration;
step S7: storing the configured components into WINDOWS system files in a exporting mode, and directly importing the components when debugging next time;
step S8: the component center sends the configured components to a display interface for display; and the display interface sends a control command to the component center, and the feedback data is transmitted to the central control PLC module through the component center. The interface display module displays key information of the equipment, changes of the oil cylinder and other numerical values are displayed in a green mode in a bar graph mode, and meanwhile fault information of a PLC program can be displayed. The interface layout can be randomly placed according to personal operation habits and stored in a page form, so that the electronic device is convenient to use when opened next time.
S9: and the central control PLC transmits the changed data to each vehicle PLC module to realize the closed-loop control of the field device mechanism.
In the present application, as a preferred embodiment, the coal car PLC module, the coke pusher PLC module, the coke guide PLC module, the electric locomotive PLC module, and the ground center PLC module are SIMATIC S7-400, and the power supply of DC24V is supplied from the rail-type power supply.
The above-mentioned serial numbers of the embodiments of the present invention are merely for description and do not represent the merits of the embodiments.
In the above embodiments of the present invention, the descriptions of the respective embodiments have respective emphasis, and for parts that are not described in detail in a certain embodiment, reference may be made to related descriptions of other embodiments.
In the embodiments provided in the present application, it should be understood that the disclosed technology can be implemented in other ways. The above-described embodiments of the apparatus are merely illustrative, and for example, the division of the units may be a logical division, and in actual implementation, there may be another division, for example, multiple units or components may be combined or integrated into another system, or some features may be omitted, or not executed. In addition, the shown or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, units or modules, and may be in an electrical or other form.
The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.
In addition, functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may exist alone physically, or two or more units are integrated into one unit. The integrated unit can be realized in a form of hardware, and can also be realized in a form of a software functional unit.
The integrated unit, if implemented in the form of a software functional unit and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a removable hard disk, a magnetic or optical disk, and other various media capable of storing program codes.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (6)
1. A virtual-real combined debugging system for large coke oven mechanical equipment is characterized by comprising:
the system comprises a PLC module in charge of running a coal charging car program, a PLC module in charge of running a coke pusher program, a PLC module in charge of running a coke guide program, a PLC module in charge of running an electric locomotive program, a PLC module in charge of running a ground coordination program, a computer for installing an OPC module compatible with a main flow controller hardware equipment interface system, a process virtual debugging platform and an Ethernet switch module for communication, wherein the PLC and the virtual debugging system are connected into a local area network under the same switch and are connected with an AC220V/DC24V power supply conversion module for supplying power to the PLC modules;
the virtual debugging platform of said process includes: the device comprises a data acquisition module, a configuration module for configuring the actual peripheral equipment of the coke oven machinery, an interface display module for displaying the configuration and a Windows system file for storing the configuration file.
2. The debugging system of the virtual-real combined large-scale coke oven mechanical equipment of claim 1, wherein: the data acquisition module comprises: a data center and a component center.
3. The debugging system of the virtual and real combined large-scale coke oven mechanical equipment of claim 2, wherein: the data center further comprises: external data and internal data; the external data is data transmitted from the PLC, and the internal data is logical operation of platform internal data;
the part center comprises two threads;
one of the threads comprises: virtual operation configuration of actual peripheral equipment of the coke oven machinery, namely error capture when a coke oven mechanical part library and a virtual platform have faults and operation fault information of an external PLC program; the other thread includes: the description of the mechanical process flow of the coke oven, namely a mechanism for judging execution through the color change of a flow tree.
4. The debugging system of the virtual-real combined large-scale coke oven mechanical equipment of claim 1, wherein: and the input of the PLC program is used as the output of the process virtual debugging platform, and the output of the PLC program is used as the input of the process virtual debugging platform.
5. A debugging method of virtual and real combined large coke oven mechanical equipment by applying the system of claims 1-4 is characterized by comprising the following steps:
s1: the PLC program is downloaded to each PLC module through STEP7 software; the PLC module includes: the system comprises a coal charging car PLC module, a coke pushing car PLC module, a coke guide car PLC module, an electric locomotive PLC module and a ground central control PLC module;
s2: the ground central control PLC module is connected with the coal charging car PLC module, the coke pushing car PLC module, the coke guide PLC module and the electric locomotive PLC module through TCP/IP, and input and output signals of the coal charging car PLC module, the coke pushing car PLC module, the coke guide PLC module and the electric locomotive PLC module are collected into a central control PLC;
s3: the ground central control PLC module is connected with the process virtual debugging platform through OPC;
the OPC is Kepware; the Kepware reads the IP address, the mark name, the input/output address, the DB data block address and the data type of the PLC module and returns the result after the virtual platform is executed to the ground central control PLC to realize control;
s4: connecting the Kepware in the step S3 with a data center of the process virtual debugging platform; the data center sends the central control PLC data read by Kepware to the component center; the component center sends the data to a configuration module;
s5: the configuration module is used for realizing simulation and feedback of field actuators and sensors related to a control program;
s6: the configuration module transmits the actual peripheral equipment required by the PLC program to the component center after completing configuration;
s7: storing the configured components into WINDOWS system files in a exporting mode, and directly importing the components when debugging next time;
s8: the component center sends the configured components to a display interface for display; and the display interface sends a control command to the component center, and the feedback data is transmitted to the central control PLC module through the component center.
S9: and the central control PLC transmits the changed data to each vehicle PLC module to realize the closed-loop control of the field device mechanism.
6. The debugging method of virtual-real combined large coke oven mechanical equipment of claim 5, wherein the debugging method comprises the following steps: the coal charging car PLC module, the coke pushing car PLC module, the coke guide car PLC module, the electric locomotive PLC module and the ground central control PLC module adopt SIMATIC S7-400, and the power supply of DC24V is provided by a guide rail type power supply.
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| CN115145218A (en) * | 2022-06-21 | 2022-10-04 | 大连华锐智能化科技有限公司 | Unattended operation control system and method for coke oven vehicle |
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| CN105425757A (en) * | 2015-12-29 | 2016-03-23 | 大连华锐重工焦炉车辆设备有限公司 | Intelligent coke oven car equipment control system and method |
| CN207216396U (en) * | 2017-09-15 | 2018-04-10 | 唐山首钢京唐西山焦化有限责任公司 | A kind of big Locomotive remote control system of capacity coke oven four |
| CN110928232A (en) * | 2019-12-31 | 2020-03-27 | 大连华锐重工焦炉车辆设备有限公司 | Mechanical digital twin control system of coke oven |
| CN216998283U (en) * | 2021-10-26 | 2022-07-19 | 大连华锐重工焦炉车辆设备有限公司 | Virtual-real combined debugging system for large coke oven mechanical equipment |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115145218A (en) * | 2022-06-21 | 2022-10-04 | 大连华锐智能化科技有限公司 | Unattended operation control system and method for coke oven vehicle |
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