CN113801666B - Virtual-real combined large-scale coke oven mechanical equipment debugging system and debugging method - Google Patents
Virtual-real combined large-scale coke oven mechanical equipment debugging system and debugging method Download PDFInfo
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- CN113801666B CN113801666B CN202111247454.5A CN202111247454A CN113801666B CN 113801666 B CN113801666 B CN 113801666B CN 202111247454 A CN202111247454 A CN 202111247454A CN 113801666 B CN113801666 B CN 113801666B
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- 239000000571 coke Substances 0.000 title claims abstract description 61
- 238000000034 method Methods 0.000 title claims abstract description 36
- 230000008569 process Effects 0.000 claims abstract description 23
- 230000003137 locomotive effect Effects 0.000 claims abstract description 16
- 239000003245 coal Substances 0.000 claims abstract description 15
- 238000004891 communication Methods 0.000 claims abstract description 8
- 238000006243 chemical reaction Methods 0.000 claims abstract description 4
- 230000007246 mechanism Effects 0.000 claims description 9
- 230000002093 peripheral effect Effects 0.000 claims description 9
- 230000008859 change Effects 0.000 claims description 6
- 238000010297 mechanical methods and process Methods 0.000 claims description 3
- 230000005226 mechanical processes and functions Effects 0.000 claims description 3
- 238000004088 simulation Methods 0.000 claims description 3
- 230000008878 coupling Effects 0.000 description 2
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- 238000005859 coupling reaction Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
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Classifications
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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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- 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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Materials Engineering (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- Testing And Monitoring For Control Systems (AREA)
Abstract
The invention provides a virtual-real combined large-scale coke oven mechanical equipment debugging system, which comprises: the system comprises a PLC module responsible for running a coal charging car program, a PLC module responsible for running a coke pusher program, a PLC module responsible for running a coke guide program, a PLC module responsible for running an electric locomotive program, a PLC module responsible for running a ground coordination program, a computer for installing an OPC module compatible with a hardware equipment interface system of a main flow controller and a process virtual debugging platform, an Ethernet switch module for communication, and an AC220V/DC24V power supply conversion module for supplying power to the PLC module, wherein the PLC module and the virtual debugging system are connected into a local area network under the same switch. 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 rapid debugging of the process logic of the mechanical PLC program of the coke oven.
Description
Technical Field
The invention relates to the technical field of virtual debugging of PLC programs, in particular to a virtual-real combined large-scale coke oven mechanical equipment debugging system and a debugging method.
Background
The large-scale coke oven mechanical equipment is influenced by factors such as the whole installation progress of customer projects in the field debugging stage, and the field debugging time is long. When the electric debugging personnel are in field debugging, the electric debugging personnel not only need to spend time to modify and perfect the program, but also can damage equipment and even endanger personnel safety in the debugging process. Most of the virtual debugging software is developed based on a three-dimensional model at present, and the coke oven mechanical equipment is not provided with the three-dimensional model during design, so that time and labor are wasted if only one set of three-dimensional model is developed for virtual debugging.
Disclosure of Invention
According to the technical problems that equipment is possibly damaged and personnel safety is possibly even jeopardized in the debugging process, the large-scale coke oven mechanical equipment debugging system combining virtual and real is provided.
The invention comprises a virtual-real combined large-scale coke oven mechanical equipment debugging system, which comprises: the system comprises a PLC module responsible for running a coal charging car program, a PLC module responsible for running a coke pusher program, a PLC module responsible for running a coke guide program, a PLC module responsible for running an electric locomotive program, a PLC module responsible for running a ground coordination program, a computer for installing an OPC module compatible with a hardware equipment interface system of a main flow controller and a process virtual debugging platform, an Ethernet switch module for communication, an AC220V/DC24V power supply conversion module for supplying power to the PLC module, wherein the PLC module and the virtual debugging system are connected into a local area network under the same switch;
the process virtual debugging platform comprises: the system comprises a data acquisition module, a configuration module for configuring actual peripheral equipment of the coke oven machinery, an interface display module for displaying configuration and Windows system files for storing configuration files.
Further, the data acquisition module includes: data centers and component centers.
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 logic operation of the internal data of the platform;
the component center includes two threads;
one of the threads comprises: virtual operation configuration of the actual peripheral equipment of the coke oven machinery, namely error capturing when the coke oven machinery component library and the virtual platform have faults and operation fault information of external PLC programs; the other thread includes: and describing the mechanical process flow of the coke oven, namely judging an executing mechanism through the color change of the 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 discloses a method for debugging the virtual-real combined large-scale coke oven mechanical equipment, which comprises the following steps:
s1: respectively downloading the PLC programs into each PLC module through STEP7 software; the PLC module includes: the system comprises a coal charging car PLC module, a coke pusher PLC module, a coke guide 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 pusher PLC module, the coke guide PLC module and the electric locomotive PLC module through TCP/IP, and the input and output signals of the coal charging car PLC module, the coke pusher PLC module, the coke guide PLC module and the electric locomotive PLC module are collected into the central control PLC;
s3: the ground central control PLC module is connected with the process virtual debugging platform through OPC;
the OPC is Kepwire; the Kepwware reads the IP address, the tag 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 Kepwware 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 Kepwware to the component center; the component center sends the data to the configuration module;
s5: the configuration module realizes simulation and feedback of the field executor and the sensor related to the control program;
s6: the configuration module completes configuration of the actual peripheral equipment required by the PLC program and then transmits the configuration to the component center;
s7: storing the configured parts into a WINDOWS system file in an export form, wherein the parts can be directly imported in next debugging;
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 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.
Further, 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 guide rail type power supply provides power for DC 24V.
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 rapid debugging of the process logic of the mechanical PLC program of the coke oven. The platform can simulate the functions of on-site frequency converters, actuators such as brakes, oil cylinders and electromagnets, limit, encoders and temperature detection elements, and can replace on-site actual controlled physical objects to assist the PLC control system in completing control flow. The PLC module only needs a power supply, a CPU and a communication module, and all the input and output modules do not need a real object. The digital quantity signal can be directly given by the platform; the analog quantity signal can be given through the DB block, so that the virtual simulation debugging of the coke oven mechanical multi-car linkage can be completed off site, the logic reliability of the control program is verified, and the debugging time of the project site is greatly shortened.
2. The virtual debugging platform and the PLC module are connected by using an OPC industrial communication protocol, and the type of the PLC is not limited by the communication protocol.
3. The visual operation interface enables the man-machine interaction of the platform to be 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 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 that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.
FIG. 1 is a flow chart of the overall structure of the present invention.
Fig. 2 is a wiring diagram of an electrical system of the present invention.
FIG. 3 is a schematic flow chart of the method of the present invention.
Detailed Description
In order that those skilled in the art will better understand the present invention, a technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, shall fall within the scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present invention and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the invention described herein may be implemented in sequences other than those illustrated or otherwise 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 fig. 1-3, the invention provides a virtual and actual combined large-scale coke oven mechanical equipment debugging system, wherein an independently developed process virtual debugging platform reads the data change of the internal variable of a PLC through OPC, detects a control instruction sent by a control system, and simulates the action of an executing mechanism. When the mechanism acts, the corresponding physical quantity changes such as strokes, positions and the like are simulated in a correlation mode, the simulated sensor and other detection elements are caused to change, 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.
A wiring diagram of a debugging system developed according to the method is shown in FIG. 1, which comprises: the system comprises a PLC module responsible for running a coal charging car program, a PLC module responsible for running a coke pusher program, a PLC module responsible for running a coke guide program, a PLC module responsible for running an electric locomotive program, a PLC module responsible for running a ground coordination program, a computer for installing an OPC module compatible with a hardware equipment interface system of a main flow controller and a process virtual debugging platform, an Ethernet switch module for communication, and an AC220V/DC24V power supply conversion module for supplying power to the PLC module, wherein the PLC module and the virtual debugging system are connected into a local area network under the same switch.
The virtual debugging platform comprises: the system comprises a data acquisition module, a configuration module, an interface display module and Windows system files.
The data acquisition module comprises a data center and a component center. The data center contains external data, i.e., data transmitted from the PLC, and internal data, i.e., logical operations of the platform internal data.
The part center contains two threads, one thread containing: virtual operation configuration of the actual peripheral equipment of the coke oven machinery, namely error capturing when the coke oven machinery component library and the virtual platform have faults and operation fault information of external PLC programs. 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 understood that as a preferred embodiment, the components may be dragged at will according to personal preference in this application. The parts have the characters and the numbers, and some parts can be visually displayed through progress bars or color changes. Such as: the stroke value of the oil cylinder can be displayed by a progress bar.
In the invention, the Windows system file is used for storing the configuration file, so that debugging personnel can copy in and out conveniently.
The invention particularly as a preferable method also comprises a method for debugging the large-scale coke oven mechanical equipment by combining virtual and real, which comprises the following steps:
step S1: respectively downloading the PLC programs into each PLC module through STEP7 software; the PLC module includes: the system comprises a coal charging car PLC module, a coke pusher PLC module, a coke guide 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 pusher PLC module, the coke guide PLC module and the electric locomotive PLC module through TCP/IP, and the input and output signals of the coal charging car PLC module, the coke pusher PLC module, the coke guide PLC module and the electric locomotive PLC module are collected into the central control PLC;
step S3: the ground central control PLC module is connected with the process virtual debugging platform through OPC;
the OPC is Kepwire; the Kepwware reads the IP address, the tag 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 used as a soft gateway, reads the IP address, the tag 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 Kepwware 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 Kepwware to the component center; the component center sends the data to the configuration module;
step S5: the configuration module realizes simulation and feedback of the field executor and the sensor related to the control program; the invention uses C# language to independently develop an industrial equipment component 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 executive components. 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 completes configuration of the actual peripheral equipment required by the PLC program and then transmits the configuration to the component center;
step S7: storing the configured parts into a WINDOWS system file in an export form, wherein the parts can be directly imported in next debugging;
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 feedback data is transmitted to the central control PLC module through the component center. The interface display module displays key information of the equipment, and the numerical value changes of the oil cylinder and the like are displayed in a bar graph mode in a green mode, and meanwhile fault information of the 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 interface layout is convenient to use when being 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.
As a preferred embodiment, in the present application, the charging car PLC module, the coke pusher PLC module, the coke guide PLC module, the electric locomotive PLC module, and the ground central control PLC module use SIMATIC S7-400, and DC24V power supply is provided by a rail type power supply.
The foregoing embodiment numbers of the present invention are merely for the purpose of description, and do not represent the advantages or disadvantages of the embodiments.
In the foregoing embodiments of the present invention, the descriptions of the embodiments are emphasized, and for a portion of this disclosure that is not described in detail in this embodiment, reference is made to the related descriptions of other embodiments.
In the several embodiments provided in the present application, it should be understood that the disclosed technology content may be implemented in other manners. The above-described embodiments of the apparatus are merely exemplary, and the division of the units, for example, may be a logic function division, and may be implemented in another manner, for example, a plurality of units or components may be combined or may be integrated into another system, or some features may be omitted, or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be through some interfaces, units or modules, or may be in electrical or other forms.
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 may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in the embodiments of the present invention may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention may be embodied essentially or in part or all of the technical solution or in part in the form of a software product stored in a storage medium, including instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to perform 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, random Access Memory), a removable hard disk, a magnetic disk, or an optical disk, or other various media capable of storing program codes.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (1)
1. A method for debugging a system of virtual-real combined large-scale coke oven mechanical equipment is characterized by comprising the following steps:
the virtual-real combined large-scale coke oven mechanical equipment debugging system comprises a PLC module responsible for running a coal charging car program, a PLC module responsible for running a coke pusher program, a PLC module responsible for running a coke guide program, a PLC module responsible for running an electric locomotive program, a PLC module responsible for running a ground coordination program, an OPC module for installing an interface system of main flow controller hardware equipment and a computer of 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 module;
the process virtual debugging platform comprises: the system comprises a data acquisition module, a configuration module for configuring actual peripheral equipment of the coke oven machinery, an interface display module for displaying configuration and Windows system files for storing configuration files;
the data acquisition module comprises: a data center and a component center;
the data center further includes: external data and internal data; the external data is data transmitted from the PLC, and the internal data is logic operation of the internal data of the platform;
the component center includes two threads;
one of the threads comprises: virtual operation configuration of the actual peripheral equipment of the coke oven machinery, namely error capturing when the coke oven machinery component library and the virtual platform have faults and operation fault information of external PLC programs; the other thread includes: describing the mechanical process flow of the coke oven, namely judging and executing a mechanism through the color change of a flow tree;
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 method for debugging the large-scale coke oven mechanical equipment based on the virtual-real combination comprises the following steps:
s1: respectively downloading the PLC programs into each PLC module through STEP7 software; the PLC module includes: the system comprises a coal charging car PLC module, a coke pusher PLC module, a coke guide 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 pusher PLC module, the coke guide PLC module and the electric locomotive PLC module through TCP/IP, and the input and output signals of the coal charging car PLC module, the coke pusher PLC module, the coke guide PLC module and the electric locomotive PLC module are collected into the central control PLC;
s3: the ground central control PLC module is connected with the process virtual debugging platform through OPC;
the OPC is Kepwire; the Kepwware reads the IP address, the tag 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 Kepwware 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 Kepwware to the component center; the component center sends the data to the configuration module;
s5: the configuration module realizes simulation and feedback of the field executor and the sensor related to the control program;
s6: the configuration module completes configuration of the actual peripheral equipment required by the PLC program and then transmits the configuration to the component center;
s7: storing the configured parts into a WINDOWS system file in an export form, wherein the parts can be directly imported in next debugging;
s8: the component center sends the configured components to a display interface for display; the display interface sends a control command to the component center, and feedback data is transmitted to the central control PLC module through the component center;
s9: the central control PLC transmits the changed data to each vehicle PLC module to realize closed-loop control of the field device mechanism;
the coal charging car PLC module, the coke pusher PLC module, the coke guide PLC module, the electric locomotive PLC module and the ground central control PLC module adopt SIMATIC S7-400, and the guide rail type power supply provides power of DC 24V.
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| 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 |
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