CN115032960A - Industrial Ethernet and control bus based field device control system and method - Google Patents
Industrial Ethernet and control bus based field device control system and method Download PDFInfo
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the network communication
- G05B19/4186—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the network communication by protocol, e.g. MAP, TOP
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- G—PHYSICS
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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
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Abstract
The invention relates to the technical field of electrical control, in particular to a field device control system and a field device control method based on industrial Ethernet and a control bus. The system is applied to the upper computer connected with all on-site complete machine equipment, and comprises an equipment PLC control module, an on-site control bus, a centralized management control center and the upper computer, wherein the control system is combined with the industrial Ethernet and on-site control bus technology to realize the automatic control of all on-site complete machine equipment; the remote maintenance is facilitated, and the time for troubleshooting of maintenance personnel is shortened.
Description
Technical Field
The invention relates to the technical field of electrical control, in particular to a field device control system and a field device control method based on industrial Ethernet and a control bus.
Background
With the continuous development of modern industrial equipment, most of the control of field complete equipment still remains wired connection control, the control and maintenance of the field equipment are generally controlled and operated manually by field operators, the manual confirmation work of the field operators is greatly increased, and the stability of the industrial equipment is influenced by manual state switching and manual operation control.
Secondly, in the control process of the field complete equipment, in order to control the field independent single equipment, remote field wiring needs to be carried out, manual button operation is needed, maintenance and debugging are inconvenient, the equipment halt risk is increased, and the cable is easily broken when a network cable or an optical fiber is connected and moved through a drag chain, so that the cable breaking risk is increased.
Disclosure of Invention
In order to solve the problems of high manual switching and wiring cost and high risk in the control process of the modern industrial equipment, the invention provides a field equipment control method and a field equipment control system based on an industrial Ethernet and a control bus, independent equipment of each working section automatically operates according to a preset sequence and requirements of a process, and the equipment is automatically started in a field signal or communication mode, so that the manual confirmation work of field operators is greatly reduced, and the system stability is higher.
In order to achieve the above purpose, the embodiment of the present invention provides the following technical solutions:
in a first aspect, in an embodiment provided by the present invention, a field device control system based on an industrial ethernet and a control bus is provided, which is applied to a host computer connected to all field devices, and includes:
the equipment PLC control module is used for being connected with and controlling the single bodies of the independent equipment of all the on-site complete equipment so as to manage and maintain the single bodies nearby;
the field control bus is used for connecting equipment PLC control modules of all on-site complete equipment and connecting a centralized management control center by combining an industrial Ethernet;
the centralized management control center is connected with the equipment PLC control modules of all on-site complete equipment through an industrial Ethernet network and is used for acquiring data of all on-site complete equipment to an upper computer;
and the upper computer is used for monitoring the working state and the fault information of the field equipment, adjusting the process data of the field equipment and performing remote centralized operation on the field equipment.
As a further scheme of the invention, the independent equipment of all the on-site complete equipment is provided with an equipment PLC control module, the equipment PLC control module forms a PLC control system for independently controlling the single equipment, and the PLC control system is arranged in the single equipment without wiring and is used for operating the single equipment on site during equipment maintenance.
As a further scheme of the present invention, the field device control system based on the industrial ethernet and the control bus further includes a centralized management subsystem, the centralized management subsystem is connected with the PLC control system of at least one single device through a Profinet communication protocol, the centralized management subsystem is connected with the local console, and is used for operating the single device on site during maintenance of the single device, and operating parameters of the field device can be modified at any time through the local console, so as to meet requirements of different products, and also the operating state of the field device can be monitored, and the state of each device on site can be displayed on a computer at any time, so that an operator and a maintenance person can conveniently observe the operating condition of the field device.
As a further scheme of the present invention, the centralized management subsystem is connected to the switch through a field control bus, and the switch of the centralized management subsystem is connected to the switch of the centralized management control center through an industrial ethernet for remote transmission of the collected data.
As a further scheme of the present invention, the switch of the centralized management control center is connected to an upper computer through an industrial ethernet, and the upper computer is at least one central control PC connected to the centralized management control center.
As a further scheme of the invention, the upper computer is a central control PC end which takes a computer as an upper computer operation station, the centralized management control center is Siemens S7-1500 series PLC, and an industrial automation control system covered by the whole factory is formed by Ethernet networking field level S7-1200 series and ET200 series devices.
As a further scheme of the present invention, when the PLC control system of the single equipment automatically operates, the independent equipment of each station automatically operates according to the preset sequence and requirement of the process, and the start signal of the automatic operation of the equipment is automatically started by the result of the action of the last equipment in the process flow through a field signal or communication mode.
As a further scheme of the invention, the centralized management subsystem comprises a batching subsystem, the batching subsystem is connected with a batching on-site operation platform, and the batching subsystem is connected with a PLC control system of the powder monomer equipment and a PLC control system of the slurry monomer equipment through a Profinet communication protocol.
As a further scheme of the invention, the centralized management subsystem comprises a cutting subsystem, the cutting subsystem is connected with a front in-situ operation table of the kettle, and the cutting subsystem is connected with a pouring ferry PLC control system, a static-stop ground remote PLC control system, a stacker PLC control system, a turnover table PLC control system, an empty turnover demolding PLC control system and a kettle feeding PLC control system through a Profinet communication protocol.
As a further scheme of the invention, the centralized management subsystem comprises a post-kettle subsystem, the post-kettle subsystem is connected with a post-kettle on-site operation table, and the post-kettle subsystem is connected with a kettle discharge ferrying PLC control system, a stacker crane PLC control system, a board severing machine PLC control system, a blank clamping machine PLC control system, a blank translation PLC control system, and a post-kettle ground remote PLC control system through a Profinet communication protocol.
In a second aspect, in an embodiment provided by the present invention, a field device control method based on an industrial ethernet and a control bus is provided, which is applied to an upper computer connected to all field devices, and the method includes:
acquiring initial signals of automatic operation of independent equipment in all on-site complete equipment, and automatically operating current equipment based on the initial signals;
the equipment PLC control module connected with the current equipment acquires data of the current equipment and transmits the data to the centralized management control center through a field control bus and an industrial Ethernet;
the centralized management control center uploads the received data to the upper computer, the upper computer monitors the working state and the fault information of the field equipment, and an alarm is given when the data are abnormal.
As a further scheme of the invention, the field equipment is remotely and centrally operated based on the upper computer, the operation parameters of the field equipment are modified based on the local operation console, the operation state of the field equipment is monitored, and the state of each field equipment is displayed on a computer at any time.
In a third aspect, in a further embodiment provided by the present invention, a computer device is provided, which includes a memory and a processor, the memory stores a computer program, and the processor implements the steps of the industrial ethernet and control bus based field device control method when loading and executing the computer program.
In a fourth aspect, in a further embodiment provided by the present invention, a storage medium is provided, which stores a computer program, and the computer program is loaded by a processor and executed to implement the steps of the industrial ethernet and control bus based field device control method.
The technical scheme provided by the invention has the following beneficial effects:
the field equipment control system and method based on the industrial Ethernet and the control bus realize automatic control of all field equipment, automatically start the next process equipment through on-line confirmation of field signals, and after the equipment is started, the equipment controls the running equipment in sequence, thereby reducing the failure rate, lightening the operation intensity and reducing unnecessary time waste; the system adopts various operation modes by combining an unattended full-automatic operation mode with regional centralized automatic management and manual and semi-automatic button operation of the system, thereby reducing the shutdown risk of the equipment as much as possible; the mobile equipment is convenient and fast to communicate by using an industrial Ethernet networking wireless connection mode, and the risk of disconnection when a traditional network cable or optical fiber is used for towline movement is reduced; the safety protection effect is good, false operation caused by sensor faults is avoided by adopting the sensor with redundant configuration, and the safety protection device is more stable and safe; when the fault is judged, an equipment alarm code is provided, so that maintenance personnel can conveniently and quickly lock the fault reason, and the time for the maintenance personnel to troubleshoot the fault is shortened; and the field device is used for controlling a systematic device program to carry out remote maintenance, so that the time for troubleshooting of maintenance personnel is shortened.
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings 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 of the present invention. In the drawings:
fig. 1 is a system block diagram of a field device control system based on an industrial ethernet and a control bus according to an embodiment of the present invention.
Fig. 2 is a block diagram of a batching subsystem in an industrial ethernet and control bus based field device control system according to an embodiment of the present invention.
Fig. 3 is a flowchart of a field device control method based on an industrial ethernet and a control bus according to an embodiment of the present invention.
Fig. 4 is a block diagram of a computer apparatus according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
In some of the flows described in the present specification and claims and in the above figures, a number of operations are included that occur in a particular order, but it should be clearly understood that these operations may be performed out of order or in parallel as they occur herein, with the order of the operations being indicated as 101, 102, etc. merely to distinguish between the various operations, and the order of the operations by themselves does not represent any order of performance. Additionally, the flows may include more or fewer operations, and the operations may be performed sequentially or in parallel. It should be noted that, the descriptions of "first", "second", etc. in this document are used for distinguishing different messages, devices, modules, etc., and do not represent a sequential order, nor limit the types of "first" and "second" to be different.
The technical solutions in the exemplary embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the exemplary embodiments of the present invention, and it is apparent that the described exemplary 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.
The control of the field complete machine equipment still mostly maintains wired connection control, the control and maintenance of the field equipment are generally controlled and operated manually by field operators, the manual confirmation work of the field operators is greatly increased, and the stability of the industrial equipment is influenced by manually switching states and manually controlling operation.
In addition, in the control process of the whole field equipment, in order to control independent single field equipment, remote field wiring needs to be carried out, manual button operation is needed, and the maintenance and debugging are inconvenient, so that the equipment shutdown risk is increased, and the disconnection is easy when a network cable or an optical fiber is connected and moved through a drag chain, so that the disconnection risk is increased.
Therefore, the invention provides a field device control method and a field device control system based on an industrial Ethernet and a control bus, which automatically run independent devices of each workshop section according to a preset sequence and requirements of a process, automatically start the devices in a field signal or communication mode, greatly reduce the manual confirmation work of field operators, ensure that the system stability is higher, and solve the problems of high manual switching and wiring cost and high risk in the control process of modern industrial devices.
Specifically, the embodiments of the present application are further described below with reference to the accompanying drawings.
Referring to fig. 1, an embodiment of the present invention provides an industrial ethernet and control bus based field device control system, which is applied to an upper computer 400 connected to all field devices, and includes a device PLC control module 100, a field control bus 200, a centralized management control center 300, the upper computer 400, a centralized management subsystem 500, and a local console 600.
The industrial Ethernet and control bus-based field device control system of the embodiment of the invention takes PLC as hardware to form a distributed control system, namely distributed control and centralized management; the field device control system based on the industrial Ethernet and the control bus has the characteristics of less manpower consumption, low failure rate and simple and convenient maintenance.
When the distributed control is carried out, all on-site equipment of the whole machine is provided with the on-site independent single PLC control system, so that the equipment can be conveniently managed and maintained nearby, the remote on-site wiring is reduced, and the equipment can be operated on site when the equipment needs to be maintained.
In this embodiment, referring to fig. 1, the device PLC control module 100 is used for controlling individual connection with independent devices of all on-site complete devices, so as to manage and maintain individual devices nearby.
The equipment PLC control modules 100 are installed on the independent equipment of all the on-site complete equipment, the equipment PLC control modules 100 form a PLC control system for independently controlling the single equipment, and the PLC control system is arranged in the single equipment in a wiring-free mode and used for on-site operation of the single equipment during equipment maintenance.
In this embodiment, the field control bus 200 is used to connect the PLC control modules 100 of all the field devices, and is connected to the centralized management control center 300 by using an industrial ethernet; the centralized management control center 300 is connected to the PLC control modules 100 of all field devices via an industrial ethernet network, and is configured to collect data of all field devices to the upper computer 400.
In this embodiment, the centralized management control center 300 is also called a centralized management operation station, and performs data acquisition on all instruments and monitoring devices of the whole plant to the upper computer 400 through an industrial ethernet.
The upper computer 400 is used for monitoring the working state and the fault information of the field equipment, adjusting the process data of the field equipment, performing remote centralized operation on the field equipment, and monitoring the working state and the fault information of the field equipment on the upper computer 400.
The centralized management subsystem 500 is connected with a PLC control system of at least one single device through a Profinet communication protocol, the centralized management subsystem 500 is connected with the local operation platform 600 and used for local operation of the single devices during maintenance of the single devices, the local operation platform 600 can modify the operation parameters of the field devices at any time to meet the requirements of different products, the operation state of the field devices can also be monitored, the state of each device on the field is displayed on a computer at any time, and operators and maintenance personnel can conveniently observe the operation condition of the field devices.
In this embodiment, the local console 600 can adjust the process data on the equipment to meet the requirements of different products, and perform remote centralized operation on the equipment.
In this embodiment, the centralized management subsystem 500 is connected to the switch 201 through the field control bus 200, and the switch 201 of the centralized management subsystem 500 is connected to the switch 201 of the centralized management control center 300 through the industrial ethernet for remote transmission of the collected data.
The switch 201 of the centralized management control center 300 is connected to an upper computer 400 through an industrial ethernet, the upper computer 400 is at least one central control PC terminal 401 connected to the centralized management control center 300, and in an embodiment of the present application, the upper computer 400 is 4 central control PC terminals 401 connected to the centralized management control center 300.
Illustratively, in the field device control system based on the industrial ethernet and the control bus according to the embodiment of the present invention, the upper computer 400 is a central control PC 401 using a computer as an operation station of the upper computer 400, the centralized management control center 300 is a siemens S7-1500 series PLC, and field-level S7-1200 series and ET200 series devices are networked through the ethernet to form a whole-plant covered industrial automation control system.
In the embodiment of the invention, when the PLC control system of the single equipment automatically runs, the independent equipment of each section automatically runs according to the preset sequence and requirements of the process, and the initial signal of the automatic running of the equipment automatically starts the equipment by the action result of the last equipment on the process flow in a field signal or communication mode.
When the equipment automatically runs, the independent equipment of each working section automatically runs according to the preset sequence and requirements of the process, and the starting signal of the automatic running of the equipment automatically starts the equipment from the action result of the last equipment in the process flow in a field signal or communication mode, so that the manual confirmation work of field operators is greatly reduced, and the system stability is higher; when the equipment needs to be overhauled, the equipment can be switched to a manual state and operated manually.
Compared with the control system during the operation of the existing equipment, the field equipment control system based on the industrial Ethernet and the control bus provided by the embodiment of the invention has the following advantages:
(1) the automatic control of all on-site complete equipment is realized, the equipment of the next process is automatically started through on-line confirmation of on-site signals, and after the equipment is started, the equipment controls the running equipment in sequence, so that the failure rate is reduced, the operation intensity is reduced, and unnecessary time waste is reduced;
(2) the system adopts various operation modes by combining an unattended full-automatic operation mode with regional centralized automatic management and manual and semi-automatic button operation of the system, thereby reducing the shutdown risk of the equipment as much as possible;
(3) the mobile equipment is convenient and fast to communicate by using an industrial Ethernet networking wireless connection mode, and the risk of disconnection when a traditional network cable or optical fiber is used for towline movement is reduced;
(4) the safety protection effect is good, false operation caused by sensor faults is avoided by adopting the sensor with redundant configuration, and the safety protection device is more stable and safe;
(5) when the fault is judged, an equipment alarm code is provided, so that maintenance personnel can conveniently and quickly lock the fault reason, and the time for the maintenance personnel to troubleshoot the fault is shortened;
(6) the field device is used for controlling a systematic device program to carry out remote maintenance, and the time for troubleshooting of maintenance personnel is shortened.
In the field device control system based on the industrial Ethernet and the control bus, a factory is divided into the following control systems according to different process area function divisions: the automatic control system comprises a raw material preparation control system, a raw material proportioning control system, a die traction control system, an overturning blank moving machine control system, a cutting machine and bottom skin removing control system, a side plate return conveying control system, a marshalling blank moving machine control system, a marshalling ferry vehicle control system, a marshalling tractor and return tractor control system, a kettle ferry vehicle control system, a die removing blank moving machine control system, a plate severing machine control system, a packaging line control system, a central centralized control system and an autoclave automatic control system, wherein the control systems can be selected according to field requirements.
When the control system is controlled by a field device control system based on an industrial ethernet and a control bus, the centralized management subsystem 500 is subdivided into the following subsystems, specifically as follows:
illustratively, referring to fig. 2, the centralized management subsystem 500 includes a batching subsystem 501, the batching subsystem 501 is connected with a batching on-site console 601, and the batching subsystem 501 is connected with a PLC control system 111 of a powder monomer plant and a PLC control system 112 of a slurry monomer plant through a Profinet communication protocol.
Illustratively, referring to fig. 2, the centralized management subsystem 500 includes a cutting subsystem 502, the cutting subsystem 502 is connected to a front in-situ operation platform 602, and the cutting subsystem 502 is connected to the pouring and ferrying PLC control system 121, the static-stop ferrying PLC control system 122, the static-stop ground remote PLC control system 123, the stacker PLC control system 124, the turnover platform PLC control system 125, the empty-turnover and demolding PLC control system 126, and the kettle-entering PLC control system 127 through Profinet communication protocol.
Illustratively, referring to fig. 2, the centralized management subsystem 500 includes a post-kettle subsystem 503, the post-kettle subsystem 503 is connected to the post-kettle on-site console 603, and the post-kettle subsystem 503 is connected to the out-kettle ferry PLC control system 131, the stacker crane PLC control system 132, the trigger PLC control system 133, the blank holder PLC control system 134, the blank translation PLC control system 135, and the post-kettle ground remote PLC control system 136 through Profinet communication protocol.
In the embodiment of the invention, the automatic control system of the still kettle is controlled by the cutting subsystem 502 and the post-kettle subsystem 503, so that steam is saved and cost is saved compared with the traditional manual gas distribution. When the autoclave works, the autoclave is heated and pressurized according to a set optimal curve, so that the die damage caused by the uncertainty of manual heating and pressurizing is avoided.
It should be noted that, in the embodiment of the present invention, the central control computer operation interface of the field device control system based on the industrial ethernet and the control bus is a window of man-machine interaction, and based on the control of the production process by the operator, the local console 601 is displayed to provide the operator with the parameter condition for observing the production operation, so as to perform the effective operation, control and management of the production process. The central control system comprises a video monitoring system, a management system PLC, a management layer computer, a network component, a printer and the like, wherein the video monitoring system acquires video monitoring pictures of all on-site complete machine equipment, the management system PLC controls independent equipment of all on-site complete machine equipment, the management layer computer is used for forming an upper computer, the upper computer is communicated with the on-site control bus 200 and an industrial Ethernet network through the network component, and meanwhile, the upper computer is connected with the printer equipment for printing acquired data.
In the automatic control system of the still kettle, when the graph is displayed, a production workshop process flow chart is drawn based on the graph symbols, and the relation between the actual process production process and the equipment is displayed. The control operation range is that under the assistance of the video monitoring system, an operator can operate all equipment in the production workshop at the central control station, the operator is not required to be arranged on the site, and during the meal rest period, the auxiliary patrolling personnel on the site can be not required, and the operation parameters of the equipment in the production workshop can be set and monitored.
When technological parameters are modified, the raw material system adjusts the mixture proportion and the feeding speed, and the batching system automatically calculates the production formula according to the automatically acquired and used slurry density and the manually input powder parameters.
When the equipment operation parameters are modified, the equipment operation parameters are modified according to the equipment operation speed, the equipment operation purpose, the equipment production yield target setting and the like.
When the equipment is in failure alarm, the equipment operation parameters are displayed at corresponding positions, the states of the electrical equipment, the on-off states, the alarm display, the equipment buttons and the like are displayed, the control system can give an alarm when the states of the equipment are wrong or the process is overtime in the operation process, and sound, light or interface alarm is provided to remind an operator to take measures.
When equipment failure analysis is carried out, the equipment failure analysis system prompts an equipment failure code when equipment has a failure or corresponding action failure, and an operator or maintenance personnel carries out quick elimination according to the operation code and possible information of failure data.
In the embodiment of the invention, the fault can be remotely processed, when the equipment has a fault, an engineer does not need to go to the site, the engineer can be contacted to communicate the site condition, the site problem is solved through the remote maintenance module, and the function greatly improves the normal operation guarantee of the user equipment.
The field device control system based on the industrial Ethernet and the control bus can also record and inquire production data: the production data plays a very key role in process stability and product quality, the central control room has the functions of setting, collecting, recording, inquiring and printing the production data, and a user can inquire and print historical production data according to time.
And managers and maintainers can also be connected with a video server of the central control station through a mobile phone in real time to know the running condition of equipment in the workshop in real time.
In one embodiment of the present invention, the control procedures and functions of the industrial ethernet and control bus based field device control system are as follows:
the raw material control system comprises a power cabinet, an on-site operation box and a PLC cabinet, wherein the model of a controller installed in the PLC cabinet adopts Siemens S7-200-SMART-SR40, a frequency converter, a button and an indicator lamp adopt Schneider, a sensor adopts double-heating, the PLC cabinet also comprises an industrial personal computer, a circuit breaker, a contactor and a drag chain cable for connection, the control mode of the raw material control system is that motors with the power of 18.5 kilowatts and below are directly started according to standards, motors with the power of 22 kilowatts and above are started by star triangles, Siemens S7-200-SMART-SR40 are used as the controller, a silo adopts a potential ruler, a slurry storage tank adopts a radar level meter, and a beater adopts a mechanical swing arm level meter.
Illustratively, the raw material control system includes a powder storage system, as shown in fig. 2, the powder storage system is included in the batching subsystem 501, and the PLC control system 111 corresponding to the powder monomer equipment of the batching subsystem 501 is configured to crush, grind and convey lime entering the factory to a corresponding lime bin for storage, and convey cement entering the factory to a corresponding powder bin for storage, so as to mix and use the batching.
The control mode of the powder storage system adopts a central control room to assist intelligent operation, the operation mode is a mode of combining manual button operation of a local machine, operation of an operation station in an original batching area and remote operation of the central control room, when the state alarm system responds, the operation state information of equipment is wrong, the material level information is wrong or the material level exceeds a preset range, and the central control room operation system can generate alarm information.
When the powder storage system takes the safety guarantee measure of equipment operation, an emergency stop button is arranged on the site; the feed bin is provided with a material level sensor, so that the failure probability of material level information is reduced to the maximum extent. The control system of the powder storage system can adopt a Siemens S7-ET200 remote site and a field signal acquisition device.
In an exemplary slurry preparation and storage system, as shown in fig. 2, the slurry preparation and storage system is included in the batching subsystem 501, and the PLC control system 112 corresponding to the slurry monomer equipment of the batching subsystem 501 is used for mixing raw materials required for pulping with water, then ball-milling the mixture into slurry, and pumping the slurry to a storage tank for storage, so as to mix the ingredients for use.
The control mode of the slurry preparation and storage system adopts a central control station to assist intelligent operation, the operation mode is a mode of combining manual button operation of the machine, operation of an operation station in a raw material proportioning region and remote operation of the central control, an operator sets a water-material ratio and a slurry making amount in a human-computer interface, the system controls the material feeding speed according to the set parameters to control the ratio of water to raw materials for making slurry, the concentration of the slurry is guaranteed to be ground into slurry, and the slurry is pumped to a storage tank by a slurry pump to be stored for later use.
When the state alarm system responds, the equipment operation state information is wrong, the material level information is wrong, or the material level exceeds a preset range, the feeding proportion of the mill is wrong, the storage tank is abnormally stopped when stirring, and the central control system can generate alarm information.
When the slurry preparation and storage system takes equipment operation safety guarantee measures, an emergency stop button is arranged on the site; the storage tank is provided with a sensor for detecting whether the stirring of the storage tank runs or not, so that the normal running of the storage tank is ensured. The control system of the slurry preparation and storage system can adopt a Siemens S7-ET200 remote site and a field signal acquisition device.
In an exemplary, metering and batching mixed pouring system, as shown in fig. 2, the metering and batching mixed pouring system corresponds to the pouring ferry PLC control system 121 in the cutting subsystem 502, and is used for mixing, stirring and heating raw materials according to a process sequence and requirements, then placing the raw materials into a mold and counting production data so as to analyze and process the production process.
The control mode of the metering and batching mixed pouring system is that a central control station assists intelligent operation, the operation mode is that an operation station of an original batching area operates, after the system automatically measures the density of slurry, materials such as additional cold water, hot water, lime, cement and the like are automatically calculated according to a production formula, the materials are automatically mixed and heated according to the process requirements and the flow, and finally aluminum powder is added, stirred and placed in a mold.
And in the stirring process of the mixed materials in the pouring stirrer, the system measures the temperature of the mixed materials in real time, and determines whether to start steam heating or not according to the temperature rise condition in the specified time. And simultaneously, the cold-hot water ratio of the next die is automatically adjusted until steam heating is not needed.
When the state alarm system responds, the central control system can generate alarm information, wherein the equipment running state information is wrong, the material metering exceeds the process requirement range, the temperature alarm, the material metering overtime alarm and the valve state alarm are carried out.
When the metering, proportioning and mixing pouring system takes equipment operation safety guarantee measures, an emergency stop button is arranged on the site; the dry material screw adopts frequency conversion speed regulation, and the slurry pump adopts frequency conversion speed regulation, so that the material metering precision is ensured. The state of the valve or the motor is detected in real time, and the equipment is interlocked according to the related process requirements, so that the waste die caused by equipment failure is reduced. The related fault central control room can generate alarm information to prompt an operator to intervene and a maintainer to maintain. The control system of the metering and batching hybrid pouring system can adopt a Siemens S7-ET200 remote station, a temperature measuring sensor, a weight measuring sensor and the like.
In an exemplary pouring ferry vehicle control system, as shown in fig. 2, the pouring ferry vehicle control system also corresponds to the pouring ferry PLC control system 121 and the static parking ferry PLC control system 122 in the cutting subsystem 502, and the pouring ferry vehicle control system is configured to take an empty mold from an empty mold tunnel, send the empty mold to a pouring mixer for waiting pouring, and convey the mold to a drill rod inserting position after pouring.
The control mode of the metering and batching mixed pouring system adopts unattended intelligent operation, and the operation mode is button operation of the system or intelligent operation assisted by a central control station. When the state alarm system responds, the local information is sent to the central control system in real time, the central control system analyzes according to the real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarm information on the operation station.
When the metering, proportioning and mixing pouring system takes equipment operation safety guarantee measures, an emergency stop button is arranged on the site; the equipment is provided with a safety limit switch, a ferry vehicle for power supply and a sensor for overhead treatment, so that slurry is prevented from splashing. The control system of the metering, batching and mixing pouring system can adopt a control cabinet consisting of a Siemens S7-1200PLC system, and a traveling motor and a friction wheel are driven by a frequency converter to regulate the speed. The PLC, the frequency converter and the coding sensor form speed and displacement control; the positioning mode is used for position identification and positioning through the encoder and the proximity switch, and is combined with mechanical positioning of the positioning motor.
In an exemplary mode, the control system of the pre-curing ferry vehicle takes the die which reaches the cutting condition from the pre-curing room, walks to a die outlet channel, conveys the die to an outlet pin inserting position, and then conveys the die which is poured at the pin inserting position to a specified position of the pre-curing room.
The control mode of the pre-maintenance ferry vehicle control system is unattended intelligent operation; the operation mode is the button operation of the machine and the intelligent operation assisted by the central control station; the state alarm system sends the local information to the central control system in real time, and the central control system analyzes the real-time data and sends out an operation instruction, and the state of the equipment, the fault code and the alarm information are displayed on the operation station.
The operation safety guarantee measure of the equipment of the pre-maintenance ferry vehicle control system is that an emergency stop button is arranged on site; the equipment machine is provided with a safety limit switch. An infrared correlation sensor is arranged between the ferry vehicle and the pre-curing kiln mould, and if the infrared correlation sensor detects that the mould is abnormal, the ferry vehicle stops immediately, so that the safety operation of the ferry vehicle is ensured.
The control system of the pre-maintenance ferry vehicle control system is composed of a control cabinet consisting of a Siemens S7-1200PLC system, and a traveling motor and a friction wheel are driven by a frequency converter to regulate speed; the PLC, the frequency converter and the coding sensor form speed and displacement control.
The location mode of the control system of the pre-maintenance ferry vehicle is that the laser ranging sensor and the proximity switch are used for redundancy position identification and location, and the mechanical location of a location motor is combined.
Illustratively, the control system of the mold conveying friction wheel and the casting side plate conveying roller way is used for automatically conveying pre-cured molds to the lower part of the turnover blank moving machine and conveying empty molds to the casting ferry vehicle. And conveying the cut empty side plate to the lower part of the turnover stripper. The control mode of the system is unattended intelligent operation; the operation mode is that the central control system assists intelligent operation.
The state alarm system sends the information of the mould positions and the friction wheels to the central control system in real time, the central control system analyzes according to real-time data and sends an operation instruction, and the state of each mould position, the temperature of the pre-curing kiln, the pre-curing time of each mould in the pre-curing kiln, the color display of the cutting state of the mould, the temperature state of the pre-curing kiln, a fault code and alarm information are displayed on an operation station.
The safety guarantee measure of the equipment operation is that an emergency stop button is arranged on the site; the key sensors are processed for redundant configuration.
The control cabinet consists of a Siemens S7-ET200 system, the friction wheel under the inserted and pulled drill rod is driven in a variable frequency mode, and a mode proximity switch for detecting the die position is arranged on site.
Illustratively, the empty turnover demoulding machine control system is used for hoisting the maintained green bodies together with the mould vehicle and the side plates in the air for 90-degree turning, then placing the green bodies on the cutting conveying vehicle for mould opening and demoulding, hoisting the empty mould frame to return to the side plate conveying roller way to be recombined and clamped with the returned empty side plates, and conveying the green bodies to the mould returning track after turning for 90-degree returning. The control mode is unattended intelligent operation; the operation mode is the button operation of the machine and the centralized operation of the cutting area operation station to assist the intelligent operation.
The parameter setting and alarming system sends the local information to the central control system in real time, and the central control system analyzes the local information according to the real-time data, sends out an operation instruction and displays equipment state, fault codes and alarming information on an operation station.
The safety guarantee measure of the equipment operation is that an emergency stop button is arranged on the site; the equipment machine is provided with a safety limit switch; the key sensors are processed for redundant configuration. The control system is composed of a control cabinet and a Siemens S7-1200PLC system, wherein a walking motor is driven by a frequency converter to regulate speed, and a hydraulic proportional amplifier is promoted to regulate speed. The PLC, the frequency converter (proportional amplifier) and the encoder form speed and displacement control; the positioning mode is that the lifting walking encoder is positioned and the proximity switch is combined for redundancy confirmation.
Illustratively, the cutting machine control system is used for placing the green bodies on the cutting trolley, the cutting trolley moves forward to finish longitudinal cutting, the plates are milled with grooves, the green bodies are conveyed to the transverse cutting position by the cutting trolley after the longitudinal cutting is finished, the green bodies reach the transverse cutting position, transverse cutting and front and back cutting and peeling are carried out on the transverse cutting position, and the cut green bodies are conveyed to the lifting position by the cutting trolley. The control mode is unattended intelligent operation; the operation mode is as follows: there are 2 modes of operation. The button operation and the central control system of the cutting area are operated in a centralized way.
The parameter setting and alarming system sends local information to the central control system in real time, the central control system analyzes according to real-time data, sends operation instructions including speed, plate specification and the like, and displays equipment state, fault codes and alarming information on an operation station.
The safety guarantee measure of the equipment operation is that an emergency stop button is arranged on the site; the equipment machine is provided with a safety limit switch; the key sensors are processed for redundant configuration.
The control system comprises: the control cabinet consists of a Siemens S7-1200PLC system, and the trolley motor and the transverse cutting motor are driven by a frequency converter to regulate the speed. The PLC, the frequency converter and the cutting trolley encoder form speed and displacement control. The positioning mode is that a cutting trolley encoder is positioned, the transverse cutting position is positioned by the end face of a side plate, and the redundancy confirmation is combined with a trolley sensor.
Illustratively, the semi-finished product conveying mechanism control system is used for hoisting the cut blanks and the side plates from the cutting trolley onto the overturning platform, and after the overturning platform removes waste bottom skins, the side plates and the blanks are hoisted and conveyed to the steam curing trolley in sequence. The control mode is unattended intelligent operation; the operation mode is the local button operation and the centralized operation of the central control system of the cutting area.
The parameter setting and alarming system sends local information to the central control system in real time, the central control system analyzes according to real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarming information on an operation station. The safety guarantee measure of the equipment operation is that an emergency stop button is arranged on the site; the equipment machine is provided with a safety limit switch; the key sensors are processed for redundant configuration.
The control system is composed of a control cabinet and a Siemens S7-1200PLC system, wherein a walking motor is driven by a frequency converter to regulate speed, and a hydraulic proportional amplifier is promoted to regulate speed. The PLC, the frequency converter (proportional amplifier) and the encoder form speed and displacement control; the positioning mode is that the lifting walking encoder is positioned and is combined with the redundancy confirmation of the photoelectric sensor.
Illustratively, after the bottom skin removing overturning platform and the edge cleaning machine are used for placing the green body on the overturning platform, the overturning platform clamps the side plate, the side plate is overturned to be vertical, the large bottom plate is loosened, and the edge cleaning machine automatically and completely removes the waste materials at the top and the bottom and then overturns the side plate; the control mode is unattended intelligent operation; the operation mode comprises 2 operation modes: the central control system for button operation and cutting area of the machine is used for centralized operation management and intelligent operation.
The parameter setting and alarm system comprises: the information of the local machine is sent to a central control center in real time, the central control center analyzes according to real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarm information on an operation station; the equipment operation safety guarantee measures are as follows: an emergency stop button is arranged on the spot; the equipment machine is provided with a safety limit switch; the key sensors are subjected to redundant configuration processing; the control system comprises: the control cabinet consists of a Siemens S7-1200PLC system, and the speed of the turnover table is regulated by a hydraulic proportional amplifier.
In an exemplary embodiment, the pre-kettle marshalling ferry vehicle control system is used for conveying blanks pre-woven on a return line and trolleys to a track needing marshalling together. Its control mode is unmanned on duty intelligence operation, and the operation mode has 2 kinds of operation modes: the central control system for button operation and cutting area of the machine is used for centralized operation management and intelligent operation.
The parameter setting and alarm system comprises: the local information is sent to a central control system in real time, the central control system analyzes according to real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarm information on an operation station; the equipment operation safety guarantee measures are as follows: an emergency stop button is arranged on the spot; the equipment machine is provided with a safety limit switch; a grating sensor is arranged between the ferry vehicle and the marshalling area, and if the grating sensor detects that the steam-curing vehicle is not normal, the ferry vehicle stops immediately to ensure that the ferry vehicle can run safely; the control system comprises: the control cabinet consists of a Siemens S7-1200PLC system, and the walking motor and the friction wheel are driven by a frequency converter to regulate the speed. The PLC, the frequency converter and the encoder form speed and displacement control; the positioning mode is as follows: the position identification and the positioning are carried out through the encoder and the proximity switch, and the mechanical positioning of the positioning motor is combined.
Illustratively, the tractor control system is used for grouping blanks and trolleys conveyed by the grouping ferry vehicle in front of the kettle in sequence by the grouping tractor; when the blank needs to be put into the kettle, the blank grouped in front of the kettle is sent into the kettle. The control mode is as follows: unattended intelligent operation; the operation mode comprises 2 operation modes: the central control system for button operation and cutting area of the machine is used for centralized operation management and intelligent operation.
The parameter setting and alarm system comprises: the information of the local machine is sent to a central control center in real time, the central control center analyzes according to real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarm information on an operation station; each channel of the pre-curing kiln in front of the kettle is provided with 1 temperature sensor, a secondary instrument for displaying temperature is arranged on site, and meanwhile, the temperature enters a control center, and the temperature of the pre-curing kiln in front of the kettle is monitored in real time according to alarm temperature setting; equipment operation safety guarantee measures: an emergency stop button is arranged on the spot; the key sensors are subjected to redundant configuration processing; and a grating sensor is arranged between the marshalling ferry vehicle and the marshalling area, and if the grating sensor detects that the steam-curing vehicle is not in a normal range, the marshalling tractor cannot push, so that the safe operation of the tractor is ensured.
The control system comprises: the control system consists of Siemens S7-1500PLC, and is provided with a photoelectric sensor or a proximity switch for detecting a tractor hook and a steam curing trolley on site.
Illustratively, the control system of the primary and secondary ferry vehicles for discharging the kettles is used for hooking out the products steamed in the kettles in sequence and pushing the products to the rail for returning the kettles, and the control mode is unattended intelligent operation; there are 2 operation modes: the button operation of the machine, the centralized operation management of the finished product area central control system and the intelligent operation.
The state alarm system sends the local information to the central control system in real time, and the central control system analyzes the local information according to the real-time data, sends out an operation instruction and displays equipment state, fault codes and alarm information on an operation station.
The equipment operation safety guarantee measures comprise: firstly, an emergency stop button is arranged on the scene; the equipment is provided with a safety limit switch; and a grating sensor is arranged between the operation areas of the devices, and if the grating sensor detects that the steam-curing vehicle is abnormal, the ferry vehicle stops immediately, so that the safety operation of the ferry vehicle is ensured.
The control system comprises the following components: the control cabinet consists of a Siemens S7-1200PLC system, and the walking motor and the push-pull speed regulation are driven by a frequency converter. The PLC, the frequency converter and the encoder form speed and displacement control; the positioning mode is that the encoder and the proximity switch are used for position identification and positioning, and the mechanical positioning of the positioning motor is combined.
Illustratively, the finished product crane control system is used for hoisting finished products and side plates on the return track to the side plate return roller way, and the air steaming trolley automatically returns for recycling. The control mode is unattended intelligent operation; the operation mode comprises 2 operation modes: the button operation of the machine, the centralized operation management of the finished product area central control system and the intelligent operation.
The state alarm system sends the local information to the central control system in real time, and the central control system analyzes the local information according to the real-time data, sends out an operation instruction and displays equipment state, fault codes and alarm information on an operation station. The equipment operation safety guarantee measures comprise: firstly, an emergency stop button is arranged on the spot; the equipment is provided with a safety limit switch; and thirdly, redundant configuration processing is carried out on the key sensor.
The control system comprises: the control cabinet consists of a Siemens S7-1200PLC system, and the walking motor drives the speed regulation through a frequency converter to promote the speed regulation of the hydraulic proportional amplifier. The PLC, the frequency converter (proportional amplifier) and the encoder form a speed and displacement control loop; the positioning mode is that the position is identified and positioned through an encoder and an off switch, and the mechanical positioning of a positioning motor is combined.
Illustratively, the severing machine control system is used for separating layer by layer according to the product specification; the control mode is unattended intelligent operation. There are 2 modes of operation: the button operation of the machine and the centralized operation management intelligent operation of the finished product area central control are carried out;
the state alarm system comprises: the local information is sent to the central control system in real time, the central control system analyzes according to the real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarm information on the operation station. The equipment operation safety guarantee measures comprise: firstly, an emergency stop button is arranged on the scene; the equipment is provided with a safety limit switch; and thirdly, redundant configuration processing is carried out on the key sensor.
The control system comprises: the control cabinet consists of a Siemens S7-1200PLC system, an encoder is adopted for detecting the displacement of the lifting platform, and the plate severing machine adopts a hydraulic proportional valve to adjust the speed of the lifting platform so as to realize the smooth stop of the rising or falling of the blank; the PLC, the lifting proportional amplifier and the encoder form a speed and displacement control loop. The positioning mode is that the lifting encoder is positioned; the separation state detection is provided with a detection sensor for completely separating the two-layer product.
Illustratively, the single-mold blank clamping machine control system is used for clamping the building blocks which are broken off by the board breaking machine onto the double-mold unstacking machine, and clamping the plates onto the plate conveying chain; the control mode is unattended intelligent operation. The operation mode comprises 2 operation modes: the button operation of the machine, the centralized operation management of the finished product area central control system and the intelligent operation.
The state alarm system sends the local information to the central control system in real time, and the central control system analyzes the local information according to the real-time data, sends out an operation instruction and displays equipment state, fault codes and alarm information on an operation station. The equipment operation safety guarantee measures comprise:
firstly, an emergency stop button is arranged on the scene;
the equipment is provided with a safety limit switch;
and thirdly, redundant configuration processing is carried out on the key sensor.
The control system adopts a control cabinet consisting of a Siemens S7-1200PLC system, a walking motor drives and regulates speed through a frequency converter, and a hydraulic proportional amplifier is promoted to regulate speed; the PLC, the frequency converter (proportional amplifier) and the encoder form a speed and displacement control loop; the positioning mode is that the position is identified and positioned through an encoder and an off switch, and the mechanical positioning of a positioning motor is combined; the control mode of the clamps is that each group of clamps can be independently selected according to the specification of the product.
Exemplarily, a double-die stacking chain control system is controlled by positions under a single-die finished product lifting appliance, so that the end faces of each die are ensured to stop at the same position, and 2 single-die end faces on a stacking chain are ensured to be aligned and used for combining and drawing 2 single dies together to achieve the purpose of combining the double dies together; the state alarm system comprises: the local information is sent to the central control system in real time, the central control system analyzes according to the real-time data, sends out an operation instruction, and displays equipment state, fault codes and alarm information on the operation station.
The equipment operation safety guarantee measures comprise:
there is a sudden stop button on site.
The equipment is provided with a safety limit switch;
and thirdly, redundant configuration processing is carried out on the key sensor.
The control system of the system consists of a control cabinet and a Siemens S7-1200PLC system.
It should be noted that, in the field device control system based on the industrial ethernet and the control bus according to the embodiment of the present invention, the operating voltage of the electrical appliance is 380V or 220V, the frequency is 50/60Hz, and the low voltage DC24V is adopted. The control system combines the industrial Ethernet and the field control bus technology, takes a Siemens commercial computer as an operation station or an engineer station, takes Siemens S7-1500 series CPUs as a centralized management control center, and manages the field level S7-1200 series and the ET200 series through the Ethernet. The operation parameters of the field equipment can be modified at any time on the operation station, the requirements of different products are met, the operation state of the field equipment can be monitored, the state of each equipment on the field is displayed on a computer at any time, and operators and maintenance personnel can conveniently observe the operation condition of the field equipment; and each master station and each slave station PLC reserve 15 percent of I/O standby points.
In the embodiment, each mould box is provided with an independent mould position detection in an inductive proximity switch, the temperature measurement adopts PT100 (diameter is 8mm, range is 0-250) detection, and a temperature instrument is provided, so that a current 4-20mA signal is output.
It should be noted that, the protection grade of the indoor control cabinet is IP43, and the indoor control cabinet does not drop paint and rust. The shell and the button box of the outdoor dust collector are made of stainless steel, and an explosion-proof junction box and a switch are used in dangerous environments such as a foaming agent warehouse, a boiler room and the like. Fluorescent lamps and cooling fans for illumination are required to be arranged in all power distribution cabinets; the proximity switch and the photoelectric switch adopt the old easy-to-measure or the Beijiafu sold on the market, and the weighing sensor adopts the Mettlertummuch sold on the market. A stainless steel table top of the central control console; protection level IP55 of field operation desk and operation box; the field maintenance power box is provided with a 36V safety power supply.
It should be noted that all cables outside the cable trench are laid by using bridges, the power system ground and the instrument protection ground are separately laid, and corresponding grounding measures should be made between bridges and in the cable trench. And (4) making an electric lightning protection measure, and installing a qualified lightning arrester if necessary.
Referring to fig. 3, an embodiment of the present invention further provides a field device control method based on an industrial ethernet and a control bus, which is applied to an upper computer 400 connected to all devices in a field, and the method includes:
step S1, obtaining a start signal of automatic operation of independent equipment in all on-site equipment, and automatically operating the current equipment based on the start signal;
step S2, the PLC control module 100 connected with the current equipment collects data of the current equipment and transmits the data to the centralized management control center 300 through the field control bus 200 and the industrial Ethernet;
step S3, the central management control center 300 uploads the received data to the upper computer 400, and the upper computer 400 monitors the working state and the fault information of the field device and gives an alarm when the data is abnormal.
In this embodiment, the upper computer 400 is used to perform remote centralized operation on the field devices, the local console 600 is used to modify the operating parameters of the field devices, monitor the operating states of the field devices, and display the states of the field devices on the computer at any time.
It should be noted that, the industrial ethernet and control bus based field device control method uses the industrial ethernet and control bus based field device control system as described above to perform the above steps, and therefore, the operation process of the industrial ethernet and control bus based field device control method in this embodiment is not described in detail.
In an embodiment, there is further provided a computer device in an embodiment of the present invention, including at least one processor, and a memory communicatively connected to the at least one processor, where the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor to cause the at least one processor to execute the industrial ethernet and control bus based field device control method, and the processor executes the instructions to implement the steps in the method embodiments.
As shown in fig. 4, in an embodiment of the invention, a computer device 1000 is provided, the computer device 1000 comprising a memory 1002 and a processor 1001, the memory 1002 having stored therein a computer program, the processor 1001 being configured for executing the computer program stored in said memory 1002. The memory 1002 is configured to store one or more computer instructions, wherein the one or more computer instructions are executed by the processor 1001 to implement the steps of the above-described method embodiments:
acquiring initial signals of automatic operation of independent equipment in all on-site complete equipment, and automatically operating the current equipment based on the initial signals;
the PLC control module 100 of the equipment connected with the current equipment acquires data of the current equipment and transmits the data to the centralized management control center 300 through the field control bus 200 and the industrial Ethernet;
the centralized management control center 300 uploads the received data to the upper computer 400, and the upper computer 400 monitors the working state and the fault information of the field device and gives an alarm when the data is abnormal.
In an embodiment of the present invention, there is further provided a storage medium having a computer program stored thereon, which when executed by a processor, performs the steps in the above-mentioned method embodiments:
acquiring initial signals of automatic operation of independent equipment in all on-site complete equipment, and automatically operating the current equipment based on the initial signals;
the equipment PLC control module 100 connected with the current equipment acquires data of the current equipment and transmits the data to the centralized management control center 300 through the field control bus 200 and the industrial Ethernet;
the centralized management control center 300 uploads the received data to the upper computer 400, and the upper computer 400 monitors the working state and the fault information of the field device and gives an alarm when the data is abnormal.
It will be understood by those skilled in the art that all or part of the processes of the methods of the embodiments described above can be implemented by hardware instructions of a computer program, which can be stored in a non-volatile computer-readable storage medium, and when executed, can include the processes of the embodiments of the methods described above. Any reference to memory, storage, database or other medium used in the embodiments provided herein can include at least one of non-volatile and volatile memory.
In summary, the field device control system and method based on the industrial ethernet and the control bus provided by the invention realize automatic control of all field complete devices, automatically start the next process device through on-line confirmation of field signals, and after the devices are started, the devices control the operation devices in sequence, thereby reducing the failure rate, lightening the operation intensity and reducing unnecessary time waste; the system adopts various operation modes by combining an unattended full-automatic operation mode with regional centralized automatic management and manual and semi-automatic button operation of the system, thereby reducing the shutdown risk of the equipment as much as possible; the mobile equipment is convenient and fast to communicate by using an industrial Ethernet networking wireless connection mode, and the risk of disconnection when a traditional network cable or optical fiber is used for towline movement is reduced; the safety protection effect is good, false operation caused by sensor faults is avoided by adopting the sensor with redundant configuration, and the safety protection device is more stable and safe; when the fault is judged, an equipment alarm code is provided, so that maintenance personnel can conveniently and quickly lock the fault reason, and the time for the maintenance personnel to troubleshoot the fault is shortened; the field device is used for controlling a systematic device program to carry out remote maintenance, and the time for troubleshooting of maintenance personnel is shortened.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention.
Claims (10)
1. A field device control system based on industrial Ethernet and control bus is characterized in that the system is applied to an upper computer connected with all field complete equipment, and the system comprises:
the equipment PLC control module is used for being connected and controlled with the single bodies of the independent equipment of all the on-site complete equipment, and managing and maintaining the single bodies of the equipment nearby;
the field control bus is used for connecting equipment PLC control modules of all on-site complete equipment and connecting a centralized management control center by combining an industrial Ethernet;
the centralized management control center is connected with the equipment PLC control modules of all on-site complete equipment through an industrial Ethernet network and is used for acquiring data of all on-site complete equipment to an upper computer;
and the upper computer is used for monitoring the working state and the fault information of the field equipment, adjusting the process data of the field equipment and performing remote centralized operation on the field equipment.
2. The industrial ethernet and control bus based field device control system of claim 1, wherein the independent devices of all the complete devices in the field are installed with device PLC control modules, the device PLC control modules form a PLC control system for independently controlling the individual devices, and the PLC control system is installed in the individual device without wiring, and is used for operating the individual device in situ during device maintenance.
3. The industrial ethernet and control bus based field device control system of claim 2, further comprising a centralized management subsystem, wherein the centralized management subsystem is connected to the PLC control system of at least one single device via Profinet communication protocol, and wherein the centralized management subsystem is connected to the local console for local operation of the single devices during maintenance of the single devices and modifying the operating parameters of the field devices.
4. The industrial ethernet and control bus based field device control system of claim 3, wherein the centralized management subsystem is connected to the switch via the field control bus, and the switch of the centralized management subsystem is connected to the switch of the centralized management control center via the industrial ethernet for remote transmission of the collected data.
5. The industrial ethernet and control bus based field device control system of claim 4, wherein the switch of the centralized management control center is connected to an upper computer through an industrial ethernet, and the upper computer is at least one central control PC connected to the centralized management control center.
6. The industrial ethernet and control bus based field device control system of claim 5, wherein the host computer is a central PC terminal using a computer as a host computer operation station, the centralized management control center is a siemens S7-1500 series PLC, and the industrial automation control system with full factory coverage is formed by ethernet networking field level S7-1200 series and ET200 series devices.
7. The industrial ethernet and control bus based field device control system according to any one of claims 1 to 6, wherein when the PLC control system of the single device automatically operates, the independent devices of each station automatically operate according to the preset sequence and requirement of the process, and the start signal of the automatic operation of the device automatically starts the device by the result of the last device action on the process flow through field signal or communication.
8. The industrial ethernet and control bus based field device control system of claim 4, wherein said centralized management subsystem comprises a batching subsystem, said batching subsystem is connected to a batching on-site console, said batching subsystem is connected to the PLC control system of the powder cell plant and the PLC control system of the slurry cell plant via the Profinet communication protocol.
9. The industrial ethernet and control bus based field device control system of claim 8, wherein said centralized management subsystem comprises a cutting subsystem, said cutting subsystem is connected to the front in-situ console of the tank, said cutting subsystem is connected to the pouring ferry PLC control system, the static ground remote PLC control system, the stacker PLC control system, the flipping station PLC control system, the flip demolding PLC control system, the tank entering PLC control system through Profinet communication protocol;
the centralized management subsystem further comprises a post-kettle subsystem, the post-kettle subsystem is connected with a post-kettle on-site operation table, and the post-kettle subsystem is connected with a kettle discharge swinging PLC control system, a stacker crane PLC control system, a trigger breaking PLC control system, a blank clamping PLC control system, a blank translation PLC control system and a post-kettle ground remote PLC control system through a Profinet communication protocol.
10. An industrial ethernet and control bus based field device control method, wherein the industrial ethernet and control bus based field device control method employs the industrial ethernet and control bus based field device control system of any one of claims 1 to 9 to perform field device based control operation; the field device control method based on the industrial Ethernet and the control bus comprises the following steps:
acquiring initial signals of automatic operation of independent equipment in all on-site complete equipment, and automatically operating the current equipment based on the initial signals;
the equipment PLC control module connected with the current equipment acquires data of the current equipment and transmits the data to the centralized management control center through the field control bus and the industrial Ethernet;
the centralized management control center uploads the received data to the upper computer, the upper computer monitors the working state and the fault information of the field equipment, and an alarm is given when the data are abnormal.
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