Today, the automated measurement and control technology for the manufacturing process is developing in the direction of the trol system. FCS will replace the DCS. This is the basic consensus of the industrial control industry. However, FCS is developed on the basis of DCS. If the company establishes a perfect DCS and now transitions to FCS, it must carefully consider the return on existing investment of existing investment. In addition, from the inheritance and control of technology The fieldbus control system FCS should also be compatible with DCS. The FCS implements the control function and moves down to the field level, so that the DCS multi-layer network is flattened, and the independent functions of each field device node are strengthened. It is necessary to increase the sum in the FCS. Improve data communication between field sub-layer devices. For historical reasons, DCS usually has large control cabinets to coordinate the various devices, while emphasizing layer-to-layer data transmission. It can be seen that the two controls have their own advantages in strategy. In order to perfect the control methods and means of FCS, it is necessary to learn from some control ideas of DCS. How to improve the production measurement and control capabilities of enterprises on the basis of existing technologies has also become a hot research topic. This paper proposes the concept of FCS and DCS hybrid measurement and control system based on the experimental system of axle production line.
1Axle production line structure and function introduction Before the introduction of the reducer performance test machine and the axle performance test machine, the production workshop of a certain automobile factory consists of the following parts: reducer assembly line, reducer transmission line, axle assembly line, axle Conveyor line, axle cleaning oven and paint drying room.
The working cycle of the reducer assembly line, the reducer conveying line, the axle assembly line, the axle cleaning drying room and the painting drying room are controlled by the workshop production monitoring center, but the production line workers can realize the reduction gear assembly line through the operation station. The movement of the single assembly trolley is controlled to realize the monitoring of the working condition of the axle cleaning drying room and the painting drying chamber and the operation of the beat control, and upload to the production monitoring center. The axle conveying line completes the transportation of the axles on the axle assembly line to the warehouse, and passes through the axle cleaning drying room and the painting drying room on the way. Due to the unpredictable situation in the assembly of the axle, such as certain parts cannot be delivered on time. To the impact of the production line, the production cycle is controlled by the operator station.
Considering that the reducer performance test machine and the axle performance test machine are introduced on the basis of the completed production line, in addition to completing the test items of the test machine, the new equipment must be well integrated with the original system to realize the test project. The parameters are uploaded to the workshop production monitoring center, and finally the data sharing in the workshop is reached. Before implementing the retrofit, the cost factors of utilizing the integrity and retrofit of the entire control system must also be considered.
From the above factors, it is decided to use the FCS and DCS input/output bus integration technology, that is, the fieldbus interface unit A80BD (E)J61BT13 interface card is attached to the I/O bus of the workshop production monitoring center. In this way, on the basis of maintaining the entire hardware structure of the original system, it is only necessary to add a software module to complete the communication. Since the interface card already contains a dynamic link library of functions required for communication, the transformation scheme has a strong Realistic feasibility. After the introduction of the reducer performance tester and the axle performance tester, the layout of the workshop is shown in Figure 1.
After the introduction of the test machine, the functions of the previous components of the axle production line remain unchanged, and the functions of the reducer performance tester and the axle performance tester are added. The reducer performance testing machine can fully realize the clamping and positioning of the reducer. The test items mainly include: assembly running resistance torque test, differential test, gear contact imprint test and so on. The axle performance testing machine can fully realize the clamping and positioning of the axle. The test items include: efficiency test, assembly running resistance torque test, noise test and sealing test instrumentation and testing modern manufacturing engineering 2005 (5). In addition, in addition to completing the test project, the two test machines also enable data storage and data exchange with the control unit. Both the operator station and the engineering station can perform various operational tasks on the two test stands.
2 Control technology points of improved axle production line 2 1 Hardware architecture of FCS and DCS input/output bus integration technology After introducing the axle performance tester and reducer performance test machine, in order to support two test machines and other workshops The communication between devices is realized. The data of the two test machines is connected into the existing DCS system. It is relatively simple and feasible to use the field bus and DCS input/output bus integration technology. The implementation of the scheme was as follows. The fieldbus interface board was installed in the existing control system. Mitsubishi was used to communicate with the tester control unit through CCLINK. The overall network structure is shown in Figure 2.
The main function of the engineering station is to configure the system hardware, form a control strategy, download the generated configuration information to each operator station and PLC station, and form a monitoring center with specific functions. The A80BD (E) J61BT13 interface card can communicate with the PC through the PCI bus. The engineer station can take the function of calling the interface card to read and write the data in the interface card, or directly call the mature software platform to test. The PLC directly operates in communication with the lower computer such as PLC. The PLC must add a communication module such as FX2N32 CCL on the existing basis. In addition, in the PLC main program, it is necessary to program the special registers that implement CCLINK communication and then communicate each communication. The module sets the exact station address according to the design requirements. Finally, the main station (monitoring center) and the PLC slave station can be connected with the existing system by connecting the standard cable and the terminating resistor. The communication diagram between the interface card and the external device is shown in Figure 3. Due to space limitations, the implementation of the integration technology in the reducer performance test machine is emphasized, and the implementation in the axle performance test machine is similar.
2 2 Brief description of the main communication through the reducer performance tester The speed reducer performance test machine adopts the form of mechanical open type, and all the tests of the final drive are realized under the control of the programmable controller (PLC) to realize automatic operation. The test bench has a set of measuring devices and alarm control devices, which can measure various parameters of the final drive, such as speed, torque, etc., and once it does not match the set parameters, even when a fault occurs, it can alarm and interrupt control until Terminate the run and upload the status data to the database for saving. The test items mainly include: efficiency test, assembly running resistance torque test, differential test, gear contact imprint test, etc.
Data exchange between blocks FX2N and FX2N32CCL realize the data exchange with the master station through the cache built on the 16-bit RAM. The cache unit not only supports remote data reading but also supports data writing. Cache 0 23 is used in the system, which respectively represent the data content of different meanings. The TO command can be used to write PLC commands and parameters to the cache and reach the master station via the CCLINK bus. The FROM command can be used to download the commands and parameters issued by the master station to the local PLC.
Data exchange between J61BT13 interface cards, the control station (referring to the engineering station or the operation station) transmits the gear ratio of the reducer to the programmable controller, the qualified set value of each test item, the motion parameters of the inverter and the magnetic powder brake The output torque value, etc., is shown in Figure 4a for the FX2N to read data from the control station.
Instrumentation and Inspection Modern Manufacturing Engineering 2005 (5) where FX2N32CCL is located in the No. 0 slave of the programmable controller, the downloaded data is located in the FX2N32CCL No. 0 and No. 1 buffer, and the data is downloaded to the programmable controller M. 0 M Stored in 15 internal relays. The downloaded parameters can then be used to modify the control parameters in the programmable controller.
At the same time, the programmable controller uploads test data of the reducer that performs the test each time to the control station, so that the engineer can record and improve the manufacturing process. The programmable controller uploads data to the control station, such as the slave station No. 0 where the FX2N32CCL is located. The programmable controller first writes the data to be uploaded to the internal register D100 D, and then writes it to the No. 8 buffer No. 23 of the FX2N32CCL. The data is uploaded to the control station during the bus scan cycle.
2 2 2 Data exchange between touch screen (HM I) and PLC The touch screen adopts Mitsubishi's F930G0T graphic display terminal and has two connectors, which are DB9 hole type connectors (RS connector can communicate with PLC through RS232). The connector can connect to the personal computer that creates the screen data, complete the data transfer and realize the monitoring of the PLC by the host computer (PC), and also realize the application of the display terminal to monitor multiple PLCs through the port.
The touch screen is directly connected to the programming port of the PLC through RS422, which can realize the function of the operation station. The content of the display and control is determined by the screen data created by the screen creation software on the personal computer. The layout of the components displayed on the screen data designation screen and the corresponding control actions performed by the touch keys have the function of displaying the word data in numerical values ​​or bar graphs. The test data can be displayed in real time through it, and the test data can be sent to the engineering station through the touch button control for the non-conforming product. The switch can be used to change the state of the bit data and access the data function according to the actual working condition of the field.
2 2 3 Communication between inverter and PLC The inverter has a wealth of various operating parameters setting functions and perfect fault diagnosis and protection functions, high reliability and easy operation. Connect the communication interface of the inverter to the PLC through the communication cable (as shown in Figure 5). The user program can be used to operate the inverter, monitor and read and write the parameters. In practical application, it controls the motor to run forward or reverse according to the specified different speeds under different loads according to the PLC's control commands to simulate the operation of the car at different speeds. Make necessary settings for communication between the PLC and the inverter. The communication format of the inverter and PLC must be set at initialization. The inverter needs to set its 124 parameters. The PLC realizes the serial data transmission by changing its special register D8120.
After the setting is completed, the transfer between the PLC and the inverter can be performed.
3 Conclusion This paper explores the specific application of FCS and DCS input/output bus integration technology, and studies how to make the axle and reducer test machine and the on-site control network of the workshop integrated in the axle production line, and can be realized by engineering. The use of bus integration technology to transform existing systems is a wise move, both economically and technically, to take care of both the real situation and the development of FCS.
1Axle production line structure and function introduction Before the introduction of the reducer performance test machine and the axle performance test machine, the production workshop of a certain automobile factory consists of the following parts: reducer assembly line, reducer transmission line, axle assembly line, axle Conveyor line, axle cleaning oven and paint drying room.
The working cycle of the reducer assembly line, the reducer conveying line, the axle assembly line, the axle cleaning drying room and the painting drying room are controlled by the workshop production monitoring center, but the production line workers can realize the reduction gear assembly line through the operation station. The movement of the single assembly trolley is controlled to realize the monitoring of the working condition of the axle cleaning drying room and the painting drying chamber and the operation of the beat control, and upload to the production monitoring center. The axle conveying line completes the transportation of the axles on the axle assembly line to the warehouse, and passes through the axle cleaning drying room and the painting drying room on the way. Due to the unpredictable situation in the assembly of the axle, such as certain parts cannot be delivered on time. To the impact of the production line, the production cycle is controlled by the operator station.
Considering that the reducer performance test machine and the axle performance test machine are introduced on the basis of the completed production line, in addition to completing the test items of the test machine, the new equipment must be well integrated with the original system to realize the test project. The parameters are uploaded to the workshop production monitoring center, and finally the data sharing in the workshop is reached. Before implementing the retrofit, the cost factors of utilizing the integrity and retrofit of the entire control system must also be considered.
From the above factors, it is decided to use the FCS and DCS input/output bus integration technology, that is, the fieldbus interface unit A80BD (E)J61BT13 interface card is attached to the I/O bus of the workshop production monitoring center. In this way, on the basis of maintaining the entire hardware structure of the original system, it is only necessary to add a software module to complete the communication. Since the interface card already contains a dynamic link library of functions required for communication, the transformation scheme has a strong Realistic feasibility. After the introduction of the reducer performance tester and the axle performance tester, the layout of the workshop is shown in Figure 1.
After the introduction of the test machine, the functions of the previous components of the axle production line remain unchanged, and the functions of the reducer performance tester and the axle performance tester are added. The reducer performance testing machine can fully realize the clamping and positioning of the reducer. The test items mainly include: assembly running resistance torque test, differential test, gear contact imprint test and so on. The axle performance testing machine can fully realize the clamping and positioning of the axle. The test items include: efficiency test, assembly running resistance torque test, noise test and sealing test instrumentation and testing modern manufacturing engineering 2005 (5). In addition, in addition to completing the test project, the two test machines also enable data storage and data exchange with the control unit. Both the operator station and the engineering station can perform various operational tasks on the two test stands.
2 Control technology points of improved axle production line 2 1 Hardware architecture of FCS and DCS input/output bus integration technology After introducing the axle performance tester and reducer performance test machine, in order to support two test machines and other workshops The communication between devices is realized. The data of the two test machines is connected into the existing DCS system. It is relatively simple and feasible to use the field bus and DCS input/output bus integration technology. The implementation of the scheme was as follows. The fieldbus interface board was installed in the existing control system. Mitsubishi was used to communicate with the tester control unit through CCLINK. The overall network structure is shown in Figure 2.
The main function of the engineering station is to configure the system hardware, form a control strategy, download the generated configuration information to each operator station and PLC station, and form a monitoring center with specific functions. The A80BD (E) J61BT13 interface card can communicate with the PC through the PCI bus. The engineer station can take the function of calling the interface card to read and write the data in the interface card, or directly call the mature software platform to test. The PLC directly operates in communication with the lower computer such as PLC. The PLC must add a communication module such as FX2N32 CCL on the existing basis. In addition, in the PLC main program, it is necessary to program the special registers that implement CCLINK communication and then communicate each communication. The module sets the exact station address according to the design requirements. Finally, the main station (monitoring center) and the PLC slave station can be connected with the existing system by connecting the standard cable and the terminating resistor. The communication diagram between the interface card and the external device is shown in Figure 3. Due to space limitations, the implementation of the integration technology in the reducer performance test machine is emphasized, and the implementation in the axle performance test machine is similar.
2 2 Brief description of the main communication through the reducer performance tester The speed reducer performance test machine adopts the form of mechanical open type, and all the tests of the final drive are realized under the control of the programmable controller (PLC) to realize automatic operation. The test bench has a set of measuring devices and alarm control devices, which can measure various parameters of the final drive, such as speed, torque, etc., and once it does not match the set parameters, even when a fault occurs, it can alarm and interrupt control until Terminate the run and upload the status data to the database for saving. The test items mainly include: efficiency test, assembly running resistance torque test, differential test, gear contact imprint test, etc.
Data exchange between blocks FX2N and FX2N32CCL realize the data exchange with the master station through the cache built on the 16-bit RAM. The cache unit not only supports remote data reading but also supports data writing. Cache 0 23 is used in the system, which respectively represent the data content of different meanings. The TO command can be used to write PLC commands and parameters to the cache and reach the master station via the CCLINK bus. The FROM command can be used to download the commands and parameters issued by the master station to the local PLC.
Data exchange between J61BT13 interface cards, the control station (referring to the engineering station or the operation station) transmits the gear ratio of the reducer to the programmable controller, the qualified set value of each test item, the motion parameters of the inverter and the magnetic powder brake The output torque value, etc., is shown in Figure 4a for the FX2N to read data from the control station.
Instrumentation and Inspection Modern Manufacturing Engineering 2005 (5) where FX2N32CCL is located in the No. 0 slave of the programmable controller, the downloaded data is located in the FX2N32CCL No. 0 and No. 1 buffer, and the data is downloaded to the programmable controller M. 0 M Stored in 15 internal relays. The downloaded parameters can then be used to modify the control parameters in the programmable controller.
At the same time, the programmable controller uploads test data of the reducer that performs the test each time to the control station, so that the engineer can record and improve the manufacturing process. The programmable controller uploads data to the control station, such as the slave station No. 0 where the FX2N32CCL is located. The programmable controller first writes the data to be uploaded to the internal register D100 D, and then writes it to the No. 8 buffer No. 23 of the FX2N32CCL. The data is uploaded to the control station during the bus scan cycle.
2 2 2 Data exchange between touch screen (HM I) and PLC The touch screen adopts Mitsubishi's F930G0T graphic display terminal and has two connectors, which are DB9 hole type connectors (RS connector can communicate with PLC through RS232). The connector can connect to the personal computer that creates the screen data, complete the data transfer and realize the monitoring of the PLC by the host computer (PC), and also realize the application of the display terminal to monitor multiple PLCs through the port.
The touch screen is directly connected to the programming port of the PLC through RS422, which can realize the function of the operation station. The content of the display and control is determined by the screen data created by the screen creation software on the personal computer. The layout of the components displayed on the screen data designation screen and the corresponding control actions performed by the touch keys have the function of displaying the word data in numerical values ​​or bar graphs. The test data can be displayed in real time through it, and the test data can be sent to the engineering station through the touch button control for the non-conforming product. The switch can be used to change the state of the bit data and access the data function according to the actual working condition of the field.
2 2 3 Communication between inverter and PLC The inverter has a wealth of various operating parameters setting functions and perfect fault diagnosis and protection functions, high reliability and easy operation. Connect the communication interface of the inverter to the PLC through the communication cable (as shown in Figure 5). The user program can be used to operate the inverter, monitor and read and write the parameters. In practical application, it controls the motor to run forward or reverse according to the specified different speeds under different loads according to the PLC's control commands to simulate the operation of the car at different speeds. Make necessary settings for communication between the PLC and the inverter. The communication format of the inverter and PLC must be set at initialization. The inverter needs to set its 124 parameters. The PLC realizes the serial data transmission by changing its special register D8120.
After the setting is completed, the transfer between the PLC and the inverter can be performed.
3 Conclusion This paper explores the specific application of FCS and DCS input/output bus integration technology, and studies how to make the axle and reducer test machine and the on-site control network of the workshop integrated in the axle production line, and can be realized by engineering. The use of bus integration technology to transform existing systems is a wise move, both economically and technically, to take care of both the real situation and the development of FCS.
Four Wheel Electric Vehicle,Mini Four Wheel Car,4 Wheel Electric Car,4 Wheel Electric Vehicle
Xuzhou Hengshang Mechanical and Electrical Co., Ltd. , https://www.hengsenergy.com