技术领域Technical Field
本发明涉及制烟技术领域，尤其涉及一种烟包包装机组控制系统。The present invention relates to the technical field of cigarette making, and in particular to a control system for a cigarette packing machine.
背景技术Background technique
在目前国内制烟领域中，通常采用的烟包包装机组是20世纪90年代初从国外引进的卷烟包装设备，该设备的包装速度为400包/分钟，机组性能较为成熟，因而广泛应用于卷烟企业。In the current domestic cigarette manufacturing field, the commonly used cigarette packing unit is the cigarette packaging equipment introduced from abroad in the early 1990s. The packaging speed of this equipment is 400 packs/minute, and the unit performance is relatively mature, so it is widely used in cigarette companies.
以GDX2型号包装机组为例，该机组整条生产线包括硬盒包装机、CH盒外透明纸包装机、CT硬条包装机、CV条外透明纸包装机及机组电控系统等部分。具体到所采用的电控系统，则是国外设备供货商的专用控制系统“MICRO II”，“MICRO II”型控制系统年代较为久远，其是以PLC为核心的传统局域网工控模式，从目前烟企发展来看，该套电控系统至少包括三方面弊端：Take the GDX2 packaging unit as an example. The entire production line of the unit includes hard box packaging machine, CH box outer transparent paper packaging machine, CT hard strip packaging machine, CV strip outer transparent paper packaging machine and the unit electronic control system. Specifically, the electronic control system used is the dedicated control system "MICRO II" of a foreign equipment supplier. The "MICRO II" control system is relatively old. It is a traditional LAN industrial control mode with PLC as the core. From the current development of tobacco companies, this electronic control system has at least three disadvantages:
其一、由于其核心部件均是采用国外设备供货商生产的专用配件，因而国内烟企对于该包装机组的电气备件采购费用较高、采购周期较长，导致维护该套电控系统的综合成本居高不下。First, since its core components are all special accessories produced by foreign equipment suppliers, domestic tobacco companies have high procurement costs and long procurement cycles for the electrical spare parts of the packaging unit, resulting in high overall costs for maintaining the electronic control system.
其二、该套传统的电控系统的开发平台是国外设备供货商针对其产品特制的一个系统平台，其采用了专用的编程语言，这大大地增加了国内烟企技术人员对这套系统的掌握难度。Second, the development platform of this traditional electronic control system is a system platform specially designed by foreign equipment suppliers for their products. It uses a dedicated programming language, which greatly increases the difficulty for domestic tobacco company technicians to master this system.
其三、尤其地，该系统的核心控制模式的开放性较差，随着时代的进步、电子信息技术的发展，原电控系统的陈旧性和封闭性对发展迅速的国内烟企当前所需的个性化升级、信息化改造等需求，带来了不小的阻碍。Third, in particular, the core control mode of the system is less open. With the progress of the times and the development of electronic information technology, the obsolescence and closed nature of the original electronic control system have brought considerable obstacles to the personalized upgrades and information transformation currently required by the rapidly developing domestic tobacco companies.
发明内容Summary of the invention
本发明的目的是结合原有包装机组的各工位的机械结构、布局以及基本功能，提供一套全新的具备自主研发、设计、拓展等优势的烟包包装机组控制系统，以便国内烟企解决传统国外设备所带来的技术挖掘、兼容、创新、拓展等方面受阻的问题，由此摆脱并终结国外设备供货商对我国制烟产业革新的束缚和技术垄断。The purpose of the present invention is to combine the mechanical structure, layout and basic functions of each station of the original packaging unit to provide a new cigarette pack packaging unit control system with the advantages of independent research and development, design, and expansion, so that domestic tobacco companies can solve the problems of technology exploration, compatibility, innovation, and expansion brought about by traditional foreign equipment, thereby getting rid of and ending the constraints and technical monopoly of foreign equipment suppliers on the innovation of my country's tobacco industry.
本发明采用的技术方案如下：The technical solution adopted by the present invention is as follows:
一种烟包包装机组控制系统，包括：A cigarette packing machine control system, comprising:
基于IPC(在领域习惯上也称为工控机、产业电脑或工业电脑等)的控制组件、现场监测平台、现场管控平台以及数据采集联网装置。也即是说，为确保新设计的系统运行稳定，并且有足够的系统资源来确保系统的检测、控制精度，本发明采用的烟包包装机组控制系统采取了如下独立的四层框架设计思路：IPC控制层、智能监控层、管控上位层以及数据采集边缘计算层。Based on IPC (also known as industrial computer, industrial computer or industrial computer in the field), control components, field monitoring platform, field management and control platform and data acquisition networking device. In other words, in order to ensure the stable operation of the newly designed system and have sufficient system resources to ensure the detection and control accuracy of the system, the cigarette packaging unit control system adopted by the present invention adopts the following independent four-layer framework design ideas: IPC control layer, intelligent monitoring layer, management and control upper layer and data acquisition edge computing layer.
所述控制组件包括设于主电控柜内的主站控制模块以及与所述主站控制模块通讯的第一I/O从站模块，还包括经由交换机分别与所述主站控制模块通讯的子电控柜内的第二I/O从站模块和模拟量输入模块；其中，所述子电控柜为多个，且分散布置在包装机组上的相应各工位的机身处。换言之，在上述框架基础上，具体构思是分布式采集+集中管理的模式，各分布式I/O从站与嵌入式PC控制器主站之间建立通讯，确保数据传输的高速和稳定可靠。具体来说，可以通过以太网总线实现一网到底，协议处理可直达各I/O层，无需任何下层子总线、且无网关延迟，单一总线系统便可涵盖所有设备工位，在实际操作中可以以最为简化的拓扑结构完成设备高速控制的任务，并确保整个系统的稳定性和高效性。The control component includes a master station control module arranged in the main electric control cabinet and a first I/O slave station module communicating with the master station control module, and also includes a second I/O slave station module and an analog input module in a sub-electric control cabinet that communicate with the master station control module via a switch; wherein the sub-electric control cabinets are multiple and are dispersedly arranged at the body of each corresponding station on the packaging unit. In other words, based on the above framework, the specific concept is a distributed acquisition + centralized management mode, and communication is established between each distributed I/O slave station and the embedded PC controller master station to ensure high-speed, stable and reliable data transmission. Specifically, the Ethernet bus can be used to achieve a one-stop network, and the protocol processing can directly reach each I/O layer without any lower-level sub-bus and gateway delay. A single bus system can cover all equipment stations. In actual operation, the task of high-speed control of equipment can be completed with the most simplified topology structure, and the stability and efficiency of the entire system can be ensured.
所述现场监测平台、所述现场管控平台以及所述数据采集联网装置分别与所述主站控制模块通讯；且所述数据采集联网装置用于将机组数据传输至外部的数据服务器和/或无线终端；所述现场监测平台以及所述现场管控平台均具有可视化的人机交互界面。通过上述设计，无需繁杂且冗余的测量仪器，通过可视化的人机交互界面，便可实时地对各监测信号状态、选通相位、检测曲线进行有效监测和管控，极大地方便了操作人员的现场应用。具体来说，可以采用不同的表现形式体现不同的检测和剔除状况，并还可以将实时数据与3D可视化仿真进行关联，管控平台还可以配置故障专家诊断库，用来协助操作人员快速查找、解决该系统的电气故障。The field monitoring platform, the field control platform and the data acquisition networking device communicate with the main station control module respectively; and the data acquisition networking device is used to transmit the unit data to an external data server and/or wireless terminal; the field monitoring platform and the field control platform both have a visual human-computer interaction interface. Through the above design, there is no need for complicated and redundant measuring instruments. Through the visual human-computer interaction interface, the status of each monitoring signal, the selection phase, and the detection curve can be effectively monitored and controlled in real time, which greatly facilitates the on-site application of the operator. Specifically, different forms of expression can be used to reflect different detection and rejection conditions, and real-time data can also be associated with 3D visual simulation. The control platform can also be equipped with a fault expert diagnosis library to assist operators in quickly finding and solving electrical faults in the system.
在其中一种可能的实现方式中：In one possible implementation:
所述控制组件内部通过EtherCAT协议通讯。如前所述，在构建主从之间通讯的具体实现方式时，可采用EtherCAT总线实现控制层内的通讯连接，该以太网总线具有良好的扩展性，最多可容纳65532个站点，完全能够覆盖和满足现场及应用的需求。The control components communicate internally via the EtherCAT protocol. As mentioned above, when constructing a specific implementation of communication between the master and the slave, the EtherCAT bus can be used to realize the communication connection within the control layer. The Ethernet bus has good scalability and can accommodate up to 65,532 sites, which can fully cover and meet the needs of the site and applications.
而所述主站控制模块与所述现场监测平台、所述现场管控平台以及所述数据采集联网装置之间则通过ADS协议通讯。为了使数据采集传输和人机交互高效、稳定，IPC控制层与人机交互平台(即监控层和上位层)的通讯可采用基于TCP/IP的ADS通讯协议，该通讯协议可在极短的时间内(<10ms)即可完成一次通讯，因而足以确保数据信息监控的高效性和实时性。而所述数据采集联网装置通过TCP/IP协议与外部的数据服务器通讯，也即是说，在实施时可利用稳定、可靠的成熟网络协议与本系统之外的站点进行交换，此种设计的优势在于，便于为本系统提供良好且多样的外部扩展性。The master station control module communicates with the field monitoring platform, the field management and control platform, and the data acquisition networking device through the ADS protocol. In order to make data acquisition transmission and human-computer interaction efficient and stable, the communication between the IPC control layer and the human-computer interaction platform (i.e., the monitoring layer and the upper layer) can adopt the ADS communication protocol based on TCP/IP. This communication protocol can complete a communication in a very short time (<10ms), which is sufficient to ensure the efficiency and real-time nature of data information monitoring. The data acquisition networking device communicates with the external data server through the TCP/IP protocol, that is, during implementation, a stable, reliable, and mature network protocol can be used to exchange with sites outside the system. The advantage of this design is that it is easy to provide good and diverse external scalability for the system.
在其中一种可能的实现方式中：In one possible implementation:
所述主站控制模块经由交换机分别与所述现场监测平台、所述现场管控平台以及所述数据采集联网装置通过ADS协议通讯。结合实际烟企车间的布局和设备结构，借由交换机确保网络总线传输的效率和稳定性。The master station control module communicates with the on-site monitoring platform, the on-site management and control platform and the data acquisition networking device through the ADS protocol via the switch. Combined with the layout and equipment structure of the actual tobacco company workshop, the efficiency and stability of the network bus transmission are ensured by the switch.
在其中一种可能的实现方式中：In one possible implementation:
设于烟包包装机组的主机工位的编码器、设于烟包包装机组的辅机CH工位的编码器、以及烟包包装机组的辅机CT工位和CV工位共用的编码器，分别且直接通过EtherCAT总线与所述主站控制模块通讯。换言之，本系统借由主从网络通信的结构框架，通过软件编程的方式+标准化的工业控制产品，即可实现传统国外系统的控制要求，并极大节省了国外现有控制系统中所采用的专用硬件，例如可经由各I/O从站将采集的关键部件的运动信号直接通过以太网络送入主站控制模块进行处理并反馈动作指令，这样的设计构思，可以使绝大部分信号通过预制的程序算法进行处理，以此减小硬件处理带来的故障，并进一步提升运算速度。The encoders at the main machine station of the cigarette packing unit, the encoders at the auxiliary machine CH station of the cigarette packing unit, and the encoders shared by the auxiliary machine CT station and CV station of the cigarette packing unit communicate with the master control module respectively and directly through the EtherCAT bus. In other words, this system can achieve the control requirements of traditional foreign systems through software programming + standardized industrial control products through the structural framework of master-slave network communication, and greatly save the dedicated hardware used in existing foreign control systems. For example, the motion signals of key components collected can be directly sent to the master control module through the Ethernet network through each I/O slave station for processing and feedback of action instructions. This design concept can enable most signals to be processed through pre-made program algorithms, thereby reducing the failures caused by hardware processing and further improving the computing speed.
在其中一种可能的实现方式中：In one possible implementation:
所述数据采集联网装置具体用于根据预先设定策略，实时采集所述主站控制模块的运行参数以及底层数据，并单向地发送至外部的数据服务器和/或无线终端。为了在保证外部扩展性的同时，降低外部设备对本系统的侵扰和影响，数据采集联网装置可以从本系统内部接收并向外传输相关数据，但数据采集联网装置不向IPC控制层的底层送入数据，从而将数据采集联网装置作为一种单向数据隔离装置，保证本系统底层数据的安全。The data acquisition and networking device is specifically used to collect the operating parameters and bottom-level data of the master station control module in real time according to a pre-set strategy, and send them unidirectionally to an external data server and/or wireless terminal. In order to reduce the intrusion and impact of external devices on the system while ensuring external scalability, the data acquisition and networking device can receive relevant data from within the system and transmit it to the outside, but the data acquisition and networking device does not send data to the bottom layer of the IPC control layer, thereby using the data acquisition and networking device as a unidirectional data isolation device to ensure the security of the bottom-level data of the system.
在其中一种可能的实现方式中：In one possible implementation:
所述数据采集联网装置还配置有多个与外部的辅联设备对接的通讯接口，其中，所述辅联设备包括如下一种或多种：MES系统、综合测试台以及物流系统。如前文提及的，本系统的设计构架中还考虑到了向外扩展的性能，因而结合烟包包装作业的现实需求，可以借助数据采集联网装置向与烟包包装相关的辅联设备进行数据对接。The data acquisition networking device is also equipped with multiple communication interfaces for connecting with external auxiliary devices, wherein the auxiliary devices include one or more of the following: MES system, comprehensive test bench and logistics system. As mentioned above, the design framework of this system also takes into account the performance of external expansion, so combined with the actual needs of cigarette packaging operations, the data acquisition networking device can be used to connect data to the auxiliary devices related to cigarette packaging.
在其中一种可能的实现方式中：In one possible implementation:
所述控制组件还包括设于主电控柜内、且与所述主站控制模块电信号连接的安全控制器，所述安全控制器具有多路I/O通道。针对本发明提供的烟包包装机组控制系统的安全控制需求，实施可采用诸如TwinSAFE等安全控制器以此实现设备相关的安全运行控制，这样，本系统通过将自动化控制、伺服控制(各工位执行端)、安全控制融为一体，整体提升了系统的可靠性和兼容性，可使得包装机组在连续生产中误差不超过千分之一。The control component also includes a safety controller that is arranged in the main electric control cabinet and is electrically connected to the main station control module, and the safety controller has multiple I/O channels. In view of the safety control requirements of the cigarette packing unit control system provided by the present invention, a safety controller such as TwinSAFE can be used to implement equipment-related safe operation control. In this way, the system improves the reliability and compatibility of the system as a whole by integrating automation control, servo control (execution end of each workstation), and safety control, so that the error of the packaging unit in continuous production does not exceed one thousandth.
在其中一种可能的实现方式中：In one possible implementation:
所述控制组件兼容包括基于IEC61131-3标准的ST结构文本编程语言。如前文提及的，国外设备供货商采用专用的软件语言进行程序编写，极大阻碍了本国技术人员的深入掌握和技术迭代，因而本发明提出可以采用简单且模块化的标准结构，使本国技术人员能够快速、高效地为自己的实际需求编写相应的控制过程。The control component is compatible with the ST structured text programming language based on the IEC61131-3 standard. As mentioned above, foreign equipment suppliers use dedicated software languages for program writing, which greatly hinders the in-depth mastery and technical iteration of domestic technicians. Therefore, the present invention proposes to adopt a simple and modular standard structure so that domestic technicians can quickly and efficiently write corresponding control processes for their actual needs.
在其中一种可能的实现方式中：In one possible implementation:
所述控制组件配置有TwinCAT软件系统。在前述实现方式基础上，本发明进一步提供了一种当今较为成熟且易用的软件系统参考，该TwinCAT系统具备多核多线程处理技术，每秒可处理两万个数据点，并且具有较佳的高兼容特性，与本发明设计初衷相辅相成。The control component is configured with a TwinCAT software system. Based on the aforementioned implementation, the present invention further provides a relatively mature and easy-to-use software system reference, the TwinCAT system has multi-core multi-thread processing technology, can process 20,000 data points per second, and has better high compatibility characteristics, which complements the original intention of the present invention.
在其中一种可能的实现方式中：In one possible implementation:
所述数据采集联网装置包括Ceres机器宝。作为前述边缘计算层的数据采集联网装置，在实际操作中可以采用现有的智能硬件–Ceres机器宝予以实现，该数据宝可将数据采集、数据分析、数据归类、数据存取、数据传递以及数据接口管理与交互等功能以一体化的形式实现，同时机器宝集成了互联网+以及移动交互等先进通讯技术，可有效增强与烟草企业管理系统的融合和数据交互。The data collection and networking device includes Ceres Machine Treasure. As the data collection and networking device of the aforementioned edge computing layer, in actual operation, it can be implemented by using the existing intelligent hardware - Ceres Machine Treasure, which can realize the functions of data collection, data analysis, data classification, data access, data transmission, data interface management and interaction in an integrated form. At the same time, Machine Treasure integrates advanced communication technologies such as Internet+ and mobile interaction, which can effectively enhance the integration and data interaction with the tobacco enterprise management system.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
为使本发明的目的、技术方案和优点更加清楚，下面将结合附图对本发明作进一步描述，其中：In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be further described below with reference to the accompanying drawings, in which:
图1为本发明提供的烟包包装机组控制系统的实施例的电气方框图；FIG1 is an electrical block diagram of an embodiment of a control system for a cigarette packing machine provided by the present invention;
图2为本发明提供的烟包包装机组控制系统的较佳实施例的电气示意图。FIG. 2 is an electrical schematic diagram of a preferred embodiment of the control system of the cigarette packing machine unit provided by the present invention.
具体实施方式Detailed ways
下面详细描述本发明的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本发明，而不能解释为对本发明的限制。Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be interpreted as limiting the present invention.
针对现有的烟包包装机组的电控技术被国外设备供货商垄断，导致我国烟草制造行业实现数字化、智能化转型升级受阻的问题，此处需进一步指出的是，本发明的初衷不在于保护单独的装置、设备、仪器和技术本身，而是考虑到当前烟企所面临的技术迭代等上述问题，提供了一种将工控领域当今先进技术与传统烟包包装设备相互有机融合的解决思路，从而摒弃传统的由国外设备供货商把持的关键的电控技术，在保留国外设备机械结构、工位功能等传统优势基础上，整合形成一套可以为本国烟企实现低成本维护、灵活升级拓展的完整技术方案。换句话说，本发明对于本领域所作出的贡献是：在充分利用现有机组设备结构的前提下，为本领域技术人员摆脱国外技术封锁、实现自主研发创新提供了启发性的指导说明。In view of the problem that the electronic control technology of the existing cigarette packing unit is monopolized by foreign equipment suppliers, which has hindered the digital and intelligent transformation and upgrading of my country's tobacco manufacturing industry, it should be further pointed out here that the original intention of the present invention is not to protect the individual devices, equipment, instruments and technologies themselves, but to take into account the above-mentioned problems such as the technical iteration faced by current tobacco companies, and provide a solution to organically integrate the current advanced technology in the field of industrial control with traditional cigarette packing equipment, thereby abandoning the traditional key electronic control technology controlled by foreign equipment suppliers, and on the basis of retaining the traditional advantages of foreign equipment such as mechanical structure and workstation function, integrating to form a complete technical solution that can achieve low-cost maintenance and flexible upgrading and expansion for domestic tobacco companies. In other words, the contribution made by the present invention to this field is: on the premise of making full use of the existing unit equipment structure, it provides inspiring guidance for technical personnel in this field to get rid of foreign technology blockades and realize independent research and development innovation.
回到本申请的实现方式，本发明立足于自动化控制技术的先进设计，采用工业PC机作为数据处理平台，以IPC技术取代背景中介绍的传统PLC技术作为控制的核心，并采用高效的工业以太网实现各从站与主站的通讯控制模式，实现了卷烟包装设备电控系统在技术上的一致性和先进性。具体来说，基于PC控制技术和高速总线技术EtherCAT的IPC智能控制系统，能够适用于包装机高速过程控制及实时数据采集、智能诊断的需求，除了能满足传统PLC的控制要求，还具备优越的数据处理能力和高速通讯能力、高度的兼容性，符合我国当今烟机机械的技术发展期待，也能满足今后我国烟草企业在信息化升级改造方面进行功能和业务拓展的实际需求。Back to the implementation of this application, the present invention is based on the advanced design of automatic control technology, adopts industrial PC as the data processing platform, replaces the traditional PLC technology introduced in the background with IPC technology as the core of control, and adopts efficient industrial Ethernet to realize the communication control mode between each slave station and the master station, thus realizing the technical consistency and advancement of the electronic control system of cigarette packaging equipment. Specifically, the IPC intelligent control system based on PC control technology and high-speed bus technology EtherCAT can be applied to the needs of high-speed process control, real-time data acquisition and intelligent diagnosis of packaging machines. In addition to meeting the control requirements of traditional PLC, it also has superior data processing capabilities and high-speed communication capabilities, and high compatibility, which meets the current technological development expectations of my country's tobacco machinery, and can also meet the actual needs of my country's tobacco enterprises in the future for functional and business expansion in information technology upgrades.
基于上述，本发明提供了一种烟包包装机组控制系统的实施例，如图1所示，该系统可以包括：Based on the above, the present invention provides an embodiment of a control system for a cigarette packing machine, as shown in FIG1 , the system may include:
基于IPC(在领域习惯上也称为工控机、产业电脑或工业电脑等)的控制组件、现场监测平台、现场管控平台以及数据采集联网装置。其中，所述控制组件包括设于主电控柜内的主站控制模块(例如嵌入式PC控制器、CPU模块)以及与所述主站控制模块通讯的第一I/O从站模块，还包括经由交换机(图1中交换机位于主电控柜内仅为示意，并不限定交换机的设置位置)分别与所述主站控制模块通讯的子电控柜内的第二I/O从站模块和模拟量输入模块；其中，前述主站控制模块、I/O从站模块以及模拟量输入模块在实际中还相应配置有电源配置模块等附属件，但此非本发明点侧重点，因而不作过多限定；而所述子电控柜结合包装机组主机及辅机各工位布局，则可以但不限于是多个分散布置在包装机组的相应各工位机身处的独立小电柜，图1中仅是以虚线框示意一个子电控柜。由上述可知，本实施例是将包装机组的控制模式设计为分布式I/O拓扑结构，各分布式I/O从站(包括仅具有输入作用的模拟量输入模块)与主站控制模块之间建立诸如EtherCAT协议通讯的单一总线系统，实现一网到底、无需任何下层子总线、且无网关延迟，并可涵盖主机、辅机各工位，在实际操作中的意义便是，通过最为简化的拓扑结构完成包装机组的高速控制任务，并确保整个电控系统的稳定性和高效性。Based on IPC (also known as industrial computer, industrial computer or industrial computer in the field), control components, field monitoring platform, field control platform and data acquisition networking device. Wherein, the control components include a master station control module (such as embedded PC controller, CPU module) arranged in the main electric control cabinet and a first I/O slave station module communicating with the master station control module, and also include a second I/O slave station module and an analog input module in the sub-electric control cabinet that communicate with the master station control module via a switch (the switch in FIG1 is located in the main electric control cabinet for illustration only, and does not limit the setting position of the switch); wherein, the aforementioned master station control module, I/O slave station module and analog input module are also correspondingly configured with accessories such as power supply configuration module in practice, but this is not the focus of the present invention, and therefore not too much limitation is made; and the sub-electric control cabinet, combined with the layout of each station of the main machine and auxiliary machine of the packaging machine unit, can be but not limited to a plurality of independent small electric cabinets dispersedly arranged at the corresponding stations of the packaging machine unit, and FIG1 is only a dotted box to illustrate a sub-electric control cabinet. From the above, it can be seen that in this embodiment, the control mode of the packaging unit is designed as a distributed I/O topology structure, and a single bus system such as EtherCAT protocol communication is established between each distributed I/O slave station (including analog input modules with input function only) and the main station control module, so as to realize a one-stop network without any lower-level sub-bus and gateway delay, and can cover all workstations of the main machine and auxiliary machine. The significance in actual operation is to complete the high-speed control task of the packaging unit through the most simplified topology structure, and ensure the stability and efficiency of the entire electronic control system.
采用分布式I/O的具体结构设计思路可参考GDX2机型来说，即可以取消原国外设备配套的电控柜内的2X101、2X401、2X501、2X751、2X595、3X101、3X151、3X451、3X501、3X901、3X931、3X721、3X595、3X599等插接件和桥架电缆，相关的检测信号、输出控制信号、安全防护等均通过重新设计相应的电气盒和安装支架，实现分布式I/O从站的信号采集和输出控制。The specific structural design ideas of using distributed I/O can refer to the GDX2 model, that is, the 2X101, 2X401, 2X501, 2X751, 2X595, 3X101, 3X151, 3X451, 3X501, 3X901, 3X931, 3X721, 3X595, 3X599 and other connectors and bridge cables in the electrical control cabinet of the original foreign equipment can be cancelled, and the relevant detection signals, output control signals, safety protection, etc. can be realized by redesigning the corresponding electrical boxes and mounting brackets to realize the signal acquisition and output control of the distributed I/O slave stations.
接续前文，所述现场监测平台、所述现场管控平台以及所述数据采集联网装置分别与所述主站控制模块通讯；且所述数据采集联网装置用于将机组数据传输至外部的数据服务器和/或无线终端(图1以虚线指代外部的电连接关系)，这里所称将机组数据可以是来自主站控制模块的数据，7也可以是来自现场监测平台以及现场管控平台的数据，当然还可以是二者皆有，本发明对此不做限定；所述现场监测平台以及所述现场管控平台均具有可视化的人机交互界面。通过上述设计，无需繁杂且冗余的测量仪器，通过可视化的人机交互界面，便可实时地对各监测信号状态、选通相位、检测曲线进行有效监测和管控，极大地方便了操作人员的现场应用。具体来说，可以采用不同的表现形式体现不同的检测和剔除状况，并还可以将实时数据与3D可视化仿真进行关联，管控平台还可以配置故障专家诊断库，用来协助操作人员快速查找、解决该系统的电气故障。例如，作业人员和维护人员可以通过可视化OPC人机界面的“3D移位链监控”界面轻松实现对检测和剔除状况的可视化在线监控，从而及时采取干预措施，便于指导设备维护。同时，为了更方便于设备维护人员监控故障原因，监控平台还可具有历史数据仿真追溯及数据仿真速度调控功能，使得维护人员可以更准确、快速的查找故障点。Continuing from the above, the field monitoring platform, the field control platform and the data acquisition networking device communicate with the master station control module respectively; and the data acquisition networking device is used to transmit the unit data to an external data server and/or wireless terminal (Figure 1 uses a dotted line to indicate the external electrical connection relationship). The unit data referred to here can be data from the master station control module, and 7 can also be data from the field monitoring platform and the field control platform. Of course, it can also be both, and the present invention does not limit this; the field monitoring platform and the field control platform both have a visual human-computer interaction interface. Through the above design, there is no need for complicated and redundant measuring instruments. Through the visual human-computer interaction interface, the status of each monitoring signal, the selection phase, and the detection curve can be effectively monitored and controlled in real time, which greatly facilitates the on-site application of the operator. Specifically, different forms of expression can be used to reflect different detection and rejection conditions, and real-time data can also be associated with 3D visual simulation. The control platform can also be configured with a fault expert diagnosis library to assist operators in quickly finding and solving electrical faults in the system. For example, operators and maintenance personnel can easily realize visual online monitoring of detection and rejection status through the "3D shift chain monitoring" interface of the visual OPC human-machine interface, so as to take timely intervention measures to guide equipment maintenance. At the same time, in order to make it more convenient for equipment maintenance personnel to monitor the cause of the fault, the monitoring platform can also have historical data simulation tracing and data simulation speed control functions, so that maintenance personnel can find the fault point more accurately and quickly.
综上可知，为确保新设计的烟包包装机组控制系统运行稳定，并且有足够的系统资源来确保系统的检测、控制精度，上述实施例采取了独立的四层框架设计思路：IPC控制层、智能监控层、管控上位层以及数据采集边缘计算层。在上述框架基础上，具体构思是分布式采集+集中管理的模式，由此，便可确保系统数据传输的高速和稳定可靠。In summary, in order to ensure the stable operation of the newly designed cigarette packaging unit control system and sufficient system resources to ensure the detection and control accuracy of the system, the above embodiment adopts an independent four-layer framework design idea: IPC control layer, intelligent monitoring layer, upper management layer and data acquisition edge computing layer. Based on the above framework, the specific concept is a distributed collection + centralized management mode, which can ensure the high speed, stability and reliability of system data transmission.
关于前述各组成部分的具体通讯方式，结合图2所示，本发明提供了如下实施参考：Regarding the specific communication methods of the aforementioned components, in combination with FIG2 , the present invention provides the following implementation references:
(1)所述控制组件内部通过EtherCAT协议通讯，即采用EtherCAT工业以太网总线技术实现前文提及的自动化底层各分布式I/O的通讯及伺服驱动的通讯，实现EtherCAT一网到底，协议处理直达I/O层，无需任何下层子总线、且无网关延迟，该单一总线系统即可涵盖所有设备，以最简化的网络结构完成设备复杂、高速的控制任务。(1) The control components communicate internally via the EtherCAT protocol, i.e., the EtherCAT industrial Ethernet bus technology is used to realize the communication of the previously mentioned distributed I/Os at the bottom layer of automation and the communication of the servo drive, so as to realize the EtherCAT one-stop network, and the protocol processing reaches the I/O layer directly without any lower-level sub-bus and gateway delay. The single bus system can cover all devices and complete the complex and high-speed control tasks of the equipment with the simplest network structure.
关于EtherCAT总线技术，EtherCAT(以太网控制自动化技术)是一个开放架构，以以太网为基础的现场总线系统，其名称的CAT为控制自动化技术(Control AutomationTechnology)字首的缩写。EtherCAT在网络性能上达到了一个新的高度。1000个分布式I/O数据的刷新周期仅为30μs，其中包括端子循环时间。通过一个以太网帧，可以交换高达1486字节的过程数据，几乎相当于12000个数字量I/O。而这一数据量的传输仅用300μs。与100个伺服轴的通讯只需100μs。在此期间，可以向所有轴提供设置值和控制数据，并报告它们的实际位置和状态。分布式时钟技术保证了这些轴之间的同步时间偏差小于1微秒。Regarding EtherCAT bus technology, EtherCAT (Ethernet Control Automation Technology) is an open-framework, Ethernet-based fieldbus system. The CAT in its name is the abbreviation of the first letter of Control Automation Technology. EtherCAT has reached a new height in network performance. The refresh cycle of 1000 distributed I/O data is only 30μs, including the terminal cycle time. Through one Ethernet frame, up to 1486 bytes of process data can be exchanged, which is almost equivalent to 12,000 digital I/Os. And this amount of data is transmitted in only 300μs. Communication with 100 servo axes only takes 100μs. During this period, setting values and control data can be provided to all axes, and their actual position and status can be reported. Distributed clock technology ensures that the synchronization time deviation between these axes is less than 1 microsecond.
利用EtherCAT技术的优异性能，可以实现用传统现场总线系统所无法实现的控制方法。这样，通过总线也可以形成超高速控制回路。传统电控系统需要本地专用硬件支持的功能现在可在软件中加以映射，巨大的带宽资源使状态数据与任何数据可并行传输。EtherCAT技术使得通讯技术与现代高性能的IPC相匹配，总线系统不再是控制理念的瓶颈，同时分布式I/O的数据传递超过了只能由本地I/O接口才能实现的性能。By utilizing the excellent performance of EtherCAT technology, control methods that cannot be achieved with traditional fieldbus systems can be realized. In this way, ultra-high-speed control loops can also be formed through the bus. Functions that traditional electronic control systems require local dedicated hardware support can now be mapped in software, and huge bandwidth resources enable state data to be transmitted in parallel with any data. EtherCAT technology matches communication technology with modern high-performance IPCs. The bus system is no longer a bottleneck in the control concept, and the data transmission of distributed I/O exceeds the performance that can only be achieved by local I/O interfaces.
这种网络性能优势在有相对中等的计算能力的小型控制器中较为明显。EtherCAT的高速循环，可以在两个控制循环之间完成。因此，控制器总有可用的最新输入数据，输出编址的延迟最小。在无需增强本身计算能力的基础上，控制器的响应行为得到显著改善。This network performance advantage is particularly evident in small controllers with relatively moderate computing power. EtherCAT's high-speed cycle can be completed between two control cycles. Therefore, the controller always has the latest input data available and the delay of output addressing is minimal. The response behavior of the controller is significantly improved without increasing its own computing power.
(2)所述主站控制模块与所述现场监测平台、所述现场管控平台以及所述数据采集联网装置之间则通过ADS协议通讯，实现数据的采集、上传、写入、下发和与监控。为了使数据采集传输和人机交互高效、稳定，IPC控制层与人机交互平台(即监控层和上位层)的通讯可采用基于TCP/IP的ADS通讯协议；Beckhoff的ADS通讯协议(自动化设备规范)作为系统的传送层，它被开发用于不同软件模块之间的数据交换，如NC和PLC之间的通讯。该协议提供了使用其它工具与控制软件程序的任何变量进行通讯的途径，例如需要和另一台PC或设备通讯，ADS协议用于TCP/IP之上，其表示在通讯网络中，所有的数据均可从所希望的地点得到，并且该通讯协议可在极短的时间内(<10ms)即可完成一次通讯，因而足以确保数据信息监控的高效性和实时性。此外，在一种可能的实现方式中，结合烟企车间的实际布局和设备结构，所述主站控制模块可经由交换机分别与所述现场监测平台、所述现场管控平台以及所述数据采集联网装置通过ADS协议通讯，以此确保网络总线传输的效率和稳定性。(2) The master station control module communicates with the field monitoring platform, the field control platform and the data acquisition networking device through the ADS protocol to achieve data acquisition, uploading, writing, sending and monitoring. In order to make data acquisition transmission and human-computer interaction efficient and stable, the communication between the IPC control layer and the human-computer interaction platform (i.e., the monitoring layer and the upper layer) can adopt the ADS communication protocol based on TCP/IP; Beckhoff's ADS communication protocol (Automation Device Specification) is used as the transmission layer of the system. It is developed for data exchange between different software modules, such as communication between NC and PLC. This protocol provides a way to use other tools to communicate with any variable of the control software program, such as communication with another PC or device. The ADS protocol is used on top of TCP/IP, which means that in the communication network, all data can be obtained from the desired location, and the communication protocol can complete a communication in a very short time (<10ms), which is sufficient to ensure the efficiency and real-time nature of data information monitoring. In addition, in a possible implementation, combined with the actual layout and equipment structure of the tobacco company's workshop, the master station control module can communicate with the on-site monitoring platform, the on-site management and control platform and the data acquisition networking device through the ADS protocol via a switch, so as to ensure the efficiency and stability of the network bus transmission.
(3)所述数据采集联网装置通过TCP/IP协议与外部的数据服务器通讯，也即是说，在实施时可利用稳定、可靠的成熟网络协议与本系统之外的站点进行交换，此种设计的优势在于，便于为本系统提供良好且多样的外部扩展性。(3) The data acquisition networking device communicates with the external data server via the TCP/IP protocol. That is to say, during implementation, a stable, reliable, and mature network protocol can be used to exchange data with sites outside the system. The advantage of this design is that it facilitates providing the system with good and diverse external scalability.
(4)所述数据采集联网装置还可通过4G、5G、WIFI、GPS等主流的无线通讯技术与外部的远程终端进行数据交互，远程交互过程中，外部设备读取机器宝内的机组相关参数数据，例如但不限于物料消耗、质量报警、设备停机报警、生产数据、机器速度、对质量检测系统参数调整、生产排版数据、综合测试台实时数据等，以使操作人员对生产状况一目了然。例如通过操作人员、管理人员的移动智能终端中的APP推送包装产线状态、设备故障信息等，以此实现远程监控、诊断等目的。(4) The data acquisition networking device can also exchange data with external remote terminals through mainstream wireless communication technologies such as 4G, 5G, WIFI, GPS, etc. During the remote interaction, the external device reads the relevant parameter data of the unit in the machine treasure, such as but not limited to material consumption, quality alarm, equipment shutdown alarm, production data, machine speed, adjustment of quality inspection system parameters, production layout data, comprehensive test bench real-time data, etc., so that the operator can see the production status at a glance. For example, the packaging production line status and equipment failure information can be pushed through the APP in the mobile smart terminal of the operator and manager, so as to achieve the purpose of remote monitoring and diagnosis.
关于前文提及的数据采集联网装置，其具体的作用可以是根据预先设定的策略，实时采集所述主站控制模块(也可包括上述两个监控平台)的运行参数以及底层数据等相关信息，并单向地发送至外部的数据服务器和/或无线终端。如前文提及的，本系统的设计构架中还考虑到了向外扩展的性能，因而结合烟包包装作业的现实需求，可以借助数据采集联网装置向与烟包包装相关的辅联设备进行数据对接。Regarding the data acquisition networking device mentioned above, its specific function can be to collect the operating parameters of the main station control module (which can also include the above two monitoring platforms) and related information such as underlying data in real time according to a pre-set strategy, and send it unidirectionally to an external data server and/or wireless terminal. As mentioned above, the design framework of this system also takes into account the performance of external expansion. Therefore, combined with the actual needs of cigarette packaging operations, the data acquisition networking device can be used to connect data to auxiliary equipment related to cigarette packaging.
具体来说，所述数据采集联网装置还配置有多个与外部的辅联设备对接的通讯接口，利用前述TCP/IP协议，使本系统与外部系统进行互联互通。其中，所述辅联设备包括如下一种或多种：MES系统(Manufacturing Execution System，制造执行系统)、综合测试台以及物流系统。与MES系统对接，直接将单机设备的质量信息、剔除信息、设备报警信息、消耗信息等相关信息上传到MSE系统，然后由MES系统处理后发送到相关人员终端。与综合测试台相连，操作人员只要将烟支放入测试台，测试台自动对烟支进行测量，测量数据(烟支重量、长度、圆周、吸阻等指标数据)可以实时传送到该智能管理平台，操作人员可根据该数据及时对设备进行调校，以满足生产需要。与物流对接，操作人员可通过该智能系统，实时对物流呼叫原辅材料，呼叫后，物流自动化仓储系统自动派出AGV送料小车，对机组空辅料托盘进行回收，然后将物流配盘的原辅材料托盘送到呼叫辅料机组，从而实现原辅材料的自动配发。Specifically, the data acquisition networking device is also equipped with a plurality of communication interfaces for connecting with external auxiliary equipment, and the aforementioned TCP/IP protocol is used to interconnect the system with external systems. Among them, the auxiliary equipment includes one or more of the following: MES system (Manufacturing Execution System), integrated test bench and logistics system. Connecting with the MES system, the quality information, rejection information, equipment alarm information, consumption information and other related information of the single-machine equipment are directly uploaded to the MSE system, and then processed by the MES system and sent to the relevant personnel terminal. Connected to the integrated test bench, the operator only needs to put the cigarette into the test bench, and the test bench will automatically measure the cigarette. The measurement data (cigarette weight, length, circumference, draw resistance and other indicators) can be transmitted to the intelligent management platform in real time, and the operator can adjust the equipment in time according to the data to meet production needs. By connecting with logistics, operators can use this intelligent system to call for raw and auxiliary materials in real time. After the call, the logistics automation warehousing system automatically dispatches the AGV feeding trolley to recycle the empty auxiliary material pallets of the unit, and then delivers the raw and auxiliary material pallets of the logistics to the calling auxiliary material unit, thereby realizing the automatic distribution of raw and auxiliary materials.
前述“单向”，是为了在保证外部扩展性的同时，降低外部设备对本系统的侵扰和影响，数据采集联网装置可以从本系统内部接收并向外传输相关数据，但数据采集联网装置不向IPC控制层的底层送入数据，从而将数据采集联网装置作为一种单向数据隔离装置，保证本系统底层数据的安全。The aforementioned "one-way" is to reduce the intrusion and impact of external devices on the system while ensuring external scalability. The data acquisition and networking device can receive relevant data from within the system and transmit it to the outside, but the data acquisition and networking device does not send data to the bottom layer of the IPC control layer, thereby using the data acquisition and networking device as a one-way data isolation device to ensure the security of the underlying data of the system.
基于上述构思，在一种较佳的实现方式中，所述数据采集联网装置可以包括Ceres机器宝。作为前述边缘计算层的数据采集联网装置，在实际操作中可采用现有的智能硬件–Ceres机器宝予以实现，该数据宝可将数据采集、数据分析、数据归类、数据存取、数据传递以及数据接口管理与交互等功能以一体化的形式实现，同时，机器宝集成了互联网+以及移动交互等先进通讯技术，可有效增强与烟草企业管理系统的融合和数据交互。也即是说，所述机器宝的主要作用是作为数据采集与设备底层数据交换的桥梁，通过程序编写、协议匹配及参数设定，可根据用户需求，将IPC底层数据实时发送到机器宝内，而数据处理器、MES等可以不断地从机器宝刷新数据。Based on the above concept, in a preferred implementation, the data acquisition networking device may include Ceres Machine Treasure. As the data acquisition networking device of the aforementioned edge computing layer, in actual operation, the existing intelligent hardware-Ceres Machine Treasure can be used to implement it. The data treasure can realize the functions of data acquisition, data analysis, data classification, data access, data transmission, and data interface management and interaction in an integrated form. At the same time, Machine Treasure integrates advanced communication technologies such as Internet+ and mobile interaction, which can effectively enhance the integration and data interaction with the tobacco enterprise management system. In other words, the main function of the Machine Treasure is to serve as a bridge for data acquisition and data exchange between the underlying equipment. Through program writing, protocol matching and parameter setting, the IPC underlying data can be sent to the Machine Treasure in real time according to user needs, and the data processor, MES, etc. can continuously refresh the data from the Machine Treasure.
此外，针对本发明提供的烟包包装机组控制系统的安全控制需求，在一个较佳的实施例中前述控制组件还可以包括设于主电控柜内、且与所述主站控制模块电信号连接的安全控制器，所述安全控制器具有多路I/O通道。这样，本系统通过将自动化控制、伺服控制(各工位执行端)、安全控制融为一体，整体提升了系统的可靠性和兼容性，可使得包装机组在连续生产中的误差降至极小。在实际操作中，例如可采用诸如TwinSAFE等安全控制器以此实现设备相关的安全运行控制；再者，出于同一目的，还可以考虑主电控柜和子电控柜所有的端子模块均可具备自诊断功能，由此便可进一步提高系统的安全性及可维护性。In addition, in response to the safety control requirements of the control system of the cigarette packing unit provided by the present invention, in a preferred embodiment, the aforementioned control component may also include a safety controller disposed in the main electric control cabinet and electrically connected to the main station control module, and the safety controller has multiple I/O channels. In this way, the system improves the reliability and compatibility of the system as a whole by integrating automation control, servo control (execution end of each workstation), and safety control, and can reduce the error of the packaging unit in continuous production to a minimum. In actual operation, for example, safety controllers such as TwinSAFE can be used to achieve equipment-related safe operation control; furthermore, for the same purpose, it can also be considered that all terminal modules of the main electric control cabinet and the sub-electric control cabinet can have self-diagnosis functions, thereby further improving the safety and maintainability of the system.
如前文提及的，国外设备供货商采用专用的软件语言进行程序编写，极大阻碍了本国技术人员的深入掌握和技术迭代，因而本发明在一个较佳的实现方式中提出所述控制组件可兼容多种通用的编成语言，这其中可以包括基于IEC61131-3标准的ST结构文本编程语言，也即是本发明的控制软件可以采用简单且模块化的标准结构，以使我国技术人员能够快速、高效地为自己的实际需求编写相应的控制过程。相应于此，本发明进一步提供了一种当今较为成熟且易用的软件系统参考，即所述控制组件可配置有TwinCAT软件系统。该TwinCAT系统具备多核多线程处理技术，每秒可处理两万个数据点，并且具有较佳的高兼容特性，与本发明设计初衷相辅相成。As mentioned above, foreign equipment suppliers use dedicated software languages for program writing, which greatly hinders the in-depth mastery and technical iteration of domestic technicians. Therefore, the present invention proposes in a preferred implementation that the control component can be compatible with a variety of general programming languages, which may include the ST structured text programming language based on the IEC61131-3 standard, that is, the control software of the present invention can adopt a simple and modular standard structure, so that Chinese technicians can quickly and efficiently write corresponding control processes for their actual needs. Correspondingly, the present invention further provides a relatively mature and easy-to-use software system reference today, that is, the control component can be configured with a TwinCAT software system. The TwinCAT system has multi-core multi-threaded processing technology, can process 20,000 data points per second, and has better high compatibility characteristics, which complements the original design intention of the present invention.
综合上述一网到底的分布I/O设计以及前述控制软件系统，本发明提出可以通过软件算法取代传统的“MICRO II”型电控系统的专用部件，以此降低系统成本，提高系统稳定，实现部分关键功能的快速更新迭代。结合包装机组的主机和辅机具体来说，设于烟包包装机组的主机工位的编码器、设于烟包包装机组的辅机CH工位的编码器、以及烟包包装机组的辅机CT工位和CV工位共用的编码器，可以分别且直接通过前述EtherCAT总线与所述主站控制模块通讯。Based on the above-mentioned distributed I/O design and the aforementioned control software system, the present invention proposes that the special components of the traditional "MICRO II" type electronic control system can be replaced by software algorithms, thereby reducing system costs, improving system stability, and realizing rapid update iteration of some key functions. Specifically, in combination with the main machine and auxiliary machine of the packaging unit, the encoder provided at the main machine station of the cigarette pack packaging unit, the encoder provided at the auxiliary machine CH station of the cigarette pack packaging unit, and the encoder shared by the auxiliary machine CT station and CV station of the cigarette pack packaging unit can communicate with the master station control module separately and directly through the aforementioned EtherCAT bus.
换言之，本系统借由主从网络通信的结构框架，通过软件编程的方式+标准化的工业控制产品，即可实现传统国外系统的控制要求，并极大节省了国外现有控制系统中所采用的专用硬件，例如可经由各I/O从站将采集的关键部件的运动信号直接通过以太网络送入主站控制模块进行处理并反馈动作指令，这样的设计构思，可以使绝大部分信号通过预制的程序算法进行处理，以此减小硬件处理带来的故障，并进一步提升运算速度。In other words, this system can achieve the control requirements of traditional foreign systems through the structural framework of master-slave network communication, software programming + standardized industrial control products, and greatly save the dedicated hardware used in existing foreign control systems. For example, the motion signals of key components collected by each I/O slave station can be directly sent to the main station control module through the Ethernet network for processing and feedback of action instructions. This design concept allows most signals to be processed through pre-made program algorithms, thereby reducing the failures caused by hardware processing and further improving the computing speed.
结合现有包装机组的实际部件来说，机组采用三台绝对值编码器来确定机器的相位，实现机器的机械相位与电气相位之间精确无误差的匹配，最大限度地提高了机器控制精度及性能，确保机器各项质量检测准确完成。绝对值编码器由于其精度较高，其测出的二进制码转换为角度后，由于其精度较高(每一圈的误差为千分之一度)，致使主电机与其余电机之间的误差较低，保证每个工位连杆机构的精准，电机间转速的精准，从而保证原辅材料的输送、裁切长度的精准。因而，通过绝对编码器来对机器主电机传动实时跟随测速，确保机电之间的最合理的配合。In combination with the actual components of the existing packaging unit, the unit uses three absolute encoders to determine the phase of the machine, achieving accurate and error-free matching between the mechanical phase and the electrical phase of the machine, maximizing the machine control accuracy and performance, and ensuring the accurate completion of various quality inspections of the machine. Due to its high precision, the absolute encoder converts the measured binary code into an angle. Due to its high precision (the error of each circle is one thousandth of a degree), the error between the main motor and the remaining motors is low, ensuring the accuracy of the linkage mechanism of each station and the speed between the motors, thereby ensuring the accuracy of the transportation of raw and auxiliary materials and the cutting length. Therefore, the absolute encoder is used to measure the speed of the main motor transmission of the machine in real time to ensure the most reasonable coordination between the electromechanical.
但在传统的电控系统中，编码器采集到的二进制码需要传送到国外设备供货商提供的专用的编码器板卡，再通过编码器板卡的硬件处理，将其转换为角度及速度信号，之后送入CPU控制设备关键部件运动。例如现有的“MICRO II”在编码器的运算处理、步进电机控制、伺服电机控制等方面均需要采用G.D公司的专用板卡和驱动器才可实现，利用G.D的编码器板卡、步进电机板卡、三轴直流无刷电机板卡，再辅以专用的步进电机驱动器、直流无刷电机驱动器、专用电源等才可能实现相关的控制应用，这些专用件不仅费用高昂而且维护不便。However, in traditional electronic control systems, the binary code collected by the encoder needs to be transmitted to a dedicated encoder board provided by a foreign equipment supplier, and then converted into angle and speed signals through hardware processing of the encoder board, and then sent to the CPU to control the movement of key components of the equipment. For example, the existing "MICRO II" requires G.D.'s dedicated boards and drivers for encoder processing, stepper motor control, servo motor control, etc., and related control applications can only be realized by using G.D.'s encoder board, stepper motor board, three-axis DC brushless motor board, and then supplemented by dedicated stepper motor drivers, DC brushless motor drivers, dedicated power supplies, etc. These dedicated parts are not only expensive but also inconvenient to maintain.
而在本发明的一种实现方式中，则可以由前述三台编码器将采集到的二进制码传送到从站的输入模块，经由EtherCAT总线直接将信号发至前述主站CPU中，通过CPU内置的软件算法将输入信号转换为函数以及格雷码，之后变换为所需的相位信号，由此便可之间计算出固定周期内采集设备转动的角度等。In one implementation of the present invention, the three encoders can transmit the collected binary codes to the input module of the slave station, and directly send the signals to the master station CPU via the EtherCAT bus. The input signals are converted into functions and Gray codes through the software algorithm built into the CPU, and then converted into the required phase signal, thereby directly calculating the rotation angle of the collection device within a fixed period, etc.
最后，以原有的GDX2机型为例，并结合前文提及的EtherCAT总线技术、ADS协议，本发明在实现过程中可以具体采用BECKHOFF的嵌入式工控机控制模块配以相应的高性能I/O模块，同时辅以TwinSAFE安全控制器以及BECKHOFF的诸如AX5000型伺服驱动、变频驱动、智能控制器等，完成GDX2包装机组的检测、动作控制、驱动控制、安全控制、温度控制等动作的执行以及实时数据采集，经进一步验证，改进后的GDX2电控系统的数据检测精度能够达到二十多个百分点的提升，并且借由100M的数据传输速度，保证了远程信息交互的实时性。Finally, taking the original GDX2 model as an example, and combining the EtherCAT bus technology and ADS protocol mentioned above, the present invention can specifically adopt BECKHOFF's embedded industrial computer control module with corresponding high-performance I/O modules in the implementation process, and at the same time, it can be supplemented by TwinSAFE safety controller and BECKHOFF's AX5000 servo drive, frequency conversion drive, intelligent controller, etc., to complete the execution of GDX2 packaging unit detection, motion control, drive control, safety control, temperature control and other actions and real-time data collection. After further verification, the data detection accuracy of the improved GDX2 electronic control system can be improved by more than 20 percentage points, and the real-time nature of remote information interaction is guaranteed by the data transmission speed of 100M.
也就是说，本发明提供的全新的烟包包装机组控制系统尽可能地取消了国外设备供货商的专用配件，并采用工业标准件或国产通用件实施对电控线路的升级改造，以此实现对各种检测信号、安全信号等点对点的准确采集，且进一步简化了原电控系统的安全线路，从而降低因线路接点引起故障停机，提高设备运行的稳定性和安全性的同时，也能够大幅缩减烟包包装机组控制系统的维护成本。在通讯协议上采用以太网总线来实现控制系统自动化层的通讯连接，采用分布式I/O的设计思想，简化电控系统的电气硬件布局和管理，有效提升系统可靠性。同时，可配置先进的数据采集技术、3D可视化技术、专家故障诊断技术，使新设计的烟包包装机组控制系统具备智能化、可视化的故障报警诊断功能，降低客户在设备维护和使用方面的技术难度。That is to say, the new cigarette packing unit control system provided by the present invention eliminates the special accessories of foreign equipment suppliers as much as possible, and adopts industrial standard parts or domestic general parts to implement the upgrade and transformation of the electric control circuit, so as to realize the point-to-point accurate collection of various detection signals, safety signals, etc., and further simplify the safety circuit of the original electric control system, thereby reducing the shutdown caused by faults due to line contacts, improving the stability and safety of equipment operation, and can also greatly reduce the maintenance cost of the cigarette packing unit control system. In terms of communication protocol, the Ethernet bus is used to realize the communication connection of the automation layer of the control system, and the design concept of distributed I/O is adopted to simplify the electrical hardware layout and management of the electric control system, effectively improving the system reliability. At the same time, advanced data acquisition technology, 3D visualization technology, and expert fault diagnosis technology can be configured, so that the newly designed cigarette packing unit control system has intelligent and visualized fault alarm diagnosis functions, reducing the technical difficulty of customers in equipment maintenance and use.
本发明的实施方式经现场检验，与现有包装机组的传统电控系统的控制工艺流程和操作习惯、操作指令位置等几乎没有变化，可充分利用原有设备的各工位特性和功能，以保证所有的检测、控制等与原电控系统保持一致；也即是本发明的设计构思紧密围绕现有包装机组设备的过程控制、安全控制、质量检测、废品剔除、故障诊断、数据采集、数据交互等应用流程和工序环节，因而可以视为是对国外现有设备机组在电气控制层面的再次创造。还需进一步说明的是，经测试，本发明提供的烟包包装机组控制系统的稳定性已完全满足30×24小时持续运转，充分符合了国内烟企的生产及管理期待。The implementation method of the present invention has been tested on site and has almost no changes in the control process flow, operation habits, operation instruction positions, etc. of the traditional electric control system of the existing packaging unit. It can make full use of the characteristics and functions of each station of the original equipment to ensure that all detection and control are consistent with the original electric control system; that is, the design concept of the present invention is closely centered on the application processes and process links such as process control, safety control, quality inspection, waste rejection, fault diagnosis, data collection, and data interaction of the existing packaging unit equipment, so it can be regarded as a re-creation of the electrical control level of the existing foreign equipment units. It should be further explained that after testing, the stability of the control system of the cigarette pack packaging unit provided by the present invention has fully met the continuous operation of 30×24 hours, which fully meets the production and management expectations of domestic tobacco companies.
以上依据图式所示的实施例详细说明了本发明的构造、特征及作用效果，但以上所述仅为本发明的较佳实施例，需要言明的是，上述实施例及其优选方式所涉及的技术特征，本领域技术人员可以在不脱离、不改变本发明的设计思路以及技术效果的前提下，合理地组合搭配成多种等效方案；因此，本发明不以图面所示限定实施范围，凡是依照本发明的构想所作的改变，或修改为等同变化的等效实施例，仍未超出说明书与图示所涵盖的精神时，均应在本发明的保护范围内。The above describes in detail the structure, features and effects of the present invention based on the embodiments shown in the drawings, but the above is only a preferred embodiment of the present invention. It should be noted that the technical features involved in the above embodiments and their preferred methods can be reasonably combined and matched into a variety of equivalent schemes by those skilled in the art without departing from or changing the design ideas and technical effects of the present invention; therefore, the present invention is not limited to the scope of implementation shown in the drawings, and all changes made in accordance with the concept of the present invention, or modifications to equivalent embodiments with equivalent changes, which still do not exceed the spirit covered by the specification and drawings, should be within the protection scope of the present invention.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911038597.8ACN110844161B (en) | 2019-10-29 | 2019-10-29 | Control system of cigarette packet packaging unit |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911038597.8ACN110844161B (en) | 2019-10-29 | 2019-10-29 | Control system of cigarette packet packaging unit |
| Publication Number | Publication Date |
|---|---|
| CN110844161A CN110844161A (en) | 2020-02-28 |
| CN110844161Btrue CN110844161B (en) | 2024-07-05 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201911038597.8AActiveCN110844161B (en) | 2019-10-29 | 2019-10-29 | Control system of cigarette packet packaging unit |
| Country | Link |
|---|---|
| CN (1) | CN110844161B (en) |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116088442A (en)* | 2022-12-23 | 2023-05-09 | 红云红河烟草(集团)有限责任公司 | A monitoring and alarm system for process parameters of filter rod forming machine |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN202033638U (en)* | 2010-12-31 | 2011-11-09 | 深圳市联君科技有限公司 | IPC-based cigarette machine set electric control system |
| CN211731920U (en)* | 2019-10-29 | 2020-10-23 | 红云红河烟草(集团)有限责任公司 | Cigarette Packing Unit Control System |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN202494900U (en)* | 2011-12-21 | 2012-10-17 | 芜湖天宇科技开发有限公司 | Control system for tobacco thin filament production line |
| CN203275977U (en)* | 2013-05-07 | 2013-11-06 | 深圳市生波尔机电设备有限公司 | Automation bus network electric control system |
| CN104176301B (en)* | 2014-08-14 | 2016-01-27 | 浙江中烟工业有限责任公司 | A kind of hyper-speed wrapping machine data acquisition system |
| CN104267711B (en)* | 2014-11-03 | 2017-01-11 | 四川烟草工业有限责任公司 | Running state monitoring and failure diagnosis method for tobacco logistics system |
| CN104820403B (en)* | 2015-04-08 | 2018-04-27 | 华南理工大学 | A kind of 8 axis robot control systems based on EtherCAT buses |
| CN106054845A (en)* | 2016-07-15 | 2016-10-26 | 常州灵骏机器人科技有限公司 | Service robot control system based on industrial ethernet |
| CN106645187B (en)* | 2016-11-29 | 2023-09-15 | 河南中烟工业有限责任公司 | A cigarette pack appearance detection and rejection device based on IPC technology |
| CN110181512A (en)* | 2019-05-22 | 2019-08-30 | 中国电子科技集团公司第十四研究所 | A control system of a transformer core automatic lamination robot workstation |
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN202033638U (en)* | 2010-12-31 | 2011-11-09 | 深圳市联君科技有限公司 | IPC-based cigarette machine set electric control system |
| CN211731920U (en)* | 2019-10-29 | 2020-10-23 | 红云红河烟草(集团)有限责任公司 | Cigarette Packing Unit Control System |
| Publication number | Publication date |
|---|---|
| CN110844161A (en) | 2020-02-28 |
| Publication | Publication Date | Title |
|---|---|---|
| Liu et al. | A method of NC machine tools intelligent monitoring system in smart factories | |
| CN111797521B (en) | Three-dimensional simulation debugging and monitoring method for automatic production line | |
| CN112995022A (en) | Industrial Internet of things gateway | |
| US20130297055A1 (en) | Network-based control method and system for controlling a whole-flow production process | |
| CN107695775B (en) | Heavy digital control machine tool heat error compensation control system and thermal error compensation method based on CPS | |
| CN205959050U (en) | All -in -one controlling means | |
| Nezhmetdinov et al. | Approach to the construction of logical control systems for technological equipment for the implementation of Industry 4.0 concept | |
| CN108908851A (en) | The electricity of injection molding machine penetrates platform servo-system and its data interaction process | |
| CN107908166A (en) | A kind of automobile making MES data acquisition system based on industry internet | |
| CN202956644U (en) | Power battery production process information monitoring system based on distributed control system (DCS) | |
| Martinova et al. | Organization of process equipment monitoring | |
| CN111427319A (en) | A glass factory intelligent MCC centralized control system and its control method | |
| CN107608272A (en) | A kind of workshop appliance monitoring system based on Powerlink | |
| Romanov et al. | Unified architecture of execution level hardware and software for discrete machinery manufacturing control systems | |
| CN111600923A (en) | An OPC UA protocol server system based on .NET Core | |
| CN102354162B (en) | Motion control interface and interface controller | |
| CN114301947A (en) | An Industrial Internet Training Assessment System | |
| CN109725588B (en) | A temperature monitoring system and method | |
| CN110844161B (en) | Control system of cigarette packet packaging unit | |
| CN108881201A (en) | The acquisition processing system and method for processing site data needed for a kind of MES | |
| CN211731920U (en) | Cigarette Packing Unit Control System | |
| CN108687285A (en) | Manufacturing industry forging machine tool group internet remote condition monitoring device and monitoring method | |
| CN101706658A (en) | Fieldbus technology based operation box with function of collecting input/output points | |
| CN204155117U (en) | A kind of big-power transducer control system | |
| Toma et al. | Application of SCADA System in an Electrical Substation and Remote Terminal Unit Parametrization |
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |