Function analysis of the configuration software of

Function analysis of industrial control configuration software and its application in industrial control

three dimensional force control industrial control configuration software is a data acquisition, monitoring, processing and control software package based on Windows environment. Using the tools provided by the configuration software, the required software functions can be formed through simple and visual configuration work. It is becoming the mainstream software of domestic computer control system with its convenient software development performance, easy maintenance and low development cost

function analysis of configuration software

1.draw

rich screen display configuration function configuration software provides users with rich and powerful drawing, animation connection and scripting tools. Draw is an integrated development environment. It uses object-oriented graphic objects to create animated display windows. At the same time, it also provides developers with a large number of commonly used functions such as industrial equipment symbols, instrument symbols, trend charts, historical curves, alarm objects, etc. it uses object-oriented graphic objects to create animated display windows. The data and graphic display of these windows can come from process I/O or Microsoft Windows third-party applications

2.view

view is used to run the graphic window created by dra w, the number of supported pictures is unlimited, and the data refresh speed is faster than 5 ms. The software provides industrial standard digital model library and control function library to meet the measurement and control requirements required by users. It can record, store, display, calculate, analyze and print measurement and control information. The interface operation is flexible and convenient. In order to ensure data security, it also has password protection function

3.db

db is the core of the whole system and the foundation of building distributed application system. It is responsible for the real-time data processing, historical data storage, statistical data processing, alarm information processing, and data service request processing of the entire force control application system. DB and dra w constitute the server and client mode. The DB on each network node can be built into a complex distributed network application system through the network service program. The data processing capacity of a single machine is more than 10000 points, the historical data can be saved for more than 10 years, and the network data processing capacity is more than 50000 points

4. I/0 server

I/O server completes the communication with various detection and control devices, is responsible for reading real-time data from process I/O devices, and writes control commands from graphical interface and real-time database to I/O devices. DB and I/O server constitute the server/client computing mode. I/O server is composed of many single programs, each of which can complete the communication function of specific equipment and support the hardware provided by most mainstream control equipment manufacturers

5. Netclient and netserver

the TCP/IP communication protocol used in netclient and netserver ensures that users can make full use of the intranet to have the function of user-defined experiments; T or internet network resources, ensuring that the data refresh speed is faster than 5 ms, and the network data processing capacity is more than 50000 points

Application of force control

according to the above function analysis of the configuration software, combined with the actual situation of the automatic control system of the drill pipe friction welding production line, the three-dimensional force control configuration software is selected as the upper computer monitoring software of this industrial control system. Based on the above considerations, its data acquisition and control devices adopt Japanese Omron cqmih series PLC, word light temperature controller, American RETEC thermometer and Japanese Toshiba frequency converter; The network connection adopts RS485 bus transmission, the connection distance is 1.5 km, and the communication rate is 9600 bits; The computer adopts Advantech industrial computer 1GHz, 256MB memory, 30GB hard disk and 20in Philips large screen display; The communication adapter adopts RS232C s484 RS422 signal conversion adapter

the monitoring system of this production line is a single centralized control system. In the future, the industrial computer can be connected to the workstations of various management departments through dial-up network or intranet to realize centralized management. In the design, it is considered that if the industrial computer fails to work, the operator can control each production line on the production line site and return to the traditional manual control mode. The hardware control mode of the whole industrial control system is shown in the figure below

Figure 1 engineering system hardware control mode

1. friction welding production line overview and monitoring requirements

(1) production overview

there are three friction welding production lines, namely annealing, quenching and annealing lines. The basic distribution of the control system is: 2 points of annealing positioning signal, 1 point of feeding signal, 1 point of intermediate frequency induction coil temperature signal; Quenching positioning signal 4 points, feeding signal l points, intermediate frequency induction coil temperature signal l points; Tempering positioning signal 2 points, feeding signal l points, intermediate frequency induction coil temperature signal l points

(2) monitoring requirements

① signal acquisition: including the acquisition of standard data signals and non-standard data signals such as the temperature signal of intermediate frequency induction coil

② monitoring operation: including operation control, parameter setting, etc

③ dynamic display: including dynamic flow chart display, alarm display, real-time temperature curve display, etc

④ operation screen: the production system can be queried and managed through screen operation, such as printing real-time reports and historical reports, and the time of printing historical reports can be set arbitrarily

⑤ the system has scalability

2. Software design

according to the actual situation of the production line and the monitoring requirements, this industrial control system is configured with 36 di (digital input); Do (digital output) 32 channels; AI (analog input) 16 channels; Ao (analog output) 3 channels. The application system mainly develops 24 display images, which are rich in content, including a variety of display components such as analog dial, digital table, trend chart, general view chart, historical curve, real-time temperature curve, historical alarm, production flow chart and so on. In the system, two methods are used to deal with the control band ij of input/output. One is that there is no need to control, and the data can be directly displayed on the display after being collected from the field to the industrial computer; Second, various parameters and variables that need to be judged and calculated need to be calculated, judged and programmed by corresponding modules, and then display, output and control

(1) digital signal

the detection of on-site solenoid valve and alarm signal is completed by cqm1h series PLC, and the force control I/O driver is responsible for reading/writing PLC data

(2) analog signal

the temperature signal of the intermediate frequency induction coil is collected by the American RETEC thermometer and sent to the Yuguang temperature controller. The temperature controller converts the signal into a digital signal, and then uses RS485 to communicate with the force control software in the upper computer. It processes the collected signal, compares its measured value with the upper limit alarm value, and then generates an over temperature alarm signal, which is displayed on the display

(3) intelligent communication transmission

since one upper computer monitors three production lines at the same time, the competitiveness of each production market must be further improved. The control equipment such as PLC and temperature controller of the line plus foamed thermal insulation aluminum profile has double thermal insulation effect to distinguish. In this system, different PLCs and temperature controllers are distinguished by different station numbers

(4) display screen

according to the production requirements proposed by the process, the force control software operation screen is designed in the form of main menu. And there are buttons in each picture to switch. The picture includes the main menu, dynamic flow chart and temperature control curve picture, report picture, alarm picture, historical data query picture, etc

in the flow chart screen (see Figure 2), the working state of each production line on site at this time can be determined according to the current instruction color and flashing state of the flow chart. For example, the circular fallback indicator block under the monitoring of the annealing flow chart is now displayed in red and constantly flashing, indicating that the drill pipe on the quenching production line is in the fallback operation

Figure 2 process screen

when the system gives an abnormal alarm, the real-time alarm screen automatically pops up, and the alarm indicator light at the top right of the screen is constantly flashing, while the upper computer sends an alarm bell to warn the operator. According to the abnormal tag number and comments given in the alarm display screen, you can determine which part of the abnormal and the type of abnormal situation occurs

by clicking the historical alarm button, you can also query all alarms that have occurred in the past

(5) DDE dynamic data link (dynamic data communication mode between client program and server program)

the server detects data changes. Once the data changes, the server automatically sends the changed data to the customer without the request of the customer. When configuring the application, you need to give the definition of DDE, including service and topic. Service is the name of the server program, which is excel in this program; The topic is the service name provided by the server program, that is, each worksheet of Excel

3. system debugging and operation

communication speed must be considered when preparing application script. If the data is repeatedly set to the controller (PLC), the data acquisition speed will be affected. Therefore, the program action of sending control commands to PLC should be executed in the data change script as far as possible

the configuration of system parameters can be adjusted repeatedly according to different devices to achieve the best working state, because different devices have different requirements for acquisition rate. Important control functions are completed by stable and reliable PLC, so that when the upper computer fails, it will not affect the on-site control, so as to achieve decentralized and centralized control

after nearly two years of practical application, the results show that since the microcomputer monitoring system of drill pipe friction welding production line was put into use in the friction welding workshop of Daqing pipe repair plant, the frequency fluctuation range should not exceed 2% of the rated value; Labor efficiency, product qualification rate, reduced work intensity, simplified operation and maintenance, reduced production costs, and significantly improved the economic benefits of the workshop. (end)