CN107070728B - State monitoring system and diagnosis method of H1000 packaging machine control network - Google Patents

Abstract

The invention relates to the field of cigarette packaging process state monitoring, in particular to an online monitoring and fault diagnosis method for an H1000 packaging equipment control network. The system comprises a CAN network to EtherCAT network module, a Profibus network to EtherCAT network module, a Profinet network to EtherCAT network module, a Modbus network to EtherCAT network module, an EtherCAT network, an EtherCAT to real-time Ethernet module, an Ethernet network, a state acquisition module, a state analysis module, a state storage module and a state display module. The system is compatible with various industrial control network protocols, and has expansibility and universal applicability; for network flash, the network state of a certain node can be diagnosed, and the state of a certain module under a certain node can also be diagnosed; for network flash, the time sequence can be accurately positioned, and then the network breakpoint is judged; the information push is accurate, fast and visual, and the presentation mode can be diversely expanded.

Description

State monitoring system and diagnosis method of H1000 packaging machine control network

Technical Field

The invention relates to the field of cigarette packaging process state monitoring, in particular to an online monitoring and fault diagnosis method for an H1000 packaging equipment control network.

Background

Tobacco is an important economic strength and tax source of China, and tobacco tax accounts for 8% -10% of government financial income in China. Due to globalization, new laws and regulations and major changes of external environment in the tobacco industry, cigarette industry enterprises face increasingly severe competitive pressure and social pressure, the quality control and equipment predictive maintenance level of cigarette products is gradually improved, and the method is an effective way and an inevitable trend for realizing the purposes of controllable equipment state and efficient operation of the cigarette industry enterprises.

H1000 is the cigarette packaging machine set which has the fastest speed and the most complex control system in the world at present, and the speed reaches 1000 packets/minute. The H1000 controller adopts a double-fortune control system based on a PC control technology, the control system structure is quite complex, a control network adopts various industrial control protocols, and the network cycle time of each node is 2-20 ms. As the blessing control system based on the PC control technology, compared with the traditional PLC control system, the blessing control system has the characteristics of high speed, multiple functions, rich configuration and the like, but relatively, because the E-BUS transmission technology is adopted, compared with the back board BUS transmission mode of the traditional PLC, the blessing control system has the defects of poor stability: the main reason is that the BUS of the E-BUS is in contact with and flash off, which often causes the whole control network to flash off, and further causes serious crash. When network fault flash occurs, because no way is available to accurately position the flash point information of the control network, diagnosis is often performed through very professional industrial control software, and information capture is also difficult, which brings great trouble to equipment maintenance.

Disclosure of Invention

The technical problem to be solved by the invention is to provide a state monitoring system for an H1000 control network and a diagnosis method thereof aiming at the defects of the prior art, and mainly aims to improve the network fault diagnosis efficiency of an H1000 ultra-high speed packaging machine and further improve the equipment efficiency.

The technical scheme adopted by the invention for solving the technical problems is as follows:

a state monitoring system of H1000 packaging machine control network comprises a CAN network to EtherCAT network module, a Profibus network to EtherCAT network module, a Profinet network to EtherCAT network module, a Modbus network to EtherCAT network module, an EtherCAT network, an EtherCAT to real-time Ethernet module, an Ethernet network, a network state acquisition module, a network state analysis module, a network state storage module and a network state display module;

the controller comprises a CAN network to EtherCAT network module, a Profibus network to EtherCAT network module, a Profinet network to EtherCAT network module and a Modbus network to EtherCAT network module, which are respectively connected with a CAN network node 1 … … n, a Profibus network node 1 … … n, a Profinet network node 1 … … n and a Modbus network node 1 … … n of a bottom layer H1000 control network, and are connected with an EtherCAT master station and an EtherCAT network;

the EtherCAT-to-real-time Ethernet module is respectively connected with an EtherCAT network and a real-time Ethernet network;

the network state acquisition module, the network state analysis module, the network state storage module and the network state display module are connected with the real-time Ethernet network; the network state acquisition module acquires communication state messages of various networks according to different network protocols; the network state analysis module is used for analyzing communication state messages of various networks; the network state storage module is used for storing current and historical network connection state data; the network state display module is used for judging and displaying the fault alarm threshold value;

the monitoring method of the system comprises the following steps:

a) the CAN network-to-EtherCAT network module, the Profibus network-to-EtherCAT network module, the Profinet network-to-EtherCAT network module, and the Modbus network-to-EtherCAT network module respectively acquire the network states of the CAN network node 1 … … n, the Profibus network node 1 … … n, the Profinet network node 1 … … n, and the Modbus network node 1 … … n of the bottom layer H1000 control network and convert the network states into EtherCAT standard messages, and then the state messages are actively sent to the EtherCAT master station on the EtherCAT network;

b) the EtherCAT master station actively sends the EtherCAT standard message with the network state and the time stamp of each network node to the real-time Ethernet through the EtherCAT-to-real-time Ethernet module;

c) the network state acquisition module acquires a bottom layer control network state message through a real-time Ethernet and transmits the bottom layer control network state message to the network state analysis module;

d) the network state analysis module judges the working state of each node and each module by analyzing the message structure, evaluates the network state of each module and each node by comparing with the standard state word, and stores the result in the network state storage module;

e) the network state display module displays the state information in real time and can set up an autonomous alarm rule, and the display mode and the alarm mode can be in various modes including but not limited to sound and light, a webpage, a client, a mail and a short message.

As a further improvement, the network port part of the CAN-to-EtherCAT network module, the Profibus-to-EtherCAT network module, the Profinet-to-EtherCAT network module, the Modbus-to-EtherCAT network module, and the EtherCAT master station module adopts double-path power supply, that is, 24V power supply inside the module and 24V power supply outside the module coexist, and have surge protection.

As a further improvement, the EtherCAT to real-time ethernet module has 3 RJ45 network interfaces, which are respectively used for connecting an EtherCAT network, a real-time ethernet network, and a configuration network.

A monitoring method of a state monitoring system of an H1000 packaging machine control network comprises the following steps: the method comprises the following steps:

a) the CAN \ Profibus \ Profinet \ Modbus to EtherCAT conversion module respectively acquires the network states of a CAN network node 1 … … n, a Profibus network node 1 … … n, a Profinet network node 1 … … n and a Modbus network node 1 … … n of a bottom layer H1000 control network and converts the network states into EtherCAT standard messages, and then the state messages are actively sent to an EtherCAT master station on an EtherCAT network;

b) the EtherCAT master station actively sends the EtherCAT standard message with the network state and the time stamp of each network node to the real-time Ethernet through the EtherCAT-to-real-time Ethernet module;

c) the network state acquisition module acquires a bottom layer control network state message through a real-time Ethernet and transmits the bottom layer control network state message to the network state analysis module;

d) the network state analysis module judges the working state of each node and each module by analyzing the message structure, evaluates the network state of each module and each node by comparing with the standard state word, and stores the result in the network state storage module

e) The network state display module displays the state information in real time and can set up an autonomous alarm rule, and the display mode and the alarm mode can be in various modes including but not limited to sound and light, a webpage, a client, a mail, a short message and the like.

The system and the method adopted by the invention have the following advantages: 1. the system can be compatible with various industrial control network protocols, and has expansibility and universal applicability; 2. for network flash, the network state of a certain node can be diagnosed, and the state of a certain module under a certain node can also be diagnosed; 3. for network flash, the time sequence can be accurately positioned, and then the network breakpoint is judged; 4. the information push is accurate, fast and visual, and the presentation mode can be diversely expanded.

Drawings

FIG. 1 is a block diagram of an H1000 control network condition monitoring system of the present invention;

FIG. 2 is a software flow diagram of a network condition diagnostic method;

fig. 3 is a schematic flow chart of time stamping.

Detailed Description

The technical solutions of the present invention are further described in detail below with reference to the accompanying drawings, but the scope of the present invention is not limited to the following.

As shown in fig. 1, a state monitoring system of an H1000 packaging machine control network is characterized in that: the system comprises a CAN network to EtherCAT network module 1, a Profibus network to EtherCAT network module 2, a Profinet network to EtherCAT network module 3, a Modbus network to EtherCAT network module 4, an EtherCAT network module 5, an EtherCAT network 6, an EtherCAT to real-time Ethernet module 7, an Ethernet network 8, a network state acquisition module 9, a network state analysis module 10, a network state storage module 11 and a network state display module 12.

The CAN network-to-EtherCAT network module 1, the Profibus network-to-EtherCAT network module 2, the Profinet network-to-EtherCAT network module 3 and the Modbus network-to-EtherCAT network module 4 are respectively connected with a connection interface of a bottom control network and a connection interface of an EtherCAT network, and respectively connected with a CAN network node 1 … … n, a Profibus network node 1 … … n, a Profinet network node 1 … … n and a Modbus network node 1 … … n of a bottom H1000 control network in a physical layer protocol connection mode. And is connected with an EtherCAT main station and an EtherCAT network 6 in an RJ45 connection mode, adopts TIA586B standard, and forms a ring network.

The EtherCAT-to-real-time Ethernet module 7 is respectively connected with the EtherCAT network 6 and the real-time Ethernet network 8 in an RJ45 connection mode by adopting a TIA586B standard.

The network state acquisition module 9, the network state analysis module 10, the network state storage module 11 and the network state display module 12 are connected with the real-time Ethernet network 8 in an RJ45 connection mode, the TIA586B standard is adopted, and the networking mode is a star topology.

CAN change EtherCAT network module 1, Profibus network change EtherCAT network module 2, Profinet network change EtherCAT network module 3, Modbus network change EtherCAT network module 4, EtherCAT network module 5's network port part adopts the double-circuit power supply, 24V power supply inside the module promptly, supply power coexistence by module inside power supply and outside direct current 24V (adopt Siemens SIPLUS high performance power) through E-BUS to take surge protection (adopt Siemens 5DS7432-5 series, carry out module protection).

The EtherCAT to real-time ethernet module 7 is provided with 3 RJ45 network interfaces, which are respectively used for connecting the EtherCAT network 6 downwards and the real-time ethernet network 8 upwards, and the other is used for connecting the module configuration network, and the network is used for setting the working address range and the AMS NETID of the conversion module.

The network state acquisition module 9 acquires communication state messages of various networks according to different network protocols.

The network state analysis module 10 is configured to analyze communication state messages of various networks.

And the network state storage module is used for storing the current and historical network communication state messages.

And the network state display module is used for judging and displaying the fault alarm threshold value.

The monitoring method of the state monitoring system of the H1000 packaging machine control network of the invention is shown in FIG. 2, and the adopted technology and steps are described as follows:

a) the CAN-to-EtherCAT network module 1, the Profibus network-to-EtherCAT network module 2, the Profinet network-to-EtherCAT network module 3 and the Modbus network-to-EtherCAT network module 4 respectively acquire the network states of the CAN network node 1 … … n, the Profibus network node 1 … … n, the Profinet network node 1 … … n and the Modbus network node 1 … … n of the underlying H1000 control network and convert the network states into EtherCAT standard messages, firstly perform synchronous processing of network conversion, as shown in FIG. 3, and then transmit the state messages to the EtherCAT master station in an active manner on the EtherCAT network.

b) The EtherCAT master station actively sends the EtherCAT standard message with the network state and the time stamp of each network node to the real-time ethernet through the EtherCAT to real-time ethernet module, and the time stamp is as shown in fig. 3, and the time difference between the converted message and the actual message is designed to be 1 EtherCAT period.

c) The network state acquisition module acquires a bottom layer control network state message through a real-time ethernet, and transmits the bottom layer control network state message to the network state analysis module, and examples of part of data acquisition codes are as follows:

Private Sub CommandButton1_Click()

Dim s1 As Integer

Dim s2 As Integer

Dim s3 As Integer

Dim s4 As Integer

AdsOcx1.AdsAmsServerNet Id = "5.4.36.169.1.1"// define AMSID

AdsOcx1.AdsAmsServerPort = "801"// defining port

TEXTBOX1.TEXT = AdsOcx1. AdsServerAdsState// reading PLC states

Call AdsOcx1. AdsSyncReadInterger req (& H4020&, 100, 2, s 1)// read MW100 to s1

Call AdsOcx1. AdsSyncReadInterger req (& HF020&, 0, 2, s 2)// read IW0 to s2

Call AdsOcx1. AdsSyncReadInterger req (& HF030&, 0, 2, s 2)// read QW0 to s3

TEXTBOX2.TEXT=s1

TEXTBOX3.TEXT=s2

TEXTBOX4.TEXT=s3

S4= TEXTBOX4.TEXT

Call AdsOcx1. AdsSyncWriteIntger Req (& H4030&, 100, 2, s 4)// write s4 to MW100

End Sub

d) The network state analysis module receives the network state message, analyzes the message structure, judges the working state of each node and each module, and evaluates the network state of each module and each node by comparing the working state with the standard state word. If the received state message is consistent with the standard state reference value, the network connection state is normal; if not, determining the abnormal type of the network state according to the content of the message. The state analysis module can analyze the state of each module below each node, and the network state analysis module can judge the station dropping time sequence of the actual network breakpoint according to the message time sequence because the network state message contains the real-time timestamp. To this end, the key elements of network diagnostics are: the node type, the node address, the node state and the timestamp are all effectively analyzed. In particular, the system design also functions: after processing a frame of communication message, the analysis module needs to transmit the discrimination result of the frame to the network state storage module for storage.

e) The network state display module reads the network state storage database, displays the state information in real time, and can set up an autonomous alarm rule, and the display mode and the alarm mode can be in various modes, such as but not limited to sound and light, a webpage, a client, a mail, a short message and the like.

The invention has been described in connection with the accompanying drawings, it is to be understood that the invention is not limited to the specific embodiments disclosed, but is intended to cover various modifications, adaptations or uses of the invention, and all such modifications and variations are within the scope of the invention.

Claims (2)

1.A state monitoring system of H1000 packagine machine control network, its characterized in that: the system comprises a CAN network to EtherCAT network module (1), a Profibus network to EtherCAT network module (2), a Profinet network to EtherCAT network module (3), a Modbus network to EtherCAT network module (4), an EtherCAT network module (5), an EtherCAT network (6), an EtherCAT to real-time Ethernet module (7), an Ethernet network (8), a network state acquisition module (9), a network state analysis module (10), a network state storage module (11) and a network state display module (12);

the CAN network-to-EtherCAT network module (1), the Profibus network-to-EtherCAT network module (2), the Profinet network-to-EtherCAT network module (3), and the Modbus network-to-EtherCAT network module (4) are respectively connected with the CAN network node 1 … … n, the Profibus network node 1 … … n, the Profinet network node 1 … … n, and the Modbus network node 1 … … n of the bottom layer H1000 control network, and are connected with the EtherCAT master station and the EtherCAT network (6);

the EtherCAT-to-real-time Ethernet module (7) is respectively connected with the EtherCAT network (6) and the real-time Ethernet network (8);

the network state acquisition module (9), the network state analysis module (10), the network state storage module (11) and the network state display module (12) are connected with the real-time Ethernet network (8); the network state acquisition module (9) acquires communication state messages of various networks according to different network protocols; the network state analysis module (10) is used for analyzing communication state messages of various networks; the network state storage module is used for storing current and historical network connection state data; the network state display module is used for judging and displaying the fault alarm threshold value;

the monitoring method of the system comprises the following steps:

a) the CAN network-to-EtherCAT network module (1), the Profibus network-to-EtherCAT network module (2), the Profinet network-to-EtherCAT network module (3), and the Modbus network-to-EtherCAT network module (4) respectively acquire the network states of the CAN network node 1 … … n, the Profibus network node 1 … … n, the Profinet network node 1 … … n, and the Modbus network node 1 … … n of the underlying H1000 control network and convert the network states into EtherCAT standard messages, and then transmit the state messages to the EtherCAT master station in an active manner on the EtherCAT network;

b) the EtherCAT master station actively sends the EtherCAT standard message with the network state and the time stamp of each network node to the real-time Ethernet through the EtherCAT-to-real-time Ethernet module;

c) the network state acquisition module acquires a bottom layer control network state message through a real-time Ethernet and transmits the bottom layer control network state message to the network state analysis module;

d) the network state analysis module judges the working state of each node and each module by analyzing the message structure, evaluates the network state of each module and each node by comparing with the standard state word, and stores the result in the network state storage module;

e) the network state display module displays the state information in real time and can set up autonomous alarm rules, and the display mode and the alarm mode can be in various modes including sound and light, web pages, clients, mails and short messages,

CAN change EtherCAT network module (1), Profibus network changes EtherCAT network module (2), Profinet network changes EtherCAT network module (3), and Modbus network changes EtherCAT network module (4), and the network port part of EtherCAT network module (5) adopts the double-circuit power supply, and the power supply of 24V inside the module and the coexistence of outside 24V power supply promptly to take surge protection, EtherCAT change real-time Ethernet module (7), possess 3 RJ45 network interface, be used for connecting the EtherCAT network respectively, real-time Ethernet to and the configuration network.

2. The monitoring method of the condition monitoring system of the H1000 packing machine control network according to claim 1, characterized in that: the method comprises the following steps:

a) the CAN network-to-EtherCAT network module (1), the Profibus network-to-EtherCAT network module (2), the Profinet network-to-EtherCAT network module (3), and the Modbus network-to-EtherCAT network module (4) respectively acquire the network states of the CAN network node 1 … … n, the Profibus network node 1 … … n, the Profinet network node 1 … … n, and the Modbus network node 1 … … n of the underlying H1000 control network and convert the network states into EtherCAT standard messages, and then transmit the state messages to the EtherCAT master station in an active manner on the EtherCAT network;

b) the EtherCAT master station actively sends the EtherCAT standard message with the network state and the time stamp of each network node to the real-time Ethernet through the EtherCAT-to-real-time Ethernet module;

c) the network state acquisition module acquires a bottom layer control network state message through a real-time Ethernet and transmits the bottom layer control network state message to the network state analysis module;

d) the network state analysis module judges the working state of each node and each module by analyzing the message structure, evaluates the network state of each module and each node by comparing with the standard state word, and stores the result in the network state storage module;

e) the network state display module displays the state information in real time and can set up an autonomous alarm rule, and the display mode and the alarm mode can be in various modes including sound and light, a webpage, a client, a mail and a short message.

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