CN110673572A - User programmable universal industrial controller device - Google Patents
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41835—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by programme execution
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention provides a user programmable universal industrial controller device which comprises a computer processing system, a universal industrial controller, a user input switching value sensor, a user input analog value sensor, switching value control user equipment and analog value control user equipment. The user programs through host computer software, then downloads to the industrial controller in, the industrial controller is through resolving user program data to store in FRAM, industrial controller reads user program data from FRAM when operation, realizes automated control. The device has the characteristics of high automation degree, simplicity in operation, high control efficiency, high safety, easiness in operation and the like. The invention has the beneficial effects that: the user program data and the running program in the industrial controller are separated, the user can realize user programming through simple operation of a computer processing system, then the user program data is downloaded into the industrial controller for calling when the industrial controller runs, the design requirement can be quickly realized, and different application scenes are met.
Description
Technical Field
The invention relates to the technical field of industrial control, in particular to a device which can be used by a user to program user data through a computer processing system and realize user programmable control.
Background
In the fields of intelligent hardware, medical instruments, industrial automation control and the like, a programmable control system is often used, generally, the conventional PLC on the market is selected, special programming software and tools are needed, and operation can be performed by professional personnel, so that the programmable control system has the defects of high price, high entrance technology threshold and the like, and the cost of the whole set of system is low, so that the product cost is greatly influenced. From the consideration of research and development period and product applicability, manufacturers with technical strength generally adopt self-research and development control systems. However, in the design or production process, in some application occasions with higher requirements, the defects of fixed processing time, relatively fixed functions, no expansibility of IO and inconvenient operation exist, and more application scene requirements cannot be met.
In order to solve the problem, the module function is required to be divided, user program data can be programmed through a computer processing system and downloaded to the industrial controller after simulation verification, and the industrial controller stores the received user program data and then calls the user program data in the running process.
The patent number CN201320517815.8 adopts an FPGA as a control logic unit, and a processor dynamically updates circuit configuration inside the FPGA to implement hardware circuit reconfiguration; however, hardware reconstruction data of the processor of the system comes from LCD touch screen input, which greatly increases interface operation difficulty, increases product cost and volume, does not segment module functions, does not describe how to implement the method, and has difficulty in specific implementation; therefore, the user programmable general industrial controller device and the implementation method which have the advantages of expandable functions, high automation degree, safety, reliability, simple operation and low cost are designed, and the problem which needs to be solved urgently in the technical field of industrial control is solved.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a user programmable universal industrial controller device, wherein a user can perform user programming on the realized function through host computer pre-programming software of a computer system without a professional programming language or a downloading tool, and a common user can select input, output and feedback variable to enable so as to realize the control function and the protection function of the system; the user programmable universal industrial controller device has the characteristics of good product universality, high integration level, small volume, low cost, high automation degree, support of a Distributed Control System (DCS), high safety, easiness in operation and the like.
In order to solve the above problems, the present invention provides a user-programmable universal industrial controller device, which comprises a computer processing system, a universal industrial controller, a user input switching value sensor, a user input analog value sensor, a switching value control user device, and an analog value control user device, and is characterized in that: the user program data and the running program of the universal industrial controller are subjected to function segmentation, and the universal industrial controller realizes different functions by calling the user program data in the running process, so that the requirements of different application scenes are met; the user can preprogram the upper computer software through the industrial controller in the computer processing system, according to the function that needs to be realized, carry on the user data programming, then download to the universal industrial controller through the communication interface, the universal industrial controller stores after receiving the user program data, the industrial controller calls this user program data when running, need not the computer processing system, can operate according to the user program data, realize the function of user's design, the data that the user programmed in the computer processing system, can preserve through the way of the file, import when convenient next time calls, this user programmable universal industrial controller device has the product commonality good, the integrated level is high, small, with low costs, the degree of automation is high, support Decentralized Control System (DCS), the security is high, easy characteristics such as operation.
The universal industrial controller supports RJ45 network interface, RS232 interface and RS485 interface input, and is communicated with a computer processing system through any one of the interfaces.
The universal industrial controller supports 4-20mA/0-5V sensor signal input.
The universal industrial controller supports 0-5VDC/PWM control signal output and can be continuously controlled in the output range.
The computer processing system uses a computer and installs upper computer software preprogrammed by an industrial controller to perform user programming, program file importing, program downloading, analog simulation and online monitoring, supports RJ45 network interface, RS232 interface and RS485 interface input, communicates with the general industrial controller through any one of the interfaces, and is an unnecessary component in the operation process of the industrial controller.
The universal industrial controller adopts an industrial ARM chip, the storage device adopts a high-speed memory, the internal mainboard adopts reinforcement processing and is arranged in the plastic shell, and the external mainboard adopts a guide rail type installation mode, so that the controller has an excellent dustproof function and is convenient to install and operate. The above measures make the industrial controller highly available.
The universal industrial controller supports 8 paths of input switching value signal processing, 8 paths of output switching value signal processing, two paths of input analog quantity signal processing, two paths of output analog quantity signal processing, RS485 communication, RJ45/RS232 communication, key input and OLED display.
The user input switching value sensor can select the controller to provide 24V power supply or use an external power supply to supply power, and a photoelectric switch sensor, a magnetic proximity switch sensor, an infrared switch sensor, a mechanical proximity switch sensor, a pressure switch sensor, an ultrasonic switch sensor, a temperature switch sensor and a radar switch sensor are selected by a user according to different application scenes, so that the user can normally work as long as an output signal meets requirements no matter which sensor is selected by the user.
The user input analog quantity sensor can select the controller to provide 24V power supply or use an external power supply to supply power, and a temperature sensor, a gas sensor, an infrared sensor, an illumination sensor, a displacement sensor, a pressure sensor, an ultrasonic distance measuring sensor and a radar sensor are selected by a user according to an application scene.
The switching value control user equipment can select the controller to provide 24V power supply or use an external power supply to supply power.
Preferably, the user programmable universal industrial controller device comprises a computer processing system, a universal industrial controller, a user input switching value sensor, a user input analog value sensor, a switching value control user device and an analog value control user device.
Preferably, the universal industrial controller comprises an ARM main control unit, an input switching value processing unit, an output switching value processing unit, an input analog value processing unit, an output analog value processing unit, a storage unit, an OLED display unit, a key input unit, a storage unit, a communication unit and a power circuit, wherein 24V direct current is used as a power supply, and after passing through an internal power circuit, the direct current is converted into +5V and +3.3V to be used by other units.
Preferably, this inside mainboard of general industrial controller adopts the reinforcement to handle, and outside wiring port all is in both sides, installs in the plastic housing, and guide rail formula mounting means is adopted to the outside.
Preferably, the switching value controls the user equipment, and the controller can be selected to provide 24V power supply or use an external power supply for power supply.
Preferably, the power supply of the OLED display unit is +3.3V, and the OLED display unit is connected with the ARM main control unit by using an IIC interface.
Preferably, the memory unit uses FRAM memory, supplies power to +3.3V, and is connected with the ARM main control unit by using IIC interface.
The invention has the beneficial effects that: the utility model provides a user programmable general industrial controller device, includes computer processing system, general industrial controller, user input switching value sensor, user input analog quantity sensor, switching value control user equipment, analog quantity control user equipment which characterized in that: the user can be through the pre-programming software of host computer among the computer processing system, according to the function that needs were realized, carry out user data programming, then download to general industrial controller through communication interface, general industrial controller saves after receiving user program data, this user program data is called in the operation of general industrial controller, need not computer processing system, can operate according to user program data, realize user's function of design, the data of processing system user programming at computer, can save through the mode of file, it leads to when convenient next time calling, the device has that the product commonality is good, the integrated level is high, small in size, with low costs, degree of automation is high, support Distributed Control System (DCS), high safety, characteristics such as easy operation.
Drawings
FIG. 1 is a schematic block diagram of the apparatus of the present invention.
FIG. 2 is a block diagram of a generic industrial controller composition of the apparatus of the present invention.
Fig. 3 is a flow chart of the overall system operation of the apparatus of the present invention.
FIG. 4 is a flow chart of the general industrial controller of the apparatus of the present invention.
FIG. 5 is a flowchart of the user program executed by the universal industrial controller of the present invention.
Fig. 6 is a block diagram of the layout of an embodiment of the apparatus of the present invention.
FIG. 7 is a general industrial controller wiring diagram of an embodiment of the apparatus of the present invention.
FIG. 8 is a user first step input output cell programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
FIG. 9 is a user second step input-output cell programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
FIG. 10 is a user third step input-output cell programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
FIG. 11 is a user fourth step input-output cell programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
Fig. 12 is a user's fifth step input-output cell programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
Fig. 13 is a user sixth step input output cell programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
FIG. 14 is a user's seventh step exception handling unit programming diagram in a computer processing system of an embodiment of the apparatus of the present invention.
FIG. 15 is a schematic circuit diagram of a memory cell and an OLED cell in a universal industrial controller for the device of the present invention.
Detailed Description
As shown in fig. 1, a user programmable universal industrial controller device includes a computer processing system, a universal industrial controller, a user input switching value sensor, a user input analog value sensor, a switching value control user device, an analog value control user device; the computer processing system consists of a computer and an industrial controller preprogrammed upper computer software, and can perform user programming, program file importing, program downloading, analog simulation and online monitoring; the general industrial controller supports RJ45 network interface, RS232 interface and RS485 interface input, and communicates with the computer processing system through any one of the interfaces.
As shown in fig. 2, the general industrial controller is a block diagram, and includes an ARM main control unit, an input switching value processing unit, an output switching value processing unit, an input analog value processing unit, an output analog value processing unit, a storage unit, an OLED display unit, a key input unit, a storage unit, a communication unit, and a power circuit, and uses 24V dc as a power supply, and after passing through an internal power circuit, converts +5V and +3.3V to be used by other units.
As shown in fig. 3, in the whole system work flow chart, after the computer processing system is in communication connection with the general industrial controller, according to a specific application scenario, new programming is performed in the computer processing system or a programmed file is imported, whether to perform a simulation test on the programmed file is prompted, then the program is downloaded to the general industrial controller, and the general industrial controller analyzes data and then stores the data to wait for a response to a user operation; through the whole system work flow chart, it can be seen that after the industrial controller obtains the user program data, the computer processing system is not a necessary component in the operation process.
As shown in fig. 4, in the work flow chart of the universal industrial controller, after power-on, program initialization is performed first, then user program data in the storage unit is read, if no user program data exists in the storage unit, the program is waited to be downloaded all the time, if user program data exists, a user is waited to start/jog an operation program, a user data execution program is started to be invoked, a download request in a computer processing system cannot be responded in the start or jog program, and the universal industrial controller responds to the download request only in a standby state.
As shown in fig. 5, the general industrial controller executes a user program workflow chart, extracts user program data, where n is a total user program step, s is a user control mode, and when s =1, the user program is sequentially controlled, and is executed in sequence from step 1, up to step n, and then from step 1; when s =0, the user program is parallel control, and steps 1 through n are simultaneously performed.
As shown in fig. 15, the memory unit and the OLED display unit in the universal industrial controller use +3.3V for power supply, and the IIC interface; the memory cell uses FRAM ferroelectric memory, IIC interface.
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings and embodiments, it being understood that the specific embodiments described below are only for explaining the present invention and are not intended to limit the present invention. In the following description, specific details are given to provide a thorough understanding of the embodiments. However, it will be understood by those of ordinary skill in the art that the embodiments may be practiced without these specific details.
Example 1
As shown in fig. 6, the layout of the embodiment is a block diagram, in a certain production line, the whole line is operated circularly, when an article passes through a position a, a first mechanical opening and a second mechanical opening are executed, and after the article passes through the position a, the first mechanical opening and the second mechanical opening are automatically closed; when the automobile passes through the position B, mechanical three-fourth opening actions are executed, and mechanical three-fourth self-closing actions are executed after the automobile passes through the position B; when the robot passes through the position C, the robot executes the opening action of the fifth mechanical part, and the robot closes automatically after passing through the fifth mechanical part; when the D position is passed, counting and adding 2; when the alarm signal passes through the position E, the prompting indicator lamp is on, and after the alarm signal passes through the position E, the prompting indicator lamp is turned off; when a defective product is detected, executing the action of a machine 6; when the temperature of the production line motor is too high, the whole line is completely stopped until the production line motor is recovered to be normal.
The method for realizing the set of functions needs six steps in total, uses 6 input switching value processing units, 1 input analog value processing unit and 8 output switching value signal processing units, and is divided into the following steps:
the method comprises the following steps that firstly, in the step A, when no article passes through the sensor S1, the high level is achieved, the article passes through the sensor S1, the low level is achieved, the trigger delay time is 0S, and the action machines 1 and 2 are output;
step two, when no article passes through the sensor S2, the level is high, the level when the article passes through is low, the trigger delay time is 0S, and the action machines 3 and 4 are output;
step three, at step C, when no article passes through the sensor S3, the level is high, when an article passes through the sensor S3, the level is low, the trigger delay time is 0S, and the action machine 5 is output;
a fourth step, between the positions C and D, a sensor S6 outputs an action machine 6, when no defective product passes through, the sensor is at a high level, when a defective product passes through, the sensor is at a low level, the trigger delay time is 5S;
step five, at the position D, when no article passes through, the sensor S4 is at a high level, when the article passes through, the level is at a low level, the falling edge is triggered, the trigger delay time is 0S, the count is increased by 2, and no mechanical action is generated;
step six, at step E, when no article passes through, the sensor S5 is at high level, the indicator light is off, when the article passes through, the indicator light is on, the low level is triggered, and the triggering delay time is 0S;
step seven, at the position F, when the production line motor works normally, the temperature is detected to be lower value <3000 by the sensor A1, when the abnormality such as overload locked rotor is greater than 3000, the triggering delay time is 6S, and the production line motor is closed by the output action.
As shown in FIG. 7, in the wiring diagram of the universal industrial controller of the embodiment, the switching value sensors are selected for S1, S2, S3, S4, S5 and S5, the switching value sensors are selected for S6, the switching value sensors are selected for high level and low level when defective products pass, A1 is a temperature sensor, the output signal is 0 ~ V and corresponds to 0-100 ℃, the over-temperature detection temperature is 75 ℃, the output signal is greater than 3.75V, the value is about 3000 after analog-to-digital conversion, X00 of the universal industrial controller is connected with the sensor S00, X00 is connected with the sensor S00, the sensor A00, the execution machine 1 is connected with the D00 of the industrial controller, the indicator lamp is connected with the production line, the power supply of the machine control line, and the control motor is connected with the VAC 6 and the indicator lamp.
As shown in fig. 8, in the computer processing system according to the embodiment, the user first step is an input/output unit programming diagram, where the longest execution time is the longest execution time of this step, and is only valid for the sequential control mode, and the trigger execution time is the time for continuing to execute the action of the current step until the trigger condition disappears when the trigger condition is satisfied; the counting increment refers to the counting increment after the step is executed; the sequential control mode means sequential control according to steps, and the parallel control means that all the steps are controlled in parallel and can be selected only when the first step is programmed.
As shown in fig. 9, the user second step input-output unit programming diagram in the computer processing system of the embodiment.
As shown in fig. 10, the user third step input-output unit programming diagram in the computer processing system of the embodiment.
As shown in fig. 11, the input/output unit programming diagram of the fourth step of the user in the computer processing system of the embodiment.
As shown in fig. 12, the input/output unit programming diagram of the fifth step of the user in the computer processing system of the embodiment.
As shown in fig. 13, the user sixth step input output unit programming diagram in the computer processing system of the embodiment.
As shown in fig. 14, in the computer processing system according to the embodiment, in the step of programming the exception handling unit, the detection of the production line motor temperature is selected for controlling the production line motor, the actual enabling upper limit value is 3000, the execution operation is performed to turn on D06, and the shutdown of the production line motor is realized by electrically connecting the outside through another method.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and any simple modification, equivalent change and modification made to the above embodiment according to the technical spirit of the present invention by those skilled in the art can be still within the protection scope of the present invention without departing from the technical scope of the present invention.
Claims (10)
1. A user programmable universal industrial controller device is characterized in that the user programmable universal industrial controller device consists of a computer processing system, a universal industrial controller, a user input switching value sensor, a user input analog value sensor, switching value control user equipment and analog value control user equipment, wherein the user program data and the universal industrial controller running program are subjected to function segmentation, and the universal industrial controller realizes different functions by calling the user program data in the running process and meets the requirements of different application scenes; the user can preprogram upper computer software through the industrial controller in the computer processing system, carry out user data programming according to the function that needs to realize, then download to general industrial controller through communication interface, general industrial controller stores after receiving user program data, this user program data is called in the industrial controller operation, need not computer processing system, can operate according to user program data, realize the function of user's design, the data of processing system user's programming at the computer, can save through the mode of file, conveniently import when calling next time.
2. A user programmable universal industrial controller device, as recited in claim 1, wherein said computer processing system, using a computer and installing industrial controller preprogrammed upper computer software, performs user programming, importing program files, downloading programs, analog simulation and on-line monitoring, supports RJ45 network interface, supports RS232 interface, supports RS485 interface input, communicates with the universal industrial controller through any of the above interfaces, and is not a necessary component during operation of the industrial controller.
3. A user programmable universal industrial controller device, as recited in claim 2, wherein said user programming is programmed in accordance with the execution steps to meet different application scenario requirements.
4. The user-programmable universal industrial controller device as claimed in claim 1, wherein the universal industrial controller comprises an ARM main control unit, an input switching value processing unit, an output switching value processing unit, an input analog value processing unit, an output analog value processing unit, a storage unit, an OLED display unit, a key input unit, a storage unit, a communication unit and a power circuit, wherein 24V dc is used as a power supply, and after passing through an internal power circuit, +5V and +3.3V are converted for use by other units.
5. The universal industrial controller device programmable by a user is characterized in that an internal main board of the universal industrial controller is reinforced, external wiring ports are arranged on two sides and are arranged in a plastic shell, and the external part of the universal industrial controller device adopts a guide rail type installation mode.
6. A user programmable universal industrial controller device, as claimed in claim 4, wherein the switching value controls the user equipment, and the controller can be selected to provide 24V power or use external power.
7. The universal industrial controller device programmable by users as claimed in claim 4, wherein the user input switch value sensor can select the controller to provide 24V power supply or use external power supply, and the user can select the photoelectric switch sensor, the magnetic proximity switch sensor, the infrared switch sensor, the mechanical proximity switch sensor, the pressure switch sensor, the ultrasonic switch sensor, the temperature switch sensor and the radar switch sensor according to different application scenarios, and the user can work normally no matter which sensor is selected by the user as long as the output signal meets the requirement.
8. The universal industrial controller device programmable by the user as claimed in claim 4, wherein the user inputs the analog quantity sensor, the controller can be selected to provide 24V power supply or use external power supply to supply power, and the temperature sensor, the gas sensor, the infrared sensor, the illumination sensor, the displacement sensor, the pressure sensor, the ultrasonic distance measuring sensor and the radar sensor are selected by the user according to the application scene, and the sensor can work normally as long as the output signal meets the requirements of the industrial controller no matter which sensor is selected by the user.
9. A user programmable universal industrial controller device, as claimed in claim 4, wherein said OLED display unit uses +3.3V power, IIC interface; the memory cell uses FRAM ferroelectric memory, IIC interface.
10. The user-programmable universal industrial controller device as recited in claim 4, wherein said input switching value processing unit is 8-way, said output switching value signal processing unit is 8-way, said input analog value processing unit is 2-way, and said output analog value signal processing unit is 2-way.
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