CN114228083A - Industrial control system and injection molding machine - Google Patents
Industrial control system and injection molding machine Download PDFInfo
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- CN114228083A CN114228083A CN202111250283.1A CN202111250283A CN114228083A CN 114228083 A CN114228083 A CN 114228083A CN 202111250283 A CN202111250283 A CN 202111250283A CN 114228083 A CN114228083 A CN 114228083A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76929—Controlling method
- B29C2945/76953—Distributed, i.e. several control units perform different tasks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76929—Controlling method
- B29C2945/76993—Remote, e.g. LAN, wireless LAN
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Abstract
The application relates to the field of industrial control and discloses an industrial control system and an injection molding machine. The application provides an industrial control system, including host computer, lower computer and power pack. The lower computer is provided with a plurality of device interfaces for respectively connecting external industrial equipment; the upper computer is connected with the lower computer and comprises a main station control module which is used for generating a control instruction, sending the control instruction to the lower computer to control the external industrial equipment and receiving state data fed back by the external industrial equipment through the lower computer; the power supply pack is connected with the lower computer, the upper computer and external industrial equipment; the master station control module is also used for establishing communication connection with the enterprise management system so as to carry out data interaction. By the mode, the industrial control system can be optimized and is in communication connection with the enterprise management system, and the interconnection and intelligent capacity is improved.
Description
Technical Field
The application relates to the technical field of industrial control, in particular to an industrial control system and an injection molding machine.
Background
The traditional control system of the injection molding machine is composed of an upper computer and a lower computer, wherein the upper computer is generally responsible for functions such as display, data storage and the like, and the lower computer is generally responsible for operation of a Central Processing Unit (CPU) and connection of external devices. The injection molding machine control system is a set of system equipment which takes a lower computer as a control core, comprises various electric appliances, electronic elements or instruments and the like, is matched with a hydraulic system, and realizes various technological processes of pressure, temperature, speed, time and the like of the injection molding machine and various program actions of mold adjustment, manual operation, semi-automatic operation, full-automatic operation and the like.
The existing control system needs to pay attention to the problems of large temperature control deviation, complex calibration, large error, small hard disk data storage, low CPU processing speed, no interface protocol butt joint and the like in the injection molding process. With technological progress and era development, such as various data curves, rapid injection, establishment of intelligent processes, equipment interconnection, factory cloud platforms and enterprise management systems, traditional industrial control systems are increasingly difficult to meet the requirements of the industrial 4.0 internet of things big data era.
Disclosure of Invention
The technical problem to be solved by the invention is how to optimize the industrial control system, and the industrial control system is in communication connection with the enterprise management system, so that the interconnection and intelligentization capabilities are improved.
In order to solve the problems, the application provides an industrial control system which comprises an upper computer, a lower computer and a power supply pack. The lower computer is provided with a plurality of device interfaces for respectively connecting external industrial equipment; the upper computer is connected with the lower computer and comprises a main station control module which is used for generating a control instruction, sending the control instruction to the lower computer to control the external industrial equipment and receiving state data fed back by the external industrial equipment through the lower computer; the power supply pack is connected with the lower computer, the upper computer and external industrial equipment; and the master station control module is also used for establishing communication connection with the enterprise management system so as to carry out data interaction.
Optionally, the upper computer further includes:
the input unit is connected with the master station control module and is configured to input control parameters, and the master station control module generates control instructions according to the control parameters;
and the display is connected with the master station control module and is configured to display a human-computer interaction interface, and the human-computer interaction interface at least comprises an input interface for displaying control parameters and a state interface for displaying state data.
Optionally, the master station control module includes:
the network card is connected with the lower computer through an Ethernet channel;
the first processor is connected with the input unit, the display and the network card and used for acquiring control parameters and state data;
the first processor reads and decodes the control parameters to generate a control instruction, the control instruction is transmitted to the network card, the network card decodes and converts the control instruction into a first data packet, and the first data packet is transmitted to the lower computer through the Ethernet channel;
the first processor acquires the state data from the Ethernet channel through the network card, transcodes the state data and the control parameters to generate image data, and transmits the image data to the display to display a state interface and an input interface of the external industrial equipment in real time.
Optionally, the master station control module further includes:
and the master station memory is connected with the first processor and used for storing control parameters, state data, image data and program data, wherein the first processor is used for executing the program data to perform corresponding operation.
Optionally, the lower computer includes:
the communication interface is connected with the network card through an Ethernet channel and is configured to receive a first data packet and transmit status data to the network card;
the industrial equipment interface group is connected with external industrial equipment;
the power supply interface is connected with the power supply pack;
the slave station control module is connected with the communication interface, the industrial equipment interface group and the power supply interface;
the slave station control module receives a first data packet through the communication interface, decodes and converts the first data packet into a control signal, and then transmits the control signal to the external industrial equipment through the industrial equipment interface group to control the external industrial equipment to operate; and
and the slave station control module acquires a state signal of the external industrial equipment according to the control signal, transcodes the state signal to form a second data packet, and transmits the second data packet to the network card through the Ethernet channel through the communication interface so that the first processor transcodes the second data packet to form state data.
Optionally, the slave station control module includes:
the second processor is connected with the communication interface and the industrial equipment interface group;
the second processor decodes the first data packet into a control signal, and transmits the control signal to the external industrial equipment through the industrial equipment interface group so as to control the operation of the external industrial equipment; and
the second processor acquires the state signal of the external industrial equipment through the industrial equipment interface group, transcodes the state signal into a second data packet, and transmits the second data packet to the network card through the Ethernet channel through the communication interface.
Optionally, the control signal comprises a digital control signal and/or an analog control signal; the status signal includes a digital status signal and/or an analog status signal.
Optionally, the industrial device interface group includes:
a digital output interface for outputting a digital control signal;
a digital input interface for inputting a digital status signal;
the analog output interface is used for outputting an analog control signal;
and the analog input interface is used for inputting an analog state signal.
Optionally, the external industrial device comprises:
any one of a heating device, a hydraulic valve, a solenoid valve, a contactor, a relay, a motor and a lubrication motor connected with the digital output interface, configured to operate according to a digital control signal;
any one of a counting sensor and a limit switch connected with the digital input interface is configured to collect a digital status signal;
any one of a proportional valve, a back pressure valve, a servo motor and a servo valve connected with the analog output interface and configured to operate according to the analog control signal;
any at least one of a thermocouple, an electronic scale, and a pressure sensor, coupled to the analog input interface, is configured to acquire an analog status signal.
Optionally, the master station control module is an X86 control module, wherein the X86 control module establishes a communication connection with the enterprise management system and/or the lower computer by using an EtherCat protocol.
Optionally, the power pack comprises:
the first power supply is connected with the upper computer and provides a first direct current for the upper computer;
the second power supply is connected with the lower computer and the external industrial equipment and provides second direct current for the lower computer and the external industrial equipment;
and the third power supply is connected with the external industrial equipment and provides third direct current for the external industrial equipment.
In order to solve the above problems, the present application also provides an injection molding machine, wherein the injection molding machine includes any one of the industrial control systems described above.
The industrial control system that this application provided has and to optimize current industrial control system to with enterprise management system communication connection, promote interconnectivity and intelligent effect. The lower computer is provided with various device interfaces and can be connected with various external industrial devices, so that the function that the industrial control system can control the operation of the various external industrial devices can be realized. Meanwhile, the master station control module of the industrial control system is arranged on the upper computer, namely the upper computer is responsible for generating control instructions and receiving state data, and the lower computer is responsible for executing the control instructions and feeding back the state data. And the master station control module can also establish communication connection with an enterprise management system to perform data interaction, so that the data, intelligence and interconnection capabilities of the industrial control system are improved.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
Wherein:
FIG. 1 is a schematic block diagram of an embodiment of an industrial control system of the present application;
FIG. 2 is a schematic structural diagram of an embodiment of an upper computer of the present application;
FIG. 3 is a schematic structural diagram of an embodiment of a master station control module according to the present application;
FIG. 4 is a schematic structural diagram of an embodiment of a lower computer of the present application;
fig. 5 is a schematic structural diagram of an embodiment of a slave station control module according to the present application;
FIG. 6 is a schematic diagram illustrating the operation of an embodiment of the EtherCAT communication protocol of the present application;
FIG. 7 is a schematic view of the external industrial equipment of the present application connected to a lower computer;
FIG. 8 is a schematic diagram of an embodiment of a solenoid valve for an external industrial device according to the present application;
FIG. 9 is a schematic diagram of a circuit configuration of an embodiment of a relay of the external industrial equipment of the present application;
FIG. 10 is a schematic diagram of a circuit configuration of an embodiment of a limit switch in the external industrial equipment of the present application;
FIG. 11 is a schematic circuit diagram of an embodiment of another limit switch in the external industrial equipment of the present application;
fig. 12 is a communication structure diagram of an embodiment of the injection molding machine of the present application.
Detailed Description
The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. It is to be understood that the specific embodiments described herein are merely illustrative of the application and are not limiting of the application. It should be further noted that, for the convenience of description, only some of the structures related to the present application are shown in the drawings, not all of the structures. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
It should be noted that, in the embodiment of the present application, directional indications (up, down, left, right, front, and back … …) are mentioned, and the directional indications are only used for explaining the relative positional relationship between the components in a certain posture (as shown in the drawing), the motion situation, and the like, and if the relative positional relationship changes, the directional indications also change accordingly.
In addition, in the embodiments of the present application, if there is a description referring to "first", "second", etc., the description of "first", "second", etc. is only for descriptive purposes and is not to be construed as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present application.
The terms "comprising" and "having," as well as any variations thereof, in this application are intended to cover non-exclusive inclusions. For example, a process, method, system, article, or apparatus that comprises a list of steps or elements is not limited to only those steps or elements listed, but may alternatively include other steps or elements not listed, or inherent to such process, method, article, or apparatus.
Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the application. The appearances of the phrase in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. It is explicitly and implicitly understood by one skilled in the art that the embodiments described herein can be combined with other embodiments.
In order to explain technical contents, technical steps, and objects and effects achieved by the present invention in detail, the following detailed description is given with reference to the accompanying drawings in combination with the embodiments.
FIG. 1 is a schematic diagram of an embodiment of an industrial control system according to the present application. Fig. 2 is a schematic structural diagram of an embodiment of the upper computer of the present application.
As shown in fig. 1 and 2, the industrial control system 10 includes an upper computer 100, a lower computer 200, and a power pack 300. The lower computer 200 is provided with a plurality of device interfaces for connecting the external industrial devices 400 respectively, so that the external industrial devices 400 can be controlled to operate and the state data of the external industrial devices 400 can be acquired through the lower computer 200. The upper computer 100 is connected with the lower computer 200, and the upper computer 100 comprises a main station control module 110. The master station control module 110 is configured to generate a control instruction and send the control instruction to the lower computer 200, and the master station control module 110 may control the external industrial equipment 400 through the lower computer 200 and receive status data fed back by the external industrial equipment 400 through the lower computer 200. The power pack 300 is connected to the lower computer 200, the upper computer 100, and the external industrial device 400, respectively, so as to supply power to the operation of the lower computer 200, the upper computer 100, and the external industrial device 400.
When the industrial control system 10 works, the master station control module 110 of the upper computer 100 generates a control instruction and sends the control instruction to the lower computer 200, the lower computer 200 controls the external industrial equipment 400 connected with the lower computer 200 to operate according to the control instruction, collects the operating state data of the external industrial equipment 400, and then feeds the state data back to the upper computer 100. The power pack 300 supplies power to the operation of the lower computer 200, the upper computer 100 and the external industrial device 400, respectively.
Optionally, the master station control module 110 may further be configured to establish a communication connection with an enterprise MES (manufacturing execution system) management system and/or a cloud server and/or the lower computer 200 for data interaction. For example, the master station control module 110 is connected to the enterprise MES management system through EtherCAT communication protocol, and the control command generated by the master station control module 110 and the status information of the received external industrial equipment 400 are transmitted to the enterprise MES management system through EtherCAT (ethernet control automation technology) communication protocol, so that the enterprise MES management system can monitor the operation status and the operation process of the industrial control system 10 in real time. And the enterprise MES management system can transmit commands or data to the master station control module 110 via the EtherCAT communication protocol to enable the enterprise MES management system to control operation of the industrial control system 10.
In an embodiment, the EtherCAT communication protocol adopts a network structure of a master-slave mode, that is, the EtherCAT communication protocol is composed of a communication master station and a communication slave station, and the master station and the slave station work cooperatively to complete data transmission and read-write, so as to realize communication between the master station and the slave station. For example, the main communication station of the EtherCAT communication protocol is the main station control module 110, and the slave communication stations are the lower computers 200, the cloud server and the enterprise MES management system. The number of the communication master stations of the EtherCAT communication protocol is only one, and the number of the communication slave stations is not less than one.
When the EtherCAT communication protocol system works, the communication master station sends out a control cycle to become a downlink telegraph, namely, the communication master station converts data and instructions into messages and sends the messages to the communication slave stations in the form of the telegraph, the communication slave stations match and read and write the messages sent by the communication master station one by one so as to convert the messages into the form of the data or the instructions for processing, and the communication slave stations feed back the processed messages to the communication master station. When the message sent by the communication master station passes through the last slave station in the network and the slave station feeds back the processed message to the communication master station, the EtherCAT communication protocol system completes the communication between the communication master station and the communication slave station in one control period.
Optionally, the master station control module 110 and the enterprise MES management system and/or the cloud server and/or the lower computer 200 may establish a communication connection through an industrial EtherNet communication protocol such as EtherCAT communication protocol, EtherNet/IP communication protocol, powerlinkeeneret communication protocol, PROFINET communication protocol, and the like, which is not limited herein. The EtherCAT communication protocol has strong adaptability and low requirements on hardware of the communication master station and the communication slave station. An ordinary PC (Personal Computer) can be used as a communication master station of the EtherCAT communication protocol, the communication protocol is modified by a standard Ethernet, the compatibility is strong, the refresh cycle of the EtherCAT communication is short, the synchronism is good, the efficiency is high, the industrial Ethernet broadband can be utilized to the maximum extent to transmit data of equipment, the system configuration is simple, and the implementation cost is low.
Referring to fig. 2, the host computer 100 further includes: an input unit 120 and a display 130. The input unit 120 is connected to the master station control module 110, and is configured to input a control parameter, and the master station control module 110 generates a control command according to the control parameter. The display 130 is connected to the master station control module 110 and is configured to display a human-machine interface. The human-computer interaction interface at least comprises an input interface for displaying control parameters and a state interface for displaying state data.
When the upper computer 100 works, a user can input control parameters through the input unit 120, and the input unit 120 transmits the control parameters to the main station control module 110, so that the main station control module 110 can generate control instructions for the control parameters and send the control instructions to the lower computer 200. The master station control module 110 converts the control parameters into digital input interface parameters and converts the received state data of the state quantities into digital state interface parameters, and transmits the input interface parameters and the state interface parameters to the human-machine interface, so that the display 130 can display the operation process of the industrial control system 10 and the operation state of the external industrial device 400 through the human-machine interface.
Alternatively, the display 130 may be an industrial-grade full-color TFT (Thin Film Transistor) screen, which may be used to display the operation interface switching, the process setting, the record query, and the like of the industrial control system 10. The input unit 120 is in the form of a keyboard, and functions such as function guidance for parameter input, input or modification of numbers or letters, operation mode switching, and manual operation are implemented.
Fig. 3 is a schematic structural diagram of an embodiment of a master station control module according to the present application.
As shown in fig. 3, the master station control module 110 includes: a first processor 111 and a network card 112. The network card 112 is in communication connection with the lower computer 200 through an ethernet channel 113, so as to be capable of sending data or receiving data through the ethernet channel 113. The first processor 111 is connected to the input unit 120, the display 130 and the network card 112, and is configured to acquire the control parameters and the status data, process the control parameters to form control instructions or input interface parameters, and process the status data to form control instructions or status interface parameters.
Specifically, the first processor 111 reads and decodes the control parameter to generate a control instruction, and transmits the control instruction to the network card 112, and the network card 112 decodes and converts the control instruction into a first data packet and transmits the first data packet to the lower computer 200 through the ethernet channel 113. And the first processor 111 acquires the status data from the ethernet channel 113 through the network card 112, transcodes the acquired status data and the generated control parameters to generate image data of the input interface parameters and the status interface parameters, and transmits the image data to the display 130 to display the status interface of the external industrial device 400 and the input interface of the industrial control system 10 in real time.
Optionally, the master station control module 110 is an X86 control module. The X86 control module establishes a communication connection with the enterprise management system and/or the cloud server and/or the lower computer 200 by using an ethercat communication protocol.
Specifically, the X86 control module is provided with the first processor 111 and the intelligent software platform, so that the development of the application layer of the EtherCatt communication protocol is faster, simpler and more efficient, the yield and the weight of the final product manufactured by the industrial control system 10 are improved, the material cost is reduced, the production efficiency is improved for the client, the production cost is reduced, and the market competitiveness is improved. The first processor 111 can provide a precise temperature control algorithm to improve the temperature control accuracy of the external industrial equipment 400, such as the temperature of the cartridge can be controlled within ± 0.5 ℃. The first processor 111 may provide a precise position algorithm to improve the precision of the processes of mold opening positioning, glue melting positioning, and the like of the external industrial equipment 400, and for example, the precision of the mold opening positioning and the glue melting positioning may be controlled within ± 0.3 mm. Based on the high-speed computing power of the first processor 111, the time for the external industrial equipment 400 to collect the status data may be less than 200us (microseconds). The intelligent software platform can provide curve data of key parameters and display the curve data through the display 130, such as providing mould opening and closing speed curve data, injection pressure curve data, injection speed and pressure maintaining history curve data, temperature curve data and the like, so that field debugging of a user is more convenient. The intelligent software platform may also provide the data of the shot page so as to display each period of time of the injection process and each period of position of the pressure maintaining process in real time through the display 130, thereby providing a reference for precise manufacturing of on-site industrial manufacturing. And the intelligent software platform has a strong calibration function, so that the pressure and flow of the external industrial equipment 400 can be automatically calibrated. The intelligent software platform also has good functions of file retrieval, alarm prompt and operation log tracing, and the file pages can store hundreds of sets of mould process parameters and provide more than 23 monitoring parameters, such as cycle time, mould opening terminal point, switching pressure and the like, so that a user can monitor the parameters in real time through the display 130.
Alternatively, the X86 control module may be based on the Liunx system or the Microsoft system for system operation. The operating system can be used for C language development, QT (application development framework) interface editing and application layer application. And is programmed with the classical combination GCC (GNU Compiler Collection) + Make/Makefile + GBD (GNU Project Debuger, GNU Project Debugger) + Valgrind (memory analysis tool) + Vim/EMACS/Gedit/Sublime Text editor). The Liunx system can provide a stable development environment, common data structures and algorithms can be packaged in C language development, and the interface library of the QT can be used for secondary development of software.
Optionally, the first processor 111 on the X86 control module is
Atom D27002.13G dual core processor to provide powerful data processing capabilities. X86 control Module adopted
NM10 high-speed chipset to provide powerful data-computing capabilities. The X86 control module is configured with VGA display output socket and LVDS display output socket for connecting with different types of displays 130 to realize interface display of the displays 130. The VGA display output socket is used for transmitting analog display signals, and the LVDS display output socket is used for transmitting digital display signals. The X86 control module is configured with 2 RTL8111F GmbH card to support network wake-up and PXE functions. The X86 control module is further provided with a PCI slot, a Mini-PCIE slot, a SATA2.0 hard disk interface, an MSATA slot, a 4-way USB2.0 interface, a 2-way RJ-45 gigabit network interface, an LPT interface and an RS232 serial port, so that the upper computer 100 can be connected with other external devices to increase and optimize the functions of the upper computer 100. For example, the upper computer may be externally connected with devices such as IO control, process control, and motion control, so as to enhance functions of the upper computer 100, such as process operation, motion operation, interface display, alarm, and device exception handling.
With continued reference to fig. 3, the master station control module 110 further includes: a master station storage 114. The master storage 114 is connected to the first processor 111 and is used for storing data to be processed by the first processor 111, such as control parameters, status data, image data, and program data. The first processor 111 is used for executing data to perform corresponding operations on the industrial control system 10. Optionally, the master storage 114 may be two DDR3 memory banks simultaneously supporting 800MHz or 1066MHz master frequency, so as to implement that the industrial control system 10 has a large-capacity data storage capability.
Fig. 4 is a schematic structural diagram of an embodiment of a lower computer of the present application.
As shown in fig. 4, the lower computer 200 includes: a slave control module 210, a communication interface 220, an industrial equipment interface group 230, and a power supply interface 240. The communication interface 220 is connected to the ethernet channel 113, is connected to the network card 112 through the ethernet channel 113, and can be configured to receive the first data packet and transmit the status data from the network card 112 to the network card 112, so as to implement communication transmission between the upper computer 100 and the lower computer 200. The industrial device interface group 230 is connected to the external industrial device 400 to enable the lower computer 200 to control the external industrial device 400 according to the control instruction. The power supply interface 240 is connected to the power pack 300 so that the power pack can supply power for the operation of the lower computer 200. The slave control module 210 is connected to the communication interface 220, the industrial equipment interface group 230, and the power supply interface 240, so that the industrial control system 10 can control the operation of the lower computer 200 through the slave control module 210.
When the lower computer 200 works, the slave control module 210 receives the first data packet from the network card 112 through the communication interface 220, decodes and converts the first data packet into a control signal, and transmits the control signal to the external industrial equipment 400 through the industrial equipment interface group 230 to control the operation of the external industrial equipment 400. And the slave station control module 210 acquires the required state signal of the external industrial equipment 400 according to the control signal, transcodes the state signal to form a second data packet, and further transmits the second data packet to the network card 112 through the communication interface 220 via the ethernet channel 113, so that the first processor 111 can transcode the second data packet to form state data.
Alternatively, the control signal decoded and converted by the secondary station control module 210 includes any at least one of a digital control signal and an analog control signal. Wherein the digital control signal is used to control the external industrial device 400 configured to be controlled by the digital signal from the station control module 210 and the analog control signal is used to control the external industrial device 400 configured to be controlled by the analog signal from the station control module 210. The status signals collected from the station control module 210 include any one of digital status signals and analog status signals. The digital state signal is obtained by the slave control module 210 acquiring a signal of the external industrial equipment 400 configured to be controlled by the digital signal, and the analog state signal is obtained by the slave control module 210 acquiring a signal of the external industrial equipment 400 configured to be controlled by the analog signal.
Fig. 5 is a schematic structural diagram of an embodiment of a slave station control module according to the present application.
Optionally, the slave control module 210 comprises: a second processor 211 and a slave store 212. The second processor 211 is connected to the communication interface 220 and the industrial device interface group 230, so that the second processor 211 can receive the first data packet from the network card 112 and convert the first data packet into a control signal, and transmit the control signal to the external industrial device 400 through the industrial device interface group 230, thereby controlling the operation of the external industrial device 400. And the second processor 211 acquires the status signal of the external industrial device 400 through the industrial device interface group 230, transcodes the status signal to form a second data packet, and transmits the second data packet to the network card 112 through the ethernet channel 113 through the communication interface 220. The slave storage 212 is connected to the second processor 211 to be able to receive and store the first and second data packets processed by the second processor 211.
Fig. 6 is a schematic diagram illustrating an operation principle of an embodiment of the EtherCAT communication protocol of the present application.
Optionally, the upper computer 100 and the lower computer 200 are connected by an EtherCAT communication protocol. The master station control module 110 of the upper computer 100 serves as a communication master station of an EtherCAT communication protocol, the slave station control module 210 of the lower computer 200 serves as a communication slave station of the EtherCAT communication protocol, and the external industrial device 400 connected with the lower computer 200 serves as a slave station device of the EtherCAT communication protocol.
Specifically, when the EtherCAT communication system works, the communication master station is closely matched with the communication slave station, and the communication master station can send a data packet (namely, a telegram message) to the communication slave station and also can receive the data packet returned by the communication slave station. The communication slave station needs to receive a data packet sent by the communication master station, and implements control of an application layer (i.e. control of the communication slave station on the slave station device) according to an instruction in the data packet, and after this operation is completed, the communication slave station writes corresponding information in the data packet, and finally feeds back the information to the communication master station. The data packets communicated between the communication master station and the communication slave station are standard Ethernet data frame structures. And the communication master station sends a data packet, and after the communication slave station receives the data packet and completes the corresponding application layer operation, the data packet is rewritten and the data packet is fed back to the communication master station, so that a complete EtherCAT communication process is formed.
As shown in fig. 6, only one communication slave (i.e., the slave control module 210), one communication master (i.e., the master control module 110), a first slave device 410, and a second slave device 420 exist in the upper computer 100 and the lower computer 200. When the communication master station and the communication slave station communicate, in a communication cycle, the first processor 111 of the communication master station first sends a downlink telegram 110a to the communication slave station, the downlink telegram 110a passes through all the communication slave stations on the communication link, the second processor 211 of each communication slave station processes the data packet, the matched communication slave station processes only the part of the downlink telegram 110a related to the second processor, and then sends the downlink telegram 110a to the communication master station and stores the downlink telegram in the slave station storage 212, and performs operations in an application layer. When the downlink telegrams 110a sent by the communication master station are processed by all the communication slave stations, the communication slave stations which finish data processing convert the downlink telegrams 110a into uplink telegrams 110b and send the uplink telegrams 110b back to the communication master station, so that bidirectional transmission of Ethernet frames of the EtherCAT communication protocol is realized. The communication slave station can only process the message correspondingly when the telegram is transmitted in the downlink, and can not process the message data when the telegram is transmitted in the uplink.
Continuing with FIG. 4, the industrial equipment interface group 230 includes: digital output interface 231, digital input interface 232, analog output interface 233, and analog input interface 234. Wherein the digital output interface 231 is used for the second processor 211 to output digital control signals to the external industrial equipment 400 configured to be controlled by the digital signals. The digital input interface 232 is used for the second processor 211 to input digital status signals to the external industrial equipment 400 configured to be controlled by digital signals. The analog output interface 233 is used for the second processor 211 to output an analog control signal to the external industrial equipment 400 configured to be controlled by the analog signal. The analog input interface 234 is used for the second processor 211 to input analog status signals to the external industrial equipment 400 configured to be controlled by analog signals.
Referring to fig. 4, the lower computer 200 further includes a hardware expansion socket 250, which is a CANBUS interface and can provide expansion of external devices such as analog input/output, digital input/output, and temperature measurement. For example, the power supply of the 0-24V expansion board can be provided with a positive electrode and a negative electrode, the 0-24V expansion equipment can be provided with a positive electrode and a negative electrode, a CANH expansion board serial port and a CANL expansion board serial port and the like.
FIG. 7 is a schematic structural diagram of the external industrial equipment connected to the lower computer according to the present application.
Optionally, the external industrial equipment 400 connected to the lower computer 200 includes:
any one of an electric heating device 4021, a hydraulic valve, a solenoid valve 401, a contactor, a relay 402, an electric motor, and a lubrication motor connected to the digital output interface 231, which is configured to operate according to a digital control signal;
and/or any of a count sensor 405, a limit switch coupled to the digital input interface 232, configured to collect a digital status signal;
and/or any one of a proportional valve, a back pressure valve, a servo motor, and a servo valve connected to analog output interface 233 and configured to operate according to an analog control signal;
and/or any of a thermocouple 407, an electronic scale 408, and a pressure sensor 409 coupled to the analog input interface 234, configured to acquire analog status signals.
FIG. 8 is a schematic circuit diagram of an embodiment of a solenoid valve in an external industrial device according to the present application.
As shown in fig. 8, the solenoid valve 401 is a solenoid directional valve, and when the first port YA11 is turned on, the solenoid valve 401 advances, thereby closing the valve. When the second port YA12 is connected, the solenoid valve 401 moves back, thereby opening the valve.
As shown in fig. 7, the electromagnetic valves 401 have positive and negative leads and two signal lines, respectively, wherein the positive and negative leads are connected to the power pack 300 for power supply operation. One ends of the two signal lines are connected with the lower computer 200, and the other ends of the two signal lines are respectively connected with the first port YA11 and the second port YA12 so as to be capable of receiving digital control signals output from the second processor 211 and further control the operation of the electromagnetic valve 401. The digital output interface 231 of the lower computer 200 is connected with a 32-way electromagnetic valve 401. The positive and negative poles of the electromagnetic valve 401 are connected with the power pack 300 to be connected with 2A high-current output, the output response time is not more than 1MS, and the electromagnetic valve can be used for controlling the opening and closing of external hydraulic valves, relays and other equipment.
Fig. 9 is a schematic circuit diagram of an embodiment of a relay in an external industrial device according to the present application.
As shown in fig. 9, the relay 402 is a solid state relay, and the relay 402 includes a first coil 402a and a second coil 402b, wherein the first coil 402a is close to a first normally open contact KM1 of the lubrication motor, and the second coil 402b is close to a second normally open contact KM2 of the lubrication motor. When the first output end 402c of the relay 402 is turned on, the first coil 402a is driven to work, so that the first normally open contact KM1 of the lubrication motor is closed, and the second normally open contact KM2 is opened, so that the relay 402 can control the external lubrication motor to operate. When the second output end 402d of the relay 402 is turned on, the second coil 402b is driven to operate, so that the first normally open contact KM1 of the lubrication motor is opened, and the second normally open contact KM2 is closed, so that the relay 402 can control the external lubrication motor to operate.
As shown in fig. 7, the positive and negative poles of the relay 402 are connected to the power pack 300 for receiving power. The first output terminal 402c and the second output terminal 402d of the relay 402 are respectively connected to the lower computer 200 to receive the digital control signal output by the second processor 211, so as to control the operation of the relay 402. The relay 402 can be connected with an external lubricating motor, and can also be connected with a large-scale device such as a motor, and further control the normally open contact of the large-scale device to achieve the purpose of controlling the external device.
As shown in fig. 7, the electric heating device 4021 is configured to receive the digital control signal output by the second processor 211 and further control the electric heating device 4021 to generate power for heating, and the output type is the same as the relay 402 and will not be described here.
FIG. 10 is a schematic circuit diagram of an embodiment of a limit switch in the external industrial equipment of the present application.
As shown in fig. 10, the first limit switch 403 is a pressure switch, the first limit switch 403 includes an i-shaped limit block 403a, a pressure block 403b is disposed above the limit block 403a, when the power is not turned on, the pressure block 403b is not moved and does not impact the limit block 403a, at this time, the i-shaped limit block 403a does not contact the moving contact a and the moving contact b, the safety door is in an open state, and the first limit switch 403 does not transmit a signal to the lower computer 200. When the power is switched on, the pressure block 403b presses the limit block 403a downwards, at this time, the i-shaped limit block 403a is respectively contacted with the break contact a and the make contact b, the safety door is in a closed state, and the first limit switch 403 transmits a signal to the lower computer 200.
FIG. 11 is a schematic circuit diagram of another embodiment of a limit switch in the external industrial equipment of the present application.
As shown in fig. 11, the second limit switch 404 is an inductive switch, and includes: a metal object 404a, a sense head 404b, an oscillator 404c, a transistor switch 404d, and an output 404 e. When the power is turned on, the metal object 404a is attracted by the inductive head 404b, and at this time, the clock frequency of the oscillator 404c increases, the transistor switch 404d is turned on, and the output device 404e outputs the emitter stop signal. When the 0V power supply is turned on, the metal object 404a is not attracted by the inductive head 404b, the clock frequency of the oscillator 404c is low, the transistor switch 404d is in an off state, and the output device 404e outputs a seating advance stop signal.
The second limit switch 404 includes an output signal line and a positive electrode and a negative electrode, the output signal line and the negative electrode are connected to the lower computer 200, the positive electrode is connected to the power supply pack 300 to enable a digital status signal to be input to the second processor 211, and the second processor 211 sends the digital status signal to the master station control module 110 to control the operation of the device.
As shown in fig. 7, the counting sensor 405 includes a level input signal line and positive and negative electrodes, the level input signal line is connected to the lower computer 200, the positive and negative electrodes are connected to the power pack 300 to input the digital status signal to the second processor 211, and then the second processor 211 transmits the digital status signal to the master station control module 110 to control the operation of the device. The counting sensor 405 includes 4-way 1MHz high-speed counting signal input terminals for melt adhesive counting and mode-adjusting counting of the external device. The counting sensor 405 further includes 32 low-level input signals for inputting digital quantity voltages of 10 to 30VDC (standard voltage 24VDC) to the lower computer 200.
As shown in fig. 7, the first proportional valve 406a is an analog output current type proportional valve, and the second proportional valve 406b is an analog output voltage type proportional valve. The analog output current type proportional valve is a 4-way proportional valve, which uses PWM control, has a maximum current of 1A, and is used to control an external current type proportional valve, for example, the first proportional valve 406a may be a back pressure proportional valve. The analog output current type proportional valve is a 4-way proportional valve which outputs 0 to ± 10VDC for controlling a servo motor or a second proportional valve 406b, and the second proportional valve 406b may be a servo valve. The greater the pressure differential across the proportional valve, the greater the flow it outputs. The proportional valve comprises an anode and a cathode, and the anode and the cathode are connected with the lower computer 200 so as to be capable of receiving the analog control signal output by the second processor 211 and further control the operation of the proportional valve.
As shown in fig. 7, the thermocouple 407 is an 8-path K-type thermocouple or a J-type thermocouple, and the temperature test range thereof is 0 to 800 ℃, and is used for collecting a voltage value fed back by an external temperature sensing line, converting the voltage value into a temperature state signal value, and sending the signal value to the lower computer 200.
As shown in fig. 7, the electronic ruler 408 and the pressure sensor 409 form a 7-way access to the lower computer 200, the electronic ruler 408 is used for measuring the position change of the external device, and the pressure sensor 409 is used for measuring the pressure change of the external device, generating an analog status signal and transmitting the analog status signal to the lower computer 200. The positive electrode and the negative electrode of the electronic ruler 408 are connected into the lower computer 200, the positive electrode of the pressure sensor 409 is connected with the power supply pack 300, and the negative electrode of the pressure sensor 409 is connected with the lower computer 200 so as to be connected with current with proper magnitude. When electronic ruler 408 and pressure sensor 409 are wired, they need to be separated from the high currents in order to avoid interference and to ground their shielding.
Continuing to refer to FIG. 1, the power pack 300 of the industrial control system 10 includes: a first power supply 310, a second power supply 320, and a third power supply 330. The first power supply 310 is connected to the upper computer 100 and provides a first direct current for the upper computer 100; the second power supply 320 is connected with the lower computer 200 and the external industrial equipment 400 and provides second direct current for the lower computer 200 and the external industrial equipment 400; third power supply 330 is coupled to external industrial unit 400 to provide a third direct current to external industrial unit 400.
Specifically, the injection molding machine is used for industrial electricity and comprises a grounding wire, a zero wire N and a live wire L. The first power supply 310 is connected to the upper computer 100 and can provide 0-24V DC power. The second power supply 320 is connected with the lower computer 200 and the external industrial equipment 400 and can provide 0-24V direct current for the lower computer 200 and the external industrial equipment 400. For example, heating devices, hydraulic valves, solenoid valves, contactors, relays, motors and lubrication motors interfaced with digital outputs need to provide 24V dc power. The counting sensor and limit switch connected to the digital input interface need to provide a 24V dc supply. The thermocouples, electronic scales and pressure sensors connected to the analog input interface need to provide 10V dc power. The third power supply 330 is connected with the proportional valve, the back pressure valve, the servo motor and the servo valve which are connected with the analog output interface, and can provide 0-48V direct current power supply.
The application also provides an injection molding machine, including as above industrial control system 10 and casing, wherein, industrial control system 10 sets up in the inside of casing, only exposes input unit 120, display 130 and host computer 100 and the external device socket on the host computer 200 to the external world through the opening that the casing set up, and the casing is used for cutting apart this industrial control system 10 with the external world and then protects this industrial control system 10 from interference and influence such as dust, electromagnetism.
Alternatively, the lower machine of the industrial control system 10 of the injection molding machine has an external shape of a rectangular parallelepiped, and the installation size thereof is not particularly limited herein, and may be, for example, 421 × 173 × 35.5 (mm). The upper machine of the industrial control system 10 of the injection molding machine is also a rectangular parallelepiped in shape, and the installation size thereof is not particularly limited, and may be, for example, 421 × 173 × 35.5 (mm).
Fig. 12 is a communication structure diagram of an embodiment of the injection molding machine of the present application.
Optionally, the upper computer 100 of the injection molding machine comprises a master station control module 110, wherein the master station control module 110 comprises a master station storage 114 for data storage of the injection molding machine, a network card 112 for communication of the injection molding machine, and a first processor 111 for control of the injection molding machine. The upper computer 100 of the injection molding machine further includes a human-machine interface 130a connected to the master station control module 110. The human-machine interface includes a display 130 for interface display of the injection molding machine and an input unit 120 for data input of the injection molding machine. The lower computer 200 of the injection molding machine includes a slave control module 210 for processing control signals and status signals of the injection molding machine. The lower computer 200 of the injection molding machine further includes an industrial equipment interface group 230 connected to the slave control module 210, for inputting and outputting digital quantity and analog quantity to and from the external industrial equipment 400. The upper computer 100 and the lower computer 200 of the injection molding machine can be connected through communication such as serial ports, internet ports and Bluetooth.
In summary, the industrial control system 10 provided in the present application has at least the following advantages:
the industrial control system 10 provided by the application has the advantages that the existing industrial control system can be optimized, the communication connection with an enterprise management system is realized, and the interconnection and the intellectualization are improved. The lower computer 200 is provided with a plurality of device interfaces and can be connected to a plurality of external industrial devices 400, so that the industrial control system 10 can control the operation of the plurality of external industrial devices 400. Meanwhile, the master station control module 110 of the industrial control system 10 is arranged on the upper computer 100, namely, the upper computer 100 is responsible for generating control instructions and receiving state data, and the lower computer 200 is responsible for executing the control instructions and feeding back the state data, compared with the case that the master station control module 110 is arranged on the lower computer 200, the data processing of the industrial control system 10 is faster, the delay of display images is less, and the program response is faster, so that the industrial control system 10 is optimized, and the stability and the processing calculation capability are improved. In addition, the master station control module 110 can also establish communication connection with the lower computer 200, the enterprise MES management system and the cloud server to perform data interaction, so that the data, intelligence and interconnection capabilities of the industrial control system 10 are improved.
The above description is only for the purpose of illustrating embodiments of the present application and is not intended to limit the scope of the present application, and all modifications of equivalent structures and equivalent processes, which are made by the contents of the specification and the drawings of the present application or are directly or indirectly applied to other related technical fields, are also included in the scope of the present application.
Claims (12)
1. An industrial control system, characterized in that the industrial control system comprises:
the lower computer is provided with a plurality of equipment interfaces for respectively connecting with external industrial equipment;
the upper computer is connected with the lower computer and comprises a main station control module, the main station control module is used for generating a control instruction, sending the control instruction to the lower computer to control the external industrial equipment and receiving state data fed back by the external industrial equipment through the lower computer;
the power pack is connected with the lower computer, the upper computer and the external industrial equipment;
the main station control module is also used for establishing communication connection with an enterprise management system so as to carry out data interaction.
2. The industrial control system of claim 1,
the host computer still includes:
the input unit is connected with the master station control module and is configured to input control parameters, and the master station control module generates the control instruction according to the control parameters;
and the display is connected with the master station control module and is configured to display a human-computer interaction interface, and the human-computer interaction interface at least comprises an input interface for displaying the control parameters and a state interface for displaying the state data.
3. The industrial control system of claim 2,
the master station control module comprises:
the network card is connected with the lower computer through an Ethernet channel;
the first processor is connected with the input unit, the display and the network card and is used for acquiring the control parameters and the state data;
the first processor reads and decodes the control parameters to generate the control instruction, transmits the control instruction to the network card, and the network card decodes and converts the control instruction into a first data packet and transmits the first data packet to the lower computer through the Ethernet channel;
the first processor acquires the state data from the Ethernet channel through the network card, transcodes the state data and the control parameters to generate image data, and transmits the image data to the display to display a state interface and an input interface of the external industrial equipment in real time.
4. The industrial control system of claim 3,
the master station control module further comprises:
and the master station memory is connected with the first processor and is used for storing the control parameters, the state data, the image data and the program data, wherein the first processor is used for executing the program data to perform corresponding operation.
5. The industrial control system of claim 4,
the lower computer comprises:
the communication interface is connected with the network card through the Ethernet channel and is configured to receive the first data packet and transmit the state data to the network card;
the industrial equipment interface group is connected with the external industrial equipment;
the power supply interface is connected with the power supply pack;
the slave station control module is connected with the communication interface, the industrial equipment interface group and the power supply interface;
the slave station control module receives the first data packet through the communication interface, decodes and converts the first data packet into a control signal, and then transmits the control signal to the external industrial equipment through the industrial equipment interface group to control the operation of the external industrial equipment; and
and the slave station control module acquires the state signal of the external industrial equipment according to the control signal, transcodes the state signal to form a second data packet, and then transmits the second data packet to the network card through the Ethernet channel through the communication interface, so that the first processor transcodes the second data packet to form the state data.
6. The industrial control system of claim 5,
the slave station control module includes:
the second processor is connected with the communication interface and the industrial equipment interface group;
the second processor decodes and converts the first data packet into the control signal, and transmits the control signal to the external industrial equipment through the industrial equipment interface group so as to control the operation of the external industrial equipment; and
the second processor collects the state signals of the external industrial equipment through the industrial equipment interface group, transcodes the state signals into the second data packet, and transmits the second data packet to the network card through the Ethernet channel through the communication interface.
7. The industrial control system of claim 6,
the control signal comprises a digital control signal and/or an analog control signal;
the status signal comprises a digital status signal and/or an analog status signal.
8. The industrial control system of claim 7,
the industrial equipment interface group includes:
a digital output interface for outputting the digital control signal;
the digital input interface is used for inputting the digital state signal;
the analog output interface is used for outputting the analog control signal;
and the analog input interface is used for inputting the analog state signal.
9. The industrial control system of claim 8,
the external industrial equipment includes:
any one of a heating device, a hydraulic valve, a solenoid valve, a contactor, a relay, a motor and a lubrication motor connected with the digital output interface is configured to operate according to the digital control signal;
any one of a count sensor and a limit switch connected to the digital input interface, configured to acquire the digital status signal;
any one of a proportional valve, a back pressure valve, a servo motor and a servo valve connected with the analog output interface and configured to operate according to the analog control signal;
any at least one of a thermocouple, an electronic scale, and a pressure sensor coupled to the analog input interface is configured to acquire the analog status signal.
10. The industrial control system of claim 1,
the main station control module is an X86 control module, and the X86 control module adopts an EtherCat protocol to establish communication connection with the enterprise management system and/or the lower computer.
11. The industrial control system of claim 1,
the power pack comprises:
the first power supply is connected with the upper computer and provides a first direct current for the upper computer;
the second power supply is connected with the lower computer and the external industrial equipment and provides second direct current for the lower computer and the external industrial equipment;
and the third power supply is connected with the external industrial equipment and provides third direct current for the external industrial equipment.
12. An injection molding machine comprising an industrial control system according to any one of claims 1-11.
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