Multi-device multi-mode centralized control system

Abstract

The invention discloses a multi-device and multi-mode centralized control system which comprises an interaction control end and a device assembly. The interactive control end is configured according to three different control modes of centralized control, independent control and hybrid control, in the centralized control mode, a set of main control unit is configured for all devices, and the main control unit comprises a main control server which is used for operating a main control program and coordinating and controlling operation of all device components; in the independent control mode, each equipment component is provided with a corresponding embedded controller, and the embedded controller comprises an embedded control server which is used for operating a main control program for controlling the corresponding equipment component; in the hybrid control mode, one or more independent devices are provided with embedded controllers, the embedded controllers communicate with the main control server, the device assembly comprises a device body and a driving unit, and the device body is driven by the driving unit to achieve various operation functions. According to the invention, centralized control of multiple devices in a large-scale manufacturing factory can be realized.

Description

TECHNICAL FIELD

[0001] The present application relates to a multi-device multi-modal centralized control system, belonging to the technical field of manufacturing equipment control system. BACKGROUND

[0002] In the existing manufacturing industry, each device is independently operated and worked, each device contains an independent complete control interaction control terminal, each brand device uses its own control architecture and debugging tool, however, with the development of manufacturing industry towards scale, centralization, unification and intelligentization, the control mode of existing manufacturing equipment also needs to be unified and centralized.

[0003] In the existing control mode, an additional centralized control system is needed to adapt to different brands and different devices to coordinate the operation of multiple devices, but due to the non-uniformity of device brands and structures, this mode cannot realize true coordination. During the debugging of a device, the corresponding brand debugging tool is usually needed, and many components of the control system are in idle state during normal operation, causing waste of resources.

[0004] The current distributed control system has many brands of controllers for each node, which increases the difficulty of unified control, only unified management is performed, and global centralized control is not possessed.

[0005] The classical centralized control system is limited to the fact that all computing tasks of the device are concentrated on the central controller, which will generate a large amount of bus data in large-scale applications, affecting the real-time performance of the control, so this scheme has no development.

[0006] Each device is deeply controlled by the control system, especially in various precision machining tools, the precision control of each motor and spatial operation have high requirements, so the existing technology in the industry is an independent control professional system scheme or an industrial PC control, and a distributed control, one control system controls one device, and the hardware performance or other factors do not support one control system to control multiple devices or even global control.

[0007] Therefore, a control method and system for unified control of multiple devices in manufacturing industry are needed to solve the defects in the centralized control system. SUMMARY

[0008] The technical problem to be solved by the present application is how to realize unified control of multiple devices in manufacturing industry.

[0009] To solve the above technical problems, the present application provides a multi-device multi-modal centralized control system, comprising an interaction control terminal and a device component.

[0010] The interaction control terminal configures according to three different control modes of centralized control, independent control and hybrid control.

[0011] In the centralized control mode, a set of main control units including a main control server is configured for all devices to run a main control program and coordinate the operation of all device components;

[0012] In the independent control mode, each device component is configured with a corresponding embedded controller including an embedded control server for running a main control program for controlling the corresponding device component;

[0013] In the hybrid control mode, one or more independent devices are provided with an embedded controller which communicates with the main control server;

[0014] The device component includes a device body and a driving unit, and the device body is driven by the driving unit to realize various operation functions.

[0015] The foregoing multi-device multi-modal centralized control system, the device component includes:

[0016] Numerical control machine tool for completing machining work, including servo motor, spindle motor and machine tool movement structure;

[0017] Measuring equipment for completing quality inspection work, including servo motor, measuring probe and machine tool movement structure;

[0018] Automation equipment for completing setting work, including automation equipment structure;

[0019] Interfacing equipment for completing specific interfacing work;

[0020] Intelligent warehousing equipment for completing goods access, including servo motor, warehousing equipment structure;

[0021] Marking or cleaning equipment for completing corresponding marking or cleaning functions, including laser drive, equipment structure.

[0022] The foregoing multi-device multi-modal centralized control system, the driving unit realizes various end functions, including:

[0023] Port module, receiving control instructions sent by the main control server or the embedded controller, executing actions or uploading data to the main control server;

[0024] Laser module, each laser device executes actions according to the control instructions sent by the main control server or the embedded controller to the device component;

[0025] Driving motor, executing movement instructions according to the control instructions sent by the main control server or the embedded controller to the device component;

[0026] Measurement module, various measurement devices send measurement data to the main control server or embedded controller;

[0027] Environment isolation management module, used to control the factory environment related doors, windows, elevators, air conditioning actions, directly connected to the main control server by the grouping road, controlled by the main control server;

[0028] Water, fire, gas and power supply detection and control module, directly connected to the main control server by the grouping road, controlled by the main control server.

[0029] The foregoing multi-device multi-modal centralized control system is configured with an operation unit module in each device component, the hardware chip processor of the operation unit module stores corresponding algorithms according to different device types, and the operation unit module directly drives the execution unit of the driving unit and collects measurement related data.

[0030] The foregoing multi-device multi-modal centralized control system, the chip processor of the operation unit module selects a general DSP, FPGA or special operation chip, including an input and output port, the interaction bus and field bus interface of the operation unit module adopt an EtherCAT field real-time bus, the upper interaction bus is connected to the main control server or embedded controller to obtain discrete data and return device state information; the lower field bus is connected to the driving unit to control the end execution and obtain the state information of the driving unit.

[0031] The foregoing multi-device multi-modal centralized control system, in the mixed control mode, includes two modes:

[0032] (1) Some device components are provided with embedded controllers J, the embedded controllers control corresponding device components, and the main control server sends control commands to the embedded controllers J, the main control server only has management functions, including sending running files, running, pausing, and monitoring device basic running states, without sending discrete control data;

[0033] (2) The main control server controls all device components, and the corresponding embedded controllers of other device components are idle, only as a bridge function to forward the discrete control data of the centralized server to the operation unit module, to realize indirect centralized control.

[0034] The foregoing multi-device multi-modal centralized control system, the software module includes a business management module, a running control module and an operation optimization module;

[0035] The business management module runs in the main control server, and realizes the following control functions:

[0036] Factory environment detection and control; multi-channel display information; multi-debugger data interaction; equipment diagnosis and maintenance; group management; order management; warehouse management; hybrid management; production process control; equipment motion planning;

[0037] The operation control module runs in the main control server or the embedded controller of each equipment component, and realizes the following control functions:

[0038] Monitoring the state of the equipment component operation;

[0039] The main control server in the centralized control mode parses the equipment motion planning in the service management module or the standard G code file in the embedded controller of the equipment component into motor continuous motion instructions, port state data streams, and discrete motion control data;

[0040] The discrete motion control data is sent to the operation unit module through the interaction bus;

[0041] The operation optimization module runs in the operation unit module of the equipment component, and realizes the following control functions:

[0042] Collecting real-time data of the equipment driving unit through the field bus, including temperature, grating, and torque;

[0043] Receiving the discrete motion control data generated by the operation control module or the port state data;

[0044] Real-time compensation calculation of motor and each driving unit control data through built-in algorithms, including optimization operation, compensation operation, space operation, and smooth operation;

[0045] Sending the optimized control data to the driving unit through the field bus;

[0046] Returning the execution of the motion control data and the state data of the equipment to the equipment monitoring module through the interaction bus, the equipment monitoring module runs in the main control server or the embedded controller of each equipment component, and is used for monitoring the state of the equipment component operation.

[0047] The aforementioned multi-device multi-modal centralized control system, the control method executed in the operation unit module of the equipment component, comprising the following steps:

[0048] Accepting the control instructions of the main control unit or the embedded controller through the operation unit module of the equipment component;

[0049] Setting upstream and downstream bus interfaces in the operation unit module; in the debugging stage, using professional measuring instruments to measure the spatial structure data, compensation data, and motion characteristic data of the equipment component, and writing the measured data into the operation unit module;

[0050] The upstream bus interface is connected to an interactive control terminal and receives discrete motion control data sent by the main control server through interactive bus communication; the downstream bus interface is connected to various drive units in the device, including port cards, measurement cards, various sensors and servo motor drives;

[0051] The operation unit module calculates continuous and smooth position data, including the position, speed and torque of each servo motor shaft, based on the theoretical data received from the main control server, the sensor data on the device and the device data written during debugging, and controls the servo motors of the device through high-speed real-time field bus; the calculation algorithm includes motion algorithm, compensation algorithm, space algorithm, look-ahead algorithm, fitting curve algorithm, smoothing algorithm, temperature variable algorithm and vibration algorithm.

[0052] The aforementioned multi-device multi-modal centralized control system, the embedded controller performs the following control steps:

[0053] Step 1: Accepting discrete control data sent by the upstream main control server;

[0054] Step 2: Reading the pre-written device current spatial structure data, compensation data and motion characteristic data;

[0055] Step 3: Obtaining the current relevant data of the device through the device sensor;

[0056] Step 3: Using the chip processor to perform algorithm operation;

[0057] Step 4: Sending control data to the drive device of the drive unit through the downstream high-speed real-time field bus, and obtaining the drive device data to realize closed-loop operation.

[0058] The aforementioned multi-device multi-modal centralized control system, in the independent control mode, the manual, automatic, editing mode is mutually exclusive in the process of controlling independent devices;

[0059] In the centralized control mode, manual, automatic and editing modes exist simultaneously in different devices in the process of centralized control of multiple devices, and the combined device or single device composed of multiple device components can be switched to a certain state.

[0060] The application has the following beneficial effects: in the control system of the application, the interactive control end is configured according to three different control modes of centralized control, independent control and hybrid control, the centralized control of a large-scale manufacturing factory can be realized, all processing equipment, automation equipment, quality inspection equipment, warehouse equipment, factory water, electricity, gas and fire source, and business management are concentrated under a central control system, compared with the independent work of each device in the existing manufacturing factory, the application has the advantages of unified management, efficiency improvement, centralized control and convenient maintenance; compared with the third-party centralized management system or the distributed control system, the application has the advantages of centralized control, unified architecture, high bottom coupling, high hardware utilization rate and convenient debugging, and can solve the problems of insufficient computing power and real-time performance of centralized control. BRIEF DESCRIPTION OF DRAWINGS

[0061] Figure 1 FIG. 1 is a schematic diagram of an independent control mode in a multi-device multi-modal independent control system in Embodiment 1 of the application;

[0062] Figure 2 FIG. 2 is a schematic diagram of a centralized control mode in a multi-device multi-modal centralized control system in Embodiment 1 of the application;

[0063] Figure 3 FIG. 3 is a schematic diagram of a hybrid control mode in a multi-device multi-modal hybrid control system in Embodiment 1 of the application. DETAILED DESCRIPTION

[0064] The application will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the application, and cannot be used to limit the protection scope of the application.

[0065] Embodiment 1

[0066] The embodiment provides a multi-device multi-modal centralized control system, which comprises an interactive control end and a device component;

[0067] The control mode of the interactive control end for the multi-device is divided into three modes of centralized control, independent control and hybrid control according to the scale of the manufacturing factory;

[0068] The interactive control end is configured according to the following three different control modes of centralized control, independent control and hybrid control:

[0069] In the centralized control mode, a set of main control unit (as above) is configured for all devices, which comprises:

[0070] The main control server communicates with the screen unit or screen group, the multi- permission terminal and the portable debugger respectively, and is used for running the main control program and coordinating the operation of all device components;

[0071] The screen unit or screen group is used for displaying the operation state of all device components;

[0072] Portable debugger: used for debugging and diagnosing devices; including general-purpose debugger and special-purpose debugger;

[0073] Multi-privilege management terminal: used for managing different matters, including production management, inventory management, environmental management;

[0074] In the independent control mode, each device component is configured with a corresponding embedded controller, including:

[0075] Embedded control server: communicates with screen unit or screen group, keyboard and hand wheel respectively, and is used for running the main control program for controlling the corresponding device component;

[0076] Screen unit or screen group: used for displaying information of the corresponding device and human-computer interaction information;

[0077] Keyboard and hand wheel: used for inputting information during manual control and debugging work;

[0078] In the hybrid control mode, one or more independent devices are provided with embedded controllers, and the embedded controllers communicate with the main control unit (in two modes of management or bridging); other devices can not be configured with corresponding embedded controllers, and are directly connected to the operation unit by the main control unit.

[0079] The device component includes a device body and a driving unit, and the device body is driven by the driving unit to realize various overall operation functions. The device component as a whole is divided into:

[0080] Numerical control machine tool, used for completing machining work, including servo motor, spindle motor and machine tool movement structure;

[0081] Measuring device, used for completing quality inspection work, including servo motor, measuring probe and machine tool movement structure;

[0082] Automation equipment, used for completing setting work, including motor, automation equipment structure, such as assembly line, labeling machine and packaging machine;

[0083] Connection device, used for completing specific connection work, including servo motor and mechanical hand structure;

[0084] Intelligent storage device, used for completing goods storage and retrieval, including servo motor and storage device structure;

[0085] Marking or cleaning device, used for completing corresponding marking or cleaning functions, including laser drive and device structure.

[0086] The driving unit realizes various end functions, including:

[0087] Port module, according to the control instruction sent by the main control server or embedded controller to the device component, to perform the action or upload data to the main control server;

[0088] Laser module, each laser device according to the control instruction sent by the control server to the device component, to perform the action, including controlling the output of laser, laser marking, laser cutting and laser welding;

[0089] Drive motor, according to the control instruction sent by the main control server to the device component, to execute the motion instruction;

[0090] Measurement module, a variety of measuring devices send the data obtained by measurement to the main control server;

[0091] Environment isolation management module: to realize the isolation management of manufacturing equipment and factory environment, to control the doors, windows, elevators, air conditioners related to the factory environment;

[0092] Water, fire and power supply detection control module, without accessing the embedded controller of each device component, directly accessing the main control server by grouping routing, controlled by the main control server.

[0093] An arithmetic unit module is configured in each device component, and a hardware chip processor of the arithmetic unit module stores corresponding algorithms according to different device types. The arithmetic unit module does not need to complete the interactive function of the traditional mode, nor does it do the non-distributed control function, which greatly reduces the chip work task, designs the arithmetic unit algorithm according to the device structure type, and directly drives the execution unit of the drive unit and collects the measurement related data.

[0094] The chip processor of the arithmetic unit module can select a general DSP, FPGA or special arithmetic chip, which has basic general functions, including basic input and output ports, interactive bus and field bus interface of the arithmetic unit module adopt EtherCAT field real-time bus, the upper interactive bus connects the main control server or embedded controller to obtain discrete data and return device state information; the lower field bus connects the drive unit to control the end execution and obtain the state information of the drive unit, and the end includes servo motor, laser module, measurement module and the like.

[0095] As Figure 1 The schematic diagram for independent control mode, Figure 1 J represents an embedded controller, P in J represents a screen unit or a screen group, A in J represents a button or a hand wheel; E represents a device body, D in E represents an electrical cabinet, B in D represents an arithmetic unit module, and C in D represents a drive unit.

[0096] The green line is the interactive bus, which receives the control data of the interactive control end; the field bus between B and C controls the drive unit in real time.

[0097] As Figure 2 It is a schematic diagram of centralized control mode, in which E represents a device body, D in E represents an electrical cabinet, B in D represents an operation unit module, and C in D represents a driving unit; P represents a screen unit or a screen group, F represents a main control server, G represents a factory environment device, T represents a portable debugger, and Q represents a multi-authorization management terminal.

[0098] As Figure 3 It is a schematic diagram of mixed control mode, in which J represents an embedded controller, P in J represents a screen unit or a screen group, A in J represents a button or a hand wheel; E represents a device; D represents an electrical cabinet, B in D represents an operation unit, and C in D represents a driving unit; P represents a screen unit or a screen group; F represents a main control server; G represents a factory environment device; T represents a portable debugger; and Q represents a multi-authorization management terminal.

[0099] In the mixed control mode, two modes are included:

[0100] 1. An embedded controller J is arranged in some device components, the embedded controller controls the corresponding device components, and meanwhile, the main control server sends control commands to the embedded controller J, the main control server only has a management function, including sending a running file, running, pausing, and monitoring a basic running state of the device, and does not send discrete control data, which is similar to a third-party centralized management or a distributed control system;

[0101] 2. All device components are controlled by an interactive control terminal of the main control server, and other embedded controllers of the device components are idle and only serve as a bridging function to realize indirect centralized control.

[0102] The centralized control mode and the independent control mode can be migrated to each other:

[0103] For the device components in the independent control mode, the embedded controller of the device components can be removed, and the operation unit module is connected to the main control server to upgrade to the centralized control mode; or the embedded controller of the device components in the interactive control terminal is connected to the main control server.

[0104] The device components in the centralized control mode can be migrated out of the main control unit by adding an embedded controller and work independently.

[0105] Embodiment 2

[0106] The software module of the multi-device multi-modal centralized control system of the application includes a business management module, a running control module, and an operation optimization module.

[0107] The business management module runs in the main control server and includes:

[0108] Factory environment detection and control, multi-channel display information, multi-debugger data interaction, equipment diagnosis and maintenance,

[0109] Group management, order management, warehouse management, hybrid management, production process control, equipment motion planning.

[0110] The stand-alone device does not set a business management module.

[0111] The operation control module runs on the main control server or the embedded controller of each device component, and realizes the following control functions:

[0112] 1. Monitor the state of the device component operation;

[0113] 2. The main control server in the centralized control mode parses the device motion planning in the business management module or the standard G code file in the embedded controller in the device component into motor continuous motion instructions and port state data streams.

[0114] 3. Discrete motion control data is sent to the operation unit module through the interaction bus.

[0115] The operation optimization module runs on the operation unit module of the device component.

[0116] The operation unit module receives the discrete motion control data generated by the operation control module or the port state data, collects drive unit data, and performs data operation according to the motion control data of the interaction bus and the compensation data of the device, to calculate the ideal trajectory of the motor in real time, and sends it to the drive unit through the high-speed field real-time bus. The data operation includes optimization operation, compensation operation, spatial operation and smoothing operation.

[0117] The execution of the discrete motion control data and the state data of the device are returned to the device monitoring module through the interaction bus for feedback monitoring. The device monitoring module runs on the main control server or the embedded controller of each device component, and is used to monitor the state of the device component operation.

[0118] The main communication system includes an interaction bus and a high-speed field real-time bus.

[0119] The interaction bus is used to connect the main control server and the interaction screen, connect the main control server and the portable debugger, connect the main control server and the key and hand wheel, connect the main control server and the operation unit of the device, and connect the embedded controller and the operation unit of the device, as shown by the green line in Figures 1-3 .

[0120] The communication data includes downlink data stream and uplink data stream. The downlink data stream is the control data of each device, and the uplink data stream is the feedback data of each device.

[0121] For running equipment, use copper wire network, optical fiber network and other reliable communication methods; for debugging equipment, use multi-mode wireless network and other portable communication methods; for screen display, use a comprehensive consideration of communication methods; for factory environment equipment, use a comprehensive consideration of communication methods.

[0122] The connection mode of the interactive bus is hybrid, supporting cascading of devices, and can also be star connection.

[0123] The high-speed field real-time bus is used to connect the operation unit B and the driving unit C of the device, as shown in Figures 1-3 .

[0124] The downstream data stream includes motor position data, port information data and the like of the driving unit, and the upstream data is data collected by the driving unit.

[0125] The high-speed field real-time bus usually uses copper wire network, optical fiber network and other reliable communication methods, and the connection mode is cascading of bus communication, without limitation on the main communication protocol and interface type.

[0126] The control method executed in the operation unit module of the device component includes the following steps:

[0127] The control instruction of the main control unit or the embedded controller is accepted by the operation unit module of the device component to control the driving side device in real time, reduce the operation amount and real-time problem of the control layer, realize the construction of a large centralized control system, and can be applied to a standalone working device to reduce the system performance requirement and development difficulty of the embedded device.

[0128] An upstream bus interface and a downstream bus interface are arranged in the operation unit module.

[0129] In the debugging stage, professional measuring instruments are used to measure the spatial structure data, compensation data and motion characteristic data of the device component, and the measured data is written into the operation unit module.

[0130] The upstream bus interface is connected to the main control unit and communicates through the interactive bus to accept the discrete motion control data sent by the main control server.

[0131] The main control server or the embedded controller gives theoretical data without considering the field situation of the device, and gives discrete data, which greatly reduces the data amount and can meet the use requirement by using low real-time communication method.

[0132] The downstream bus interface is connected to various control devices of the device end, including port cards, measurement cards, various sensors and servo motor drives.

[0133] According to the theoretical data of the master control server and the sensor data on the device, as well as the device data written in the debugging stage, the continuous and smooth position data is calculated, including the position, speed and torque of each servo motor shaft, and the servo motor of the device is controlled through the high-speed real-time field bus. The calculation algorithm includes motion algorithm, compensation algorithm, space algorithm, look-ahead algorithm, curve fitting algorithm, smoothing algorithm, temperature variable algorithm, vibration algorithm, etc., which is selected according to the actual needs on site.

[0134] The embedded controller performs the following control steps:

[0135] Step 1: Accept the discrete control data sent by the upstream master control server;

[0136] Step 2: Read the pre-written device current space structure data, compensation data, motion characteristic data;

[0137] Step 3: Obtain the current relevant data of the device through the device sensor, including temperature, vibration, position grating, etc.;

[0138] Step 3: Use chip processor for algorithm operation, including FPGA, DSP, etc.

[0139] Step 4: Send control data to the drive device of the drive unit through the downstream high-speed field real-time bus, and obtain the drive device data to realize closed-loop operation.

[0140] The current communication protocol can be EtherCAT.

[0141] Example 3

[0142] In the independent control mode, the factory environment control is not included, and the screen, keyboard, hand wheel, joystick, storage and other devices are integrated in an embedded device, which is suitable for controlling independent or cooperative devices, including the following steps:

[0143] Step 1. The server of the embedded controller performs power-on self-test, including CPU, memory, external storage, keyboard, communication, status.

[0144] Step 2. Read the device parameters preset by the server of the embedded controller;

[0145] Step 3. The embedded controller initializes the operation unit through the interaction bus.

[0146] Step 4. The embedded controller sends a command to the operation unit module through the interaction bus, and the operation unit module performs initialization operation on the downstream bus drive unit;

[0147] Step 5. The operation unit module returns the initialization state of the field bus drive unit through the interaction bus;

[0148] Step 6. The server of the embedded controller checks whether the field bus driver unit state is consistent with the preset device parameters;

[0149] Step 7. Wait for user operation.

[0150] In the independent control mode, the independent device is controlled, and the manual, automatic, editing and other modes are mutually exclusive, and any one of the operation modes can be switched by the user.

[0151] In the editing mode, it includes:

[0152] Step 1. Switch to the editing mode by pressing the key or the touch screen;

[0153] Step 2. Read the parameters or programs and place them in the editing area and display them on the current interface;

[0154] Step 3. Select the parameters or programs to be edited through the touch screen or the keyboard;

[0155] Step 4. Modify the data through the physical or screen keyboard;

[0156] Step 5. Perform the save operation.

[0157] In the manual mode, it includes:

[0158] Step 1. Switch the manual mode by pressing the key or the touch screen;

[0159] Step 2. Enable the related manual operation device, including operation keyboard enable, operation hand wheel enable, touch operation enable;

[0160] Step 3. Operation keyboard, hand wheel, touch screen, upload control data to the embedded controller;

[0161] Step 4. The embedded controller processes the control data, and obtains discrete control data after optimization;

[0162] Step 5. Send the discrete control data to the operation unit module through the interaction bus;

[0163] Step 6. The operation unit module performs operation operation;

[0164] Step 7. The operation unit module sends continuous and smooth control instructions to the drive motor of the drive unit to realize precise position control;

[0165] Step 8. The data returned by the operation unit module is displayed on the current interface through the embedded controller.

[0166] In the automatic mode, it includes:

[0167] Step 1. Switch the automatic mode by the button or touch screen;

[0168] Step 2. Select the user program to be executed by the screen and keyboard operation;

[0169] Step 3. Analyze the user program line by line, calculate and optimize it into discrete control data;

[0170] Step 4. Send the discrete control data to the operation unit module through the interactive bus;

[0171] Step 5. The operation unit module performs the operation;

[0172] Step 6. The operation unit module sends the continuous and smooth control instructions to the drive motor of the drive unit to realize precise position control;

[0173] Step 7. The data returned by the operation unit module is displayed on the current interface through the embedded controller;

[0174] Step 8. After the program execution, the running status is displayed on the screen.

[0175] In the centralized control mode, multiple devices in the centralized control mode can exist in different modes such as manual, automatic, and editing, and can switch the combined device or single device composed of multiple device components to a certain state, including:

[0176] The execution of the factory environment control process is as follows:

[0177] Step 1. The environment acquisition device uploads the collected data to the main control server through the interactive bus;

[0178] Step 2. The main control server processes the collected data according to the set algorithm and sends it to each debugger, display screen or management terminal through the bus to generate state data or animation data; the state data includes temperature data, door and window opening or closing state, elevator floor data, etc.

[0179] Step 3. Detect whether each data meets certain trigger conditions, such as temperature exceeding 25 degrees, air pressure below 0.6 megapascals, elevator button floor trigger, door and window switch;

[0180] Step 4. Send control instructions to the corresponding control terminal, including turning on the air conditioner, turning on the air pump, stopping the elevator operation, opening or closing the door and window, etc.

[0181] Step 5. Return the instruction results through the corresponding detection device;

[0182] Step 6. Identify the corresponding state of the control abnormal device on the terminal;

[0183] Early warning measures are implemented to monitor the connection status of the communication bus in real time. If the connection is lost, the system will immediately stop operation and move to a designated position according to the set actions, such as turning it off or on.

[0184] Emergency measures include equipping each terminal with an emergency control button to disconnect the main control server in case of an emergency, and ensuring that critical equipment, such as elevators and fire doors, retains manual mechanical control devices.

[0185] The process of implementing hybrid management and control is as follows:

[0186] This is a device management module that connects to the main control server via an embedded controller, serving as a distributed control and centralized management mode.

[0187] The process of controlling the multi-channel information display is as follows:

[0188] Step 1. Connect to the main control server via the interactive bus to allocate channels for display terminals in groups;

[0189] Step 2. Through the main control server configuration center, distribute the data to be displayed on different display screens.

[0190] The process of executing multi-debugger data interaction control is as follows:

[0191] Step 1. The main control server pre-pairs the debuggers and groups their permissions to prevent debugging confusion;

[0192] Step 2. Select the corresponding group or device using the debugger;

[0193] Step 3. Use buttons or visual interaction to input debugging commands;

[0194] Step 4. Debugging commands are sent to the control bus via a wireless interactive bus;

[0195] Step 5. The main control server processes multiple sets of debugging equipment data simultaneously and performs mutual exclusion control.

[0196] Step 6. The main control server sends the processed data to the corresponding device components via the interaction bus;

[0197] Step 7. Control and process the device components accordingly via the interactive bus;

[0198] Step 8. The device components upload operating status data to the main control server via the interactive bus;

[0199] Step 9. The main control server sends the operating status of the device components to the corresponding debugger.

[0200] The control process for performing equipment diagnostic and maintenance functions is as follows:

[0201] Step 1. Initial connection, master gets device data stored in operation unit.

[0202] Step 2. Device real-time upload through interactive bus, current state and running data of device.

[0203] Step 3. Real-time detection of whether device data exceeds set early warning data

[0204] Step 4. Trigger different level measures according to early warning data

[0205] Step 5. Send to corresponding debugging device and terminal through interactive bus.

[0206] Step 6. Confirm processing mode, temporarily suspend, emergency stop, etc.

[0207] Step 7. Return processing result and store in maintenance database for ready reference.

[0208] The above only describes preferred embodiments of the present application, and it should be noted that for ordinary skilled persons in the art, several improvements and modifications can be made without departing from the technical principles of the present application, and these improvements and modifications should also be considered as the protection scope of the present application.

Claims

1. A multi-device multi-modal centralized control system, characterized in that, The interactive control terminal and the device assembly are included. The interactive control terminal is configured according to three different control modes, namely, centralized control, independent control and hybrid control. In the centralized control mode, a main control unit is configured for all devices, including a main control server, for running a main control program and coordinating the operation of all device assemblies. In the independent control mode, each device assembly is configured with a corresponding embedded controller, including an embedded control server, for running a main control program for controlling the corresponding device assembly. In the hybrid control mode, one or more independent devices are provided with an embedded controller, which communicates with the main control server. The device assembly includes a device body and a driving unit, and the device body is driven by the driving unit to realize various operation functions.

2. The multi-device multi-modal centralized control system of claim 1, wherein, The device assembly includes: A numerical control machine tool for completing machining work, including a servo motor, a spindle motor and a machine tool movement structure; A measuring device for completing quality inspection work, including a servo motor, a measuring probe and a machine tool movement structure; An automation device for completing setting work, including an automation device structure; A docking device for completing specific docking work; An intelligent storage device for completing goods storage and retrieval, including a servo motor and a storage device structure; A marking or cleaning device for completing corresponding marking or cleaning functions, including a laser drive and a device structure.

3. The multi-device multi-modal centralized control system of claim 1 or 2, wherein, The driving unit realizes various end functions, including: A port module that receives control instructions sent by the main control server or the embedded controller, executes actions or uploads data to the main control server; A laser module that executes actions according to the control instructions sent by the main control server or the embedded controller to the device assembly; A driving motor that executes movement instructions according to the control instructions sent by the main control server or the embedded controller to the device assembly; A measurement module that sends measurement data obtained by various measuring devices to the main control server or the embedded controller; An environmental isolation management module for controlling the actions of factory environment-related doors, windows, elevators and air conditioners, which are directly connected to the main control server by a grouping line and controlled by the main control server; A water, fire, gas and power supply detection and control module, which is directly connected to the main control server by a grouping line and controlled by the main control server.

4. The multi-device multi-modal centralized control system of claim 1, wherein, An arithmetic unit module is configured in each device assembly, and the hardware chip processor of the arithmetic unit module stores corresponding algorithms according to different device types, and the arithmetic unit module directly drives the execution unit of the driving unit and collects measurement-related data.

5. The multi-device multi-modal centralized control system of claim 4, wherein, The chip processor of the arithmetic unit module selects a general-purpose DSP, FPGA or special-purpose arithmetic chip, including input and output ports, and the interactive bus and field bus interface of the arithmetic unit module use EtherCAT field real-time bus, which connects the main control server or the embedded controller upward to obtain discrete data and return device state information, and connects the driving unit downward to control the end execution and obtain the state information of the driving unit.

6. The multi-device multi-modal centralized control system of claim 1, wherein, In the hybrid control mode, two modes are included: (1) In some device components, embedded controllers J are provided, which control the corresponding device components, and at the same time, the main control server sends control commands to the embedded controllers J, the main control server only has a management function, including sending running files, running, pausing, monitoring the basic running state of the device, and does not send discrete control data; (2) All device components are controlled by the main control server, and the corresponding embedded controllers of other device components are idle, only as a bridge function, forwarding the discrete control data of the centralized server to the operation unit module, realizing indirect centralized control.

7. The multi-device multi-modal centralized control system of claim 1, wherein, The software module includes a business management module, a running control module and an operation optimization module; The business management module runs in the main control server, and realizes the following control functions: Factory environment detection and control; Multi-channel display information; Multi-debugger data interaction; Device diagnosis and maintenance; Group management; Order management; Warehouse management; Hybrid management; Production process control; Device motion planning; The running control module runs in the main control server or the embedded controller of each device component, and realizes the following control functions: Monitoring the running state of the device component; The main control server in the centralized control mode parses the device motion planning in the business management module or the standard G code file in the embedded controller of the device component into motor continuous motion instructions, port state data streams and discrete motion control data; The discrete motion control data is sent to the operation unit module through the interaction bus; The operation optimization module runs in the operation unit module of the device component, and realizes the following control functions: Collecting device drive unit real-time data including temperature, grating and torque through the field bus; Receiving the discrete motion control data generated by the running control module or the port state data; Real-time compensation calculation of motor and each drive unit control data through the built-in algorithm, which includes optimization operation, compensation operation, space operation and smooth operation; Sending the optimized control data to the drive unit through the field bus; Returning the execution of the motion control data and the state data of the device to the device monitoring module through the interaction bus, the device monitoring module runs in the main control server or the embedded controller of each device component, and is used for monitoring the running state of the device component.

8. The multi-device multi-modal centralized control system of claim 4, wherein, The control method executed in the operation unit module of the device component includes the following steps: Accepting the control instruction of the main control unit or the embedded controller through the operation unit module of the device component; Setting an upstream bus interface and a downstream bus interface in the operation unit module; In the debugging stage, professional measuring instruments are used to measure the spatial structure data, compensation data and motion characteristic data of the device component, and the measured data is written into the operation unit module; The upstream bus interface is connected to the interaction control end, and the discrete motion control data sent by the main control server is accepted through the interaction bus communication; the downstream bus interface is connected to various drive units in the device, including port cards, measurement cards, various sensors and servo motor drives; The operation unit module calculates continuous and smooth position data, including the position, speed and torque of each servo motor shaft, according to the theoretical data accepted from the main control server, the sensor data on the equipment and the equipment data written in the debugging stage, and controls the servo motor of the equipment through the high-speed real-time field bus. The calculation algorithm includes motion algorithm, compensation algorithm, space algorithm, look-ahead algorithm, fitting curve algorithm, smoothing algorithm, temperature variable algorithm and vibration algorithm.

9. The multi-device multi-modal centralized control system of claim 1, wherein, The embedded controller performs the following control steps: Step 1: Accept the discrete control data sent by the upstream main control server; Step 2: Read the pre-written current spatial structure data, compensation data and motion characteristic data of the equipment; Step 3: Obtain the current relevant data of the equipment through the equipment sensor; Step 3: Perform algorithm operation using the chip processor; Step 4: Send control data to the driving equipment of the driving unit through the downstream high-speed real-time field bus, and obtain the driving equipment data to realize closed-loop operation.

10. The multi-device multi-modal centralized control system of claim 1, wherein, In the independent control mode, the manual, automatic and editing modes are mutually exclusive during the control of independent equipment; In the centralized control mode, the manual, automatic and editing modes exist simultaneously in different equipment during the centralized control of multiple equipment, and the combined equipment or single equipment composed of multiple equipment components can be switched to a certain state.

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