An automated processing unit edge control system and method based on OPC UA events

Abstract

The present invention discloses an edge control system and method for an automated processing unit based on OPC UA events. The present invention constructs an information model of edge devices involved in the process according to the automated processing unit process, and configures it into the corresponding edge controller. The method in the information model is bound one-to-one with the event of the corresponding device task. By processing the corresponding task information of the triggering event, each edge controller completes the control of the device, and the data can be processed in real time, making the unit system control method more flexible, and further enabling the automated processing unit to be quickly constructed, reducing the time required for configuring and transforming and upgrading the flexible automated production line; the subsequent configuration of the automated processing unit system does not require changes to the existing system configuration, avoiding duplication of work, reducing the time required for configuring and transforming and upgrading the flexible automated production line, and saving manpower and time costs.

Description

Technical Field

[0001] The present invention relates to the field of industrial automation, and in particular to an edge control system and method for an automated processing unit based on OPC UA events. Background Art

[0002] In the industrial production and manufacturing process, the current flexible automated processing technology will involve the unified control and management of automated loading and unloading, processing and warehousing processes using a single controller (PLC, etc.), thereby realizing the automation of manufacturing processes such as loading and unloading, processing, and warehousing.

[0003] However, the automated production units composed of the above single or multiple processes are integrated from equipment from different equipment manufacturers. These devices rely on their own proprietary control interfaces. When the production line control mode needs to be adjusted according to production needs or equipment failures, when the equipment in the production line needs to be changed and adjusted, the original system configuration work needs to be repeated from the equipment to the control system configuration work, which takes a lot of time and labor costs, thus affecting production efficiency.

[0004] In addition, this centralized integrated automation control mode in the factory will increase the communication lines of the entire production line, resulting in increased communication complexity of the automated production units and data processing delays, seriously affecting the operating efficiency of the entire automation control management system. Summary of the Invention

[0005] The present invention provides an OPC UA event-based automated processing unit edge control system and method;

[0006] The present invention can flexibly configure the hardware resources involved in manufacturing processes such as automated loading and unloading, processing, etc., reduce the time for reconfiguration of automated production units, and eliminate the need to set up a controller for the central integration system of the equipment, thereby realizing a collaborative control production method at the edge device layer for intelligent manufacturing.

[0007] The present invention is achieved through the following technical solutions:

[0008] The present invention provides an OPC UA event-based automated processing unit edge control system, comprising an upper-layer control system, an edge device, and an edge controller device, wherein:

[0009] The upper control system is used to act as an OPC UA client to send an automation control start request command to the edge controller device;

[0010] The edge device is used to receive control commands sent by the edge controller device and send its own execution completion result data information;

[0011] The edge controller device is used to receive requests from an upper-layer control system or an external edge control device; the edge controller device is also used to trigger OPC UA events and send control commands corresponding to the events to edge devices; the edge controller device is also used to send requests to external edge control devices based on internally triggered events;

[0012] Furthermore, the edge controller device includes an OPC UA client, an OPC UA server, a task event module, and a communication control conversion module;

[0013] The OPC UA client is used to receive internal requests from the task event module and call external OPC UA server method nodes; the OPC UA client is also used to start a processing cycle of the automated processing unit as an edge control system of the automated processing unit;

[0014] The OPC UA server is used to receive node requests from the upper control system or the external edge control device OPC UA client; the OPC UA server is also used to trigger events and send events to the task event module; the OPC UA server is also used to receive and process the edge device operation results fed back by the communication control conversion module, trigger new events, and send the data information of the new events to the task event module;

[0015] The task event module is used to receive event information sent by the OPC UA server, perform diversion processing on the event information, and send the control command specifically referred to by the event to the communication conversion module or send an event request instruction to the OPC UA client;

[0016] The communication control conversion module is used to convert the control command according to the communication protocol of the edge device and send it to the edge device to realize control communication interaction of the device;

[0017] The communication control conversion module is also used to receive the edge device operation results and feed the results back to the OPC UA server.

[0018] An OPC UA event-based edge control method for an automated processing unit includes the following steps:

[0019] Step 1: Edge controller device event configuration: Build OPC UA events and OPC UA information models for the edge devices in the automated processing unit, configure them uniformly to the edge controller device, and establish communication connections between the edge devices and the corresponding edge controller device.

[0020] The specific sub-steps are as follows:

[0021] Step 1.1: Set the OPC UA events for each edge device according to the edge device operation sequence in the automated processing control process;

[0022] Step 1.2: Based on all OPC UA events, build an OPC UA information model containing method nodes for the edge device and configure it in the edge control device OPC UA server.

[0023] Step 1.3: Store the material information table in the system database into the edge controller device;

[0024] In step 1.4, the communication conversion module of the edge controller device performs communication configuration with the edge device.

[0025] Step 2, Edge Control: The OPC UA client first initiates a request to the edge controller device. Based on the triggered event information, each edge controller sequentially controls the edge devices in the automated processing unit according to the established automation control process;

[0026] The specific sub-steps are as follows:

[0027] In step 2.1, the OPC UA client (belonging to the upper-level control system or edge control device) calls the method node of the edge controller device OPC UA server to trigger an event. The OPC UA server passes the event information to the task event module.

[0028] Step 2.2: The task event module of the edge controller performs diversion processing on the received event information. If the triggered event belongs to the edge device corresponding to the device, step 2.3 is executed; otherwise, step 2.4 is executed.

[0029] Step 2.3: The task event module analyzes and processes the received event information, generates the final specific control command, and sends it to the communication conversion module, and then executes step 2.5;

[0030] In step 2.4, the task event module sends a request to call the external method node to the OPC UA client, and then jumps to step 2.1, where the OPC UA client accesses the external edge controller method node.

[0031] Step 2.5: The communication conversion control module receives the control command, converts it according to the communication protocol of the edge device, and sends it to the edge device. The edge device operates according to the received control command and feeds back the operation results to the communication conversion control module.

[0032] In step 2.6, the OPC UA server of the edge controller receives the feedback result sent by the communication conversion control module, triggers a new event, and sends the event information to the task event module, and jumps to step 2.3.

[0033] Furthermore, in the step 1 of configuring the edge controller device event, the OPC UA information model of the edge device includes edge device attributes, materials, and device method set information;

[0034] The edge device attribute information includes device number, device operating status, and device operating parameter information;

[0035] The material information includes material number, material status, and material type information;

[0036] The method set information includes all methods corresponding to the set OPC UA events, and OPC UA events and methods are one-to-one corresponding; when the method node is called, its input parameter is the material identification information;

[0037] Compared with the prior art, the present invention has at least the following beneficial effects:

[0038] It is necessary to adapt existing hardware to the semantic skill concept, but this initial one-time effort will yield recurring efficiency gains during system reconfiguration.

[0039] 1. It can directly control the underlying equipment without the central control system, realize the "machine-to-machine" control mode of distributed collaboration between equipment, realize real-time data processing, and form independent system entities in the automated processing unit, making the overall processing unit system control method more flexible;

[0040] 2. By controlling the equipment through event triggering, the automated processing unit can be quickly constructed. The subsequent configuration of the unit system does not require changes to the existing system configuration, avoiding duplication of work, thereby reducing the time required to configure and transform and upgrade the flexible automated production line, saving manpower and time costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 This is a schematic diagram of the edge control system architecture of the automated processing unit based on OPC UA events in the present invention.

[0042] Figure 2 This is a schematic diagram of the internal structure of the edge controller device and its external communication structure.

[0043] Figure 3 Schematic diagram of the edge control.

[0044] Figure 4Schematic diagram of the OPC UA information model of the edge controller device.

[0045] Figure 5 FIG2 is a schematic diagram of an OPC UA event-based edge control architecture for an automated processing unit according to a preferred embodiment of the present invention. DETAILED DESCRIPTION

[0046] The present invention is described in further detail below with reference to specific embodiments.

[0047] like Figure 1 As shown, the present invention discloses an edge control system for an automated processing unit based on OPC UA events, which includes an upper-layer control system, edge devices, and an edge controller device. The functions of each part are as follows:

[0048] The upper control system acts as an OPC UA client and sends an automation control start request command to the edge controller device i (i = 1, 2, 3, ..., n, where n is the total number of edge controller devices in the control system);

[0049] Edge device i (i = 1, 2, 3, ..., n, where n is the total number of edge devices in the control system) is used to receive control commands sent by edge controller device i and send its own execution result data information;

[0050] Edge controller device i is used to receive requests from the upper-level control system or external edge controllers. Edge controller device i is also used to trigger OPC UA events and send control commands corresponding to the events to edge device i. The edge controller device is also used to send requests to external edge controller j (j = 1, 2, 3, ..., n, and j ≠ i, where n is the total number of edge devices in the control system) based on the internally triggered events.

[0051] like Figure 2 As shown, the edge controller device i includes an OPC UA client, an OPC UA server, a task event module, and a communication control conversion module;

[0052] The OPC UA client is used to receive internal requests from the task event module and call external OPC UA server method nodes; the OPC UA client is also used to start a processing cycle of the automated processing unit as an edge control system of the automated processing unit;

[0053] The OPC UA server is used to receive node requests from the upper control system or the external edge control device OPC UA client; the OPC UA server is also used to trigger events and send events to the task event module; the OPC UA server is also used to receive and process the edge device operation results fed back by the communication control conversion module, and trigger new events, and send the data information of the new event to the task event module;

[0054] The task event module is used to receive event information sent by the OPC UA server, perform diversion processing on the event information, and send the control command specifically referred to by the event to the communication conversion module or send an event request instruction to the OPC UA client;

[0055] The communication control conversion module is used to receive the control command of the task event module, convert it according to the communication protocol of the edge device i, and send it to the edge device i to realize the communication interaction of its control; the communication control conversion module is also used to receive the operation result of the edge device i and feed the result back to the OPC UA server;

[0056] The method for the edge control system of the above automated processing unit mainly consists of two parts: edge controller device event configuration and edge control.

[0057] The edge controller device event configuration is to construct OPC UA events and OPC UA information models for edge devices of the automated processing unit, and uniformly configure them to the edge controller device, while simultaneously establishing a communication connection between the edge device and the corresponding edge controller device;

[0058] The edge control is that the OPC UA client first initiates a request to the edge controller device, and each edge control device controls the edge devices in the automated processing unit in sequence according to the established automated control process based on the triggered event information.

[0059] The edge controller device i event configuration (each independent edge controller device is configured in the same way based on the edge device) includes the following steps:

[0060] Step 1.1: Set the OPC UA event for each edge device i according to the edge device operation sequence in the automated processing control process;

[0061] Step 1.2: Based on all OPC UA events, build an OPC UA information model containing method nodes for edge device i and configure it in the OPC UA server of edge device i.

[0062] Step 1.3: Store all material information tables in the system database into the edge controller device i;

[0063] In step 1.4, the edge controller device i communication conversion module configures communication with the edge device.

[0064] like Figure 3 As shown, the step 2 edge control includes the following steps:

[0065] In step 2.1, the OPC UA client (belonging to the upper control system or edge control device j) calls the method node of the OPC UA server of edge controller device i to trigger an event. The OPC UA server passes the event information to the task event module.

[0066] Step 2.2: The task event module of edge controller device i performs diversion processing on the received event information. If the triggered event belongs to edge device i corresponding to device i, step 2.3 is executed; otherwise, step 2.4 is executed.

[0067] Step 2.3: The task event module analyzes and processes the received event information, generates the final specific control command, and sends it to the communication conversion module, and then executes step 2.5;

[0068] In step 2.4, the task event module sends a request to call an external method node to the OPC UA client, which then jumps to step 2.1 and makes a method node access request to the OPC UA server of edge control device k (k = 1, 2, 3, ..., n, where k replaces i and n is the total number of edge devices in the control system).

[0069] Step 2.5: The communication conversion control module receives the control command, converts it according to the communication protocol of edge device i, and sends it to edge device i. Edge device i operates according to the received control command and feeds back the operation results to the communication conversion control module.

[0070] In step 2.6, the OPC UA server of the edge controller device i receives the feedback result sent by the communication conversion control module, triggers a new event, and sends the event information to the task event module, and jumps to step 2.3.

[0071] like Figure 4 As shown, in the event configuration of the edge controller device i in step 1, the OPC UA information model of the edge device i includes edge device attributes, materials, and device method set information;

[0072] The edge device attribute information includes device number, device operating status, and device operating parameter information;

[0073] The material information includes material number, material status, and material type information;

[0074] The method set information includes all methods p corresponding to the set OPC UA events (p = 1, 2, 3, ..., n, where n is the number of all set events). OPC UA events and methods have a one-to-one correspondence. When the method node is called, its input parameter is the material identification information.

[0075] In the application scenario of the mold electrode automated processing unit, identification, handling, and processing are required, and the edge devices required include CNC machine tools, industrial robots, barcode readers, and material racks. By using an MES system with an OPC UA client as the upper-level control system for startup control, the control process communicates and interacts through the edge controller device belonging to each edge device. The device is a small industrial computer connected to the edge device. In this scenario, the upper-level control system does not need to be connected to the edge controller device of each edge device (the edge controller device connected to the material rack is only used as an implementation example). In addition, control startup can be performed at the edge control device of the automation unit (started by the edge controller device of the material rack).

[0076] The OPC UA event-based automated processing unit edge control system method configures the edge controller device event in step 1 as follows (each independent edge controller device is configured in the same way based on the edge device):

[0077] Step 1.1. Set OPC UA events based on the mold electrode automated processing process. The events include material preparation, material identification, loading, processing, and unloading. Material preparation events are configured on the edge controller of the material rack, material identification events are configured on the material identifier edge controller, loading events are configured on the industrial robot edge controller, and processing and unloading events are configured on the CNC machine tool edge controller.

[0078] In step 1.2, based on the above OPC UA events, a corresponding OPC UA information model containing method nodes is constructed for each edge device, and the model is configured in the OPC UA server of the edge controller of the edge device (the OPC UA information model of each edge device contains the method nodes corresponding to all events);

[0079] Step 1.3: Store the material information table in the system database into each edge controller device;

[0080] Step 1.4, configuring the communication conversion module of each edge controller device to communicate with the edge device;

[0081] like Figure 3 As shown, the implementation of step 2 edge control (an automated processing cycle) includes the following steps:

[0082] Step 2.1: The upper management system first initiates a request to the edge controller device of the material rack, triggering the material rack preparation event. The material rack selects and prepares the materials to be processed.

[0083] In step 2.2, after the rack preparation operation is completed, the rack edge controller device OPC UA client calls the method in the material identifier edge controller device OPC UA server to trigger the material identification event and identify the material to be grabbed in the rack;

[0084] In step 2.3, based on the identification and verification completion signal, the material identifier edge controller OPC UA client calls the method in the industrial robot edge controller OPC UA server to trigger a loading event. The industrial robot then grabs the requested material and places it on the designated CNC machine tool.

[0085] In step 2.4, based on the material placement action, the industrial robot edge controller OPC UA client calls the method in the CNC machine tool edge controller OPC UA server to trigger a processing event. The CNC machine tool starts the processing program to process the material.

[0086] In step 2.5, after the material processing is completed, the edge controller of the industrial robot triggers a unloading event. According to the unloading event information, the material is placed in the processing completion area by the industrial robot, and the industrial robot returns to the initialization position.

[0087] The input parameters of the method in step 2.1 come from the database scheduling results and are used to make the materials to be processed enter a ready state in the material rack.

[0088] The input parameters of the method in step 2.2 come from the database scheduling results and are used to verify the number and status of the material ready for processing.

[0089] The input parameters of the method in step 2.3 come from the database scheduling results and are used to update the status of processing specified materials in the control management system.

[0090] The input parameters of the method in step 2.4 come from the information identified by the material identifier and are used to determine the processing program code number.

[0091] The input parameters of the method in step 2.5 come from the information identified by the material identifier and are used to determine the number of the processing program code corresponding to the material information.

[0092] As described above, the present invention constructs an information model of edge devices involved in the process based on the automated processing unit process, and configures it into the corresponding edge controller. The methods in the information model are bound one by one to the events of the corresponding device tasks. By processing the corresponding task information of the triggering event, each edge controller completes the control of the equipment, and the data can be processed in real time, making the unit system control method more flexible, and further enabling the automated processing unit to be quickly constructed, reducing the time required for configuration and transformation and upgrading of flexible automated production lines; the subsequent configuration of the automated processing unit system does not require changes to the existing system configuration, avoiding duplication of work, reducing the time required for configuration and transformation and upgrading of flexible automated production lines, and saving manpower and time costs.

[0093] The implementation methods of the present invention are not limited to the above-mentioned embodiments. Any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principles of the present invention should be considered as equivalent replacement methods and are included in the scope of protection of the present invention.

Claims

1. An OPC UA event-based automated processing unit edge control method, characterized in that The following steps are involved: Step 1: Edge controller device event configuration Build OPC UA events and OPC UA information models for edge devices in automated processing units, configure them uniformly to edge controllers, and establish communication connections between edge devices and corresponding edge controllers. Step 2, Edge Control The OPC UA client first initiates a request to the edge controller device. Based on the triggered event information, each edge controller device sequentially controls the edge devices in the automated processing unit according to the established automation control process. The edge controller device event configuration described in step 1 includes the following sub-steps: Step 1.1, set the OPCUA events of each edge device according to the edge device operation sequence in the automated processing control process; Step 1.2: Based on all OPC UA events, build an OPC UA information model containing method nodes for the edge device and configure it in the OPC UA server of the edge controller device. Step 1.3: Store the material information table in the system database into the edge controller device; Step 1.4: The edge controller device communication conversion module configures communication with the edge device; The edge control in step 2 includes the following sub-steps: In step 2.1, the OPC UA client of the upper-layer control system or edge controller device calls the method node of the edge controller device OPC UA server to trigger an event. The OPC UA server passes the event information to the task event module. Step 2.2: The task event module of the edge controller performs diversion processing on the received event information. If the triggered event belongs to the edge device corresponding to the device, step 2.3 is executed; otherwise, step 2.4 is executed. Step 2.3: The task event module analyzes and processes the received event information, generates the final specific control command, and sends it to the communication conversion module, and then executes step 2.5; In step 2.4, the task event module sends a request to call the external method node to the OPC UA client, and then jumps to step 2.1, where the OPC UA client accesses the external edge controller method node. Step 2.5: The communication conversion control module receives the control command, converts it according to the communication protocol of the edge device, and sends it to the edge device. The edge device operates according to the received control command and feeds back the operation results to the communication conversion control module. In step 2.6, the OPC UA server of the edge controller receives the feedback result sent by the communication conversion control module, triggers a new event, and sends the event information to the task event module, and jumps to step 2.

3.

2. The OPC UA event-based automated processing unit edge control method according to claim 1, characterized in that: In step 1, edge controller device event configuration, the OPC UA information model of the edge device includes edge device attributes, material information, and device method set information.

3. The OPC UA event-based automated processing unit edge control method according to claim 2, characterized in that: The edge device attribute information includes: device number, device operating status, and device operating parameter information; The material information includes: material number, material status, and material type information; The device method set information includes: all methods corresponding to the set OPC UA events, and OPC UA events and methods are one-to-one corresponding; when the method node is called, its input parameter is material identification information.

4. An OPC UA event-based automated processing unit edge control system, configured to implement the automated processing unit edge control method according to any one of claims 1 to 3; the automated processing unit edge control system comprises an upper-layer control system, an edge device, and an edge controller device, and is characterized in that: The upper control system is used to act as an OPC UA client to send an automation control start request command to the edge controller device; The edge device is used to receive control commands sent by the edge controller device and send its own execution completion result data information; The edge controller device is used to receive requests from an upper-level control system or an external edge controller device; the edge controller device is also used to trigger OPC UA events and send control commands corresponding to the events to edge devices; the edge controller device is also used to send requests to external edge controller devices based on internally triggered events.

5. The OPC UA event-based automated processing unit edge control system according to claim 4, characterized in that: The edge controller device includes an OPC UA client, an OPC UA server, a task event module, and a communication control conversion module; The OPC UA client is used to receive internal requests from the task event module and call external OPC UA server method nodes; The OPC UA client is also used as an edge control system of the automated processing unit to start a processing cycle of the automated processing unit.

6. The OPC UA event-based automated processing unit edge control system according to claim 5, characterized in that: The OPC UA server is used to receive node requests from an upper-layer control system or an external edge controller device OPC UA client; The OPC UA server is also used to trigger events and send events to the task event module; The OPC UA server is also used to receive and process the edge device operation results fed back by the communication control conversion module, trigger a new event, and send the data information of the new event to the task event module.

7. The OPC UA event-based automated processing unit edge control system according to claim 5, characterized in that: The task event module is used to receive event information sent by the OPC UA server, perform diversion processing on the event information, and send the control command specifically referred to by the event to the communication conversion module or send an event request instruction to the OPC UA client.

8. The OPC UA event-based automated processing unit edge control system according to claim 5, characterized in that: The communication control conversion module is used to convert the control command according to the communication protocol of the edge device and send it to the edge device to realize control communication interaction of the device; The communication control conversion module is also used to receive the edge device operation results and feed the results back to the OPC UA server.

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