Control System and Method for Rail Flash Welding Machine Based on Distributed Fieldbus

Abstract

This invention provides a control system and method for a rail flash welding machine based on a distributed fieldbus. The system includes a host module, a DC power supply module, a voltage regulator, and multiple fieldbus slave modules. The host module, the DC power supply module, and the voltage regulator are housed in a control system cabinet. The multiple fieldbus slave modules are distributed among the power supply unit, the chiller, the hydraulic station, the crane, the flash welding head, and the voltage regulator. Therefore, the host module and the multiple slave modules in this invention can select either a fieldbus or an Ethernet bus based on the characteristics of the transmitted signals to achieve collaborative communication between the host and slave modules, meeting the real-time requirements of the signals. Furthermore, the data transmission lines of this invention are simple, have strong anti-interference capabilities and stability, and improve the high-speed data acquisition requirements and the execution efficiency of the carrier.

Description

Technical Field

[0001] This invention relates to the field of flash welding technology, and in particular to a control system and method for a rail flash welding machine based on a distributed fieldbus. Background Technology

[0002] Flash welding, also known as contact welding, involves the contact of two metal workpieces at their cross-sections. The contact points conduct electricity, and the resistance heat generated by the contact resistance heats the ends of the workpieces. When the temperature reaches a certain level, the metal at the contact surface of the workpieces melts to form a liquid metal layer. The liquid metal is then extruded by an external longitudinal force, causing the high-temperature metal to undergo plastic deformation. Common grains are generated at the joint surface, resulting in a dense hot-forged structure that forms the butt joint.

[0003] Currently, the control system of rail flash welding machines employs a multi-computer, independent operation approach: a general-purpose industrial control computer (IPC) is used for parameter setting, data acquisition, monitoring, and historical data browsing, while a programmable logic controller (PLC) is used for logic control and welding process control. Because each PLC manufacturer uses its own operating system and none has access to the PLC's internal read / write permissions, the IPC cannot effectively read data from the PLC, making it difficult for the IPC to retrieve data from the PLC. To obtain more welding process data, the IPC must use its own acquisition card to re-acquire data, resulting in redundant investment and wasted resources and funds. Furthermore, the lack of a real-time synchronization clock between the IPC and PLC often leads to data asynchrony, and in severe cases, data corruption.

[0004] It is evident that the current control system of rail flash welding machines faces difficulties in data coordination among multiple independently operating computers, which affects the control efficiency of the rail flash welding machine. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a control system and method for a rail flash welding machine based on a distributed fieldbus. This system solves the problem of data collaboration difficulties between multiple independently operating computers in existing technologies. In this invention, the host module and multiple slave modules can select either a fieldbus or an Ethernet bus based on the characteristics of the transmitted signals to achieve collaborative communication between the host and slave modules, meeting the real-time requirements of the signals. Furthermore, this invention features simple data transmission lines, strong anti-interference capabilities and stability, improving the high-speed data acquisition requirements and the execution efficiency of the carrier.

[0006] In a first aspect, the present invention provides a control system for a rail flash welding machine based on a distributed fieldbus. The rail flash welding machine includes a power supply unit, a chiller, a hydraulic station, a control system cabinet, a crane, and a flash welding head. The control system includes a host module, a DC power supply module, a voltage regulator, and multiple fieldbus slave modules. The host module, the DC power supply module, and the voltage regulator are housed in the control system cabinet. The multiple fieldbus slave modules are distributed among the power supply unit, the chiller, the hydraulic station, the crane, the flash welding head, and the voltage regulator. The input terminal of the DC power supply module is connected to a three-phase AC output terminal, and the output terminal of the DC power supply module is connected to a fieldbus. The bus is connected to the host module and the multiple fieldbus slave modules respectively, and is used to convert the three-phase AC power into multiple DC voltages, so that the multiple DC voltages supply power to the corresponding host module and fieldbus slave module respectively; the input terminal of the voltage regulator is connected to the output terminal of the three-phase AC power, and the output terminal of the voltage regulator is connected to the welding transformer in the flash welding head, and is used to convert the three-phase AC power into two-phase AC power to provide primary current and voltage for the welding transformer; the multiple fieldbus slave modules are connected to the host module through the fieldbus, and are used to control the operation of the distributed carrier according to the control commands sent by the host module, and also to collect the operation data of the distributed carrier according to the data commands sent by the host module.

[0007] Optionally, the control system further includes: a first Ethernet slave module, disposed in the voltage regulator and connected to the host module; and a second Ethernet slave module, disposed in the flash welding head and connected to the host module.

[0008] Optionally, the host module includes: a real-time Ethernet controller, a real-time Ethernet switch, a real-time Ethernet expansion module, a fieldbus gateway, and a wireless intelligent cloud gateway; the real-time Ethernet controller is connected to the fieldbus gateway, the real-time Ethernet expansion module, and the wireless intelligent cloud gateway through the real-time Ethernet switch.

[0009] Optionally, the fieldbus slave module in the voltage regulator includes a fieldbus slave communication module, a voltage regulation setpoint module, and a voltage regulation and stabilization drive module; the first Ethernet slave module in the voltage regulator includes an Ethernet slave communication module and a high-speed welding current and voltage acquisition module.

[0010] Optionally, the fieldbus slave module in the flash welding head includes a fieldbus slave communication module, an acquisition module for the operation panel switch buttons, and a drive amplification module for the electromagnetic reversing valve; the second Ethernet slave module in the flash welding head includes an Ethernet slave communication module, a high-speed acquisition module for upsetting pressure and welding displacement, and a drive amplification module for the proportional servo valve.

[0011] Optionally, the fieldbus slave module in the hydraulic station includes a fieldbus slave communication module, a digital signal acquisition module, a solenoid directional valve drive amplification module, a start / stop control module, an analog signal acquisition module, and a system pressure regulation drive module.

[0012] Optionally, the fieldbus slave module in the chiller includes a fieldbus slave communication module, a chiller start / stop control module, a cooling water temperature and flow detection module, and a chiller status acquisition module.

[0013] Optionally, the fieldbus slave module in the power supply device includes a fieldbus slave communication module, a diesel engine start / stop control module, and a generator status monitoring module.

[0014] Optionally, the DC power supply module includes a controller, a sensor power supply module, an actuator power supply module, a fieldbus power supply module, and a fieldbus auxiliary power supply module.

[0015] Optionally, the control system may further include a local area network auxiliary machine monitor, a cloud-based mobile monitor, a cloud-based IoT database server, a cloud-based enterprise dashboard monitor, and / or a local area network rail welding machine monitor.

[0016] Secondly, the present invention provides a control method for a rail flash welding machine based on a distributed fieldbus. The method includes: when a host module and / or multiple fieldbus slave modules send a data frame, monitoring whether the fieldbus is in an idle state; wherein the data frame includes an arbitration field, an address field, a data field, a CRC check field, and an acknowledgment field; when the fieldbus is in an idle state, sending the arbitration field in the data frame bit by bit to arbitrate bus conflicts; when the right to use the bus is obtained, establishing a communication connection with the data receiver according to the address field in the data frame, and releasing the bus after sending the data field and CRC check field in the data frame; when the data receiver successfully verifies the received data field according to the received CRC check field, obtaining the instructions or data parameters in the data field.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0018] This invention distributes multiple fieldbus slave modules across multiple distributed carriers within a rail flash welding machine, connecting them to a master module via fieldbuses. This allows the multiple fieldbuses to directly control the operating parameters of the distributed carriers based on control commands sent by the master module, and to collect the operating data of the distributed carriers based on data commands sent by the master module. Therefore, the master module and the multiple slave modules in this invention can choose between a fieldbus or an Ethernet bus based on the characteristics of the transmitted signals to achieve collaborative communication between the master and slave modules, meeting the real-time requirements of the signals. Furthermore, this invention features simple data transmission lines, strong anti-interference capabilities and stability, improving the high-speed data acquisition requirements and the execution efficiency of the carriers. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 The diagram shown is a schematic diagram of the control system of the first rail flash welding machine based on a distributed fieldbus according to an embodiment of the present invention.

[0022] Figure 2 The diagram shown is a schematic diagram of the control system of a rail flash welding machine in the prior art;

[0023] Figure 3 The diagram shown is a structural schematic of a host module provided in an embodiment of the present invention;

[0024] Figure 4 The diagram shown is a schematic representation of the control system of a second type of rail flash welding machine based on a distributed fieldbus, provided in an embodiment of the present invention.

[0025] Figure 5 The diagram shown is a structural schematic of the control system of the third type of rail flash welding machine based on distributed fieldbus provided in the embodiment of the present invention. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Functional units with the same reference numerals in the examples of this invention have the same and similar structures and functions.

[0027] Figure 1 The diagram shown is a structural schematic of a control system for a rail flash welding machine based on a distributed fieldbus, according to an embodiment of the present invention. Figure 1 As shown, the rail flash welding machine includes a power supply unit, a chiller, a hydraulic station, a control system cabinet, a crane, and a flash welding head. The control system includes:

[0028] The system includes a host module, a DC power supply module, a voltage regulator, and multiple fieldbus slave modules. The host module, the DC power supply module, and the voltage regulator are located in the control system cabinet, while the multiple fieldbus slave modules are distributed among the power supply unit, the chiller, the hydraulic station, the crane, the flash welding head, and the voltage regulator.

[0029] The input terminal of the DC power supply module is connected to the three-phase AC power output terminal, and the output terminal of the DC power supply module is connected to the host module and the multiple fieldbus slave modules respectively through the fieldbus, which is used to convert the three-phase AC power into multiple DC voltages, so that the multiple DC voltages supply power to the corresponding host module and fieldbus slave module respectively.

[0030] The input terminal of the voltage regulator is connected to the output terminal of the three-phase AC power, and the output terminal of the voltage regulator is connected to the welding transformer in the flash welding head, which is used to convert the three-phase AC power into two-phase AC power to provide primary current and voltage for the welding transformer.

[0031] The multiple fieldbus slave modules are connected to the host module via fieldbus, and are used to control the operation of the distributed carrier according to the control commands sent by the host module, and also to collect the operation data of the distributed carrier according to the data commands sent by the host module.

[0032] It should be noted that the control system in this embodiment includes multiple distributed carriers, which are respectively... Figure 1The system comprises: 1. a power supply unit; 2. a chiller; 3. a hydraulic station; 4. a control system cabinet; 5. a crane; and 6. a flash welding head. The main unit module, DC power supply module, and voltage regulator are respectively housed in the control system cabinet, and the multiple fieldbus slave modules are distributed among the power supply unit, the chiller, the hydraulic station, the crane, the flash welding head, and the voltage regulator.

[0033] The working principle of the control system provided by the present invention is as follows: (1) Power supply circuit working process: The power supply device provides three-phase 380V AC power to the chiller, hydraulic station and control system cabinet respectively; after the main power enters the control system cabinet, it provides power to the voltage regulator and DC power module respectively. After the voltage regulator provides the primary current voltage to the welding transformer in the flash welding head, the secondary of the welding transformer provides power to the rail flash welding to complete the flash and realize the rail welding; the power entering the DC power module provides working voltage to the sensors, actuators, controllers and fieldbus of the control system through each power module. (2) Control circuit working principle: With the host module as the core, the entire rail flash welding process is realized through multiple fieldbus slave modules distributed in the power supply device, the chiller, the hydraulic station, the crane, the flash welding head and the voltage regulator. Each slave module performs local real-time processing of equipment status data information.

[0034] Figure 2 The diagram shown is a schematic representation of the control system of a rail flash welding machine in the prior art. Figure 2 The numbers in the diagram represent the number of cables required. It can be seen that the input of each acquisition signal in a traditional rail flash welding machine control system involves first connecting each signal to the core computer (i.e., the programmable controller) via several wires, then having the core computer centrally convert and process the signals, storing them in input variables. This completes the process of inputting each acquisition signal to the core computer: each detected object --> sensor --> signal conditioning --> DI or A / D interface module --> processing by the core computer. Taking welding voltage acquisition as an example: AC380V --> step-down transformer AC5V --> transmitter DC 0~10V --> A / D converter --> core computer --> voltage variable acquisition value 0~380.0V. Such input wiring is numerous and complex, resulting in poor anti-interference performance, high failure rate, and poor stability. The centralized processing by the core computer is time-consuming, causing a prolonged data acquisition lag time, with the fastest acquisition speed only reaching 100 data points per second, often failing to meet the needs of high-speed data acquisition.

[0035] Furthermore, the output of various control signals in the traditional rail flash welding machine control system involves first centrally outputting and converting the various output control variables from the core computer, then centrally isolating and driving them before connecting them to their respective actuators for execution, thereby realizing the control output function: Computer --> DO or D / A interface module --> Isolation driver --> Actuator --> Controlled object; Taking welding voltage regulation as an example: Welding voltage output variable in the core computer --> D / A converter conditioning 4~20mA --> Isolation driver --> Voltage regulator --> Output welding voltage; Such output circuit connections are numerous and complex, with poor anti-interference performance, high failure rate, and poor stability; the centralized processing of the core computer takes a long time, causing the execution of the control actuators to lag, and the response characteristics of the control system deteriorate.

[0036] In this invention, a real-time computer network control system with single master and multiple slave distributed network collaborative control is adopted. A single high-performance, embedded real-time Ethernet controller capable of real-time network communication is selected as the core computer (also called the host) of the entire control system. It mainly realizes the data processing and communication functions such as organization and collaboration of the slaves in the entire system, logic and process control, human-machine interface, data exchange, and cloud communication. In order to realize different bus network protocol functions, the host is also configured with different types of real-time Ethernet switches, real-time Ethernet expansion modules, fieldbus gateways, and wireless intelligent cloud gateways. These, together with the host, are collectively referred to as host modules. According to the control objects or signal acquisition requirements distributed in different areas, embedded computers with corresponding communication functions are selected as distributed computers (also called slaves) of the control system. They mainly complete the signal acquisition of various signals and the drive control of various actuators. In addition to the fieldbus communication module, the slave generally includes an input signal conditioning and acquisition module and an output signal conversion and drive module. Therefore, the distributed bus slave is also called a slave module. The host and slave can choose fieldbus or Ethernet bus according to the characteristics of the transmitted signal to realize the collaborative communication function between the master and slave and meet the real-time requirements of the signal.

[0037] Furthermore, this invention employs a method where each input signal is first processed and converted in a distributed fieldbus slave module, and then the data is sent to the input variables of the core computer via the fieldbus. Taking welding voltage acquisition as an example: AC380V --> Slave module <<===>> Host --> Voltage variable acquisition value 0~380.0V. Additionally, this invention uses a method where the core computer first distributes each output control variable to each distributed bus module via the fieldbus, then the fieldbus modules perform output signal conversion, isolation, and driving, and finally, the controlled object is manipulated by the drive actuator. Taking welding voltage regulation as an example: Welding voltage output variable in the host <<===>> Slave module --> Voltage regulator --> Output welding voltage. It is evident that this invention features a simple data transmission line, strong anti-interference and stability, and high host data processing efficiency, thus improving the high-speed data acquisition requirements and the execution efficiency of the carrier.

[0038] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0039] This invention distributes multiple fieldbus slave modules across multiple distributed carriers within a rail flash welding machine, connecting them to a master module via fieldbuses. This allows the multiple fieldbuses to directly control the operating parameters of the distributed carriers based on control commands sent by the master module, and to collect the operating data of the distributed carriers based on data commands sent by the master module. Therefore, the master module and the multiple slave modules in this invention can choose between a fieldbus or an Ethernet bus based on the characteristics of the transmitted signals to achieve collaborative communication between the master and slave modules, meeting the real-time requirements of the signals. Furthermore, this invention features simple data transmission lines, strong anti-interference capabilities and stability, improving the high-speed data acquisition requirements and the execution efficiency of the carriers.

[0040] In another embodiment of the present invention, the control system further includes: a first Ethernet slave module disposed in a voltage regulator and connected to the host module; and a second Ethernet slave module disposed in the flash welding head and connected to the host module.

[0041] like Figure 3As shown, the host module includes: a real-time Ethernet controller, a real-time Ethernet switch, a real-time Ethernet expansion module, a fieldbus gateway, and a wireless intelligent cloud gateway. The real-time Ethernet controller is connected to the fieldbus gateway, the real-time Ethernet expansion module, and the wireless intelligent cloud gateway through the real-time Ethernet switch. The real-time Ethernet controller uses a high-performance Intel controller based on PC control technology, and has program execution functions for the entire control system, including the rail welding process control program, the rail welding machine data management program, the fieldbus gateway communication program, the IoT collaboration program, the local network service program, and the cloud gateway data communication program. It also has a keyboard display interface for easy implementation of the local monitoring interface. The real-time Ethernet expansion module has the expansion functions of the fieldbus gateway module and the Ethernet module of the voltage regulator, and realizes functions such as a high-speed acquisition module for welding current and voltage. The fieldbus gateway is responsible for the collaborative communication between the host and slave devices. The wireless intelligent cloud gateway can realize the wireless operation monitoring function of the rail welding machine's local area network and the wireless operation monitoring function of the cloud IoT.

[0042] In this embodiment, the fieldbus slave module in the voltage regulator includes a fieldbus slave communication module, a voltage regulation setpoint module, and a voltage regulation and stabilization drive module; the first Ethernet slave module in the voltage regulator includes an Ethernet slave communication module and a high-speed welding current and voltage acquisition module.

[0043] In this embodiment, the fieldbus slave module in the flash welding head includes a fieldbus slave communication module, an acquisition module for the operation panel switch buttons, and a drive amplification module for the electromagnetic reversing valve; the second Ethernet slave module in the flash welding head includes an Ethernet slave communication module, a high-speed acquisition module for upsetting pressure and welding displacement, and a drive amplification module for the proportional servo valve.

[0044] In this embodiment, the fieldbus slave module in the hydraulic station includes a fieldbus slave communication module, a digital signal acquisition module, a solenoid directional valve drive amplification module, a start / stop control module, an analog signal acquisition module, and a system pressure regulation drive module.

[0045] In this embodiment, the fieldbus slave module in the chiller includes a fieldbus slave communication module, a chiller start / stop control module, a cooling water temperature and flow detection module, and a chiller status acquisition module.

[0046] In this embodiment, the fieldbus slave module in the power supply device includes a fieldbus slave communication module, a diesel engine start / stop control module, and a generator status monitoring module.

[0047] In this embodiment, the DC power supply module includes a controller, a sensor power supply module, an actuator power supply module, a fieldbus power supply module, and a fieldbus auxiliary power supply module.

[0048] In this embodiment, the control system further includes a local area network auxiliary machine monitor, a cloud-based mobile monitor, a cloud-based IoT database server, a cloud-based enterprise dashboard monitor, and / or a local area network rail welding machine monitor.

[0049] like Figure 1 , 4 and 5, Figure 1 This is a schematic diagram of a wired network control system for a distributed fieldbus rail flash welding machine. The host module communicates with each Ethernet slave module through a wired network. Figure 4 This is a schematic diagram of a wired + WIFI network control system for a distributed fieldbus rail flash welding machine. The host module communicates with each Ethernet slave module, the LAN auxiliary machine monitor, and the LAN rail welding machine monitor through a wired network and WIFI within the LAN. Figure 5 This diagram illustrates a wired + Wi-Fi + cloud (4G, 5G) network control system for a distributed fieldbus-based rail flash welding machine. The host module communicates with each Ethernet slave module, LAN auxiliary machine monitor, LAN rail welding machine monitor, cloud mobile monitor, cloud enterprise dashboard monitor, and LAN rail welding machine monitor via wired network, LAN Wi-Fi, and cloud network, respectively. Figure 1 The fieldbus connecting the host module to multiple fieldbus slave modules includes power lines and signal lines, while the fieldbus connecting the host module to multiple Ethernet slave modules includes communication lines.

[0050] This control system is centered around a real-time Ethernet controller (host) within the control system cabinet. It functions as both a local area network (LAN) real-time monitoring system, enabling real-time local acquisition and control of the controlled components of the rail welding machine through a fieldbus gateway or real-time Ethernet switch, and a cloud-based IoT real-time monitoring system, centered on a cloud-based IoT database server and equipped with a wireless intelligent cloud gateway, allowing for remote operation and monitoring of the rail welding machine. The rail flash welding machine, employing a distributed fieldbus and a real-time Ethernet cloud control system, offers both wired and wireless operation monitoring modes. In wired control mode, a distributed fieldbus installation and wiring method is adopted. The distributed installation carriers mainly include power supply stations, chillers, hydraulic stations, control system cabinets, cranes, and rail flash welding heads. Each distributed carrier contains slave modules related to this control system. Due to the different data collected and controlled objects, the composition and function of each slave module group are not the same. The wireless control part of the control system includes local area network wireless terminal controllers for rail welding machines and wireless controllers for rail welding auxiliary tools distributed near the rail welding machine, as well as IoT database servers, mobile terminal controllers, and enterprise dashboard monitors distributed in the remote cloud.

[0051] The present invention has the following beneficial effects: (1) The real-time Ethernet controller is used as the core of the control system, which makes the response speed of the entire control system very high and the system expansion easy. (2) The acquisition rate is high, reaching more than 20K / s, while the traditional rail welding machine is only 0.1k / s at most. (3) The intelligent cloud gateway is used as the bridge between the rail welding machine system and the external network, which makes it easy to build a cloud IoT control system and realize the cloud control function of the rail welding machine. (4) The fieldbus gateway is used as the relay station for information transmission between the control system and the field sensors and actuators, which makes the information transmission between the host and the slave simple, fast and reliable. (5) The distributed fieldbus control system structure is adopted, which makes the structure of the entire control system simple, easy to maintain and has a low failure rate. (6) The distributed fieldbus wiring method is adopted, which greatly reduces the number of control cables used in the entire control system, less than 10% of the original control system cables. (7) The fully digital network redundant control system is adopted, which greatly improves the safety and reliability of the entire system, and the failure rate is less than 10% of the original system.

[0052] In another embodiment of the present invention, a control method for a rail flash welding machine based on a distributed fieldbus is provided. The method includes: when a host module and / or multiple fieldbus slave modules send a data frame, monitoring whether the fieldbus is in an idle state; wherein the data frame includes an arbitration field, an address field, a data field, a CRC check field, and an acknowledgment field; when the fieldbus is in an idle state, sending the arbitration field in the data frame bit by bit to arbitrate bus conflicts; when the right to use the bus is obtained, establishing a communication connection with the data receiver according to the address field in the data frame, and releasing the bus after sending the data field and CRC check field in the data frame; when the data receiver successfully verifies the received data field according to the received CRC check field, obtaining the instructions or data parameters in the data field.

[0053] It should be noted that the fieldbus communication process in this embodiment follows the following pattern: establishing a link—sending and receiving data—disconnecting the link. The specific communication process is as follows:

[0054] The sender first listens to the bus. Once the bus is deemed idle, after a synchronization period, it begins sending an arbitration field and simultaneously arbitrates bus collisions. If the arbitration field is fully transmitted, the sender considers itself to have secured bus access, indicating a successful connection with the receiver (the sender always assumes the receiver is intact and in data receiving mode, therefore no connection success feedback signal from the receiver is needed). The connection establishment process is entirely controlled by the protocol program. After a successful connection, data transmission and reception are entirely handled automatically by the CPU's serial port. Therefore, the bit stream on the bus follows the serial port standard, with each byte being 11 bits. The disconnection process differs depending on the communication type: For communication without acknowledgment, the sender automatically releases the bus and disconnects from the receiver; for communication with acknowledgment, the sender directly transfers bus access to the receiver, the receiver sends an acknowledgment field, and then releases the bus and disconnects from the sender.

[0055] In this embodiment, the CRC code detection method treats the bit sequence to be transmitted as the coefficients of a polynomial f(x). The sender divides this coefficients by a pre-agreed generator polynomial G(x) to obtain a remainder polynomial. This remainder polynomial is added to the data polynomial and sent to the receiver. The receiver divides the received data polynomial f(x) by the same generator polynomial G(x) to obtain a calculated remainder polynomial. If the calculated remainder polynomial is the same as the received remainder polynomial, the transmission is error-free; if the calculated remainder polynomial is not equal to the received remainder polynomial, the transmission has an error, and the sender retransmits the data until it is correct.

[0056] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0057] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A control system for a rail flash welding machine based on a distributed fieldbus, characterized in that, The rail flash welding machine includes a power supply unit, a chiller, a hydraulic station, a control system cabinet, a crane, and a flash welding head. The control system includes: The system includes a host module, a DC power supply module, a voltage regulator, and multiple fieldbus slave modules. The host module, the DC power supply module, and the voltage regulator are located in the control system cabinet, while the multiple fieldbus slave modules are distributed among the power supply unit, the chiller, the hydraulic station, the crane, the flash welding head, and the voltage regulator. The input terminal of the DC power supply module is connected to the three-phase AC power output terminal, and the output terminal of the DC power supply module is connected to the host module and the multiple fieldbus slave modules respectively through the fieldbus, which is used to convert the three-phase AC power into multiple DC voltages, so that the multiple DC voltages supply power to the corresponding host module and fieldbus slave module respectively. The input terminal of the voltage regulator is connected to the output terminal of the three-phase AC power, and the output terminal of the voltage regulator is connected to the welding transformer in the flash welding head, which is used to convert the three-phase AC power into two-phase AC power to provide primary current and voltage for the welding transformer. The multiple fieldbus slave modules are connected to the host module via fieldbus, and are used to control the operation of the distributed carrier according to the control commands sent by the host module, and also to collect the operation data of the distributed carrier according to the data commands sent by the host module. The control system further includes: The first Ethernet slave module is located in the voltage regulator and is connected to the host module. A second Ethernet slave module is disposed in the flash welding head and connected to the host module; The host module includes: The system includes a real-time Ethernet controller, a real-time Ethernet switch, a real-time Ethernet expansion module, a fieldbus gateway, and a wireless intelligent cloud gateway; the real-time Ethernet controller is connected to the fieldbus gateway, the real-time Ethernet expansion module, and the wireless intelligent cloud gateway respectively through the real-time Ethernet switch. The real-time Ethernet controller runs a rail welding process control program, an IoT collaboration program, and a cloud gateway data communication program.

2. The control system for the rail flash welding machine based on distributed fieldbus as described in claim 1, characterized in that, The fieldbus slave module in the voltage regulator includes a fieldbus slave communication module, a voltage regulation setpoint module, and a voltage regulation drive module. The first Ethernet slave module in the voltage regulator includes an Ethernet slave communication module and a high-speed acquisition module for welding current and voltage.

3. The control system for the rail flash welding machine based on distributed fieldbus as described in claim 1, characterized in that, The fieldbus slave module in the flash welding head includes a fieldbus slave communication module, an acquisition module for the operation panel switch buttons, and a drive amplification module for the electromagnetic reversing valve. The second Ethernet slave module in the flash welding head includes an Ethernet slave communication module, a high-speed acquisition module for upsetting pressure and welding displacement, and a drive amplification module for a proportional servo valve.

4. The control system for the rail flash welding machine based on distributed fieldbus as described in claim 1, characterized in that, The fieldbus slave module in the hydraulic station includes a fieldbus slave communication module, a digital quantity acquisition module, a solenoid directional valve drive amplification module, a start / stop control module, an analog quantity acquisition module, and a system pressure regulation drive module.

5. The control system for the rail flash welding machine based on distributed fieldbus as described in claim 1, characterized in that, The fieldbus slave module in the chiller includes a fieldbus slave communication module, a chiller start / stop control module, a cooling water temperature and flow detection module, and a chiller status acquisition module.

6. The control system for the rail flash welding machine based on distributed fieldbus as described in claim 1, characterized in that, The fieldbus slave module in the power supply device includes a fieldbus slave communication module, a diesel engine start / stop control module, and a generator status monitoring module. Or / The DC power supply module includes a controller, a sensor power supply module, an actuator power supply module, a fieldbus power supply module, and a fieldbus auxiliary power supply module.

7. The control system for a rail flash welding machine based on a distributed fieldbus as described in any one of claims 1-6, characterized in that, The control system also includes a local area network auxiliary machine monitor, a cloud-based mobile monitor, a cloud-based IoT database server, a cloud-based enterprise dashboard monitor, and / or a local area network rail welding machine monitor.

8. A method for implementing the control system of the rail flash welding machine based on distributed fieldbus as described in claim 1, characterized in that, The method includes: When the host module and / or multiple fieldbus slave modules send data frames, the system monitors whether the fieldbus is in an idle state; wherein the data frame includes an arbitration field, an address field, a control field, a data field, a CRC check field, and an acknowledgment field; When the fieldbus is idle, the arbitration field in the data frame is sent bit by bit to arbitrate bus conflicts. When the right to use the bus is obtained, a communication connection is established with the data receiver according to the address field in the data frame, and the bus is released after sending the data field and CRC check field in the data frame. Once the data receiver successfully verifies the received data field based on the received CRC check field, it obtains the instructions or data parameters in the data field.

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