Robot communication system based on Modbus TCP and Profinet protocol

Abstract

The invention discloses a robot communication system based on Modbus TCP and Profinet protocols. The system comprises a robot main body, a PLC arranged in the robot main body and a lower hanging device. The robot is communicated with the PLC through a Modbus TCP (Transmission Control Protocol) protocol of the robot; the PLC is in communication with the lower hanging equipment through a Profinet communication protocol of the PLC; a control unit is arranged in the robot body, software supports a Modbus TCP protocol and can send a control instruction to a PLC and receive data from the PLC, the control unit is further provided with a user interface and is used for an operator to set control parameters, monitor the state of the robot body and display fault diagnosis information, and the software design is of a modular structure and is convenient to upgrade and maintain. According to the invention, the PLC is directly used for communication, and no extra communication assembly is needed, so that the cost is saved, the system structure is simplified, the stability and reliability of the system are improved, the maintenance difficulty is reduced, the data transmission efficiency is improved, and the safety of the system is enhanced.

Description

Technical Field

[0001] The present invention belongs to the field of device communication, and more specifically, particularly relates to a robot communication system based on Modbus TCP and Profinet protocols. Background Art

[0002] In traditional industrial automation systems, the communication between robots and PLCs (Programmable Logic Controllers) and between PLCs and downstream devices usually requires the use of specialized communication components. These communication components include but are not limited to communication protocol converters, gateways, routers, etc. Such traditional designs have the following shortcomings:

[0003] Cost issue: You need to purchase additional communication components, which increases the overall cost of the system. At the same time, installing and maintaining these components also requires additional manpower and time costs;

[0004] Increased complexity: After the introduction of communication components, the system architecture becomes more complex. Operators need to configure and manage communication components, which increases the complexity of system deployment;

[0005] Reduced reliability: Additional hardware components increase the number of failure points in the system. The communication components themselves may fail, affecting the stable operation of the entire system;

[0006] Therefore, in view of the above-mentioned deficiencies in the prior art, the present invention provides a robot communication system based on Modbus TCP and Profinet protocols. Summary of the invention

[0007] The purpose of the present invention is to solve the shortcomings of the prior art, and to propose a robot communication system based on Modbus TCP and Profinet protocols, which directly uses PLC for communication without the need for additional communication components, thereby saving costs, simplifying the system structure, improving the stability and reliability of the system, reducing the difficulty of maintenance, improving data transmission efficiency, and enhancing the security of the system.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] A robot communication system based on Modbus TCP and Profinet protocols, the system comprising a robot body, a PLC arranged inside the robot body and a hanging device;

[0010] The robot communicates with the PLC via its own Modbus TCP protocol; the PLC communicates with the downstream device via its own Profinet communication protocol;

[0011] The PLC includes one or more digital input / output modules for receiving control signals from the robot and sending control instructions to the down-hung equipment.

[0012] Preferably, the robot body is equipped with a built-in control unit, the software of which supports the Modbus TCP protocol, can send control instructions to the PLC and receive data from the PLC. The control unit also has a user interface for the operator to set control parameters, monitor the status of the robot body and display fault diagnosis information. The software design adopts a modular structure to facilitate upgrading and maintenance.

[0013] Preferably, the downstream device is connected to the network topology of the PLC through a one-in-one-out network connection method to achieve data exchange with the PLC. This connection method allows the downstream device to flexibly join or remove the system without interfering with the operation of other devices in the existing network.

[0014] Preferably, the downstream devices are connected in parallel to the network topology of the PLC through a Profinet industrial switch, so that multiple downstream devices can exchange data with the PLC at the same time. The use of the industrial switch improves the reliability of the network and the data transmission efficiency, while providing the system with better real-time performance.

[0015] Preferably, the system also includes a network configuration unit for configuring and managing network communication parameters between the robot, PLC and downstream devices. The network configuration unit supports automatic identification of newly connected devices and can automatically assign network addresses, thereby simplifying the network setup process.

[0016] Preferably, the PLC also includes at least one analog input / output module for receiving and sending analog signals to control the simulation process of the downstream equipment. The input / output module can process temperature and pressure sensor signals and convert control commands into analog signals and output them to the actuator.

[0017] Preferably, the system supports real-time monitoring and fault diagnosis functions to ensure stable operation and rapid response of the system. The system has a self-checking program that can detect the status of all devices at startup and issue an alarm when an abnormality is found;

[0018] The system supports remote monitoring and operation, and the operator can remotely control the robot, PLC and hanging equipment through the network. This function is implemented using a secure network protocol to ensure the safe and reliable transmission of control instructions;

[0019] The system has data recording and storage functions, and can record key data and events during operation for subsequent analysis and optimization. Data storage uses highly reliable storage media and supports automatic backup functions.

[0020] Preferably, the PLC integrates a data analysis and learning algorithm, which can analyze the collected operating data, automatically optimize control parameters, improve production efficiency and product quality, and can analyze the performance data of robots and hanging equipment in real time, identify areas with low efficiency or frequent failures, and optimize operations by adjusting control strategies.

[0021] Preferably, the data analysis learning algorithm is used to predict the time required for the robot to perform a task based on its motion speed and acceleration parameters; evaluate the impact of different control parameters on product quality; and optimize energy consumption by modeling the relationship between energy consumption and robot operating parameters, expressed as:

[0022] y=β0+β1x1+β2x2+...+β n x n +∈;

[0023] In the formula, y is the dependent variable, x1, x2, …, x n are independent variables, β0,β1,…,β n is the regression coefficient and ∈ is the error term.

[0024] Preferably, the PLC further comprises one or more safety modules for realizing high-level safety control of the robot body and the hanging equipment. The safety module can handle emergency situations. When a potential danger or failure is detected, the power supply can be immediately cut off or other necessary safety measures can be taken to protect the safety of personnel and equipment.

[0025] The safety module is tightly integrated with the control unit to ensure that control instructions can be executed quickly and accurately in an emergency. The safety module supports multi-level safety settings, allowing operators to configure safety parameters according to different application requirements and safety standards.

[0026] The robot communication system based on Modbus TCP and Profinet protocols provided by the present invention has the following advantages compared with the prior art:

[0027] Cost saving: By directly using PLC for communication, no additional communication components are required, thus saving the overall cost of the system. At the same time, the manpower and time costs of installation and maintenance are reduced.

[0028] Simplified system structure: Additional communication components are omitted, making the system architecture more concise and clear, and reducing the complexity of system deployment.

[0029] Improve stability and reliability: Reduce hardware components, reduce system failure rate, and improve the reliability of stable operation.

[0030] Enhanced real-time performance: Data is transmitted directly between the PLC and the robot or downstream equipment, reducing latency and improving the system’s real-time responsiveness.

[0031] Reduce maintenance difficulty: After the system structure is simplified, maintenance and troubleshooting become easier, reducing maintenance costs.

[0032] Improve data transmission efficiency: Direct communication avoids the transmission of data between multiple components and improves the efficiency of data transmission.

[0033] Enhanced system security: The simplified system structure reduces potential sources of security risks and improves the overall security of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a topological diagram of the robot communication system based on Modbus TCP and Profinet protocols of the present invention. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical scheme and advantages of the present invention clearer, the present invention is further described in detail below in conjunction with specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0036] The present invention provides Figure 1 The robot communication system based on Modbus TCP and Profinet protocols shown in the figure has brought significant technological progress and benefit improvement to the field of industrial automation by simplifying the system structure, improving stability and real-time performance, reducing costs, and enhancing safety.

[0037] The system specifically includes:

[0038] The robot body, the PLC installed inside the robot body and the hanging equipment;

[0039] The robot communicates with the PLC through its built-in Modbus TCP protocol; the PLC communicates with the downstream equipment through its built-in Profinet communication protocol; the robot body is equipped with a control unit, the software of which supports the Modbus TCP protocol and can send control instructions to the PLC and receive data from the PLC. The control unit also has a user interface for the operator to set control parameters, monitor the status of the robot body and display fault diagnosis information. The software design adopts a modular structure to facilitate upgrading and maintenance.

[0040] The downstream devices are connected to the network topology of the PLC through a one-in-one-out network connection to achieve data exchange with the PLC. This connection method allows the downstream devices to be flexibly added or removed from the system without interfering with the operation of other devices in the existing network.

[0041] Another real-time method is that the downstream devices are connected in parallel to the PLC network topology through the Profinet industrial switch, so that multiple downstream devices can exchange data with the PLC at the same time. The use of industrial switches improves the network reliability and data transmission efficiency, and provides better real-time performance for the system.

[0042] The PLC includes one or more digital input / output modules for receiving control signals from the robot and sending control instructions to the hanging equipment. The PLC also includes at least one analog input / output module for receiving and sending analog signals to control the analog process of the hanging equipment. The input / output module can process temperature and pressure sensor signals, and can convert control commands into analog signals and output them to the actuator.

[0043] Furthermore, the PLC integrates data analysis and learning algorithms, which can analyze the collected operation data, automatically optimize control parameters, improve production efficiency and product quality, and analyze the performance data of robots and hanging equipment in real time, identify areas with low efficiency or frequent failures, and optimize operations by adjusting control strategies;

[0044] The data analysis learning algorithm is used to predict the time required for the robot to perform a task based on its motion speed and acceleration parameters; evaluate the impact of different control parameters on product quality; and optimize energy consumption by modeling the relationship between energy consumption and robot operating parameters, expressed as:

[0045] y=β0+β1x1+β2x2+...+β n x n +∈;

[0046] In the formula, y is the dependent variable, x1, x2, …, x n are independent variables, β0,β1,…,β n is the regression coefficient and ∈ is the error term.

[0047] It should be noted that the data analysis learning algorithm further integrates pattern recognition and machine learning technology to enhance the system's adaptive capabilities and intelligent decision-making process. Specifically, the algorithm uses machine learning models to train historical operation data, so that it can identify patterns and trends in the production process and predict and optimize future production activities. The pattern recognition function enables the system to automatically select the most appropriate control strategy based on the identified pattern, while machine learning improves the accuracy of prediction and the effectiveness of optimization by continuously learning from past experience.

[0048] Pattern recognition technologies include but are not limited to hidden Markov models, decision trees or neural networks, which can help the system identify key operating modes in complex production environments, such as the most common failure modes, the most efficient operating modes, etc. At the same time, machine learning models such as support vector machines, random forests or deep learning networks are used to build accurate prediction models, which can process high-dimensional data and provide more complex and accurate prediction and optimization solutions.

[0049] In addition, the system also supports real-time learning and adaptive adjustment, which means that during the production process, the PLC can continuously update the machine learning model based on the data collected in real time to ensure that the control strategy is always optimized. This capability is particularly important because it allows the system to self-adjust for factors such as changes in raw material quality, equipment wear or changes in the external environment, ensuring that production efficiency and product quality are always in the best state.

[0050] In addition, the PLC also contains one or more safety modules to achieve advanced safety control of the robot body and the hanging equipment. The safety module can handle emergency situations. When potential dangers or failures are detected, the power supply can be immediately cut off or other necessary safety measures can be taken to protect the safety of personnel and equipment.

[0051] The safety module is tightly integrated with the control unit to ensure that control instructions can be executed quickly and accurately in an emergency. The safety module supports multi-level safety settings, allowing operators to configure safety parameters according to different application requirements and safety standards.

[0052] The system also includes a network configuration unit for configuring and managing network communication parameters between the robot, PLC and downstream devices. The network configuration unit supports automatic identification of newly connected devices and can automatically assign network addresses, simplifying the network setup process.

[0053] The system supports real-time monitoring and fault diagnosis functions to ensure stable operation and rapid response of the system. The system has a self-check program that can detect the status of all devices at startup and issue an alarm when an abnormality is found; when the system detects a potential fault or performance problem, it immediately starts the fault diagnosis program. This program can analyze the cause of the fault, determine whether it is a hardware problem, software error or external interference, and provide a detailed fault report. At the same time, the system will automatically take recovery measures according to the type and severity of the fault, such as restarting the device, switching to the backup system, or notifying maintenance personnel for manual intervention.

[0054] The system supports remote monitoring and operation, and the operator can remotely control the robot, PLC and hanging equipment through the network. In order to improve the flexibility and convenience of the system, the present invention also supports remote monitoring and operation functions. The operator can monitor and control the robot, PLC and hanging equipment from any location through a secure network connection. This function uses advanced encryption technology and security authentication protocols to ensure that the transmission of control instructions and monitoring data is safe and reliable, preventing data leakage and unauthorized access.

[0055] The remote monitoring function allows managers to understand the operating status of the production line in real time and promptly discover and solve problems without having to go to the site. In addition, the remote operation function also allows technicians to maintain and adjust the system without going to the site, greatly improving maintenance efficiency and flexibility.

[0056] The system has data recording and storage functions, and can record key data and events during operation for subsequent analysis and optimization. Data storage uses highly reliable storage media and supports automatic backup functions.

[0057] In addition, the system also has data recording and storage functions, which is the key to subsequent analysis and optimization. The system can record key data during the operation, such as the robot's motion parameters, PLC control instructions, and status information of the hanging equipment. These data are stored in a highly reliable storage medium to ensure the security and integrity of the data.

[0058] The data storage system also supports automatic backup function, which can regularly back up data to remote servers or cloud storage to prevent data loss. The recorded data can be used for a variety of purposes, including performance analysis, fault diagnosis, production statistics and maintenance plan formulation. By analyzing this data, enterprises can find bottlenecks in production, optimize production processes, and improve production efficiency and product quality.

[0059] In summary, the robot communication system based on Modbus TCP and Profinet protocols provided by the present invention has the following advantages compared with the prior art:

[0060] Cost saving: By directly using PLC for communication, no additional communication components are required, thus saving the overall cost of the system. At the same time, the manpower and time costs of installation and maintenance are reduced.

[0061] Simplified system structure: Additional communication components are omitted, making the system architecture more concise and clear, and reducing the complexity of system deployment.

[0062] Improve stability and reliability: Reduce hardware components, reduce system failure rate, and improve the reliability of stable operation.

[0063] Enhanced real-time performance: Data is transmitted directly between the PLC and the robot or downstream equipment, reducing latency and improving the system’s real-time responsiveness.

[0064] Reduce maintenance difficulty: After the system structure is simplified, maintenance and troubleshooting become easier, reducing maintenance costs.

[0065] Improve data transmission efficiency: Direct communication avoids the transmission of data between multiple components and improves the efficiency of data transmission.

[0066] Enhanced system security: The simplified system structure reduces potential sources of security risks and improves the overall security of the system.

[0067] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. Robot communication system based on Modbus TCP and Profinet protocols, characterized by: The system includes a robot body, a PLC arranged inside the robot body, and a hanging device; The robot communicates with the PLC via its own Modbus TCP protocol; the PLC communicates with the downstream device via its own Profinet communication protocol; The PLC includes one or more digital input / output modules for receiving control signals from the robot and sending control instructions to the down-hung equipment.

2. The robot communication system based on Modbus TCP and Profinet protocol according to claim 1, characterized in that: The robot body is equipped with a control unit. The software supports the Modbus TCP protocol and can send control instructions to the PLC and receive data from the PLC. The control unit also has a user interface for the operator to set control parameters, monitor the robot body status and display fault diagnosis information. The software design adopts a modular structure to facilitate upgrading and maintenance.

3. The robot communication system based on Modbus TCP and Profinet protocols according to claim 1, characterized in that: The downstream device is connected to the network topology of the PLC through a one-in-one-out network connection method to achieve data exchange with the PLC. This connection method allows the downstream device to flexibly join or remove the system without interfering with the operation of other devices in the existing network.

4. The robot communication system based on Modbus TCP and Profinet protocols as described in claim 1, characterized in that: The downstream devices are connected in parallel to the network topology of the PLC through the Profinet industrial switch, so that multiple downstream devices can exchange data with the PLC at the same time. The use of the industrial switch improves the reliability and data transmission efficiency of the network, and provides better real-time performance for the system.

5. The robot communication system based on Modbus TCP and Profinet protocol according to claim 1, characterized in that: The system also includes a network configuration unit for configuring and managing network communication parameters between the robot, PLC and downstream devices. The network configuration unit supports automatic identification of newly connected devices and can automatically assign network addresses, thereby simplifying the network setting process.

6. The robot communication system based on Modbus TCP and Profinet protocol according to claim 1, characterized in that: The PLC also includes at least one analog input / output module for receiving and sending analog signals to control the simulation process of the downstream equipment. The input / output module can process temperature and pressure sensor signals and convert control commands into analog signals and output them to the actuator.

7. The robot communication system based on Modbus TCP and Profinet protocols according to claim 1, characterized in that: The system supports real-time monitoring and fault diagnosis functions to ensure stable operation and rapid response of the system. The system has a self-checking program that can detect the status of all equipment at startup and issue an alarm if an abnormality is found; The system supports remote monitoring and operation, and the operator can remotely control the robot, PLC and hanging equipment through the network. This function is implemented using a secure network protocol to ensure the safe and reliable transmission of control instructions; The system has data recording and storage functions, and can record key data and events during operation for subsequent analysis and optimization. Data storage uses highly reliable storage media and supports automatic backup function.

8. The robot communication system based on Modbus TCP and Profinet protocols according to claim 1, characterized in that: The PLC integrates a data analysis and learning algorithm, which can analyze the collected operation data, automatically optimize control parameters, improve production efficiency and product quality, and can analyze the performance data of robots and hanging equipment in real time, identify areas of low efficiency or frequent failures, and optimize operations by adjusting control strategies.

9. The robot communication system based on Modbus TCP and Profinet protocol according to claim 8, characterized in that: The data analysis learning algorithm is used to predict the time required for the robot to perform a task based on its motion speed and acceleration parameters; evaluate the impact of different control parameters on product quality; and optimize energy consumption by modeling the relationship between energy consumption and robot operating parameters, expressed as: y=β0+β1x1+β2x2+...+β n x n +∈; In the formula, y is the dependent variable, x1, x2, …, x n are independent variables, β0,β1,…,β n is the regression coefficient and ∈ is the error term.

10. The robot communication system based on Modbus TCP and Profinet protocols according to claim 6, characterized in that: The PLC also includes one or more safety modules for implementing advanced safety control of the robot body and the hanging equipment. The safety module can handle emergency situations. When potential danger or failure is detected, the power supply can be immediately cut off or other necessary safety measures can be taken to protect the safety of personnel and equipment. The safety module is tightly integrated with the control unit to ensure that control instructions can be executed quickly and accurately in an emergency. The safety module supports multi-level safety settings, allowing operators to configure safety parameters according to different application requirements and safety standards.

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