Conveying line software control system based on EtherCAT acquisition card control

Abstract

The invention discloses a transmission line software control system based on EtherCAT acquisition card control, the transmission line control system controlled by the EtherCAT acquisition card comprises an EtherCAT master station, an EtherCAT slave station and a transmission line control unit, the EtherCAT master station is used as the core of the system and is responsible for sending a control instruction and collecting field data, and the EtherCAT slave station is responsible for sending the control instruction and collecting the field data; data exchange with the central controller is carried out; the main controller adopts a high-performance processor and an enough memory, so that the real-time performance and the stability are ensured; according to the transmission line control system controlled by the EtherCAT acquisition card, high-speed data exchange and cooperative work between the master station and the slave station are realized through the EtherCAT bus; the master station is responsible for sending a control instruction and receiving and processing data; the slave stations are responsible for data acquisition, control instruction execution and other operations; the transmission line control logic is responsible for task scheduling, control strategy execution, real-time monitoring and other functions; the whole system has the characteristics of high performance, high reliability, easy expansion and the like, and can be widely applied to various industrial conveying line scenes.

Description

Technical Field

[0001] The invention relates to the technical field of conveyor line software control systems, in particular to a conveyor line software control system based on EtherCAT acquisition card control. Background Art

[0002] The conveyor line software control system is mainly used in the food industry, logistics, manufacturing and medical industries. Through intelligent automatic arrangement and control, it can realize the fully automatic transportation of semi-finished products on the assembly line. The system usually adopts PLC programmable logic controller control system and pneumatic execution system configuration, which can be flexibly adjusted and optimized according to the various types of motion requirements of multiple stations on the conveyor line;

[0003] However, the existing conveyor line software control system may cause transmission line failure and thus transmission problems due to system stability and latency during operation, and its performance stability is poor during use. Therefore, a conveyor line software control system based on EtherCAT acquisition card control is proposed. Summary of the invention

[0004] The object of the present invention is to provide a conveyor line software control system based on EtherCAT acquisition card control to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] The invention discloses a conveyor line software control system based on EtherCAT acquisition card control, comprising: a conveyor line control system controlled by EtherCAT acquisition card, wherein the conveyor line control system controlled by EtherCAT acquisition card comprises an EtherCAT master station, an EtherCAT slave station and a conveyor line control unit, wherein the EtherCAT master station, as the core of the system, is responsible for sending control instructions, collecting field data, and exchanging data with a central controller; the main controller adopts a high-performance processor and sufficient memory to ensure real-time performance and stability; the EtherCAT slave station comprises a plurality of input and output devices for realizing field data collection and control signal output; these devices are connected to the master station through an EtherCAT bus to realize high-speed and large-capacity communication control; the physical layer uses standard Ethernet physical layer devices, such as 100BASE-TX twisted pair and LVDS, to ensure reliable data transmission; different transmission media have different transmission distances and performance characteristics, which can be selected according to actual needs; the conveyor line control unit HM I realizes management and operation of the entire control system through the central controller; the control strategy can be customized according to actual needs, such as speed adjustment and path optimization based on real-time data; meanwhile, the system also has monitoring and alarm functions to ensure safe operation of the conveyor line.

[0007] As a further solution of the present invention: the EtherCAT master station includes a main controller, the EtherCAT master station communication structure type adopts Ethernet to use the Ethernet interface to achieve high-speed communication with the EtherCAT slave station, and ensures that the master station and the slave station are in the same network segment to facilitate data exchange, the EtherCAT master station also includes a system configuration tool using an EtherCAT configuration tool, such as ZDevel op V3.10 version controller programming software, calling a device description, generating an XML file describing a process image area, and simplifying the configuration process, the main controller model is LX800, and the main frequency is 500MHz.

[0008] As a further solution of the present invention: the EtherCAT slave station includes input and output devices and a physical layer, the input and output devices are respectively a motor control module, an I / O switch quantity control module, and an analog input and output module, the transmission medium in the physical layer is 100BASE-TX twisted pair and LVDS, and the physical layer communication chip model is ET ll 00 or KS8721 BL.

[0009] As a further solution of the present invention: the conveyor line control unit includes an HMI central controller for managing and operating the entire system; the control strategy group adjusts the speed and optimizes the path based on real-time data, and the monitoring and alarm module monitors the conveyor line status in real time and sends out an alarm signal when an abnormality occurs.

[0010] As a further solution of the present invention: the EtherCAT bus port of the EtherCAT master station is connected to the EtherCAT slave station interface through a network cable to form an EtherCAT bus network. The EtherCAT slave station interface is divided into IN and OUT. The IN port is connected to the upper-level device, and the OUT port is connected to the lower-level device to avoid mixing.

[0011] Compared with the prior art, the present invention has the following beneficial effects:

[0012] The conveyor line control system controlled by the EtherCAT acquisition card in the present invention realizes high-speed data exchange and collaborative work between the master station and the slave stations through the EtherCAT bus; the master station is responsible for sending control instructions, receiving and processing data; the slave station is responsible for data acquisition, control instruction execution and other operations; the conveyor line control logic is responsible for task scheduling, control strategy execution and real-time monitoring and other functions; the entire system has the characteristics of high performance, high reliability, easy expansion, etc., and can be widely used in various industrial conveyor line scenarios. Through the EtherCAT bus control technology, the automatic control of the conveyor line is realized. At the same time, through detailed system design and configuration, the stability and real-time performance of the system are ensured, and the operation efficiency and management level of the conveyor line are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a schematic diagram of the overall structure of the conveyor line software control system based on EtherCAT acquisition card control.

[0014] Figure 2 This is a schematic diagram of the structure of the EtherCAT master station in the system of the conveyor line software control system controlled by the EtherCAT acquisition card.

[0015] Figure 3 This is a schematic diagram of the structure of the EtherCAT slave station in the system of the conveyor line software control system controlled by the EtherCAT acquisition card.

[0016] Figure 4 This is a schematic diagram of the structure of the conveyor line control unit in the system of the conveyor line software control system controlled by the EtherCAT acquisition card. DETAILED DESCRIPTION

[0017] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] See also Figures 1 to 4In an embodiment of the present invention, a conveyor line software control system based on EtherCAT acquisition card control, a conveyor line control system controlled by EtherCAT acquisition card, the conveyor line control system controlled by EtherCAT acquisition card includes an EtherCAT master station, an EtherCAT slave station and a conveyor line control unit, the EtherCAT master station as the core of the system is responsible for sending control instructions, collecting field data, and exchanging data with a central controller; the main controller adopts a high-performance processor and sufficient memory to ensure real-time performance and stability, the EtherCAT slave station: includes multiple input and output devices for realizing field data collection and control signal output; these devices are connected to the master station through the EtherCAT bus to achieve high-speed, large-capacity communication control, physical layer: using standard Ethernet physical layer devices, such as 100BASE-TX twisted pair and LVDS, etc., to ensure reliable data transmission; different transmission media have different transmission distances and performance characteristics, which can be selected according to actual needs, the conveyor line control unit: HM I realizes the management and operation of the entire control system through the central controller; the control strategy can be customized according to actual needs, such as speed adjustment based on real-time data, path optimization, etc.; at the same time, the system also has monitoring and alarm functions to ensure the safe operation of the conveyor line.

[0019] Embodiment 1

[0020] The EtherCAT master station includes a main controller. The communication structure type of the EtherCAT master station adopts Ethernet to realize high-speed communication with the EtherCAT slave station by using an Ethernet interface, and ensures that the master station and the slave station are in the same network segment to facilitate data exchange. The EtherCAT master station also includes a system configuration tool using an EtherCAT configuration tool, such as ZDevel op V3.10 version controller programming software, calling a device description, generating an XML file describing a process image area, and simplifying the configuration process. The main controller model is LX800, and the main frequency is 500MHz.

[0021] Embodiment 2

[0022] The EtherCAT slave station includes input and output devices and a physical layer. The input and output devices are respectively a motor control module, an I / O switch quantity control module, and an analog quantity input and output module. The transmission medium in the physical layer is 100BASE-TX twisted pair and LVDS. The model of the physical layer communication chip is ET 1100 or KS8721 BL.

[0023] Embodiment 3

[0024] The conveyor line control unit includes an HMI central controller for managing and operating the overall system; the control strategy group adjusts the speed and optimizes the path based on real-time data, and the monitoring and alarm module monitors the status of the conveyor line in real time and sends out an alarm signal when an abnormality occurs.

[0025] Embodiment 4

[0026] The EtherCAT bus port of the EtherCAT master station is connected to the EtherCAT slave station interface through a network cable to form an EtherCAT bus network. The EtherCAT slave station interface is divided into IN and OUT. The IN port is connected to the upper-level device, and the OUT port is connected to the lower-level device to avoid mixing.

[0027] The working principle of the present invention is as follows: start the EtherCAT master station controller, load the operating system and the EtherCAT master station software, initialize the Ethernet card, configure the network parameters, ensure that it is in the same network segment as the EtherCAT slave station, use the EtherCAT configuration tool, load the device description file, generate an XML file describing the process image area, configure the master station parameters, including the scanning cycle, communication rate, etc., the master station controller sends the EtherCAT data frame to the slave station through the Ethernet interface, the data frame is transmitted on the EtherCAT bus, each slave station device performs a corresponding operation according to the information in the data frame, the slave station device inserts the collected data into the data frame, and returns it to the master station, and the master station controller receives the EtherCAT data frame. Receive data frames, parse data, and process as needed. The master controller generates control instructions based on the control logic and encapsulates them into EtherCAT data frames. The data frames containing control instructions are sent to the EtherCAT bus. The slave devices receive and execute control instructions, start the EtherCAT slave devices, load device firmware, and configure slave parameters, including device address, input and output configuration, etc. The slave devices listen to the data frames on the EtherCAT bus. When receiving the data frames, the slave devices perform corresponding operations based on the information in the data frames. The slave devices collect field data such as motor status, sensor data, etc. according to the configuration, insert the collected data into the data frames, and prepare to return them to the master. , sends the data frame containing the collected data to the EtherCAT bus, waits for the response of the master controller or the arrival of the next data frame, and when the slave device receives the data frame containing the control instruction, it parses the control instruction and performs the corresponding operation such as motor control, IO switch control, etc. According to the requirements of the conveying task, the HMI central controller dispatches the corresponding control strategy, and according to the dispatch result, executes the corresponding control strategy such as real-time data speed adjustment, path optimization, etc. The central controller monitors the status of the conveyor line such as equipment status, data parameters, etc. in real time through the EtherCAT master station. When an abnormal situation occurs, the central controller automatically sends an alarm signal to remind the operator to deal with it, and the operator takes corresponding measures according to the alarm information. To solve the problem, the conveyor line control system controlled by the EtherCAT acquisition card realizes high-speed data exchange and collaborative work between the master station and the slave station through the EtherCAT bus; the master station is responsible for sending control instructions, receiving and processing data; the slave station is responsible for data acquisition, control instruction execution and other operations; the conveyor line control logic is responsible for task scheduling, control strategy execution and real-time monitoring and other functions; the entire system has the characteristics of high performance, high reliability and easy expansion, and can be widely used in various industrial conveyor line scenarios. Through EtherCAT bus control technology, the automatic control of the conveyor line is realized. At the same time, through detailed system design and configuration, the stability and real-time performance of the system are ensured, and the operation efficiency and management level of the conveyor line are improved.

[0028] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

[0029] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A conveyor line software control system based on EtherCAT acquisition card control, characterized in that: include: The conveyor line control system controlled by the EtherCAT acquisition card includes an EtherCAT master station, an EtherCAT slave station and a conveyor line control unit. The EtherCAT master station, as the core of the system, is responsible for sending control instructions, collecting field data, and exchanging data with the central controller. The main controller adopts a high-performance processor and sufficient memory to ensure real-time performance and stability. The EtherCAT slave station includes multiple input and output devices for collecting field data and outputting control signals. These devices are connected to the master station through the EtherCAT bus to achieve high-speed and large-capacity communication control. The physical layer uses standard Ethernet physical layer devices, such as 100BASE-TX twisted pair and LVDS, to ensure reliable data transmission. Different transmission media have different transmission distances and performance characteristics, which can be selected according to actual needs. The conveyor line control unit: HMI manages and operates the entire control system through the central controller. The control strategy can be customized according to actual needs, such as speed adjustment and path optimization based on real-time data. At the same time, the system also has monitoring and alarm functions to ensure the safe operation of the conveyor line.

2. The conveyor line software control system based on EtherCAT acquisition card control according to claim 1 is characterized in that: The EtherCAT master station includes a main controller. The communication structure type of the EtherCAT master station adopts Ethernet to utilize the Ethernet interface to achieve high-speed communication with the EtherCAT slave station, and ensures that the master station and the slave station are in the same network segment to facilitate data exchange. The EtherCAT master station also includes a system configuration tool that uses an EtherCAT configuration tool, such as ZDevelop V3.10 version controller programming software, calls a device description, generates an XML file describing the process image area, and simplifies the configuration process. The main controller model is LX800, and the main frequency is 500 MHz.

3. The conveyor line software control system based on EtherCAT acquisition card control according to claim 1 is characterized in that: The EtherCAT slave station includes input and output devices and a physical layer. The input and output devices are respectively a motor control module, an I / O switch control module, and an analog input and output module. The transmission medium in the physical layer is 100BASE-TX twisted pair and LVDS, and the physical layer communication chip model is ET1100 or KS8721BL.

4. The conveyor line software control system based on EtherCAT acquisition card control according to claim 1 is characterized in that: The conveyor line control unit includes an HMI central controller for managing and operating the overall system; the control strategy group adjusts the speed and optimizes the path based on real-time data, and the monitoring and alarm module monitors the status of the conveyor line in real time and sends out an alarm signal when an abnormality occurs.

5. The conveyor line software control system based on EtherCAT acquisition card control according to claim 1 is characterized in that: The EtherCAT bus port of the EtherCAT master station is connected to the EtherCAT slave station interface through a network cable to form an EtherCAT bus network. The EtherCAT slave station interface is divided into IN and OUT. The IN port is connected to the upper-level device, and the OUT port is connected to the lower-level device to avoid mixing.

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