Gypsum board production line network connection system and network load shunting method

Abstract

The invention discloses a gypsum board production line network connection system and a network load shunting method, the gypsum board production line network connection system comprises at least one network management type switch, the network port of each network management type switch is also connected with at least one intelligent communication management machine, and the intelligent communication management machine is respectively connected with application equipment in a production line process section; the PLC control system and the upper computer are connected with a network port of one network management type switch in the same group; each intelligent communication management machine is used for receiving production data of application equipment in a correspondingly connected production line process section and receiving an instruction of the PLC control system, and each intelligent communication management machine monitors a system network load in real time; the PLC control system regulates and controls a sending path of a control instruction and a data uploading path of each intelligent communication management machine based on a system network load of each intelligent communication management machine; according to the method, the scanning period duration of the system program can be effectively reduced, and stable and efficient operation of the system network is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of gypsum board production lines, and in particular to a gypsum board production line network connection system and a network load diversion method. Background Art

[0002] For the control core PLC, the gypsum board production line needs to control more and more equipment, whether it is equipment added by the factory according to process requirements, or external third-party systems added for a certain function, these devices or systems need to be connected to the PLC control system through hard wire connection or network connection.

[0003] Under the existing factory production network structure, if a hard-wired connection is used, many I / O interface modules need to be expanded, which will increase the operating load of the PLC and increase the system program scanning cycle time. If a network connection is used to access the PLC control system, it will be necessary to face the problem of different communication interfaces and communication protocols of certain devices or third-party systems. In addition, the increase in devices in the gypsum board production line network or the increase in third-party systems will also increase the data communication load of the PLC.

[0004] At the same time, as the technological level of the gypsum board production line is continuously optimized, the corresponding electrical measurement points are increasing, and with the diversification of control requirements, the gypsum board production line has added refined operation control systems and high-precision motion control systems, which will increase the system program scanning cycle time and increase the data communication load of the PLC. In serious cases, it will affect the normal production operation of the factory.

[0005] For the current gypsum board production line, the way to solve the network system problem is simply to avoid ring network storms, reduced communication efficiency caused by heavy communication load, and frequent equipment disconnection when designing and planning the network topology structure, but it does not fundamentally solve the problem of network congestion. Summary of the invention

[0006] The purpose of the present invention is to provide a gypsum board production line network connection system and a network load diversion method to solve the problem that the prior art only avoids ring network storms when designing and planning the network topology structure, reduces communication efficiency due to heavy communication load, and frequently disconnects of equipment, but does not fundamentally solve the technical problem of network congestion.

[0007] In order to solve the above technical problems, the present invention specifically provides the following technical solutions:

[0008] A gypsum board production line network connection system, comprising:

[0009] At least one network-managed switch, and each network port of the network-managed switch is also connected to at least one intelligent communication management machine, and the intelligent communication management machines are respectively connected to application equipment in the process section of the production line;

[0010] The managed switches are divided into different network groups according to the IP network segments of the application devices in the process section of the production line. The network ports of one of the managed switches in the same group are connected to the PLC control system and the host computer. The managed switches in different network groups communicate in a ring network through optical fibers to exchange production data of the application devices in all the process sections of the production line.

[0011] Each of the intelligent communication management machines is used to receive production data of application equipment in the corresponding connected production line process section. The production data of each of the intelligent communication management machines is processed by the network management switch and forwarded to the PLC control system and the host computer. The intelligent communication management machine can also receive control instructions from the PLC control system and regulate the application equipment in the production line process section according to the control instructions.

[0012] Each of the intelligent communication management machines monitors its system network load in real time, and the PLC control system adjusts the sending path of the control instructions and the data upload path of each of the intelligent communication management machines based on the system network load of each of the intelligent communication management machines.

[0013] As a preferred solution of the present invention, a network monitor is installed at the communication interface of each intelligent communication management machine. The network monitor can monitor the system network between the intelligent communication management machine and the network management switch, and can also monitor the system network between the intelligent communication management machine and the application equipment in the production line process section.

[0014] As a preferred solution of the present invention, each intelligent communication management machine is equipped with a wireless communication module, and the intelligent communication management machines in the same IP network segment forward data through the wireless communication module;

[0015] The PLC control system forms network load data of each of the intelligent communication management machines based on the monitoring result of the system network by the intelligent communication management machine, and the PLC control system selects the intelligent communication management machine for data forwarding based on the network load data of each of the intelligent communication management machines;

[0016] Among them, the PLC control system divides the intelligent communication management machine into an overloaded intelligent communication management machine that sends an alarm signal and a loaded intelligent communication management machine that sends a normal signal based on the network load data of the intelligent communication management machine.

[0017] As a preferred solution of the present invention, the network management switches in the same group in the same IP network segment are connected for communication, and all the network management switches in the same group share the same PLC control system;

[0018] The control instructions of the PLC control system carry an instruction forwarding path. When the overload intelligent communication manager and the capacity intelligent communication manager are respectively connected to different network-managed switches, the control instructions of the PLC control system are forwarded between the network-managed switches in the same group according to the instruction forwarding path.

[0019] As a preferred solution of the present invention, the intelligent communication management machine includes a communication interface, a data processing module, a management and control module, a storage module and a power module;

[0020] The intelligent communication management machine is connected to the network management switch and the application equipment in the process section of the production line through the communication interface respectively;

[0021] The data processing module is used to process and analyze the collected production data;

[0022] The management and control module is used to manage and forward the processed production data, and process the communication data and instructions sent by the PLC control system;

[0023] The storage module is used to temporarily store the collected production data.

[0024] As a preferred solution of the present invention, the communication interfaces of all intelligent communication management machines are configured with different communication interface cards according to the actual network conditions, so that all intelligent communication management machines form the required multiple network structures;

[0025] The intelligent communication management machines in the same IP network segment form a local area network through Ethernet.

[0026] As a preferred solution of the present invention, the management and control module intelligently splits, integrates and sends the control instructions sent by the PLC control system to identify the control instructions that need to be forwarded to other intelligent communication management machines in the same local area network, as well as the control instructions that are directly sent to the application equipment connected to the current intelligent communication management machine.

[0027] In order to solve the above technical problems, the present invention also provides a network load diversion method for a gypsum board production line, comprising the following steps:

[0028] Divide the application equipment in the process section of the production line of the same IP network segment into different production groups according to their functions, connect the same production group to the intelligent communication management machine, and connect the intelligent communication management machine to the switch, which is connected to the PLC control system;

[0029] Each of the intelligent communication management machines monitors the network load of the network cable to which it is connected in real time, and sends the network load to the PLC control system;

[0030] The PLC control system forwards communication data and control instructions using other intelligent communication management machines in the same IP network segment according to the network load of each intelligent communication management machine.

[0031] As a preferred solution of the present invention, a safety network load value is set in each of the intelligent communication management machines. When the real-time monitored network load exceeds the safety network load value, the intelligent communication management machine sends an alarm signal to the PLC control system. When the real-time monitored network load does not exceed the safety network load value, the intelligent communication management machine sends a normal signal to the PLC control system.

[0032] The PLC control system uses the intelligent communication management machine that sends the normal signal to forward the control instruction to the intelligent communication management machine that sends the alarm signal;

[0033] The intelligent communication manager forwards the data collected by the intelligent communication manager to the container-carrying intelligent communication manager that sends the normal signal based on the control instruction, and the container-carrying intelligent communication manager that sends the normal signal performs data forwarding.

[0034] As a preferred solution of the present invention, the equipment functions of the application equipment in the process section of the production line connected to each of the intelligent communication management machines are the same or similar, and the PLC control system sets the priority of all the intelligent communication management machines based on the equipment function of each of the intelligent communication management machines, so that when the overloaded intelligent communication management machine that sends a normal signal forwards data, the overloaded intelligent communication management machine that sends an alarm signal forwards data in sequence according to the priority order;

[0035] Each of the intelligent communication management machines sets a priority level according to the criticality of the application devices connected to it. When the real-time monitored network load exceeds the safety network load value, the collected production data of the application devices with different priorities are sent to the network management switch in order of priority.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] The present invention sets up an intelligent communication management machine between the production equipment and the switch. The intelligent communication management machine has multi-network function, multi-serial port function, multi-protocol function, data acquisition and forwarding function, reduces the operation load of the PLC control system and the host computer, relieves the pressure of the PLC control system and the host computer, and can realize linkage control with the production equipment signal, which can minimize the communication volume between the PLC control system and the production equipment. Even if the network between the PLC control system and the intelligent communication management machine is congested, it can also achieve rapid response work.

[0038] In addition, the intelligent communication management machine can monitor and manage the production equipment routers, switches and other communication equipment in the network, select data forwarding lines according to the system network load of each intelligent communication management machine, avoid single point failures and network congestion, and effectively improve the stability and real-time performance of the system network. It can effectively reduce the system program scanning cycle time, ensure the stable and efficient operation of the system network, and greatly guarantee the normal and stable production operation of the factory gypsum board production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0040] Figure 1 A schematic diagram of the structure of a network connection system according to an embodiment of the present invention;

[0041] Figure 2 A schematic diagram of the connection structure of an intelligent communication management machine according to an embodiment of the present invention;

[0042] Figure 3 A schematic diagram of a flow chart of a network load distribution method according to an embodiment of the present invention;

[0043] The numbers in the figure represent the following:

[0044] 1-Network managed switch; 2-Intelligent communication management machine; 3-PLC control system; 4-Host computer; 5-Network monitor; 6-Wireless communication module. DETAILED DESCRIPTION

[0045] 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.

[0046] like Figure 1 As shown, the present invention provides a gypsum board production line network connection system, comprising:

[0047] At least one network-managed switch 1 is provided, and the network port of each network-managed switch 1 is also connected to at least one intelligent communication management machine 2, and the intelligent communication management machines 2 are respectively connected to application devices in the process section of the production line.

[0048] The managed switch 1 is divided into different network groups according to the IP network segments of the application equipment in the process section of the production line. The network port of one of the managed switches 1 in the same group is connected to the PLC control system 3 and the host computer 4. The managed switches 1 in different network groups communicate in a ring network through optical fibers to exchange production data of the application equipment in all the process sections of the production line. Figure 1 The red line in the figure is an optical fiber, which enables the managed switch of the current IP network segment to be connected to the managed switches of other process segments and with different IP addresses through the optical fiber.

[0049] Each intelligent communication management machine 2 is used to receive production data of application equipment in the corresponding connected production line process section. The production data of each intelligent communication management machine 2 is processed by the network management switch 1 and forwarded to the PLC control system 3 and the host computer 4. The intelligent communication management machine 2 can also receive control instructions from the PLC control system 3 and regulate the application equipment in the production line process section according to the control instructions.

[0050] Each intelligent communication management machine 2 monitors its system network load in real time, and the PLC control system 3 adjusts the sending path of the control instructions and the data upload path of each intelligent communication management machine 2 based on the system network load of each intelligent communication management machine 2.

[0051] In this embodiment, the managed switch 1 is divided into different network groups based on the IP network segment of the application equipment in the front-end production line process segment, wherein the managed switch 1 in the same network group corresponds to a production process segment, and the PLC control system 3 can be used to uniformly control the production process segment.

[0052] Different IP network segments correspond to different production process segments, and the network management switches 1 in different production process segments perform ring network communication through optical fibers, thereby interactively managing all production process segments.

[0053] As an advantage of this embodiment, when managing the production equipment of the production process section, the production equipment is divided into different groups according to function, each functional group is connected to the intelligent communication management machine 2, and the intelligent communication management machine 2 is connected upward to the network management switch 1. The location where the intelligent communication management machine 2 accesses the network is between the network management switch 1 and the equipment layer.

[0054] The present invention sets up an intelligent communication management machine between the production equipment and the switch. The intelligent communication management machine has multi-network function, multi-serial port function, multi-protocol function, data acquisition and forwarding function, reduces the operation load of the PLC control system and the host computer, relieves the pressure of the PLC control system and the host computer, and can realize linkage control with the production equipment signal, which can minimize the communication volume between the PLC control system and the production equipment. Even if the network between the PLC control system and the intelligent communication management machine is congested, it can also achieve rapid response work.

[0055] In addition, the intelligent communication management machine can monitor and manage the production equipment routers, switches and other communication equipment in the network, select data forwarding lines according to the system network load of each intelligent communication management machine, avoid single point failures and network congestion, and effectively improve the stability and real-time performance of the system network. It can effectively reduce the system program scanning cycle time, ensure the stable and efficient operation of the system network, and greatly guarantee the normal and stable production operation of the factory gypsum board production line.

[0056] Specific as Figure 1 As shown, Figure 1 All production devices in the system are set up in the same IP network segment.

[0057] like Figure 1 The intelligent communication management machine a shown in the figure has frequency conversion devices connected to it, which are similar in function and can be designed and planned in one area. The specific network wiring is to enter from the network port of one frequency conversion device and go to the network port of the next frequency conversion device from another network port of the frequency conversion device. The two network ports of the same frequency conversion device are interconnected and have the function of data exchange. Networking in this way makes it convenient for the intelligent communication management machine to centrally control and collect data for frequency conversion devices with similar functions.

[0058] Figure 1 The intelligent communication management machine b shown in the figure can collect data from multiple different third-party systems, centrally summarize, classify and pre-process the data, and can realize the access and conversion of multiple communication methods, solving the communication needs of different devices and systems;

[0059] Figure 1The intelligent communication management machine c shown in the figure can collect various types of electrical measurement point data and equipment status data, etc., use its powerful data processing and analysis capabilities to efficiently process and analyze the communication data, and transmit the data to the PLC control system through the network, so as to realize real-time monitoring and analysis of the data, and realize the summary and output of communication data as well as report production; at the same time, using its edge computing means performing data calculations after signal collection, which can reduce latency, save bandwidth function, reduce the operating load of the PLC control system 3 and the host computer 4, and relieve the pressure on the PLC control system 3 and the host computer 4.

[0060] If data upload fails, the data and calculations can be placed in the intelligent communication management machine 2 for local processing and storage, and the linkage control of the underlying device signals can still be achieved. The communication volume between the PLC control system 3 and the production equipment can be minimized, which is very important for some factory application scenarios that require fast response and high reliability.

[0061] Figure 1 The intelligent communication management machine d shown in the figure is connected to a refined operation control system and a high-precision motion control system. It can realize intelligent management and forwarding of processed communication data, receive communication data and instructions sent by the PLC control system 3, intelligently split, integrate and send the control instructions sent by the PLC control system 3, and then issue control instructions to the downstream controlled equipment or system.

[0062] Among them, the intelligent communication management machine 2 has multiple network functions, multiple serial port functions, multiple protocol functions, data collection and forwarding functions, and realizes the advantages of automated, intelligent and efficient data processing, and can realize the collection, processing, storage and control of communication information.

[0063] In addition, the intelligent communication management machine 2 can also realize communication monitoring and management of communication equipment such as device-side routers and network-managed switches 1 in the network connection system, and can monitor the status of communication lines and broadband utilization. Therefore, each intelligent communication management machine 2 intelligently forwards data to the communication channel composed of other intelligent communication management machines 2 according to the load conditions of the system network, avoiding single point failures and network congestion, effectively improving the stability and real-time performance of the system network, ensuring the stable and efficient operation of the system network, and greatly ensuring the normal and stable production operation of the factory gypsum board production line.

[0064] Among them, in order to monitor the status of communication lines and bandwidth utilization, such as Figure 2As shown, a network monitor 5 is installed at the communication interface of each intelligent communication management machine 2. The network monitor 5 can monitor the system network between the intelligent communication management machine 2 and the network management switch 1, and can also monitor the system network between the intelligent communication management machine 2 and the application equipment in the production line process section.

[0065] Each intelligent communication management machine 2 is installed with a wireless communication module 6 , and the intelligent communication management machines 2 in the same IP network segment forward data through the wireless communication module 6 .

[0066] The PLC control system 3 forms network load data of each intelligent communication management machine 2 based on the monitoring results of the system network by the intelligent communication management machine 2, and the PLC control system 3 selects the intelligent communication management machine 2 for data forwarding based on the network load data of each intelligent communication management machine 2.

[0067] Among them, the intelligent communication management machine 2 that realizes data forwarding is divided into an overload intelligent communication management machine that sends an alarm signal, and a capacity intelligent communication management machine that sends a normal signal.

[0068] The control instructions of the PLC control system 3 carry an instruction forwarding path. When the overload intelligent communication management machine and the capacity intelligent communication management machine are respectively connected to different network managed switches 1, the control instructions of the PLC control system 3 are forwarded between the network managed switches 1 in the same group according to the instruction forwarding path.

[0069] Specifically, if the intelligent communication management machine 2 monitors through the network monitor 5 that the traffic communication of its access to the managed switch 1 exceeds the preset safety load value, the intelligent communication management machine 2 sends out a congestion alarm signal. If the intelligent communication management machine 2 monitors through the network monitor 5 that the traffic communication of its access to the managed switch 1 does not exceed the preset safety load value, indicating traffic communication, the intelligent communication management machine 2 gives normal feedback and sends a system normal signal to the PLC control system 3.

[0070] like Figure 1 and Figure 2 As shown, assuming that the intelligent communication management machine a sends a congestion alarm signal, and the intelligent communication management machines b, c, and d send a system normal signal, the control instructions of the PLC control system 3 can be selected through the intelligent communication management machine b, c, or d, and then the intelligent communication management machine b, c, or d sends the control instructions to the intelligent communication management machine a through the wireless communication module 6, wherein the selection of the intelligent communication management machine b, c, or d is specifically determined according to the network load value of the intelligent communication management machines b, c, and d, and is selected according to the smallest network load value.

[0071] Among them, the control instructions of the PLC control system 3 include a specifically designated intelligent communication management machine (b, c or d) for data forwarding, so the intelligent communication management machine a sends the production data it collects and processes to the selected intelligent communication management machine (b, c or d), and the intelligent communication management machine (b, c or d) forwards the data of the intelligent communication management machine a to the PLC control system 3.

[0072] Furthermore, if each intelligent communication management machine (a, b, c and d) sends out a congestion alarm signal at the same time, each intelligent communication management machine (a, b, c and d) transmits data according to its directly connected communication line.

[0073] like Figure 1 and Figure 2 As shown, each intelligent communication management machine 2 is installed with a network monitor 5. The intelligent communication management machine 2 can collect production data from the production equipment end downward, and can send the collected and processed production data to the network management switch 1 upward. Therefore, the network monitor 5 in this embodiment is used to monitor the network status of the communication connection between the intelligent communication management machine 2 and the production equipment end, as well as the network status of the connection between the intelligent communication management machine 2 and the network management switch 1.

[0074] Each intelligent communication management machine 2 communicates directly through a communication interface. At the same time, the intelligent communication management machine 2 also has a wireless communication function, and the intelligent communication management machines 2 in the same IP network segment can also be interconnected.

[0075] For example, when remotely monitoring a production line, most remote terminals can directly access the intelligent communication management machine 2 corresponding to a certain production process segment, which will increase the communication load of the intelligent communication management machine 2. Therefore, when the intelligent communication management machine 2 sends the collected and processed production data to the network management switch 1, the data transmission is slow due to the heavy burden on the system network.

[0076] At this time, data can be forwarded through the wireless communication module 6 of the intelligent communication management machine 2 in the same IP network segment, such as Figure 1 As shown, if congestion occurs when the channel of intelligent communication management machine a transmits production data to PLC control system 3, the production data can be transmitted to intelligent communication management machine b, intelligent communication management machine c or intelligent communication management machine d, and the data transmission data collected and processed by intelligent communication management machine a can be forwarded to PLC control system 3 through these unobstructed communication channels.

[0077] Furthermore, in order to realize the collection, processing, transmission and storage of production data, the intelligent communication management machine 2 used in this embodiment includes a communication interface, a data processing module, a management and control module, a storage module and a power module.

[0078] The intelligent communication management machine 2 is connected to the application equipment in the process section of the production line through the communication interface and the network management switch 1. The communication interface of the intelligent communication management machine 2 is the core part of the communication management machine. It can realize the connection with various production equipment, thereby realizing the management control and information collection of the production equipment.

[0079] The data processing module is used to process and analyze the collected production data in order to summarize and output the production data as well as generate reports.

[0080] The management and control module is used to manage and forward the processed production data, and to process the communication data and instructions sent by the PLC control system 3. The management and control module intelligently splits, integrates and sends the control instructions sent by the PLC control system 3 to identify the control instructions that need to be forwarded to other intelligent communication management machines 2 in the same local area network, as well as the control instructions that are directly sent to the application equipment connected to the current intelligent communication management machine 2.

[0081] The storage module is used to temporarily store the collected production data.

[0082] The power module is responsible for providing power support for the entire intelligent communication management machine.

[0083] As a preferred embodiment of this embodiment, the communication interfaces of all intelligent communication management machines 2 are configured with different communication interface cards according to the actual network usage, so that all intelligent communication management machines 2 can form the required multiple network structures, and the intelligent communication management machines 2 in the same IP network segment can form a local area network through Ethernet to realize wireless communication.

[0084] For example, when the network structures of production equipment with the same function in a production process section are different, it is necessary to use a communication network port card to configure the intelligent communication management machine 2 into multiple network structures.

[0085] The main functions and features of the intelligent communication management machine 2 in the entire system network are:

[0086] 1. Multi-network function: different communication interface cards can be configured according to the actual network conditions to form the required multiple network structures, such as RS232 full-duplex star network structure, RS485 bus half-duplex bus structure, RS422 bus full-duplex bus structure, CAN bus masterless bus structure, and Ethernet function to form a local area network;

[0087] 2. Multiple serial port function: The intelligent communication management machine has the function of flexibly configuring serial ports. It can configure serial ports according to specific needs and has different numbers of serial ports for different interface cards;

[0088] 3. Multi-protocol function: supports thousands of collection and forwarding protocols, the maximum capacity of the real-time database reaches 100,000 points, which can be customized according to specific needs. At the same time, it can provide the underlying communication interface for domestic and international mainstream platform software systems and support multi-level redundant communication scheduling mechanism;

[0089] 4. Communication flow control: monitor and control the communication flow in the system network to ensure the stability and efficient operation of the system network. Classify, limit and optimize the flow according to different strategies and rules to meet the needs of different applications;

[0090] 5. Security management: Provide powerful security functions, including firewalls, intrusion detection and prevention systems, virtual private networks (VPNs), etc. Monitor and prevent potential network attacks and intrusions, provide encryption and authentication of channel data, and ensure the confidentiality and integrity of communications;

[0091] 6. Load balancing: balance and distribute network traffic to improve network performance and reliability. Intelligently distribute traffic to different communication channels or servers according to the network load to avoid single point failure and network congestion;

[0092] 7. QoS Management: Implement and manage QoS policies to ensure the priority and performance of key applications and services. Prioritize, schedule and limit traffic based on the needs of different applications and services to ensure efficient transmission and response time of key services;

[0093] 8. Scalability: It usually has good scalability and can be flexibly configured and expanded according to the network scale and needs. It supports a large number of communication devices and users and has the ability to adapt to the growing communication traffic and business needs;

[0094] 9. High performance: Adopt high-performance hardware and optimized software algorithms to achieve fast and reliable communication processing and management. Able to handle large amounts of data traffic and complex communication protocols, ensuring high-speed transmission and low latency of the network;

[0095] 10. Simplified management: By providing comprehensive monitoring and management functions, the complexity of network management is simplified. It can fully monitor the status, traffic and connection of the network, display the network topology in real time, detect faults and anomalies in the network, issue alarms in time and provide fault diagnosis functions;

[0096] 11. Remote management and monitoring support: Remotely access and control devices through the Internet, allowing administrators to easily manage and maintain the network no matter where they are, thereby improving the operation and maintenance efficiency of the system network.

[0097] Based on the above gypsum board production line network connection system, such as Figure 3As shown, this embodiment also provides a network load diversion method for a gypsum board production line, comprising the following steps:

[0098] Divide the application equipment in the process section of the production line of the same IP network segment into different production groups according to their functions, connect the same production group to the intelligent communication management machine, and connect the intelligent communication management machine to the switch, which is connected to the PLC control system;

[0099] Each intelligent communication management machine monitors the network load of its connected network cable in real time and sends the network load status to the PLC control system;

[0100] The PLC control system forwards communication data and control instructions using other intelligent communication management machines in the same IP network segment according to the network load of each intelligent communication management machine.

[0101] Among them, a safe network load value is set in each intelligent communication management machine. When the real-time monitored network load exceeds the safe network load value, the intelligent communication management machine sends an alarm signal to the PLC control system. When the real-time monitored network load does not exceed the safe network load value, the intelligent communication management machine sends a normal signal to the PLC control system.

[0102] The PLC control system uses the load-carrying intelligent communication management machine that sends normal signals to forward control instructions to the overload intelligent communication management machine that sends alarm signals.

[0103] Based on the control instruction, the intelligent communication management machine forwards the data collected by the intelligent communication management machine to the container-carrying intelligent communication management machine that sends the normal signal, and the container-carrying intelligent communication management machine that sends the normal signal performs data forwarding.

[0104] The equipment functions of the application equipment in the process section of the production line connected to each intelligent communication management machine are the same or similar. The PLC control system sets the priority of all intelligent communication management machines based on the equipment function of each intelligent communication management machine, so that when the overloaded intelligent communication management machine sending a normal signal forwards data, the overloaded intelligent communication management machine sending an alarm signal forwards data in order of priority.

[0105] Each intelligent communication management machine sets a priority level according to the criticality of the application equipment connected to it. When the real-time monitored network load exceeds the safe network load value, the collected production data of the application equipment with different priorities will be sent to the network management switch in order of priority.

[0106] In this embodiment, in order to solve the problem that the communication line connected to the intelligent communication management machine is often overloaded, this embodiment specifically makes the following adjustments:

[0107] First, the application equipment in the process section of the production line is divided into sections and controlled, that is, the application equipment with the same or similar functions is connected to an intelligent communication management machine, and the communication channel connected to the intelligent communication management machine is avoided as much as possible to occupy too many application equipment, so as to minimize the situation where the communication load is heavy.

[0108] Secondly, the equipment functions of the application devices connected to each intelligent communication management machine are relatively similar. When the communication of the intelligent communication management machine is smooth, all the collected and processed production data will be sent to the network management switch through the directly connected communication line. If it is monitored that the network load of the intelligent communication management machine at this time is relatively serious and an overload problem occurs, and the number of overloaded intelligent communication management machines (that is, overloaded intelligent communication management machines that send alarm signals) is greater than the number of capacity intelligent communication management machines (that is, capacity intelligent communication management machines that send normal signals), then the priority is set according to the equipment function of the overloaded intelligent communication management machine, and the capacity intelligent communication management machine forwards data to the overloaded intelligent communication management machine in order of priority from high to low.

[0109] Secondly, priorities can also be set for the production data in each overloaded intelligent communication management machine, and the production equipment can be configured with priorities. For example, data from key production equipment with high forwarding priorities can be collected first, and production equipment for data collection can be added one by one after the communication load is alleviated.

[0110] The present invention sets an intelligent communication management machine between the production equipment and the switch. The intelligent communication management machine has multi-network function, multi-serial port function, multi-protocol function, data collection and forwarding function, and the intelligent communication management machine can realize the monitoring and management of the production equipment routers and communication equipment such as switches in the network, selects the data forwarding line according to the system network load of each intelligent communication management machine, avoids single point failure and network congestion, effectively improves the stability and real-time performance of the system network, can effectively reduce the system program scanning cycle time, ensure the stable and efficient operation of the system network, and greatly guarantee the normal and stable production operation of the factory gypsum board production line.

[0111] The above embodiments are only exemplary embodiments of the present application and are not intended to limit the present application. The protection scope of the present application is defined by the claims. Those skilled in the art may make various modifications or equivalent substitutions to the present application within the essence and protection scope of the present application, and such modifications or equivalent substitutions shall also be deemed to fall within the protection scope of the present application.

Claims

1. A gypsum board production line network connection system, characterized in that: include: At least one network-managed switch (1), and each network port of the network-managed switch (1) is also connected to at least one intelligent communication management machine (2), and the intelligent communication management machines (2) are respectively connected to application equipment in a process section of the production line; The network-managed switch (1) is divided into different network groups according to the IP network segments of the application equipment in the process section of the production line, a network port of one of the network-managed switches (1) in the same network group is connected to a PLC control system (3) and a host computer (4), and the network-managed switches (1) in different network groups perform ring network communication via optical fibers to exchange production data of the application equipment in all the process sections of the production line; Each of the intelligent communication management machines (2) is used to receive production data of a correspondingly connected application device. The production data of each of the intelligent communication management machines (2) is forwarded by the network management switch (1) to the PLC control system (3) and the host computer (4). The intelligent communication management machine (2) is also capable of receiving control instructions from the PLC control system (3) and regulating the application devices in the process section of the production line according to the control instructions. Each of the intelligent communication management machines (2) monitors its system network load in real time, and the PLC control system (3) regulates the sending path of the control instructions and the data upload path of each of the intelligent communication management machines (2) based on the system network load of each of the intelligent communication management machines (2).

2. A gypsum board production line network connection system according to claim 1, characterized in that: A network monitor (5) is installed at the communication interface of each intelligent communication management machine (2), and the network monitor (5) is capable of monitoring the system network between the intelligent communication management machine (2) and the network management switch (1), and monitoring the system network between the intelligent communication management machine (2) and the application equipment in the process section of the production line.

3. A gypsum board production line network connection system according to claim 2, characterized in that: Each intelligent communication management machine (2) is equipped with a wireless communication module (6), and the intelligent communication management machines (2) in the same IP network segment forward data through the wireless communication module (6); The PLC control system (3) forms network load data of each of the intelligent communication management machines (2) based on the monitoring result of the system network by the intelligent communication management machine (2), and the PLC control system (3) selects the intelligent communication management machine (2) for data forwarding based on the network load data of each of the intelligent communication management machines (2); Wherein, the PLC control system (3) divides the intelligent communication management machine (2) into an overloaded intelligent communication management machine that sends an alarm signal and a loaded intelligent communication management machine that sends a normal signal based on the network load data of the intelligent communication management machine (2).

4. A gypsum board production line network connection system according to claim 3, characterized in that: The network-managed switches (1) in the same group and in the same IP network segment are connected for communication, and all the network-managed switches (1) in the same group share the same PLC control system (3); The control instructions of the PLC control system (3) carry an instruction forwarding path. When the overload intelligent communication management machine and the capacity intelligent communication management machine are respectively connected to different network management switches (1), the control instructions of the PLC control system (3) are forwarded between the network management switches (1) in the same group according to the instruction forwarding path.

5. A gypsum board production line network connection system according to claim 1, characterized in that: The intelligent communication management machine (2) comprises a communication interface, a data processing module, a management and control module, a storage module and a power supply module; The intelligent communication management machine (2) is connected to the network management switch (1) and the application equipment in the process section of the production line through the communication interface respectively; The data processing module is used to process and analyze the collected production data; The management and control module is used to manage and forward the processed production data, and to process the communication data and instructions sent by the PLC control system (3); The storage module is used to temporarily store the collected production data.

6. A gypsum board production line network connection system according to claim 5, characterized in that: The communication interfaces of all intelligent communication management machines (2) are configured with different communication interface cards according to the actual network conditions, so that all intelligent communication management machines (2) form the required multiple network structures; The intelligent communication management machines (2) in the same IP network segment form a local area network via Ethernet.

7. A gypsum board production line network connection system according to claim 5, characterized in that: The management and control module intelligently splits, integrates and sends the control instructions sent by the PLC control system (3) to identify control instructions that need to be forwarded to other intelligent communication management machines (2) within the same local area network, as well as control instructions that are directly sent to application devices connected to the current intelligent communication management machine (2).

8. A network load diversion method for a gypsum board production line, characterized in that: A gypsum board production line network connection system according to any one of claims 1 to 7 comprises the following steps: Divide the application equipment in the process section of the production line of the same IP network segment into different production groups according to their functions, connect the same production group to the intelligent communication management machine, and connect the intelligent communication management machine to the switch, which is connected to the PLC control system; Each of the intelligent communication management machines monitors the network load of the network cable to which it is connected in real time, and sends the network load to the PLC control system; The PLC control system forwards communication data and control instructions using other intelligent communication management machines in the same IP network segment according to the network load of each intelligent communication management machine.

9. A network load diversion method for a gypsum board production line according to claim 8, characterized in that: A safety network load value is set in each of the intelligent communication management machines. When the real-time monitored network load exceeds the safety network load value, the intelligent communication management machine sends an alarm signal to the PLC control system. When the real-time monitored network load does not exceed the safety network load value, the intelligent communication management machine sends a normal signal to the PLC control system. The PLC control system uses the intelligent communication management machine that sends the normal signal to forward the control instruction to the intelligent communication management machine that sends the alarm signal; The intelligent communication manager forwards the data collected by the intelligent communication manager to the container-carrying intelligent communication manager that sends the normal signal based on the control instruction, and the container-carrying intelligent communication manager that sends the normal signal performs data forwarding.

10. A network load diversion method for a gypsum board production line according to claim 9, characterized in that: The equipment functions of the application equipment in the process section of the production line connected to each of the intelligent communication management machines are the same or similar, and the PLC control system sets the priority of all the intelligent communication management machines based on the equipment functions of each of the intelligent communication management machines, so that when the overloaded intelligent communication management machine that sends a normal signal forwards data, the overloaded intelligent communication management machine that sends an alarm signal forwards data in sequence according to the priority order; Each of the intelligent communication management machines sets a priority level according to the criticality of the application devices connected to it. When the real-time monitored network load exceeds the safety network load value, the collected production data of the application devices with different priorities are sent to the network management switch in order of priority.

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