Distributed industrial Ethernet control system and control system setting method

Abstract

The invention provides a distributed industrial Ethernet control system and a control system setting method. The distributed industrial Ethernet control system comprises a master station controller, a plurality of secondary master station controllers, a plurality of first servo drivers and a plurality of groups of second servo drivers. The master station controller is used for sending a first control instruction and a second control instruction; the plurality of secondary master station controllers are connected with the master station controller, the plurality of first servo drivers are connected with the master station controller, and the first servo drivers are used for receiving a first control instruction; the plurality of second servo drivers in each group are connected with one secondary master station controller, and the plurality of second servo drivers receive a third control instruction. The load of the master station controller is reduced, and the expandability and flexibility of the whole system are improved. Besides, each controller can control a plurality of servo drivers, each servo driver corresponds to one motor shaft, and the master station controller enables a part of motion control to be completed by the secondary master station controller, so that the pressure of the motion control of the master station controller is greatly reduced, and the period and the capability under the multi-shaft control are not influenced.

Description

Technical Field

[0001] The present invention relates to the technical field of distributed industrial Ethernet applications, and in particular to a distributed industrial Ethernet control system and a control system setting method. Background Art

[0002] At present, with the increasing number of axes integrated into the system, faster operating speeds, and higher levels of automation in the industrial control industry, efficient and secure industrial Ethernet has become a key indicator of the project.

[0003] Traditional industrial Ethernet distributes information to distributed controllers through switches. Distributed controllers need to collect information and transmit it through communication rules for interaction. The communication is complicated, inefficient and unstable.

[0004] Traditional industrial Ethernet can only configure interrupt DMA within a single motion control card loop. Each motion control loop interacts with the network through Ethernet or by adding a communication module. The interaction consumes a lot of hardware and software resources. Summary of the invention

[0005] The main purpose of the present invention is to provide a distributed industrial Ethernet control system and a control system setting method, so as to at least solve the problems of complicated communication, low efficiency and poor stability in the prior art.

[0006] In order to achieve the above-mentioned object, the present invention provides a distributed industrial Ethernet control system, comprising a master station controller, a plurality of secondary master station controllers, a plurality of first servo drivers and a plurality of groups of second servo drivers; the master station controller is used to send a first control instruction and a second control instruction; a plurality of secondary master station controllers are connected to the master station controller, and are used to receive the second control instruction and generate a third control instruction according to the second control instruction; a plurality of first servo drivers are connected to the master station controller, and the first servo driver is used to receive the first control instruction, and the first control instruction is used to control a plurality of the first servo drivers; a plurality of groups of the second servo drivers correspond to a plurality of the secondary master station controllers one by one, each group of the second servo drivers is a plurality, and each group of the plurality of the second servo drivers is connected to a corresponding one of the secondary master station controllers, and a plurality of groups of the second servo drivers are used to receive the third control instruction, and the third control instruction is used to control a plurality of groups of the second servo drivers; wherein the control of the first servo driver by the master station controller is servo control and motion control, and the control of the second servo driver by the secondary master station controller is servo control and motion control; the servo control is used to control the motion of a single motor shaft, and the motion control is used to control the coordinated motion between motor shafts.

[0007] Optionally, the distributed industrial Ethernet control system also includes a high-speed transmission channel, which is used for transmitting instructions between the master station controller and the first servo controller, between the master station controller and the secondary master station controller, and between the secondary master station controller and the second servo controller.

[0008] Optionally, the distributed industrial Ethernet control system adopts gLink-II technology.

[0009] Optionally, the servo control sends control instructions via network point-to-point communication, and the motion control sends control instructions via an interrupt mechanism preset in a high-speed transmission channel.

[0010] The present invention also provides a distributed Ethernet control system setting method, which is applied to the distributed Ethernet control system of the present invention, comprising:

[0011] Determine a master station controller, a secondary master station controller, a first servo drive, and a second servo drive;

[0012] Determine a path for sending instructions between the master station controller, the secondary master station controller, the first servo driver, and the second servo driver;

[0013] Setting the control of the first servo driver by the master controller to servo control and motion control, and setting the control of the servo driver by the secondary master controller to servo control and motion control, and determining that the servo control controls the motion of a single motor shaft, and the motion control controls the coordinated motion between the motor shafts;

[0014] The servo driver is set to drive the corresponding motor shaft to move according to the received control command.

[0015] Optionally, the setting method also includes: configuring high-speed transmission channels between the master station controller and the first servo controller, between the master station controller and the secondary master station controller, and between the secondary master station controller and the second servo controller.

[0016] Optionally, the setting method also includes: setting a network interruption time.

[0017] Optionally, the setting method further includes:

[0018] Set the motor axes that need to move in real time to be controlled through motion control;

[0019] Set up motor axes that require non-real-time motion to be controlled via servo control.

[0020] A distributed industrial Ethernet control system of the technical solution of the present invention comprises a master station controller, a plurality of sub-master station controllers, a plurality of first servo drivers and a plurality of groups of second servo drivers; the master station controller is used to send a first control instruction and a second control instruction; a plurality of sub-master station controllers are connected to the master station controller, and are used to receive the second control instruction, and generate a third control instruction according to the second control instruction; a plurality of first servo drivers are connected to the master station controller, and the first servo driver is used to receive the first control instruction, and the first control instruction is used to control the plurality of first servo drivers; a plurality of groups of second servo drivers correspond to a plurality of sub-master station controllers one by one, each group of second servo drivers is a plurality, and each group of a plurality of second servo drivers is connected to a corresponding sub-master station controller, and a plurality of groups of second servo drivers are used to receive the third control instruction, and the third control instruction is used to control the plurality of groups of second servo drivers; wherein the control of the first servo driver by the master station controller is servo control and motion control, and the control of the second servo driver by the sub-master station controller is servo control and motion control; the servo control is used to control the motion of a single motor shaft, and the motion control is used to control the coordinated motion between motor shafts. Thus, the burden of the master station controller is reduced, and the scalability and flexibility of the whole system are improved. In addition, each controller can control multiple servo drives, each servo drive corresponds to a motor axis. The master controller will hand over part of the motion control to the sub-master controller, which will greatly reduce the pressure of the master motion control and ensure that the cycle and capacity under multi-axis control are not affected. Moreover, the master controller sends the motion control instructions of the servo drive directly controlled by the sub-master controller to the sub-master controller, which will be calculated and distributed to the servo drive directly controlled by it, improving the network control efficiency, reducing the calculation pressure of the master controller, and reducing the load pressure of the network. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0022] Figure 1 This is an optional distributed industrial Ethernet control system architecture diagram according to an embodiment of the present invention.

[0023] Reference numerals:

[0024] 10. Master station controller; 20. Sub-master station controller; 30. First servo driver; 40. Second servo driver. DETAILED DESCRIPTION

[0025] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0026] like Figure 1 As shown, a distributed industrial Ethernet control system includes: a master station controller 10, multiple sub-master station controllers 20, multiple first servo drivers 30, and multiple groups of second servo drivers 40. The master station controller 10 is used to send a first control instruction and a second control instruction; multiple sub-master station controllers 20 are connected to the master station controller 10, and are used to receive the second control instruction and generate a third control instruction according to the second control instruction; multiple first servo drivers 30 are connected to the master station controller 10, and the first servo drivers 30 are used to receive the first control instruction, and the first control instruction is used to control the multiple first servo drivers 30; multiple groups of second servo drivers 40 correspond to multiple sub-master station controllers 20 one by one, each group of second servo drivers 40 is multiple, and each group of multiple second servo drivers 40 is connected to a corresponding sub-master station controller 20, and multiple groups of second servo drivers 40 are used to receive the third control instruction, and the third control instruction is used to control multiple groups of second servo drivers 40;

[0027] The master station controller 10 controls the first servo driver 30 with servo control and motion control, and the sub-master station controller 20 controls the second servo driver 40 with servo control and motion control; servo control is used to control the movement of a single motor shaft, and motion control is used to control the coordinated movement between motor shafts.

[0028] Specifically, the Ethernet control system in the present application is a multi-level network topology. Among them, the master station controller 10 is the hub of the entire control system, responsible for sending the first control instruction and the second control instruction. Among them, the first control instruction is directly sent to a plurality of first servo drivers 30 connected to the master station controller 10, and these first servo drivers 30 and the motor shafts controlled by them are precisely servo-controlled and motion-controlled. Servo control focuses on the movement of a single motor shaft to ensure that it moves according to a predetermined trajectory, speed and acceleration, while motion control focuses more on the coordinated movement between multiple motor shafts to achieve more complex mechanical actions. The master station controller 10 sends a second control instruction to a plurality of secondary master station controllers 20. The second control instruction mainly includes motion control instructions for the system movement between the second servo drivers 40 directly connected to the secondary master station controller 20. Each secondary master station controller 20 receives the control instructions of the master station and generates a third control instruction based on these instructions. Each group of second servo drivers 40 includes a plurality of second servo drivers 40, and the third control instruction includes specific control requirements for each of these second servo drivers 40. The third control instruction is decomposed and sent to the second servo driver 40 connected thereto, so as to realize the control of the coordinated motion between the second servo controllers that have received the instruction.

[0029] The servo control of the first servo driver 30 by the master controller 10 is controlled by the servo DSP on the master controller 10 side. The DSP is a digital signal processor. When receiving the control demand, the control instructions for the servo control actions that need to be executed by the motor shaft corresponding to the first servo driver 30 are directly sent to the first servo driver 30 by the servo DSP of the master controller 10, and the motion control instructions that need to be coordinated between the motor shafts corresponding to the first servo driver 30 are sent to the first servo driver 30 by the motion control DSP of the master controller 10. The control instructions that need to be coordinated between the motor shafts corresponding to the second servo driver 40 are sent by the master controller 10 to each sub-master controller 20, and each sub-master controller 20 decomposes the control instructions and sends them to the corresponding second servo driver 40. The sub-master decomposes the instructions into servo control instructions and motion control instructions. The servo control instruction is decomposed by the servo DSP of the secondary master controller 20 and sent to the corresponding second servo driver 40, while the motion control instruction is decomposed by the operation control DSP of the secondary master controller 20 and sent to the corresponding second servo driver 40, so that all servo drivers control the corresponding motor shaft movement according to the received control instruction to meet the control requirements. The number of servo drivers controlled by the operation control DSP is determined by the number of channels of the operation control DSP chip itself, while the number of servo drivers controlled by the servo DSP depends on the computing power of the CPU.

[0030] The hierarchical control method reduces the burden on the master station controller 10 and improves the scalability and flexibility of the entire system. In addition, each controller can control multiple servo drives, each servo drive corresponds to a motor axis, and the master station controller 10 hands over part of the motion control to the sub-master station controller 20, which will greatly reduce the pressure of the master station motion control and ensure that the cycle and capacity under multi-axis control are not affected. Moreover, the master station controller 10 sends the motion control instructions of the servo drive directly controlled by the sub-master station controller 20 to the sub-master station controller 20, which is calculated by the sub-master station controller 20 and then distributed to the servo drive directly connected to it for control, which can also increase the control efficiency of the network, reduce the calculation pressure of the master station controller 10, and reduce the load pressure of the network.

[0031] In the present application, the master station controller and its correspondingly connected multiple first servo drivers form a master station drive-control integration, each sub-master station controller and its correspondingly connected multiple second servo drivers form a sub-master station drive-control integration, wherein the first servo driver and the second servo driver are slave stations, which respectively receive the drive and control from the master station controller and the sub-master station controller, thereby realizing the control of the motor shaft corresponding to the first servo driver and the second servo driver. The present application allocates each motor shaft to its respective drive-control integration, so that the maximum number of motor shafts that each drive-control integration needs to control will be much less, thereby reducing the calculation and control pressure of the controller and greatly improving the control effect. Moreover, servo control is a simple non-real-time movement of a single motor shaft, and the user needs to send control instructions by himself, while motion control is a synchronous real-time movement between complex motor shafts. The user only needs to send the target control demand, and the controller can automatically plan the path, decompose the required target action into different drive-control integrations, and control the corresponding motor shaft movements through different drive-control integrations, and finally realize the target control demand, so that the computing power of the internal servo DSP chip and the operation control DSP chip of the drive-control integration can be greatly utilized to improve efficiency.

[0032] In one possible implementation, the distributed industrial Ethernet control system also includes a high-speed transmission channel, which is used for command transmission between the master station controller 10 and the first servo controller 30, between the master station controller and the secondary master station controller 20, and between the secondary master station controller 20 and the second servo controller 20.

[0033] Specifically, the high-speed transmission channel allows external devices to exchange data directly with the system memory without the intervention of the CPU. The high-speed transmission channel improves the speed and efficiency of data transmission, reduces the burden on the CPU, and allows data to be transmitted at a higher speed between the master station controller 10 and the first servo driver 30, between the master station controller 10 and the secondary master station controller 20, and between the secondary master station controller 20 and the second servo driver 40, thereby reducing the delay in data transmission. Moreover, since both the master station controller 10 and the secondary master station controller 20 can directly access the servo driver that they directly control, more servo drivers and controllers can be easily added to expand the scale of the system; the master station controller 10 and the secondary master station controller 20 need to process a large amount of data and send control instructions to the servo driver, and by setting up a high-speed transmission channel, these data can be processed more efficiently and instructions can be sent, thereby giving full play to its processing capabilities, improving the overall performance of the system, and reducing the burden on the CPU. For example, the high-speed transmission channel in the present application can be a transmission channel using DMA. The introduction of DMA technology allows the CPUs of the master station controller 10 and the secondary master station controller 20 to focus on performing other tasks, such as control logic, data processing, etc., thereby improving the overall performance and response speed of the system. By introducing the secondary master controller 20 and the corresponding high-speed transmission channel, the system can be expanded more easily. When more servo drives need to be added, it can be achieved by adding additional secondary master controllers 20 and high-speed channels without major modifications to the master controller 10.

[0034] In a possible implementation, the distributed industrial Ethernet control system adopts the gLink-II technology of the ring network.

[0035] Specifically, the equal ring network gLink-II is an advanced industrial field bus technology with the characteristics of high speed, high precision and high reliability. It adopts the Gigabit Ethernet physical layer, and reconstructs the data link layer according to the needs of the industrial field, realizing multi-master-slave peer-to-peer ring network communication. This technology not only improves the communication rate and real-time performance, but also enhances the stability and reliability of the system. The master station controller 10 and the secondary master station controller 20 communicate based on the equal ring network gLink-II industrial bus, the master station controller 10 and the first servo drive 30 communicate based on the equal ring network gLink-II industrial bus, and the secondary master station controller 20 and the second servo drive 40 communicate based on the equal ring network gLink-II industrial bus. Using the equal ring network gLinkII technology, the master station controller 10 can quickly send control instructions to the first servo drive 30 and the secondary master station controller 20, and the secondary master station controller 20 can quickly send control instructions to the second servo drive 40. The control instructions are almost not affected by delays and packet loss during transmission, thereby ensuring the accuracy and timeliness of control. In addition, the communication efficiency is improved, the communication difficulty between controllers and between controllers and servo drives is reduced, and it is convenient for users to expand. Moreover, if a single station in the control system fails or the cable is damaged, other devices in the control system can operate normally.

[0036] In a possible implementation, the servo control sends control instructions via network point-to-point communication, and the motion control sends control instructions via an interrupt mechanism preset in a high-speed transmission channel.

[0037] Specifically, the control instructions for servo control are sent directly to the servo driver in a point-to-point manner through the network. That is, each servo driver has established a direct communication link with its corresponding controller (whether it is the master station controller 10 or the secondary master station controller 20), and this communication method is usually based on TCP / IP or other industrial Ethernet protocols to ensure the accurate transmission of instructions and the immediate response of the servo driver. Point-to-point communication enables each servo driver to receive and execute instructions independently, thereby improving the flexibility of the system. Moreover, as the scale of the system expands, more servo drivers can be easily added without major modifications to the existing communication network. The interrupt mechanism in this application is a specific interrupt mechanism. When specific conditions are met (such as receiving a complete data packet, the interrupt will be triggered to notify the controller to process this data packet). In motion control, the operation control DSP can directly access the high-speed transmission channel and read the configured interrupt parameters, such as the interrupt time, from it, so as to realize the real-time sending of motion control instructions. Setting an interrupt mechanism can realize real-time data processing, improve efficiency, and enhance reliability.

[0038] The present invention also provides a distributed Ethernet control system setting method, which is applied to the distributed Ethernet control system in the present invention, comprising:

[0039] Determine the master station controller 10, the secondary master station controller 20, the first servo drive 30 and the second servo drive 40;

[0040] Determine a path for sending instructions between the master station controller 10, the secondary master station controller 20, the first servo driver 30 and the second servo driver 40;

[0041] Setting the control of the first servo driver 30 by the master controller 10 to servo control and motion control, and setting the control of the servo driver by the secondary master controller 20 to servo control and motion control, and determining that the servo control controls the motion of a single motor shaft, and the motion control controls the coordinated motion between the motor shafts;

[0042] The servo driver is set to drive the corresponding motor shaft to move according to the received control command.

[0043] Specifically, all nodes of the Ethernet control system are first determined, including the master station controller 10, the secondary master station controller 20, the first servo drive 30 and the second servo drive 40. After the type of the secondary master station controller 20 is determined, each secondary master station controller 20 is numbered for ease of management.

[0044] The transmission path of the control instructions between the nodes is determined, that is, the master station controller 10 sends instructions to the secondary master station controller 20 and the first servo driver 30 , and the secondary master station controller 20 sends instructions to the second servo driver 40 .

[0045] The control of the first servo driver 30 by the master station controller 10 is set to be composed of two parts: servo control and motion control. The servo control includes control instructions for independent simple motion of the first servo driver 30 and its corresponding controlled motor shaft, and the motion control includes control instructions for coordinated motion between the motor shafts correspondingly controlled by each first servo driver 30. Similarly, the control of the second servo driver 40 by the sub-master station controller 20 is set to be composed of two parts: servo control and motion control. The servo control includes control instructions for independent simple motion of the second servo driver 40 and its corresponding controlled motor shaft, and the motion control includes control instructions for coordinated motion between the motor shafts correspondingly controlled by each second servo driver 40, and the motion parameters included in the servo control and motion control are set.

[0046] The first servo driver 30 and the second servo driver 40 are set to control their corresponding motor shafts to perform corresponding actions according to the received control instructions.

[0047] In this application, the physical wiring of each node does not matter. Distributed wiring can be done nearby according to the on-site situation, and the control rights are divided only by the network topology structure, which greatly solves the problem of complex wiring harnesses. In addition, both the master station controller 10 and the secondary master station controller 20 can be equipped with axis modules, input / output modules, object detection and recognition modules, etc., which greatly improves the scalability of the system. The equipment can be wired nearby to reduce on-site wiring harnesses.

[0048] In a possible implementation, the setting method further includes:

[0049] High-speed transmission channels are configured between the master station controller and the first servo controller, between the master station controller and the secondary master station controller, and between the secondary master station controller and the second servo controller.

[0050] Specifically, DMA controllers are configured between the master controller 10 and the first servo driver 30, between the master controller 10 and the secondary master controller 20, and between the secondary master controller 20 and the second servo driver 40 to establish a high-speed data transmission channel and improve the data transmission rate.

[0051] In a possible implementation, the setting method further includes: setting a network interruption time.

[0052] Specifically, the network interruption time is the update time of the motion control command data received by the servo drive. The network interruption time corresponds to the motion control scan operation cycle. The faster the interruption time, the faster the adjustment and the higher the responsiveness. The shorter the scan operation cycle, the shorter the system can receive new data in a shorter time and immediately adjust the control parameters according to this data, reducing the error caused by delay. In addition, a shorter interruption time also helps to improve the responsiveness of the system. Responsiveness refers to the time required for the system to generate the corresponding output action from receiving the input signal. When the interruption time is reduced, the motion control can recognize and respond to the input signal faster, thereby achieving instant control of the motor shaft. The network interruption time is generally set to 500 microseconds or 250 microseconds.

[0053] In a possible implementation, the setting method further includes:

[0054] Set the motor axes that need to move in real time to be controlled through motion control;

[0055] Set up motor axes that require non-real-time motion to be controlled via servo control.

[0056] Specifically, real-time motion refers to the motion of the motor shaft that has very strict time requirements, requires the system to respond quickly and execute accurately, and requires the motor shaft to reach the specified position or speed quickly and accurately while maintaining high stability and repeatability. The motor shaft that moves in real time is generally the motor shaft that needs to move in coordination with other motor shafts. The motor shaft that needs to move in real time is set to be controlled by the operation control DSP. Non-real-time motion refers to the motion that is not so strict in time requirements, allows time delays or errors within a certain range, does not cooperate with other motor shafts or perform complex movements, and the motor shaft that does not move in real time is controlled by servo control. Due to different control requirements, the control instructions received by each servo drive are different. When a motor shaft needs to stop the current motion immediately and switch to another motion state or perform a specific operation according to the change of the received control instruction to coordinate with other motor shafts, this control instruction is sent by the operation control DSP of the motion control, that is, the motor shaft is controlled by the motion control. When a motor shaft only needs to perform simple point motion according to the received control instruction, this control instruction is sent by the servo DSP of the servo control, that is, the motor is controlled by the servo control. That is, the control right of the motor shaft can be transferred.

[0057] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A distributed industrial Ethernet control system, characterized in that: include: A master station controller, the master station controller is used to send a first control instruction and a second control instruction; a plurality of secondary master station controllers, connected to the master station controller, configured to receive the second control instruction and generate a third control instruction according to the second control instruction; A plurality of first servo drivers, the plurality of first servo drivers are connected to the master station controller, the first servo drivers are used to receive the first control instruction, and the first control instruction is used to control the plurality of first servo drivers; A plurality of groups of second servo drivers, the plurality of groups of second servo drivers correspond one to one with the plurality of sub-master station controllers, each group of the second servo drivers is a plurality of the second servo drivers, each group of the plurality of the second servo drivers is connected to a corresponding sub-master station controller, the plurality of groups of the second servo drivers are used to receive the third control instructions, and the third control instructions are used to control the plurality of groups of the second servo drivers; Among them, the control of the first servo driver by the master station controller is servo control and motion control, and the control of the second servo driver by the secondary master station controller is servo control and motion control; the servo control is used to control the movement of a single motor shaft, and the motion control is used to control the coordinated movement between motor shafts.

2. A distributed industrial Ethernet control system according to claim 1, characterized in that: The distributed industrial Ethernet control system also includes: A high-speed transmission channel is used for transmitting instructions between the master station controller and the first servo controller, between the master station controller and the sub-master station controller, and between the sub-master station controller and the second servo controller.

3. A distributed industrial Ethernet control system according to claim 1, characterized in that: The distributed industrial Ethernet control system adopts the gLink-II technology of the iso-ring network.

4. A distributed industrial Ethernet control system according to claim 2, characterized in that: The servo control sends control instructions through network point-to-point communication, and the motion control sends control instructions through an interrupt mechanism preset in a high-speed transmission channel.

5. A distributed Ethernet control system setting method, characterized in that: The distributed Ethernet control system as claimed in any one of claims 1 to 4 comprises: Determine a master station controller, a secondary master station controller, a first servo drive, and a second servo drive; Determine a path for sending instructions between the master station controller, the secondary master station controller, the first servo driver, and the second servo driver; Setting the control of the first servo driver by the master controller to servo control and motion control, and setting the control of the servo driver by the secondary master controller to servo control and motion control, and determining that the servo control controls the motion of a single motor shaft, and the motion control controls the coordinated motion between the motor shafts; The servo driver is set to drive the corresponding motor shaft to move according to the received control command.

6. A distributed Ethernet control system setting method according to claim 5, characterized in that: The setting method also includes: High-speed transmission channels are configured between the master station controller and the first servo controller, between the master station controller and the secondary master station controller, and between the secondary master station controller and the second servo controller.

7. A distributed Ethernet control system setting method according to claim 5, characterized in that: The setting method also includes: setting a network interruption time.

8. A distributed Ethernet control system setting method according to claim 5, characterized in that: The setting method further includes: Set the motor axes that need to move in real time to be controlled through motion control; Set up motor axes that require non-real-time motion to be controlled via servo control.

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