Centralized alarm system and method for production line linkage

Abstract

The centralized alarm system comprises an industrial personal computer, a hot area device and a finishing area device, the industrial personal computer is connected with the hot area device and the finishing area device through the Ethernet, the industrial personal computer uses WinCC software to access all PLC sites of a hot area and a finishing area on an Ethernet ring network according to a TCP / IP protocol, and the hot area device and the finishing area device are connected with the industrial personal computer. And meanwhile, the industrial personal computer utilizes a multi-CPU configuration technology to configure monitoring data of equipment operation by utilizing different IP addresses and integrate the monitoring data into a WinCC project on one industrial personal computer, so that a centralized alarm platform is constructed for monitoring, and centralized alarm is realized. When single equipment grid connection is implemented at the present stage, main signals and data of key areas such as pipe blanks, annular furnaces, perforation, continuous rolling, sizing, cold areas, pipe gang saws and straighteners are presented to the operation point inspectors through a large amount of software programming work by the point inspectors in a mode of erecting a centralized alarm platform; therefore, an operation point inspector can conveniently monitor the operation of the equipment for 24 hours, and the operation point inspector is guided to process the fault at the same time.

Description

Technical Field

[0001] The invention belongs to the technical field of metallurgical automatic production, and in particular to a centralized alarm system and method for production line linkage. Background Art

[0002] The production line industry refers to the industrial field that optimizes and manages the product production process through automation and intelligent technology. The core of the production line industry is to improve production efficiency, reduce costs, improve product quality, and achieve production flexibility and sustainability. The following are some key technologies and application examples of the production line industry:

[0003] Key technologies

[0004] Automation technology: Through robots, automated equipment and sensors, the production process can be automated to reduce manual intervention and improve production efficiency and consistency.

[0005] Intelligent technology: Use big data, cloud computing, artificial intelligence and other technologies to conduct real-time analysis and optimization of production data to achieve intelligent scheduling and decision-making.

[0006] Internet of Things Technology: Through the Internet of Things technology, the interconnection between devices can be realized, the production status can be monitored in real time, and the problems in production can be responded to quickly.

[0007] Lean production: adopt lean management concepts to optimize production processes, reduce waste, and improve production efficiency and flexibility.

[0008] The current production line industrial Ethernet adopts a ring topology structure, connecting the main PLC and industrial computer on the main rolling line to realize functions such as material tracking and point-to-point communication of the units. Since only some major equipment is connected to the Internet, other single equipment cannot communicate through Ethernet, highlighting the shortcomings of difficult data communication and decentralized equipment management.

[0009] The following problems occur in the current production line:

[0010] (1) Some single devices are not integrated into the industrial Ethernet, and data transmission is limited and slow. In particular, key single devices such as pipe gang saws, hydraulic stations, and fluid stations cannot be networked and centrally managed. Many equipment operation data are only communicated through DP couplers or hard lines, with slow transmission speeds and simple data structures, which cannot adapt to large-scale production tasks at this stage.

[0011] (2) Detailed data monitoring of equipment operation can only be viewed on the PC side of each operation station through HMI and S7 program, and it is impossible to achieve timely human-machine information interaction;

[0012] (3) When equipment fails, the operator cannot immediately understand the equipment's operating status. Usually, the fault phenomenon is described orally by the operator or recorded in curves, and the equipment status at the time of the failure cannot be accurately reproduced, resulting in a long fault judgment time and inaccurate judgment;

[0013] (4) Existing equipment management mainly relies on full-time inspectors to predict and manage the deterioration trend of equipment through the implementation of three major plans and other measures. However, there is a large gap in the professional level of personnel, and it is impossible to truly predict equipment failures. Summary of the invention

[0014] The purpose of the present invention is to overcome the shortcomings of the prior art and propose a centralized alarm system and method for production line linkage, which can maintain the stable operation of the power grid, quickly and accurately provide the optimal load transfer plan, greatly improve the work efficiency of dispatchers, and ensure the safe and stable operation of the power grid.

[0015] The present invention solves the technical problem by adopting the following technical solutions:

[0016] A centralized alarm system for production line linkage includes an industrial computer, hot zone equipment and finishing zone equipment, wherein the industrial computer is connected to the hot zone equipment and the finishing zone equipment via Ethernet respectively, and the industrial computer uses WinCC software to access various PLC sites of the hot zone and the finishing zone on the Ethernet ring network according to the TCP / IP protocol. At the same time, the industrial computer uses multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation of the finishing zone using different IP addresses, and integrates them into a WinCC project on an industrial computer.

[0017] Moreover, the hot zone equipment includes an annular furnace, a perforation area hydraulic station H1, a borax station, a graphite station and a hot zone fluid station, wherein the annular furnace realizes data exchange based on Profibus-DP with the perforation by adding a DP-DP-Coupler, and the annular furnace data is packaged and transmitted to the perforation PLC to realize communication. The perforation area hydraulic station H1 adds a communication module 6GK7343-1EX30-0XE0 on the PLC framework, which is connected to the Ethernet switch in the CS3 operating console network cabinet through a network cable, and the IP in the same network segment is set. The H1 hydraulic station can be accessed through Ethernet, and the borax station, graphite station, hot zone fluid station and hydraulic station communicate through Ethernet by expanding the Ethernet card of S7-300.

[0018] Moreover, the finishing area equipment includes the Profibus network of the pipe gang saw host, the Profibus network of the straightener host and the auxiliary machine Ethernet, and the three independently communicate a small amount of data through the SIEMENS coupler module; the existing network structure of the pipe gang saw and the straightener is modified, and the pipe gang saw and the straightener host are incorporated into the auxiliary machine network, and the auxiliary machine industrial computer is used as a redundant device for the pipe gang saw and the straightener host operation HMI. In the event of a failure of the pipe gang saw and the straightener host industrial computer, the auxiliary machine industrial control can be directly used as the host operation screen with zero delay, and data exchange between the host and the auxiliary machine is convenient and six communication module spare parts are saved. At the same time, the auxiliary machine industrial computer can be used to monitor the equipment parameters of the pipe gang saw and the straightener in real time without affecting production.

[0019] Moreover, the equipment parameters include the main motor current, the current of each servo motor, the pressure of each fixture and balance cylinder and the temperature index of the hydraulic station.

[0020] An alarm method for a centralized alarm system for production line linkage, comprising the following steps:

[0021] Step 1: Connect the industrial computer, hot zone equipment and finishing zone equipment via Ethernet;

[0022] Step 2: Write a visualization interface using WinCC software on the industrial computer to build a centralized alarm platform;

[0023] Step 3: According to the TCP / IP protocol, the centralized alarm platform communicates with each PLC and collects data centrally;

[0024] Step 4: Build a fault judgment expert system to judge the data. If it is judged that there is a problem with the data, an alarm will be issued, otherwise continue monitoring.

[0025] Moreover, the specific implementation method of step 2 is: the industrial computer uses WinCC software according to the TCP / IP protocol to access the PLC sites in the hot zone and the finishing zone on the Ethernet ring network. At the same time, the industrial computer uses multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation in the finishing zone using different IP addresses, and integrates them into a WinCC project on an industrial computer to obtain a centralized alarm platform.

[0026] Moreover, the specific implementation method of step 3 is: using the existing industrial Ethernet, through the TCP / IP protocol, the centralized alarm platform communicates with each PLC, in the WinCC software, different sites on the Ethernet are accessed through different IPs, so the PLCs with different IPs are configured to realize centralized data collection.

[0027] Moreover, the specific implementation method of step 4 is: build a fault judgment expert system to judge the data. If it is judged that there is a problem with the data, an alarm will be issued, otherwise monitoring will continue. At the same time, the equipment status is judged according to the data, and the fault points that occur are written into the alarm information, so as to guide the operation inspectors to handle the faults quickly and accurately.

[0028] The advantages and positive effects of the present invention are:

[0029] 1. The present invention includes an industrial computer, hot zone equipment and finishing zone equipment, wherein the industrial computer is connected to the hot zone equipment and the finishing zone equipment via Ethernet respectively, and the industrial computer uses WinCC software according to the TCP / IP protocol to access each PLC site of the hot zone and the finishing zone on the Ethernet ring network, and at the same time, the industrial computer uses multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation in the finishing zone using different IP addresses, and integrates them into a WinCC project on an industrial computer, and builds a centralized alarm platform for monitoring, thereby realizing centralized alarm. At this stage, while implementing the grid connection of single equipment, the inspector, through a large amount of software compilation work, presents the main signals and data of key areas such as pipe blanks, annular furnaces, perforation, continuous rolling, sizing, cold zones, pipe row saws, straightening machines, etc., to the operation inspector by setting up a centralized alarm platform, so that the operation inspector can monitor the operation of the equipment 24 hours a day, and guide the operation inspector to handle faults at the same time, and the time for handling faults is reduced by 5 minutes each time according to statistics.

[0030] 2. The present invention reduces the number of spare parts for terminal equipment and achieves timely and unified management of software backup. The shared device software backup requires the inspectors to perform it on a spare industrial computer, and the manager can achieve the timeliness of the backup by regularly checking the computer. At the same time, this spare machine can also be used as a field terminal device through simple settings. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 Schematic diagram of DP-DP-Coupler hardware configuration and network configuration of the present invention;

[0032] Figure 2 It is the monitoring interface of the centralized alarm platform of the present invention;

[0033] Figure 3 It is the data interface of the centralized alarm platform of the present invention;

[0034] Figure 4 This is a schematic diagram of the fault judgment expert system of the present invention. DETAILED DESCRIPTION

[0035] The present invention is further described in detail below with reference to the accompanying drawings.

[0036] A centralized alarm system for production line linkage includes an industrial computer, hot zone equipment and finishing zone equipment, wherein the industrial computer is connected to the hot zone equipment and the finishing zone equipment via Ethernet respectively, and the industrial computer uses WinCC software to access various PLC sites of the hot zone and the finishing zone on the Ethernet ring network according to the TCP / IP protocol. At the same time, the industrial computer uses multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation of the finishing zone using different IP addresses, and integrates them into a WinCC project on an industrial computer.

[0037] The hot zone equipment includes an annular furnace, perforation area hydraulic station H1, borax station, graphite station and hot zone fluid station.

[0038] Since the IP segment of the ring furnace PLC was set to be different from the industrial Ethernet at the beginning of installation and commissioning, Figure 1 As shown, a DP-DP-Coupler is installed in the annular furnace to realize data exchange based on Profibus-DP with the perforator, and the annular furnace data is packaged and transmitted to the perforator PLC to realize communication.

[0039] The hydraulic station H1 in the punching area was originally a single device. Its PLC and the main punching PLC only had hard-line point-to-point communication, and big data communication could not be achieved. Therefore, a communication module 6GK7343-1EX30-0XE0 was added to the PLC frame of the H1 hydraulic station, and connected to the Ethernet switch in the network cabinet of the CS3 operating console via a network cable. The IP in the same network segment was set, and the H1 hydraulic station could be accessed via Ethernet.

[0040] Borax station, graphite station, hot zone fluid station and hydraulic station expand the Ethernet card of S7-300, and upgrade step7 to version 5.5. After hardware configuration, download the program, and lay the network cable to the nearest network cabinet for Ethernet communication.

[0041] The equipment in the finishing area includes the Profibus network of the gang saw host, the Profibus network of the straightener host and the Ethernet of the auxiliary machine. The three independently communicate a small amount of data through the SIEMENS coupler module. The existing network structure of the gang saw and the straightener is modified, and the gang saw and the straightener host are incorporated into the auxiliary machine network. The auxiliary machine industrial computer is used as a redundant device for the gang saw and the straightener host operation HMI. In the event of a failure of the gang saw and the straightener host industrial computer, the auxiliary machine industrial control can be directly used as the host operation screen with zero delay, which facilitates data exchange between the host and the auxiliary machine and saves six communication module spare parts. At the same time, the auxiliary machine industrial computer can be used to monitor the equipment parameters of the gang saw and the straightener in real time without affecting production.

[0042] Moreover, the equipment parameters include the main motor current, the current of each servo motor, the pressure of each fixture and balance cylinder and the temperature index of the hydraulic station.

[0043] An alarm method for a centralized alarm system for production line linkage, comprising the following steps:

[0044] Step 1: Connect the industrial computer, hot zone equipment and finishing zone equipment via Ethernet.

[0045] Step 2: Use WinCC software to write a visualization interface on the industrial computer and build a centralized alarm platform.

[0046] like Figure 2 As shown, the industrial computer uses WinCC software according to the TCP / IP protocol to access each PLC site in the hot zone and finishing zone on the Ethernet ring network. At the same time, the industrial computer uses multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation in the finishing zone using different IP addresses, and integrates them into a WinCC project on an industrial computer to obtain a centralized alarm platform.

[0047] Step 3: According to the TCP / IP protocol, the centralized alarm platform communicates with each PLC and collects data centrally.

[0048] By using the existing industrial Ethernet and TCP / IP protocol, the centralized alarm platform can communicate with each PLC. In WinCC software, different sites on the Ethernet are accessed through different IPs. Therefore, PLCs with different IPs are configured to realize centralized data collection. At the same time, the monitoring points of the required monitoring equipment are clarified and the monitoring points are visualized, such as Figure 3 The picture shows the perforation and core rod circulation. Through the animation design of the picture, the operating status of the on-site equipment is reflected in real time.

[0049] Step 4: Build a fault judgment expert system to judge the data. If it is judged that there is a problem with the data, an alarm will be issued, otherwise continue monitoring.

[0050] like Figure 4 As shown, a fault judgment expert system is built to judge the data. If it is judged that there is a problem with the data, an alarm is issued, otherwise monitoring continues. At the same time, the equipment status is judged according to the data, and the fault points that occur are written into the alarm information, which is convenient for guiding the operation inspectors to quickly and accurately handle the faults.

[0051] At the same time, PT100 temperature measuring resistors are installed on key motors, and the temperature data is directly transmitted to the PLC and presented on the centralized alarm platform. For example, the motor of the capillary tube trolley cannot be inspected at close range due to the movement of the equipment. Therefore, PT100 temperature measuring resistors are installed on the load and non-load ends of the motor on the capillary tube trolley, and the temperature values ​​are input into the PLC through the analog input module. The temperature values ​​are reflected in real time on the centralized alarm platform, so that someone can monitor it 24 hours a day. At the same time, alarm values ​​are set for the temperature values, and timely alarms are issued if there are any abnormalities.

[0052] It should be emphasized that the embodiments described in the present invention are illustrative rather than restrictive. Therefore, the present invention includes but is not limited to the embodiments described in the specific implementation manner. Any other implementation manners derived by those skilled in the art based on the technical solution of the present invention also fall within the scope of protection of the present invention.

Claims

1. A centralized alarm system for production line linkage, characterized by: It includes industrial computers, hot zone equipment and finishing zone equipment. The industrial computers are connected to the hot zone equipment and the finishing zone equipment through Ethernet respectively. The industrial computers use WinCC software according to the TCP / IP protocol to access various PLC sites in the hot zone and the finishing zone on the Ethernet ring network. At the same time, the industrial computers use multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation in the finishing zone using different IP addresses, and integrate them into a WinCC project on an industrial computer.

2. A centralized alarm system for production line linkage according to claim 1, characterized in that: The hot zone equipment includes an annular furnace, a perforation area hydraulic station H1, a borax station, a graphite station and a hot zone fluid station, wherein the annular furnace realizes data exchange based on Profibus-DP with the perforation by installing a DP-DP-Coupler, and the annular furnace data is packaged and transmitted to the perforation PLC to realize communication. The perforation area hydraulic station H1 adds a communication module 6GK7343-1EX30-0XE0 on the PLC framework, and is connected to the Ethernet switch in the CS3 operating console network cabinet through a network cable, and the IP of the same network segment is set. The H1 hydraulic station can be accessed through Ethernet, and the borax station, graphite station, hot zone fluid station and hydraulic station communicate through Ethernet by extending the Ethernet card of S7-300.

3. The centralized alarm system for production line linkage according to claim 1 is characterized by: The finishing area equipment includes the Profibus network of the pipe gang saw host, the Profibus network of the straightener host and the auxiliary machine Ethernet. The three independently communicate a small amount of data through the SIEMENS coupler module; the existing network structure of the pipe gang saw and the straightener is modified, and the pipe gang saw and the straightener host are incorporated into the auxiliary machine network. The auxiliary machine industrial computer is used as a redundant device for the pipe gang saw and the straightener host operation HMI. In the event of a failure of the pipe gang saw and the straightener host industrial computer, the auxiliary machine industrial control is directly used as the host operation screen with zero delay, which facilitates data exchange between the host and the auxiliary machine and saves six communication module spare parts. At the same time, the auxiliary machine industrial computer is used to monitor the equipment parameters of the pipe gang saw and the straightener in real time without affecting production.

4. A centralized alarm system for production line linkage according to claim 3, characterized in that: The equipment parameters include the main motor current, the current of each servo motor, the pressure of each fixture and balance cylinder and the temperature index of the hydraulic station.

5. An alarm method for a centralized alarm system for production line linkage according to any one of claims 1 to 4, characterized in that: The following steps are involved: Step 1: Connect the industrial computer, hot zone equipment and finishing zone equipment via Ethernet; Step 2: Write a visualization interface using WinCC software on the industrial computer to build a centralized alarm platform; Step 3: According to the TCP / IP protocol, the centralized alarm platform communicates with each PLC and collects data centrally; Step 4: Build a fault judgment expert system to judge the data. If it is judged that there is a problem with the data, an alarm will be issued, otherwise continue monitoring.

6. The alarm method of the centralized alarm system for production line linkage according to claim 5 is characterized by: The specific implementation method of step 2 is: the industrial computer uses WinCC software according to the TCP / IP protocol to access each PLC site in the hot zone and the finishing zone on the Ethernet ring network. At the same time, the industrial computer uses multi-CPU configuration technology to configure the monitoring data of the key areas of the hot zone, such as perforation, continuous rolling and sizing, and the equipment operation in the finishing zone using different IP addresses, and integrates them into a WinCC project on an industrial computer to obtain a centralized alarm platform.

7. The alarm method of the centralized alarm system for production line linkage according to claim 5 is characterized by: The specific implementation method of step 3 is: using the existing industrial Ethernet, through the TCP / IP protocol, the centralized alarm platform communicates with each PLC, in the WinCC software, different sites on the Ethernet are accessed through different IPs, so the PLCs with different IPs are configured to realize centralized data collection.

8. The alarm method of the centralized alarm system for production line linkage according to claim 5 is characterized by: The specific implementation method of step 4 is: construct a fault judgment expert system to judge the data. If it is judged that there is a problem with the data, an alarm will be issued, otherwise monitoring will continue. At the same time, the equipment status is judged according to the data, and the fault points that occur are written into the alarm information to facilitate the guidance of the operation inspectors to quickly and accurately handle the faults.

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