Tobacco-making production time synchronous control system based on NTP

Abstract

The invention discloses an NTP-based cut tobacco production time synchronization control system, and the system comprises an enterprise-level time server which is used for obtaining UTC time through double time sources and converting the UTC time into Beijing time, and the UTC time serves as a system time reference source; the workshop-level high-precision clock server is used for keeping time synchronization with the enterprise-level time server according to a first preset frequency through an NTP protocol and sending an NTP message to the programmable logic controller through the NTP protocol; the programmable logic controller is used for analyzing the received NTP message and synchronizing a PLC system clock; and the cut tobacco making equipment controller is used for requesting and acquiring the PLC system clock time from the programmable logic controller according to a preset period, and acquiring the time deviation between the PLC system clock time and the local clock so as to calibrate the local clock. The system effectively solves the problem of time deviation of cut tobacco making equipment.

Description

Technical Field

[0001] This invention relates to the field of tobacco processing production control technology, and more specifically to an NTP-based time synchronization control system for tobacco processing production. Background Technology

[0002] In modern tobacco processing, the time parameters of key steps such as cutting, drying, and flavoring directly affect the physical properties and sensory quality of tobacco leaves. Currently, the following pain points exist in production sites:

[0003] Accumulated time deviation problem: Traditional equipment relies on local clocks to operate. After long-term operation, the time difference between monitoring screens can reach several seconds to tens of seconds, causing timing disorder when tracing process parameters and affecting the accuracy of batch quality analysis.

[0004] Manual calibration is inefficient: The method of manually modifying the equipment time requires operation on each machine and is affected by human error. In a large silk-making workshop with hundreds of machines, a single calibration takes more than 4 hours, which cannot meet the needs of continuous production.

[0005] Data traceability obstacles: Time asynchrony causes production data (such as temperature curves and material flow rates) to be misaligned with the actual timeline, making it difficult to construct a complete process execution timeline and increasing the difficulty of locating quality anomalies.

[0006] Therefore, how to solve the time deviation problem of the silk-making equipment, reduce the time error of the entire production line, and improve the reliability of production data and the accuracy of process control are problems that urgently need to be solved by those skilled in the art. Summary of the Invention

[0007] In view of the above problems, the present invention provides an NTP-based yarn production time synchronization control system to at least solve some of the technical problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] This invention provides an NTP-based time synchronization control system for silk production, comprising: an enterprise-level time server, a workshop-level high-precision clock server, a programmable logic controller, and a silk production equipment controller;

[0010] The enterprise-level time server is used to obtain UTC time from dual time sources and convert it to Beijing time as the system's time reference source.

[0011] The workshop-level high-precision clock server is used to maintain time synchronization with the enterprise-level time server at a first preset frequency via the NTP protocol, and simultaneously send NTP messages to the programmable logic controller via the NTP protocol.

[0012] The programmable logic controller is used to parse the received NTP messages and synchronize the PLC system clock;

[0013] The wire-making equipment controller is used to request and obtain the PLC system clock time from the programmable logic controller according to a preset cycle, and to obtain the time deviation between the PLC system clock time and the local clock to calibrate the local clock.

[0014] Furthermore, the dual time sources include an Internet NTP server and a local BeiDou clock.

[0015] Furthermore, the programmable logic controller is also used to collect silk production parameters in real time and associate the collected data with the synchronized timestamp for use by the silk production equipment controller or host computer.

[0016] Furthermore, the NTP protocol includes a three-level time layering; specifically:

[0017] The enterprise-level time server is used as a primary time node, directly associated with a standard time source; the workshop-level high-precision clock server is used as a secondary time node; and the programmable logic controller is used as a tertiary time node.

[0018] Each time node records the sending time, receiving time, server response time, and client receiving time of the NTP message.

[0019] Furthermore, in the controller of the silk-making equipment, the local clock is dynamically adjusted by calculating the time deviation and combining it with the Kalman filter algorithm.

[0020] Furthermore, the time deviation Δt is expressed as:

[0021] Δt=[(T2-T1)+(T3-T4)] / 2

[0022] Where T1 represents the NTP message sending time; T2 represents the NTP message receiving time; T3 represents the server response time; and T4 represents the client receiving time.

[0023] Furthermore, if the time deviation exceeds a preset range, the system automatically triggers a level three alarm:

[0024] 1) A pop-up notification appears on the host computer.

[0025] 2) Send SMS alerts to maintenance personnel;

[0026] 3) Activate the backup clock source switching mechanism.

[0027] Furthermore, it also includes the host computer;

[0028] The host computer synchronizes with the workshop-level high-precision clock server at a second preset frequency and performs system time calibration through the time service interface provided by the operating system.

[0029] Furthermore, it also includes a timestamp database;

[0030] The timestamp database is used to record the material input time, process parameter change time, and equipment start-up and shutdown time of each yarn-making process at the millisecond level. It supports backtracking the production process by time axis and generating OEE analysis reports that include the time dimension.

[0031] As can be seen from the above technical solution, compared with the prior art, the present invention discloses an NTP-based yarn production time synchronization control system, which has the following beneficial effects:

[0032] This invention achieves high-precision time calibration of various equipment in the tobacco processing production line by constructing a hierarchical time synchronization architecture, which is suitable for tobacco processing scenarios with strict requirements for time consistency.

[0033] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the NTP-based yarn production time synchronization control system framework provided in an embodiment of the present invention.

[0036] Figure 2 A schematic diagram of the login page for the NTP-based yarn production time synchronization control system provided in an embodiment of the present invention. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example 1:

[0039] This invention discloses an NTP-based yarn production time synchronization control system, see [link to relevant documentation]. Figure 1 and Figure 2 As shown, it includes: an enterprise-level time server, a workshop-level high-precision clock server, a programmable logic controller (PLC), and a silk-making equipment controller; wherein:

[0040] An enterprise-grade time server is used to obtain UTC time from dual time sources and convert it to Beijing time as the system's time reference source.

[0041] Workshop-level high-precision clock server, used to maintain time synchronization with enterprise-level time server at a first preset frequency via NTP protocol, and to send NTP messages to programmable logic controller via NTP protocol;

[0042] A programmable logic controller (PLC) is used to parse received NTP messages and synchronize the PLC system clock.

[0043] The silk-making equipment controller is used to request and obtain the PLC system clock time from the programmable logic controller according to a preset cycle, and to obtain the time deviation between the PLC system clock time and the local clock to calibrate the local clock.

[0044] This system achieves high-precision time calibration of various devices in the tobacco processing production line by constructing a hierarchical time synchronization architecture, making it suitable for tobacco processing scenarios with strict time consistency requirements. The following is a detailed explanation of the above:

[0045] 1. This system adopts a four-level time synchronization architecture, and the functions of each component are as follows:

[0046] (1) Enterprise-level time server: As the system time reference source, it obtains UTC time through dual time sources (Internet NTP server + local Beidou clock), converts it to Beijing time (UTC+8 in East 8 zone) through time zone, and supports hot standby switching to ensure the stability of the time source.

[0047] (2) Workshop-level high-precision clock server: integrates GPS / Beidou dual-mode receiving module, provides time signal with an accuracy of 1μs, and maintains time synchronization with enterprise-level time server at a first preset frequency (e.g., once every 10 minutes) via industrial Ethernet according to NTP protocol. At the same time, it sends NTP messages to the lower-level programmable logic controller via NTP protocol.

[0048] (3) Programmable Logic Controller (PLC): As a time relay node for field devices, it receives NTP messages from the workshop-level high-precision clock server, synchronizes its own system time through the Modbus protocol, and collects filament production parameters such as roller speed and steam pressure in real time, with a timestamp accuracy of 1ms.

[0049] (4) Wire making equipment controller: a PLC or embedded controller including terminal equipment such as wire cutter and wire dryer, which requests and obtains the PLC system clock time from the upper PLC according to a preset cycle (default 5 minutes), and obtains the time deviation between the PLC system clock time and the local clock, so as to calibrate the local clock through hardware timer to ensure that the action time of the actuator is completely matched with the process formula.

[0050] 2. NTP time synchronization mechanism:

[0051] The aforementioned NTP protocol includes a three-level time layer (Stratum0-2); specifically: an enterprise-level time server is used as the first-level time node (Stratum1), directly associated with a standard time source; a workshop-level high-precision clock server is used as the second-level time node (Stratum2); and a programmable logic controller is used as the third-level time node (Stratum3); and a symmetrical time interaction algorithm is used to reduce the impact of network latency.

[0052] Each time node records the sending time, receiving time, server response time, and client receiving time of NTP packets;

[0053] In the controller of the silk-making equipment, the local clock is dynamically adjusted by calculating the time deviation and combining it with the Kalman filter algorithm; the time deviation Δt is expressed as:

[0054] Δt=[(T2-T1)+(T3-T4)] / 2

[0055] Where T1 represents the NTP packet sending time; T2 represents the NTP packet receiving time; T3 represents the server response time; and T4 represents the client receiving time.

[0056] If the time deviation exceeds the preset range, the system will automatically trigger a three-level alarm: 1) a pop-up notification on the host computer; 2) an SMS alarm sent to the maintenance personnel; 3) the activation of the backup clock source switching mechanism.

[0057] Example 2:

[0058] In Embodiment 2 of the present invention, based on Embodiment 1 above, a host computer (SCADA system) is also included; the host computer synchronizes with the workshop-level high-precision clock server at a second preset frequency, and performs system time calibration through the time service interface provided by the operating system (e.g., Windows Time Service Interface) to ensure that the time displayed on the HMI screen is consistent with that of the field equipment.

[0059] Example 3:

[0060] Embodiment 3 of the present invention, based on Embodiment 2 above, further includes a timestamp database; this timestamp database is used to record the material input time, process parameter change time, and equipment start-up and shutdown time of each yarn-making process at the millisecond level, supporting backtracking of the production process along the time axis and generating an OEE (Overall Equipment Effectiveness) analysis report containing the time dimension; the OEE analysis report is shown in Table 1:

[0061] Table 1: OEE Analysis Report

[0062]

[0063] Next, a specific embodiment will be used to illustrate the NTP-based yarn production time synchronization control system provided in this application.

[0064] 1. System deployment process:

[0065] (1) Hardware installation:

[0066] Enterprise servers (2U rack-mount, dual power supply redundancy) are deployed in the central control room, workshop servers (supporting a wide temperature range of -20℃ to 70℃) are installed in the workshop sub-control rooms, and field PLCs are installed in control cabinets with an IP65 protection rating.

[0067] The network configuration adopts a three-layer switch architecture, isolating the time synchronization data stream from the production control data stream, and setting VLAN priority to ensure that the time message transmission delay is ≤5ms.

[0068] (2) Software configuration:

[0069] Enterprise servers deploy NTPServer software (such as Chrony) and configure a primary NTP server (ntp.aliyun.com) and a backup Beidou clock interface; workshop servers enable the PTP (IEEE 1588) protocol to enhance synchronization accuracy.

[0070] 2. Calibration and Testing:

[0071] (1) Accuracy verification:

[0072] Ten typical pieces of equipment (shredder, shredder, flavoring machine) were continuously monitored for 24 hours using a time synchronization tester (such as Keysight 53132A). The results showed that:

[0073] The error between servers in the enterprise workshop is ≤500ns;

[0074] The error between workshop server PLCs is ≤2μs;

[0075] The maximum time difference between terminal devices is ≤8ms;

[0076] (2) Exception handling:

[0077] When a time deviation exceeding 10ms is detected, the system automatically triggers a level three alarm:

[0078] 1) A pop-up notification appears on the host computer.

[0079] 2) Send SMS alerts to maintenance personnel;

[0080] 3) Activate the backup clock source switching mechanism;

[0081] 3. Production application scenarios:

[0082] (1) Batch timestamp management:

[0083] When each batch of tobacco leaves enters the production line, the system automatically generates a unique timestamp containing year / month / day / hour / minute / second / millisecond, which is linked to material flow records and process parameter change records to form a complete digital twin timeline.

[0084] (2) Preventive maintenance:

[0085] By analyzing the drift trend of the device's clock crystal oscillator, the lifespan of the clock module can be predicted in advance. When the drift rate exceeds 5ppm, a maintenance work order is automatically generated to prompt the replacement of hardware.

[0086] In summary, the embodiments of the present invention solve the time deviation problem of the silk-making equipment by constructing an NTP-based silk-making production time synchronization control system, achieving a time error of ≤10ms for the entire production line, and improving the reliability of production data and the accuracy of process control.

[0087] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0088] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A time synchronization control system for yarn production based on NTP, characterized in that, include: Enterprise-level time servers, workshop-level high-precision clock servers, programmable logic controllers, and silk-making equipment controllers; The enterprise-level time server is used to obtain UTC time from dual time sources and convert it to Beijing time as the system's time reference source. The workshop-level high-precision clock server is used to maintain time synchronization with the enterprise-level time server at a first preset frequency via the NTP protocol, and simultaneously send NTP messages to the programmable logic controller via the NTP protocol. The programmable logic controller is used to parse the received NTP messages and synchronize the PLC system clock; The wire-making equipment controller is used to request and obtain the PLC system clock time from the programmable logic controller according to a preset cycle, and to obtain the time deviation between the PLC system clock time and the local clock to calibrate the local clock.

2. The NTP-based yarn production time synchronization control system according to claim 1, characterized in that, The dual time sources include an Internet NTP server and a local BeiDou clock.

3. The NTP-based yarn production time synchronization control system according to claim 1, characterized in that, The programmable logic controller is also used to collect silk production parameters in real time and associate the collected data with the synchronized timestamp for use by the silk production equipment controller or host computer.

4. The NTP-based yarn production time synchronization control system according to claim 1, characterized in that, The NTP protocol includes three levels of time layering; specifically: The enterprise-level time server is used as a primary time node, directly associated with a standard time source; the workshop-level high-precision clock server is used as a secondary time node; and the programmable logic controller is used as a tertiary time node. Each time node records the sending time, receiving time, server response time, and client receiving time of the NTP message.

5. The NTP-based yarn production time synchronization control system according to claim 4, characterized in that, In the controller of the silk-making equipment, the local clock is dynamically adjusted by calculating the time deviation and combining it with the Kalman filter algorithm.

6. The NTP-based yarn production time synchronization control system according to claim 4, characterized in that, The time deviation Δt is expressed as: Δt=[(T2-T1)+(T3-T4)] / 2 Where T1 represents the NTP message sending time; T2 represents the NTP message receiving time; T3 represents the server response time; and T4 represents the client receiving time.

7. The NTP-based yarn production time synchronization control system according to claim 1, characterized in that, If the time deviation exceeds the preset range, the system will automatically trigger a level three alarm: 1) A pop-up notification appears on the host computer. 2) Send SMS alerts to maintenance personnel; 3) Activate the backup clock source switching mechanism.

8. The NTP-based yarn production time synchronization control system according to claim 1, characterized in that, It also includes the host computer; The host computer synchronizes with the workshop-level high-precision clock server at a second preset frequency and performs system time calibration through the time service interface provided by the operating system.

9. The NTP-based yarn production time synchronization control system according to claim 1, characterized in that, It also includes a timestamp database; The timestamp database is used to record the material input time, process parameter change time, and equipment start-up and shutdown time of each yarn-making process at the millisecond level. It supports backtracking the production process by time axis and generating OEE analysis reports that include the time dimension.

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