Data acquisition device and data acquisition method based on Bergai programmable controller

Abstract

The invention relates to a data acquisition device and a data acquisition method based on a Bergai programmable controller. The data acquisition device comprises a production equipment flow control unit, a switch and an acquisition server, the production equipment flow control unit comprises a plurality of Bergai programmable controllers; the acquisition server is an industrial server containing an acquisition program; and the Bellyfish programmable controller, the acquisition server and the switch are connected through network cables. The acquisition method comprises the following steps: acquiring a data structure of data information of a Bergai programmable controller in a production equipment flow control unit to obtain a global variable and a task internal variable; and transmitting and storing the global variable and the task internal variable in a data server through an acquisition program in an acquisition server. According to the Bergai programmable controller, the switch and the acquisition server, data acquisition of the production equipment is realized through direct acquisition, the data manageability of the production equipment is enhanced, and the read data is uniformly stored and managed according to variable names under the condition of traditional data dispersion.

Description

Technical Field

[0001] This invention relates to the technical field of Industrial Internet of Things (IIoT) and industrial automation data acquisition, and particularly to a data acquisition device and method based on B&R programmable controllers. Background Technology

[0002] In the traditional pipeline industry, production equipment operates independently, and data is not interconnected, forming data silos with production equipment as the main body.

[0003] Currently, in the pipeline industry, gas pipeline production equipment typically uses Battenfeld Cincinnati extruders according to industry standards. These extruders use B&R Programmable Logic Controllers (PLCs). Because B&R PLCs have their own proprietary PVI protocol for communication, and the data in B&R PLCs is stored in the PLC's memory address, it is impossible to obtain the data in the B&R PLC by reading the PLC address using a method similar to the publicly available Modbus protocol.

[0004] High-end equipment manufacturers such as Battenfeld Cincinnati, Rieter Textile Machinery, and Modan, relying on B&R's closed-loop technology, strongly require manufacturers to use the OPC UA protocol and charge high data acquisition licensing fees. The licensing fee for a single OPC solution can be as high as ¥15,000+ per device.

[0005] To achieve the data acquisition objective, a compromise solution using a relay PLC was adopted for B&R data acquisition, as follows: A data acquisition device based on a B&R programmable controller is provided, which connects to the B&R PLC on the production line through a second B&R PLC as a relay. Since the relay PLC has configuration rights, it can convert the data into common Modbus data or other communication protocols and transmit it to the server for storage.

[0006] This plan has the following drawbacks:

[0007] 1. A relay PLC must be installed. When the IP addresses of foreign devices are all fixed values ​​and cannot be changed, a relay PLC must be installed for each single device, resulting in high data acquisition costs.

[0008] 2. Data acquisition is delayed due to the relay PLC, resulting in a loss of real-time industrial data.

[0009] 3. Data needs to be programmed and converted in the relay PLC, making it impossible to write to the production equipment PLC in real time, and thus impossible to achieve flexible control of the equipment through algorithms. Summary of the Invention

[0010] The present invention aims to address the shortcomings of the prior art by providing a data acquisition device and data acquisition method based on a B&R programmable controller.

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] A data acquisition device based on B&R programmable controllers includes a production equipment process control unit, a switch, and a data acquisition server.

[0013] The production equipment process control unit includes multiple B&R programmable controllers;

[0014] The data acquisition server is an industrial server containing data acquisition software;

[0015] The B&R programmable controller in the process control unit of the production equipment is connected to the switch via a network cable; the data acquisition server is also connected to the switch via a network cable.

[0016] The data acquisition server is configured as follows:

[0017] The data structure for acquiring data information from the B&R programmable controller in the process control unit of the production equipment is used to acquire the same data information from the acquisition server, forming a data block, and custom variable names are assigned to the data block.

[0018] The data structure of B&R programmable controller data information includes B&R global variables and task-specific variables.

[0019] The custom variable name set by the acquisition server for the data block may be the same as or different from the original variable name of the data block.

[0020] B&R programmable logic controllers, switches, and data acquisition servers acquire data from production equipment through direct data acquisition. The acquired data is stored and managed uniformly by variable name and published in MQTT / MODBUS / OPCUA format.

[0021] The data acquisition method of the B&R programmable controller-based data acquisition device described above includes the following steps:

[0022] S1. Obtain the data structure of the B&R programmable controller in the process control unit of the production equipment. Obtain the data information of the corresponding production equipment through the Automation Studio software provided by B&R and the information of the production equipment panel to obtain global variables and task-specific variables.

[0023] S2. Global variables and task-specific variables are transmitted and stored on the data server through the acquisition program in the acquisition server, and forwarded to the MQTT, OPCUA, and Modbus protocol servers to provide a unified reading interface for the host computer.

[0024] The production equipment panel in step S1 is a display used by the production equipment to display production equipment data and modify production equipment parameters.

[0025] The beneficial effects of this invention are: the data structure of this invention for acquiring data information from the B&R programmable controller in the process control unit of production equipment, and realizing data acquisition of production equipment through mapping, the B&R programmable controller, switch and acquisition server realize data acquisition of production equipment through direct acquisition, enhance the data manageability of production equipment, and in the case of traditional data dispersion, the read data is uniformly stored and managed according to variable name. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of the present invention;

[0027] In the picture:

[0028] 1-Production equipment process control unit; 2-Switch; 3-Data acquisition server;

[0029] 101 - B&R Programmable Controller;

[0030] The following will describe in detail, with reference to the accompanying drawings, embodiments of the present invention. Detailed Implementation

[0031] The principles and features of the present invention are described below with reference to the accompanying drawings. The embodiments given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0032] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0033] The purpose of this invention is to overcome the technical problem that data in B&R PLCs cannot be collected by reading PLC addresses using traditional methods.

[0034] To achieve the above objectives, the present invention adopts the following technical solution:

[0035] Data acquisition devices based on B&R programmable controllers, such as Figure 1 As shown, it includes a production equipment process control unit 1, a switch 2, and a data acquisition server 3.

[0036] The production equipment process control unit 1 includes multiple B&R programmable controllers 101.

[0037] The production equipment uses a B&R programmable controller 101 as the process control unit 1. The B&R PLC has its own proprietary protocol for communication, and the data in the B&R PLC is stored in the PLC memory address. B&R is a manufacturer in the field of automation technology. The B&R programmable controller does not have a Modbus communication function interface. Automation Studio is B&R's control software development platform, and the software can run on B&R's PC-based controllers.

[0038] Data acquisition server 3 is an industrial server containing data acquisition software.

[0039] The B&R programmable controller 101 of the production equipment process control unit 1 is connected to the switch 2 via a network cable; the data acquisition server 3 is connected to the switch 2 via a network cable.

[0040] Data acquisition server 3 is configured as follows:

[0041] The data structure for acquiring data information from the B&R programmable controller 101 in the process control unit 1 of the production equipment is obtained. The acquisition server 3 constructs the same data information to form a data block, and the data block is assigned a custom variable name.

[0042] The data structure of the B&R programmable controller 101 includes B&R global variables and task-specific variables.

[0043] The custom variable name set by the acquisition server 3 for the data block may be the same as or different from the original variable name of the data block.

[0044] B&R programmable controller 101, switch 2, and acquisition server 3 realize data acquisition from production equipment through direct acquisition, enhance the data manageability of production equipment, and in the case of traditional data being scattered, the read data is uniformly stored and managed according to variable names and published in MQTT / MODBUS / OPCUA format.

[0045] The data acquisition method of the B&R programmable controller-based data acquisition device described above includes the following steps:

[0046] S1. Obtain the data structure of B&R programmable controller 101 in the process control unit 1 of the production equipment. Obtain the data information of the corresponding production equipment through the Automation Studio software and the information of the production equipment panel provided by B&R, and obtain global variables and intra-task variables.

[0047] The production equipment panel is a display used to show production equipment data and modify production equipment parameters.

[0048] S2. Global variables and task-specific variables are transmitted and stored on the data server through the acquisition program in the acquisition server 3, and forwarded to the MQTT, OPCUA, and Modbus protocol servers to provide a unified reading interface for the host computer.

[0049] The production equipment can be that of Battonfield Cincinnati, including equipment such as extruders and vacuum chambers.

[0050] Of course, production equipment is not limited to extrusion and printing equipment; it can also be used in other production equipment that utilize B&R programmable controllers.

[0051] This invention provides a data structure for acquiring data information from the B&R programmable controller in the process control unit of production equipment. By mapping, it enables data acquisition from production equipment, enhances the manageability of production equipment data, and, in the case of traditionally scattered data, stores and manages the read data in a unified manner according to address order.

[0052] This invention provides a data acquisition device and method based on B&R programmable controllers. It is a relay-free industrial data direct acquisition and multi-protocol publishing system based on the B&R PVI protocol, including a production equipment process control unit 1, a switch 2, and a data acquisition server 3. The production equipment process control unit includes multiple B&R programmable controllers 101, and the data acquisition server 3 is an industrial server containing the acquisition program. The B&R programmable controllers 101 of the production equipment process control unit 1 are connected to the switch 2 via network cables. The data acquisition server 3 is also connected to the switch 2 via network cables. The system acquires the raw data structure of the data information from the B&R programmable controllers 101 in the production equipment process control unit 1 and converts it into MQTT, Modbus, or OPCUA communication protocol formats for easy acquisition by host computers such as SACADA, MESS, and ERP.

[0053] The above content is only for illustrating the technical concept of this application and should not be used to limit the scope of protection of this application. Any modifications made to the technical solution based on the technical concept proposed in this application shall fall within the scope of protection of the claims of this application.

[0054] Furthermore, unless expressly stated in the claims, the order of processing elements and sequences, the use of numbers and letters, or other names described in this application are not intended to limit the order of the processes and methods of this application. Although some embodiments that are currently considered useful have been discussed through various examples in the foregoing disclosure, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments. Rather, the claims are intended to cover all modifications and equivalent combinations that conform to the substance and scope of the embodiments of this application. For example, while the system components described above can be implemented by hardware devices, they can also be implemented solely by software solutions, such as installing the described system on existing servers or mobile devices.

[0055] Similarly, it should be noted that, in order to simplify the description of the present application and thus aid in the understanding of one or more embodiments, the foregoing description of the embodiments of the present application sometimes combines multiple features into a single embodiment, drawing, or description thereof. However, this disclosure method does not imply that the subject matter of the present application requires more features than those mentioned in the claims. In fact, the embodiments contain fewer features than all the features of the single embodiments disclosed above.

[0056] For each patent, patent application, patent application publication, and other material such as articles, books, specifications, publications, and documents referenced in this application, the entire contents of that patent are incorporated herein by reference. This excludes historical application documents that are inconsistent with or conflict with the content of this application, as well as documents that limit the broadest scope of the claims in this application (currently or subsequently appended to this application). It should be noted that if there are any inconsistencies or conflicts between the descriptions, definitions, and / or terminology used in the supplementary materials of this application and the content of this application, the descriptions, definitions, and / or terminology used in this application shall prevail.

Claims

1. Data acquisition device based on a B&R programmable controller, characterized in that The application relates to a production equipment data acquisition system, which comprises a production equipment process control unit (1), a switch (2) and an acquisition server (3). The production equipment process control unit (1) comprises a plurality of Beckhoff programmable controllers (101). The acquisition server (3) is an industrial server comprising an acquisition program. The Beckhoff programmable controllers (101) of the production equipment process control unit (1) are connected with the switch (2) through network cables; and the acquisition server (3) is connected with the switch (2) through network cables.

2. The data acquisition device based on a B&R programmable controller according to claim 1, characterized in that The acquisition server (3) is configured to: obtain the data structure of the data information of the Beckhoff programmable controllers (101) in the production equipment process control unit (1), build the same data information, form a data block, and set a custom variable name for the data block.

3. The data acquisition device based on a B&R programmable controller according to claim 2, characterized in that The data structure of the data information of the Beckhoff programmable controllers (101) comprises Beckhoff global variables and task internal variables.

4. The data acquisition device based on a B&R programmable controller according to claim 3, characterized in that The custom variable name set by the acquisition server (3) for the data block is the same as or different from the original variable name of the data block.

5. The data acquisition device based on a B&R programmable controller according to claim 4, characterized in that The Beckhoff programmable controllers (101), the switch (2) and the acquisition server (3) realize the data acquisition of the production equipment through direct acquisition, uniformly store and manage the read data according to the variable names, and publish the data in the form of MQTT / MODBUS / OPCUA.

6. The data acquisition method of a data acquisition device based on a B&R programmable controller according to claim 5, characterized in that, The specific steps are as follows: S1, obtaining the data structure of the data information of the Beckhoff programmable controllers (101) in the production equipment process control unit (1), obtaining the data information of the corresponding production equipment through the Automation Studio software provided by Beckhoff and the information of a production equipment panel, and obtaining global variables and task internal variables; S2, transmitting and storing the global variables and the task internal variables in a data server through an acquisition program in the acquisition server (3), and selecting to forward the data to an mqtt, opcua and modbus protocol server, so as to provide a unified reading interface for an upper computer.

7. The data acquisition method of a data acquisition device based on a B&R programmable controller according to claim 6, characterized in that, The production equipment panel in step S1 is a display used for displaying the data of the production equipment and modifying the parameters of the production equipment.

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