Control system and control method for industrial plant

Abstract

The application relates to a control system and a control method of an industrial equipment. The system comprises a data acquisition unit, a service processing unit and an interaction unit; the data acquisition unit is in communication connection with an industrial controller of at least one industrial equipment, and is used for acquiring operation data of the at least one industrial equipment; the service processing unit is in communication connection with the data acquisition unit, and is used for accepting and processing the operation data collected by the data acquisition unit, and providing a service logic service; and the interaction unit is based on a browser / server (B / S) architecture, and is used for providing a visual operation interface for interacting with the service processing unit, so as to realize the control of the industrial equipment. The scheme provided by the application can solve the technical problems of poor cross-platform capability and limited remote access of the control system in the related art.

Description

Technical Field

[0001] This application relates to the field of industrial automation technology, and in particular to a control system and control method for industrial equipment. Background Technology

[0002] Industrial automation technology, as a core support for modern manufacturing, is widely used in the monitoring and management of various production equipment. During the operation of industrial equipment such as coating machines, real-time data acquisition, status monitoring, and remote operation are crucial for ensuring production continuity and product quality.

[0003] The equipment monitoring systems of related technologies generally adopt a client / server (C / S) architecture, which realizes data interaction by deploying dedicated client software in the factory's local area network. This solution relies on the local application installation of a specific operating system, and users need to operate on a fixed computer. When the system is expanded, a separate client needs to be configured for the new equipment and the software needs to be distributed. This results in high deployment and maintenance costs and limited cross-platform compatibility, making it difficult to meet the urgent needs for centralized equipment management and remote operation and maintenance in the industrial Internet environment. Summary of the Invention

[0004] To address or partially address the problems existing in related technologies, this application provides a control system and control method for industrial equipment, which can solve the technical problems of poor cross-platform capability and limited remote access in related technologies.

[0005] The first aspect of this application provides a control system for industrial equipment, comprising: A data acquisition unit is communicatively connected to the industrial controller of at least one industrial device and is used to collect the operating data of the at least one industrial device. The service processing unit is communicatively connected to the data acquisition unit, and is used to receive and process the running data collected by the data acquisition unit, and provide business logic services. The interaction unit, based on a browser / server (B / S) architecture, is used to provide a visual operation interface for interacting with the service processing unit in order to control the industrial equipment.

[0006] In one embodiment, the service processing unit includes a parameter management module; the parameter management module is configured to: Receive the target parameter value input by the user through the human-computer interaction interface of the interaction unit; Invoke the preset parameter constraint rules to determine whether the target parameter value meets the preset process safety range; After the verification is successful, a parameter writing instruction is generated and sent to the industrial controller.

[0007] In one implementation, after generating the parameter writing instruction and sending it to the industrial controller, the corresponding feedback parameter value is read from the industrial controller. The feedback parameter value is compared with the target parameter value; If the comparison results are inconsistent, an error alarm will be triggered; or, if they are consistent, the parameter writing will be confirmed as successful.

[0008] In one embodiment, the data acquisition unit includes a protocol conversion module; the protocol conversion module is configured as follows: The industrial communication protocol data used by the industrial controller is parsed into a common data format; The parsed general data format is converted into standard network protocol data suitable for transmission over wide area networks or local area networks.

[0009] In one embodiment, the service processing unit includes an action control module; the action control module is configured to: The human-computer interaction interface of the interactive unit provides device control controls; In response to the user's triggering operation on the device control controls, a security confirmation request is generated and displayed on the interactive terminal; After receiving confirmation from the user, the device generates an action command and transmits it to the execution unit to control the operation of the industrial equipment.

[0010] In one embodiment, the industrial equipment is an industrial coating machine, wherein: The equipment action commands include at least the die head forward command, die head backward command, or system reset command of the industrial coating machine; The action control module is configured to pop up the security confirmation request when the device action command is detected.

[0011] In one embodiment, the service processing unit further includes an alarm management module; the alarm management module is configured as follows: The system monitors the status data of the industrial equipment in real time, generates an alarm record when an anomaly is detected, and displays it on the human-machine interface of the interactive unit; it receives a user's reset request for the alarm record, generates an alarm reset command, and sends it to the industrial controller to clear the fault flag; and / or, The system also includes a data traceability module; the data traceability module is configured to: capture user modifications to equipment parameters, generate operation logs containing values ​​before and after the operation; and call a preset WebAPI interface to upload the operation logs to a remote database or manufacturing execution system.

[0012] A second aspect of this application provides a method for controlling industrial equipment, comprising: The data acquisition unit communicates with the industrial controller of the industrial equipment to collect the operating data of the industrial equipment in real time. Receive and process the operational data, and generate corresponding control instructions based on preset business logic; A visual operation interface is provided through an interaction unit based on a B / S architecture, which receives user operation commands and transmits the commands to the service processing unit to execute the corresponding control logic.

[0013] In one embodiment, receiving and processing the operational data, and generating corresponding control instructions based on preset business logic, includes: Receive the target parameter value input by the user and verify whether it is within the preset process safety range; After the verification is passed, the parameter writing command is generated and transmitted to the industrial controller; The feedback parameter values ​​are read from the industrial controller and compared with the target parameter values ​​for verification. If the verification passes, the device's operating settings are updated; if the verification fails, the exception handling mechanism is triggered.

[0014] In one embodiment, the real-time acquisition of the industrial equipment's operating data includes: The protocol conversion module parses the industrial communication protocol data used by the industrial controller into a general data format; it then converts the parsed general data format into communication protocol data suitable for wide area network or local area network transmission, and sends it to the service processing unit for processing; or, The step of providing a visual operation interface through a B / S architecture-based interactive unit, receiving user operation commands, and transmitting the commands to the service processing unit to execute corresponding control logic includes: A visual operation interface is provided through an interaction unit based on a B / S architecture. The interface accepts user trigger operations on the device control controls. A safety confirmation request is generated and a confirmation prompt is displayed on the interactive terminal. After receiving the user's confirmation response, the final device action command is generated and sent to the industrial controller.

[0015] The control system for industrial equipment provided in this application collects operational data through a data acquisition unit that communicates with the industrial controller of the industrial equipment. An interactive unit based on a browser / server (B / S) architecture provides a visual operating interface, while a service processing unit receives and processes the collected data to provide business logic services. By adopting a B / S architecture instead of the traditional C / S architecture, users can access the system through any browser without installing dedicated client software, solving the problem of limited user access. The service processing unit centrally processes data and provides business logic services, avoiding the need for multi-operating system adaptation and simplifying system maintenance. The layered design of the data acquisition unit and the service processing unit achieves functional decoupling; when adding new industrial equipment, only the data acquisition unit configuration needs to be expanded, without redistributing client software, significantly improving system scalability. This effectively improves the current situation of complex deployment and maintenance, insufficient flexibility, and poor scalability of traditional monitoring systems, realizing cross-platform, centralized, and lightweight management of remote monitoring of industrial equipment.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0017] The above and other objects, features and advantages of this application will become more apparent from the more detailed description of exemplary embodiments thereof in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same components in the exemplary embodiments thereof.

[0018] Figure 1 This is a schematic diagram of the control system modules shown in an embodiment of this application; Figure 2 This is a schematic diagram of another module of the control system shown in the embodiments of this application; Figure 3 This is a schematic diagram of the human-computer interaction interface of the interaction unit shown in the embodiments of this application; Figure 4 This is another schematic diagram of the human-computer interaction interface of the interaction unit shown in the embodiments of this application; Figure 5 This is another schematic diagram of the human-computer interaction interface of the interaction unit shown in the embodiments of this application; Figure 6 This is a schematic flowchart illustrating the control method in an embodiment of this application; Figure 7 This is another schematic flowchart illustrating the control method in an embodiment of this application. Detailed Implementation

[0019] Preferred embodiments of the present application will now be described in more detail with reference to the accompanying drawings. While preferred embodiments of the present application are shown in the drawings, it should be understood that the present application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to make the present application more thorough and complete, and to fully convey the scope of the present application to those skilled in the art.

[0020] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The singular forms “a,” “the,” and “the” used in this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0021] It should be understood that although the terms "first," "second," "third," etc., may be used in this application to describe various information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0022] In the description of this application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0023] Unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances. To address the above-mentioned problems, this application provides a control system and control method for industrial equipment, which can solve the technical problems of poor cross-platform capability and limited remote access in related technologies.

[0024] The technical solutions of the embodiments of this application are described in detail below with reference to the accompanying drawings.

[0025] Figure 1 This is a schematic diagram of the control system modules shown in an embodiment of this application.

[0026] See Figure 1 This application provides a control system 100 for industrial equipment, including a data acquisition unit 101, a service processing unit 102, and an interaction unit 103. The data acquisition unit 101 is communicatively connected to the industrial controller of at least one industrial device 104 and is used to acquire the operating data of the at least one industrial device 104. The service processing unit 102 is communicatively connected to the data acquisition unit 101 and is used to receive and process the operating data acquired by the data acquisition unit 101 and provide business logic services. The interaction unit 103 is based on a browser / server (B / S) architecture and is used to provide a visual operation interface for interacting with the service processing unit 102 to realize the control of the industrial device 104.

[0027] The industrial equipment 104 of this application can be an industrial coating machine for lithium battery manufacturing. Its industrial controller can be a programmable logic controller (PLC), an industrial PC, or an embedded motion controller. The industrial controller is used to execute the coating process logic control, including temperature closed-loop regulation, constant tension control, speed synchronization coordination, and die gap servo positioning. The operating data of the industrial coating machine (such as real-time oven temperature, unwinding tension value, coating line speed, die gap feedback value, and alarm status bits) is output externally through an industrial fieldbus or Ethernet interface.

[0028] The data acquisition unit 101 can refer to an embedded gateway device or industrial control computer deployed at the edge of the industrial site, which establishes a communication connection with the industrial controller through an interface. After establishing a stable communication connection with the controller, the data acquisition unit 101 periodically polls or collects the operating data of the industrial equipment based on event triggering. The types of data collected include, but are not limited to, analog quantities (such as temperature, pressure, and speed), digital quantities (such as emergency stop signals, operating status, and fault flags), and structured data blocks (such as recipe parameter groups and historical alarm records).

[0029] Service processing unit 102 can refer to an application service cluster deployed on a cloud server, private data center or factory local server. Service processing unit 102 is a collection of microservices including real-time data service, alarm monitoring module, set value management module, equipment action control module, user authentication and permission management module and data persistence module. Each module can communicate loosely coupled through internal RESTful API or message queue.

[0030] The business logic services provided by the service processing unit 102 can be receiving standardized data streams from the data acquisition unit 101, performing business logic such as data cleaning, anomaly filtering, threshold comparison, alarm triggering, instruction generation, and log recording, and providing a structured API interface to the interaction unit 103. The service processing unit 102 and the data acquisition unit 101 can adopt a hybrid communication architecture, in which the real-time data channel is based on the MQTT protocol to achieve a low-latency, high-concurrency publish / subscribe mode, and the business data channel is based on the HTTPS protocol Web API to achieve instruction issuance with authentication and transaction semantics.

[0031] The interaction unit 103 in this application can refer to a responsive web application developed based on the ASP.NET Web Forms or Vue.js framework. Its front-end page accesses the RESTful API interface provided by the service processing unit 102 through the standard HTTP(S) protocol. Specifically, the interaction unit 103 is an adaptive interface adapted to terminal devices (such as computers, tablets, and industrial touch screens). The main functional modules of its human-machine interface can include a real-time monitoring and alarm interface, a setpoint modification interface, a device action control interface, and a historical data query interface. The interaction unit 103 is used to render the JSON data returned by the service processing unit 102 into visual elements that conform to human factors engineering specifications, such as displaying the status of the A / B head die of the industrial coating machine in a dynamic table, displaying the oven temperature in a colored progress bar, and pushing critical alarms in the form of pop-up windows.

[0032] In some specific embodiments, the communication method of the control system of this application is as follows: the industrial controller of the industrial coating machine continuously collects data from the sensors of the coating machine body and sends the raw messages to the data acquisition unit 101 via Ethernet. The data acquisition unit 101 parses the S7 protocol, extracts fields such as temperature, speed, and position of the industrial coating machine, encapsulates them into a JSON message with a timestamp, and publishes it to the topic ` / device / 123456 / status` via the MQTT protocol. The service processing unit 102 subscribes to this topic, stores the received message in the time series database, and triggers the alarm rule engine for real-time analysis. When a user accesses the interaction unit 103 through any terminal browser, the interaction unit 103 sends a GET request to the service processing unit 102 to obtain the latest status data. The service processing unit 102 reads from the Redis cache and returns the data. After the user inputs new parameters on the setting modification interface of the interactive unit, the front end constructs a POST request and submits it to the ` / api / parameter / write` interface. The service processing unit 102 verifies the user's permissions and process safety scope. After the verification is successful, it generates a parameter writing instruction, which is forwarded to the industrial controller by the data acquisition unit 101. The industrial controller executes the writing and returns a feedback value. The data acquisition unit 101 captures the feedback and publishes it to the ` / device / 123456 / feedback` topic. The service processing unit 102 subscribes to this topic to complete the closed-loop verification.

[0033] The technical solution of this application embodiment avoids cross-platform compatibility issues and security risks caused by B / S front-end directly calling PLC drivers by setting the data acquisition unit 101 independently and communicating directly with the industrial controller, thus improving the deployment flexibility and operational stability of the system. Since the service processing unit 102 centrally carries all business logic, it realizes unified management and hot updates of control strategies, alarm rules and permission models, reducing the complexity of system maintenance. Since the interaction unit 103 is implemented based on the standard Web technology stack, users can access the monitoring interface instantly on any terminal (including mobile devices) with a browser, avoiding the limitations of C / S architecture on operation location and device type in related technologies, and significantly improving the efficiency of remote operation and maintenance response.

[0034] One possible implementation is, such as Figure 2 As shown, the service processing unit 102 includes a parameter management module 112. The parameter management module 112 is configured to: receive the target parameter value input by the user on the human-machine interface of the interaction unit 103, call the preset parameter constraint rules, determine whether the target parameter value meets the preset process safety range, and after the verification is passed, generate a parameter writing instruction and send it to the industrial controller.

[0035] The parameter management module 112 is a functional module in the service processing unit 102 that undertakes parameter verification and secure writing control logic. It can be deployed in the service layer server in software form to realize controlled modification of key process parameters of industrial equipment 104. The parameter management module 112 can communicate with the interaction unit 103 via HTTP / HTTPS protocol in a request-response manner, and communicate with the data acquisition unit 101 via MQTT topic subscription or Web API interface to issue instructions and synchronize status. It is used to transform the parameter modification operation initiated by the user terminal into a closed-loop control behavior with process safety guarantee, so as to avoid unverified parameters directly acting on the industrial controller, thereby preventing abnormal equipment operation or safety accidents caused by mis-input, out-of-bounds setting or illegal overwriting.

[0036] In this embodiment, the human-computer interaction interface 113 of the interaction unit 103 presents a structured parameter editing interface (e.g., a process parameter setting page in tabular form) to the user based on a B / S architecture. The operation triggered by the user entering values ​​in the corresponding fields and clicking the submit or save button is that the target parameter value can be any one or more process parameters such as coating speed setting value, die gap setting value, oven temperature setting value, or unwinding tension setting value. The parameter value is encapsulated in JSON format during transmission and carries parameter identifier, target device ID, and operator identity information.

[0037] The parameter management module can load a set of constraint rules bound to the current parameter identifier from a local configuration file or a relational database. This set of rules includes minimum value, maximum value, step value, allowable rate of change, dependencies between related parameters, and multi-condition combination logic. For example, when the target parameter is the die gap setting value, the constraint rule can be defined as: minimum value 0.05mm, maximum value 2.0mm, step 0.01mm, and must simultaneously meet the prerequisite condition that the current coating speed is <30m / min. When a user submits a parameter modification request in the browser, the interaction unit 103 encapsulates the target parameter value and context information (device ID, parameter identifier, operator account) into an HTTP POST request and sends it to the designated API endpoint of the service processing unit 102. Upon receiving the request, the parameter management module 112 first performs identity authentication and operation permission verification. Then, it queries the preset process safety constraint rules based on the parameter identifier and performs item-by-item verification of the target parameter value. If all verifications pass, a standardized write instruction object is generated and forwarded to the data acquisition unit 101 by the instruction distribution component within the service processing unit 102. After receiving the object, the data acquisition unit 101 calls the underlying driver to establish a connection with the industrial controller and performs the write operation according to the address and data type. The technical solution of this embodiment avoids the direct transmission of illegal parameter values ​​to the industrial controller by the parameter management module only after successful verification, thus preventing the technical problem of equipment malfunction or safety accidents caused by human error leading to process parameters exceeding limits.

[0038] In another optional embodiment, the parameter management module 112 is further configured to: after generating a parameter writing instruction and sending it to the industrial controller, read the corresponding feedback parameter value from the industrial controller; compare the feedback parameter value with the target parameter value; if the comparison result is inconsistent, trigger an abnormal alarm; if they are consistent, confirm that the parameter writing was successful.

[0039] The parameter management module can read the current value actually written and stored by the industrial controller. The read and write operations are sequentially determined in time and are not dependent on external triggers or timed polling mechanisms; they are driven by the parameter writing action itself. The read latency can be set with a timeout threshold based on network conditions and PLC responsiveness, for example, 500ms. A timeout is considered a communication anomaly. This mechanism is used in closed-loop verification scenarios for key process parameters such as coating speed settings and die gap settings to establish an observable basis for parameter command execution status, providing a basis for subsequent comparisons. The parameter management module performs a bit-by-bit or tolerance-range consistency check in the service processing unit 102 memory between the actual value read from the industrial controller and the target parameter value input and verified by the user in the human-machine interface of the interaction unit 103.

[0040] When the feedback parameter value and the target parameter value do not meet the preset consistency conditions, the parameter management module calls the standard interface provided by the alarm management module to generate a structured alarm record. The alarm record includes, but is not limited to: alarm timestamp, alarm type (parameter write failure), associated device identifier (e.g., coating machine A), parameter name (e.g., die gap setting value), target value, feedback value, difference value, and triggering module (parameter management module). This alarm record can be synchronously pushed to the human-machine interface of the interaction unit 103, providing real-time notification to the user in the form of a pop-up window or highlighted table row, and written to the alarm_log table in the relational database, where the alarm level can be set to a three-level alarm classification system.

[0041] When the comparison results meet the consistency conditions, the parameter management module generates a parameter writing success confirmation event. This event can include fields such as operator ID, parameter name, target value, feedback value, execution time, and device IP address. It is then uploaded to a remote database or manufacturing execution system (MES) via the WebAPI interface. This confirmation event also triggers a status update on the interface of the interaction unit 103. For example, the background color of the input box for the corresponding parameter item is changed from yellow (pending confirmation) to green (effective), and a line [time] is added to the operation log area. User XXX successfully set the die head gap to 0.12mm.

[0042] In the solution of this application embodiment, since the parameter management module actively reads and compares the feedback parameter values ​​after the parameter write command is issued, it can promptly detect the problem of instruction non-execution caused by network interruption, PLC program abnormality or address mapping error. Since the structured abnormality alarm is triggered and pushed to the human-machine interface when the comparison results are inconsistent, the observability and response efficiency of parameter setting failure are improved.

[0043] See Figure 2 In one possible implementation, the data acquisition unit 101 of this application includes a protocol conversion module 111; the protocol conversion module 111 is configured to: parse the industrial communication protocol data used by the industrial controller into a general data format; and convert the parsed general data format into standard network protocol data suitable for transmission over a wide area network or a local area network.

[0044] The protocol conversion module 111 can refer to an intermediate processing unit deployed in the data acquisition layer between the industrial controller and the service processing unit 102. It is used to realize bidirectional semantic mapping and format adaptation between heterogeneous industrial communication protocols and standard network protocols, so as to shield the differences in underlying device protocols and eliminate the need for the service processing unit 102 to develop dedicated drivers for different brands of PLCs, thereby improving system access compatibility and scalability.

[0045] After the data acquisition unit 101 obtains the raw communication message from the industrial controller, it forwards it to the protocol conversion module 111. The protocol conversion module 111 first matches the corresponding protocol parser according to the device configuration information, completes the unpacking and field extraction of the raw message, and then encapsulates the extracted process parameters (such as coating speed setpoint, die gap setpoint, and oven temperature) and their metadata into a general data format. Finally, according to the current network status and server configuration, it selects MQTT or WebAPI protocol to serialize the general data format into standard network protocol data, and uploads it to the service processing unit 102 through the corresponding communication channel.

[0046] In this embodiment, since the protocol conversion module 111 parses the proprietary protocol data of the industrial controller into a universal data format with a unified structure, the service processing unit 102 does not need to repeatedly develop multiple protocol drivers, thereby reducing the technical threshold for the system to connect to new devices. Since the universal data format is further encapsulated into MQTT or WebAPI standard network protocol data, it can be stably transmitted in local area network and wide area network environments, supporting cross-regional remote monitoring.

[0047] In another optional embodiment, the service processing unit 102 includes an action control module 122, which is configured to: provide device control controls on the human-machine interface of the interaction unit 103; generate a safety confirmation request and display it on the interactive terminal in response to the user's trigger operation on the control controls; and generate device action instructions and transmit them to the execution unit through the data acquisition unit 101 after receiving the user's confirmation response, so as to control the operation of the industrial equipment 104.

[0048] The motion control module 122 can refer to a functional logic component deployed in the service processing unit 102, used to uniformly receive, verify, and schedule device control operation requests from the B / S architecture interaction unit 103. Device control controls can refer to visual operation elements presented in the form of buttons, switches, drop-down menus, or icons in a Web HMI page developed based on ASP.NET Web Forms, such as start, stop, emergency stop, mold head forward, mold head backward, system reset, etc. These controls can support mouse click, touch screen click, or keyboard shortcut triggering. Their style, layout, and status feedback (such as enable / disable, hover highlight, rotating icon during execution) can be configured according to industrial human factors engineering specifications, and this application embodiment does not impose special limitations on this.

[0049] When a user clicks any device control control, the interaction unit 103 initiates an HTTP request to the service processing unit 102. After receiving the request, the action control module 122 constructs a structured confirmation message (including operation type, target device identifier, expected action description, and countdown closing prompt) and pushes it to the browser front-end of the same interactive terminal in real time via WebSocket or long polling mechanism. The front-end can render it as a modal dialog box or a top floating prompt bar. The action control module 122 hands over the generated device action command to the instruction distribution submodule in the data acquisition unit 101 for processing. The instruction distribution submodule calls the corresponding protocol driver according to the target device information specified in the instruction, serializes the instruction into a data frame conforming to the industrial controller communication protocol, and sends it to the target PLC via Ethernet. After receiving the instruction, the PLC triggers the corresponding output point in its local execution logic, thereby driving the execution unit (such as servo motor, pneumatic valve, hydraulic cylinder, etc.) to move, thereby controlling the operation of the industrial coating machine.

[0050] In some specific embodiments, the user can click the A head die forward control on the human-machine interface 113. The motion control module immediately intercepts the operation and pops up a confirmation dialog box: Confirm execution of A head die forward? This operation will drive the die forward by 10mm, affecting the current coating thickness. After the user clicks confirm, the motion control module verifies that the user's role is an engineer and that there are no serious alarms. Then, it generates a Modbus TCP format control instruction (function code 06, register address 40001, value 0x0001), which is forwarded to the coating machine PLC by the data acquisition unit 101. After the PLC executes the instruction, it returns a response. The data acquisition unit 101 sends the execution result back to the service processing unit 102. The service processing unit 102 updates the A head die position field in the interface to "forwarding" and generates an operation log in the background containing a timestamp, operator, instruction content, and execution result, which is then stored in a relational database.

[0051] The equipment action commands include die head forward commands, die head backward commands, or system reset commands. These can refer to three specific control signals generated by the motion control module and forwarded to the coating machine PLC by the data acquisition unit 101: The die head forward command drives the die head actuator to move slightly forward along the coating direction to adjust the coating gap. The die head backward command drives the die head actuator to retract in the opposite direction to avoid scratching the substrate or to facilitate maintenance. The system reset command clears all current operating flags, alarm latch states, and motion enable signals of the PLC and restores the equipment to its initial standby state. These three types of commands are all key commands that directly affect the physical position of the die head or the overall operating status of the machine in the coating process. Their naming is based on the type of underlying hardware action they trigger and the corresponding safety risk level. The die head forward command and the die head backward command together constitute the entire subset of the die head position adjustment commands. Both are implemented by controlling servo motors or pneumatic actuators through PLC output points. The system reset command acts on the PLC main control unit and requires the simultaneous reset of multiple process subsystems.

[0052] After receiving the control command issued by the interaction unit 103, the motion control module 122 first parses the command type identifier. If it is identified that the command belongs to the preset high-risk command set (i.e., system reset command, head forward command, or head backward command), it immediately interrupts the command issuance process, calls the front-end interface rendering engine, and pops up a safety confirmation request in the form of a modal dialog box in the user's current browser view. The safety confirmation request includes the command name, target device identifier, operation impact description (such as clearing all alarm latches and restarting motion control), countdown automatic cancellation option (default 30 seconds), and explicit confirmation and cancellation buttons.

[0053] In another embodiment, the service processing unit 102 further includes an alarm management module 132, which is configured to: monitor the status data of the industrial equipment 104 in real time, generate an alarm record when an anomaly is detected and display it on the human-machine interface of the interaction unit 103; receive user reset requests for alarm records, generate an alarm reset command and send it to the industrial controller to clear the fault flag bit.

[0054] The alarm management module 132 can refer to a real-time status analysis and response module deployed within the service processing unit 102. It is used to establish an autonomous operation and maintenance path of monitoring-alarm-response-closed loop. The alarm management module 132 maintains a continuous data subscription relationship with the data acquisition unit 101, receives status data streams from the industrial equipment 104 via the MQTT protocol, and performs item-by-item comparisons based on a preset alarm rule engine. The alarm rule engine can be configured with multi-level threshold judgment logic. For example, a level 1 warning is triggered when the oven temperature remains above 120℃ for 3 seconds, a level 2 general alarm is triggered when it remains above 135℃ for 1 second, and a level 3 severe alarm is immediately triggered when it exceeds 150℃. Each type of alarm is associated with a unique alarm code, descriptive text, affected equipment, and recommended handling actions. When the alarm management module detects any rule match, it generates an alarm record and simultaneously pushes it to the human-machine interface of the interaction unit 103, presenting it as a pop-up window, flashing icon, or highlighted table row. The alarm record can include at least: alarm time, alarm code, alarm level, trigger condition, current measurement value, and equipment identifier.

[0055] After receiving a user's reset operation request for a specific alarm record in the interactive interface, the alarm management module 132 parses the device identifier and alarm type associated with the request, generates a standardized alarm reset command, and forwards it to the corresponding industrial controller through the data acquisition unit 101. The alarm reset command targets the flag bit in the industrial controller used to mark the fault status. The execution result needs to be read back and verified by the data acquisition unit 101. If the flag bit has been cleared, the reset is successfully reported to the interactive unit 103; otherwise, a reset failure message is displayed, and the device status is checked.

[0056] In another optional embodiment, the service processing unit 102 of this application may further include a data traceability module, which is configured to: capture user modification operations on device parameters, generate operation logs containing values ​​before and after the operation, call a preset WebAPI interface, and upload the operation logs to a remote database or manufacturing execution system (MES).

[0057] The data traceability module can refer to a functional module deployed inside the service processing unit 102, used to listen for and intercept parameter modification request events from the interaction unit 103. The data traceability module communicates with the interaction unit 103 via the HTTP protocol and works in conjunction with the parameter management module in the service processing unit 102. After the user submits the parameter modification form and before the parameter write command is generated, it automatically reads the current value of the corresponding parameter in the industrial controller (i.e., the value before the operation). After the parameter write command is successfully executed and the feedback value is confirmed to be correct, it reads the updated value (i.e., the value after the operation), thereby generating a structured operation log. The operation log includes at least: operation timestamp, operator account, parameter identifier, value before the operation, value after the operation, PLC communication address, and operation result status. The data traceability module can be an independently running service process or integrated into the business logic layer of the service processing unit 102.

[0058] In some specific embodiments, the interaction unit 103 of this application is provided with a human-machine interface 113, through which the industrial equipment 104 is controlled. See [link to relevant documentation]. Figure 3 For example, the parameter setting module of the human-machine interface provides engineers with a centralized interface for managing process parameters. When an engineer needs to adjust production indicators (e.g., increasing the coating speed from 20 m / min to 25 m / min), they can directly locate the "Coating Speed ​​Setting Value" field in the web form with modification permissions, change the value from 20 to 25, and click submit. After receiving the request, the system first performs strict identity and permission verification to confirm that the operator has engineer permissions. Then, it performs logical validation on the input value to determine whether the new value conforms to the preset reasonable range (e.g., set between 10-30 m / min), ensuring the security of parameter changes. After successful verification, the system service layer generates a control instruction and writes it to a specific register address of the PLC. This instruction is converted and forwarded via an industrial gateway and finally transmitted to the underlying PLC control system of the coating machine. After receiving the new setting value, the PLC adjusts the frequency of the inverter of the drive motor through an internal algorithm, thereby physically changing the operating speed of the coating machine. Simultaneously, the system automatically captures the context information of this change, packages the old value before modification and the new value after modification, and transmits them to the MES system through the data interface to complete the traceability recording of production data. To achieve real-time human-machine interaction, this application's system establishes a closed-loop feedback mechanism between equipment status and the front-end interface. After the PLC executes a speed adjustment, the system immediately re-collects the latest operating values ​​of the equipment and pushes them to the web front-end via WebSocket or a polling mechanism. Engineers can observe in real-time in the parameter list that the "coating speed setpoint" has been stably updated to 25 m / min without refreshing the page, thus intuitively confirming that the control command has been accurately executed by the equipment, ensuring the accuracy and transparency of coating process adjustments.

[0059] See Figure 4 The interactive unit 103 of this application provides an intuitive and safe die head movement control interface for the operator in the "Control Function" module of the human-machine interface 113. When the operator needs to make fine adjustments to the equipment (such as executing the die head forward movement), they can click the corresponding operation button on the web control panel (such as "Die Head A Forward" or "Die Head B Forward" at the bottom of the interface). To prevent accidental touches that could cause equipment accidents, the system will not immediately issue a command after receiving a click event, but will trigger a safety protection mechanism, popping up a secondary confirmation dialog box on the front end of the web page, prompting "Are you sure you want to start the die head forward movement?", forcing the operator to perform a secondary logical confirmation. When the operator clicks "OK" in the dialog box, the system determines that the operation is a valid command and then starts the underlying communication process. The control command is encapsulated through the service layer, undergoes protocol conversion and transparent transmission through the industrial gateway, and is finally sent to the PLC controller of the coating machine. After receiving the instruction, the PLC parses and executes the preset start-up logic, drives the corresponding actuator (such as a servo motor or hydraulic system) to move, thereby controlling the die head of machine head A or machine head B to move forward physically, achieving precise process position adjustment.

[0060] See Figure 5 The interactive unit 103 of this application, within the "Alarm Information Display and Operation" interface of the "Data Storage Function" module of the human-machine interface 113, realizes real-time monitoring and fault response of equipment operating status. The system dynamically presents alarm records in tabular form, clearly listing the alarm time, alarm ID, alarm level, and specific alarm information (such as "1# Climbing Drive Roller Frequency Converter Fault!"), enabling operators to immediately grasp equipment abnormalities. For each alarm, the system also marks the current status (such as "Cannot Operate") in the "Alarm Operation" column according to the fault type, and provides an interactive entry point (such as a "Select" checkbox) in the "Alarm Reset Operation" column to guide users in troubleshooting and handling.

[0061] When operators confirm that the fault has been resolved and the equipment needs to be restored to operation, they can initiate a reset request by checking the checkbox for the corresponding alarm record and clicking the "Alarm Reset" button at the bottom. Upon receiving this instruction, the system encapsulates it into a standard control message and sends it to the coating machine's PLC controller via the industrial gateway. After receiving and parsing the message, the PLC executes its internally preset alarm reset logic, clears the fault flag, and restores the equipment to standby or running state. This completes the closed-loop control process from fault discovery and manual confirmation to system reset, ensuring production continuity and equipment safety.

[0062] This application also provides a method for controlling industrial equipment.

[0063] See Figure 6 The method includes the following steps: S110: It communicates with the industrial controller of the industrial equipment through the data acquisition unit to collect the operating data of the industrial equipment in real time.

[0064] In this step, the data acquisition unit 101 can be an edge computing module or an embedded gateway device deployed on the local side of the industrial equipment 104. It is equipped with an industrial communication interface and protocol parsing capability. The industrial controller can be a programmable logic controller (PLC), an industrial PC, or a motion controller, used to execute the underlying equipment control logic and provide operating status data. The operating data can refer to a set of status parameters reflecting the current working condition of the industrial equipment 104, such as temperature value, running speed, die head position, tension value, alarm flag, and equipment start / stop status. Real-time acquisition can refer to continuously initiating communication requests and obtaining the latest data at preset time intervals, or reading updated values ​​based on data change events.

[0065] S120: Receives and processes operational data, and generates corresponding control commands based on preset business logic.

[0066] The receiving and processing can refer to the service processing unit 102 receiving structured data from the data acquisition unit 101 and completing decoding, verification, caching, and routing distribution. The preset business logic can refer to the rule engine or process script built into the service processing unit 102, which is used to map the running data into executable control actions. For example, when the oven temperature is detected to be >120℃ and lasts for 3 seconds, a cooling control command is triggered, or when the user-set target coating speed = 35m / min is received, a corresponding parameter writing command is generated. The control command can refer to the operation command used to change the operating state of the industrial equipment 104, including parameter modification commands (such as setting value writing), equipment action commands (such as start, stop, reset), and alarm reset commands (such as clearing the fault flag).

[0067] S130: The interactive unit 103 based on the B / S architecture provides a visual operation interface, receives user operation instructions, and transmits the instructions to the service processing unit 102 to execute the corresponding control logic.

[0068] In this step, the interaction unit 103 based on the B / S architecture can be a web application deployed on a web server. Its front end is built using HTML5 / CSS3 / JavaScript, and its back end provides services through ASP.NET Web Forms or RESTful API. The visual operation interface can be a responsive web page for users with different roles, including a real-time monitoring dashboard, parameter setting form, device control panel, and alarm information list. User operation instructions can be structured requests triggered by user interactions such as clicking, inputting, and dragging in the browser. For example, modifying the mold head gap setting value in the parameter table and clicking submit, or clicking the system reset button. Transmission to the service processing unit 102 can refer to submitting the operation instructions in JSON or form data format to the server API interface via HTTP / HTTPS protocol, where the service processing unit 102 will uniformly schedule and execute them.

[0069] This application acquires real-time operating data of industrial equipment 104 through data acquisition unit 101, providing accurate and low-latency data input foundation for service processing unit 102. With the help of the business logic embedded in service processing unit 102, the raw data is transformed into structured instructions with clear control intentions. Then, relying on the B / S architecture interaction unit 103, users can complete all operations such as parameter setting, equipment start / stop, and alarm handling through a standard browser on any terminal. Thus, without relying on a dedicated client, a complete remote control closed loop covering data perception, logical decision-making, instruction execution, and human-machine interaction is constructed. This closed loop not only meets the stringent requirements of industrial sites for control reliability and security, but also takes into account the flexibility of system deployment and the convenience of operation and maintenance, effectively solving the technical bottlenecks of traditional solutions such as cross-platform limitations, difficulty in upgrading and maintenance, and weak scalability.

[0070] See Figure 7 In one possible implementation, step S120 receives and processes the runtime data, and generates corresponding control instructions based on preset business logic, including: S121: Receive the target parameter value input by the user and verify whether it is within the preset process safety range.

[0071] The target parameter value can refer to a numerical parameter set by the user in the human-machine interface of the interaction unit 103 to adjust the operating status of the industrial equipment 104, such as the coating speed setting value, the die gap setting value, or the oven temperature setting value. For example, in this application, when the user enters 120 m / min in the coating speed setting value input box, the system calls the process safety rules of the coating machine model TBD-3500, confirms that its allowable range is 80–110 m / min, determines that the target parameter value exceeds the upper limit, the verification fails, and the interface pops up a prompt that the input value exceeds the safe range and please re-enter.

[0072] S122: After the verification is passed, a parameter writing instruction is generated and transmitted to the industrial controller.

[0073] The parameter write instruction can be a structured control instruction that carries the target parameter value, target PLC address, data type, and write timing identifier. This parameter write instruction can be a data frame conforming to the Siemens S7 communication protocol specification, or a standardized instruction format adapted to other mainstream PLCs.

[0074] This application may, for example, construct a write request object that conforms to the S7Net driver library interface requirements based on the PLC communication information (including IP address, data block number, byte offset, and data type) corresponding to the target parameter value. This application may also encapsulate the target parameter value into a JSON format Web API request body and forward it to the industrial controller via the protocol conversion module of the data acquisition unit 101. Furthermore, this application may also dynamically parse the parameter write request with unified semantics into a sequence of underlying instructions that can be recognized by the corresponding industrial controller based on the protocol mapping relationship pre-stored in the device registry.

[0075] S123: Read feedback parameter values ​​from the industrial controller and compare them with target parameter values ​​for verification.

[0076] The feedback parameter value can refer to the value that the industrial controller sends back to the service processing unit 102 after receiving the parameter write instruction and completing the internal register update, reflecting the actual effective parameter status. The feedback parameter value can be actively obtained through the same communication link (such as the S7 protocol read function block), or it can be a response data packet actively pushed by the PLC after the write is completed. In this embodiment, the feedback parameter value and the target parameter value form a closed-loop verification relationship, and the comparison result directly determines whether the parameter modification is truly effective.

[0077] S124: If the verification passes, update the device operating settings; if the verification fails, trigger the exception handling mechanism.

[0078] In this context, "validation passed" can mean that the feedback parameter value and the target parameter value are equal within a preset tolerance range. This tolerance can be an absolute error (e.g., ±0.002 mm) or a relative error (e.g., ±0.5%), and the data type, unit, and semantic identifier are all consistent. "Validation failed" can mean that the feedback parameter value is missing, the timeout period has expired and no return has been made, the numerical deviation exceeds the tolerance, or the data type parsing has failed.

[0079] This application ensures the legality of parameter modifications by receiving user-input target parameter values ​​and performing process safety range verification. Upon successful verification, a parameter write command is generated and issued, guaranteeing accurate communication of control intent. Subsequently, the feedback parameter values ​​returned by the industrial controller are read and compared with the target values ​​for verification, forming a closed-loop confirmation of the write result. Finally, based on the verification result, the local setpoint is updated or an anomaly handling mechanism is activated. This achieves full automation, traceability, and high reliability of the parameter control process without requiring manual on-site verification. This technical solution addresses the technical shortcomings of traditional B / S architectures in remote parameter modification, which lacks process monitoring and result confirmation, improving the process stability and system robustness of high-precision industrial equipment such as coating machines in remote operation and maintenance scenarios.

[0080] In some embodiments, real-time acquisition of operational data from industrial equipment 104 includes: parsing industrial communication protocol data used by the industrial controller into a general data format via a protocol conversion module; converting the parsed general data format into communication protocol data suitable for wide area network or local area network transmission; and sending it to the service processing unit 102 for processing. The protocol conversion module is a logical unit in the data acquisition layer responsible for protocol adaptation. This module can refer to data middleware deployed at the edge or on the device side, possessing multi-protocol parsing capabilities, used to interface with proprietary communication protocols adopted by industrial controllers from different manufacturers and of different models.

[0081] In some embodiments, a visual operation interface is provided through a B / S architecture-based interaction unit 103 to receive user operation commands and transmit the commands to a service processing unit 102 to execute the corresponding control logic. This includes: providing a visual operation interface through the B / S architecture-based interaction unit 103, receiving user trigger operations on device control controls through the human-machine interface, generating a safety confirmation request and displaying a confirmation prompt on the interactive terminal, and generating the final device action command and sending it to the industrial controller after receiving the user's confirmation response.

[0082] Among them, equipment control controls are user-facing operational elements with clear functional semantics in the presentation layer, such as the head forward button, system reset button, and A-head positioning switch. Equipment control controls are configured to only be enabled when preset safety conditions are met (e.g., the current user role is engineer, the current equipment is in a ready state, and there are no outstanding serious alarms). When the user clicks the control, the front-end script immediately sends an HTTP POST request carrying the control ID and context parameters to the service processing unit 102. Upon receiving the request, the service processing unit 102 does not directly generate an action command, but instead constructs a safety confirmation request containing the operation type, target device, expected effect, and countdown prompt, and pushes it to the current browser session via WebSocket. A modal dialog box pops up on the interactive terminal to display the prompt. After the user clicks confirm, the front-end sends the confirmation response along with the original operation context back to the service processing unit 102. The service processing unit 102 verifies the timeliness of the confirmation and the validity of the user's permissions, generates the corresponding action command, and sends it to the industrial controller for execution via the data acquisition unit 101.

[0083] The technical solution of this application, by adopting a B / S architecture instead of the traditional C / S architecture, allows users to access the system through any browser without installing dedicated client software, solving the problem of restricted user access. The service processing unit centrally processes data and provides business logic services, avoiding the need for multi-operating system adaptation and simplifying the system maintenance process. The layered design of the data acquisition unit and the service processing unit achieves functional decoupling. When adding new industrial equipment, only the configuration of the data acquisition unit needs to be expanded, without redistributing the client software, significantly improving the system's scalability. It effectively improves the current situation of complex deployment and maintenance, insufficient flexibility, and poor scalability of traditional monitoring systems, realizing cross-platform, centralized, and lightweight management of remote monitoring of industrial equipment.

[0084] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A control system for industrial equipment, characterized in that, include: A data acquisition unit is communicatively connected to the industrial controller of at least one industrial device and is used to collect the operating data of the at least one industrial device. The service processing unit is communicatively connected to the data acquisition unit, and is used to receive and process the running data collected by the data acquisition unit, and provide business logic services. The interaction unit, based on a browser / server (B / S) architecture, is used to provide a visual operation interface for interacting with the service processing unit in order to control the industrial equipment.

2. The control system according to claim 1, characterized in that: The service processing unit includes a parameter management module; the parameter management module is configured as follows: Receive the target parameter value input by the user through the human-computer interaction interface of the interaction unit; Invoke the preset parameter constraint rules to determine whether the target parameter value meets the preset process safety range; After the verification is successful, a parameter writing instruction is generated and sent to the industrial controller.

3. The control system according to claim 2, characterized in that, The parameter management module is also configured as follows: After generating the parameter writing instruction and sending it to the industrial controller, the corresponding feedback parameter value is read from the industrial controller; The feedback parameter value is compared with the target parameter value; If the comparison results are inconsistent, an error alarm will be triggered; or, if they are consistent, the parameter writing will be confirmed as successful.

4. The control system according to claim 2, characterized in that, The data acquisition unit includes a protocol conversion module; the protocol conversion module is configured as follows: The industrial communication protocol data used by the industrial controller is parsed into a common data format; The parsed general data format is converted into standard network protocol data suitable for transmission over wide area networks or local area networks.

5. The control system according to claim 1, characterized in that: The service processing unit includes an action control module; the action control module is configured as follows: The human-computer interaction interface of the interactive unit provides device control controls; In response to the user's triggering operation on the device control controls, a security confirmation request is generated and displayed on the interactive terminal; After receiving confirmation from the user, the device generates an action command and transmits it to the execution unit to control the operation of the industrial equipment.

6. The control system according to claim 5, characterized in that, The industrial equipment is an industrial coating machine, wherein: The equipment action commands include at least the die head forward command, die head backward command, or system reset command of the industrial coating machine; The action control module is configured to pop up the security confirmation request when the device action command is detected.

7. The control system according to claim 1, characterized in that, The service processing unit further includes an alarm management module; the alarm management module is configured as follows: The system monitors the status data of the industrial equipment in real time, generates an alarm record when an anomaly is detected, and displays it on the human-machine interface of the interactive unit; it receives a user's reset request for the alarm record, generates an alarm reset command, and sends it to the industrial controller to clear the fault flag; and / or, The system also includes a data traceability module; the data traceability module is configured to: capture user modifications to equipment parameters, generate operation logs containing values ​​before and after the operation; and call a preset WebAPI interface to upload the operation logs to a remote database or manufacturing execution system.

8. A control method for industrial equipment, characterized in that, include: The data acquisition unit communicates with the industrial controller of the industrial equipment to collect the operating data of the industrial equipment in real time. Receive and process the operational data, and generate corresponding control instructions based on preset business logic; A visual operation interface is provided through an interaction unit based on a B / S architecture, which receives user operation commands and transmits the commands to the service processing unit to execute the corresponding control logic.

9. The method according to claim 8, characterized in that, The process of receiving and processing the operational data, and generating corresponding control instructions based on preset business logic, includes: Receive the target parameter value input by the user and verify whether it is within the preset process safety range; After the verification is passed, the parameter writing command is generated and transmitted to the industrial controller; The feedback parameter values ​​are read from the industrial controller and compared with the target parameter values ​​for verification. If the verification passes, the device's operating settings are updated; if the verification fails, the exception handling mechanism is triggered.

10. The method according to claim 8, characterized in that, The real-time acquisition of the industrial equipment's operating data includes: The protocol conversion module parses the industrial communication protocol data used by the industrial controller into a general data format; it then converts the parsed general data format into communication protocol data suitable for wide area network or local area network transmission, and sends it to the service processing unit for processing; or, The step of providing a visual operation interface through a B / S architecture-based interactive unit, receiving user operation commands, and transmitting the commands to the service processing unit to execute corresponding control logic includes: A visual operation interface is provided through the B / S architecture-based interactive unit, which accepts user trigger operations on the device control controls through the human-machine interface; generates a safety confirmation request and displays a confirmation prompt on the interactive terminal; after receiving the user's confirmation response, it generates the final device action command and sends it to the industrial controller.

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