Industrial wireless WiFi-based shunting machine signal transmission system and method

Abstract

The application relates to a shunting machine signal transmission system and method based on industrial wireless WiFi, which comprises a ground communication unit, an industrial POE switch and an industrial wireless AP; wherein one end of the industrial POE switch is in communication connection with the industrial wireless AP, the other end is in connection with an optical cable of a backhaul control room, and the optical cable is in communication connection with a central control adaptation unit; a shunting machine end communication control unit comprises an industrial wireless client, a PLC controller and a relay isolation module; the relay isolation module is in communication connection with the shunting machine and the PLC controller respectively, is used for inputting various state signals of the shunting machine into the PLC controller, and the PLC controller is used for wirelessly transmitting communication signals to the industrial wireless AP to complete communication with the central control adaptation unit. Through customized wireless architecture construction, PLC signal processing adaptation and central control system configuration optimization, the application realizes uninterrupted wireless communication between the shunting machine and the control room, reduces fault risks and operation and maintenance costs, and guarantees continuous and stable production.

Description

Technical Field

[0001] This invention relates to the field of industrial equipment signal transmission technology, specifically to a shunting locomotive signal transmission system and method based on industrial wireless WiFi. Background Technology

[0002] In a tippler production system, the shunting locomotive is the core equipment connecting empty wagon transfers, and the continuity of its signal transmission directly determines production efficiency. In existing technologies, the power supply and photoelectric signal transmission of the shunting locomotive rely on wired equipment such as tow cables, reels, sliding contact current collectors, and fiber optic couplers, which have insurmountable technical drawbacks: the transmission link includes seven fiber optic splicing and conversion nodes, and structural redundancy leads to an increase in failure points; the low temperatures in northern winters easily cause reel breakage and insulation damage, resulting in an average of 12 failures per year, with each failure requiring 5 people / 4 hours of handling, severely hindering production progress; the reels need to be replaced every 6 months, with annual replacement costs (including labor) reaching as high as 105,000 yuan; wired transmission routes are affected by equipment wear and environmental corrosion, resulting in poor long-term stability, and installation and maintenance require disassembling related equipment, making operations cumbersome. Existing wireless transmission technologies are mostly used in office or general industrial scenarios and are not adapted to the special needs of shunting locomotive movement, industrial electromagnetic interference, and signal attenuation in obstructed areas. Direct application of these technologies will result in signal packet loss, transmission delay, and insufficient anti-interference capabilities. Therefore, there is an urgent need to develop a signal transmission method and system that adapts to the operating characteristics of shunting locomotives, simplifies the transmission structure, reduces the failure rate, and takes cost into account, so as to solve the pain points of existing technologies. Summary of the Invention

[0003] To address the aforementioned problems, the purpose of this invention is to provide a shunting locomotive signal transmission system and method based on industrial wireless WiFi.

[0004] A shunting locomotive signal transmission system based on industrial wireless WiFi includes:

[0005] The ground communication unit includes an industrial PoE switch and an industrial wireless AP; wherein, one end of the industrial PoE switch is connected to the industrial wireless AP and the other end is connected to the optical cable for backhaul control room, and the optical cable is connected to the central control adapter unit.

[0006] The shunting locomotive communication control unit is installed on the shunting locomotive body and includes an industrial wireless client, a PLC controller, and a relay isolation module. The relay isolation module is connected to both the shunting locomotive and the PLC controller to transmit various status signals of the shunting locomotive to the PLC controller. The PLC controller is connected to the industrial wireless client to wirelessly transmit communication signals to the industrial wireless AP to complete communication with the central control adapter unit.

[0007] Preferably, it also includes: an omnidirectional fiberglass antenna, connected to the industrial wireless client, for transmitting and receiving communication signals to and from the industrial wireless AP.

[0008] Preferably, it also includes: a photoelectric encoder, which is communicatively connected to the industrial wireless client.

[0009] Preferably, the industrial PoE switch model is GPEM2006GP.

[0010] Preferably, the industrial wireless AP model is GP-AP1200.

[0011] Preferably, the PLC controller is an S7-200smart PLC.

[0012] Preferably, the industrial wireless client is model GP-AG1000.

[0013] This invention also provides a shunting locomotive signal transmission method based on industrial wireless WiFi, comprising:

[0014] Configure the communication parameters of the S7-200smart PLC, generate the GSDML file and import it into the central control adapter unit, complete the addition of slave stations, IP address matching, tag number configuration and compilation download, and start the debug mode to confirm that the configuration is effective;

[0015] When the shunting locomotive is running, its various statuses are transmitted to the S7-200smart PLC via a relay isolation module. The S7-200smart PLC then transmits the signals to the industrial wireless client.

[0016] The industrial wireless client transmits wirelessly to the industrial wireless AP via an omnidirectional fiberglass antenna.

[0017] The industrial wireless AP transmits the signal to the central control adapter unit via an industrial PoE switch and optical cable.

[0018] After receiving the signal, the central control unit outputs control commands and transmits them to the S7-200smart PLC to control the shunting machine.

[0019] This invention relates to a shunting locomotive signal transmission system based on industrial wireless WiFi. Compared with the prior art, this invention achieves uninterrupted wireless communication between the shunting locomotive and the control room through customized wireless architecture construction, PLC signal processing adaptation, and central control system configuration optimization. This simplifies the transmission process, reduces the risk of failure and maintenance costs, and ensures continuous and stable production.

[0020] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0021] 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 some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 A schematic diagram of a shunting locomotive signal transmission system based on industrial wireless WiFi is provided for this invention.

[0023] Figure 2 The present invention provides a flowchart of a shunting locomotive signal transmission method based on industrial wireless WiFi. Detailed Implementation

[0024] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention 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. Therefore, they should not be construed as limitations on this invention.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0026] In this invention, 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 connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0027] Please see Figure 1-2 A shunting locomotive signal transmission system based on industrial wireless WiFi, comprising:

[0028] The ground communication unit includes an industrial PoE switch and an industrial wireless AP; wherein, one end of the industrial PoE switch is connected to the industrial wireless AP and the other end is connected to the optical cable for backhaul control room, and the optical cable is connected to the central control adapter unit.

[0029] The shunting locomotive communication control unit is installed on the shunting locomotive body and includes an industrial wireless client, a PLC controller, and a relay isolation module. The relay isolation module is connected to both the shunting locomotive and the PLC controller to transmit various status signals of the shunting locomotive to the PLC controller. The PLC controller is connected to the industrial wireless client to wirelessly transmit communication signals to the industrial wireless AP to complete communication with the central control adapter unit.

[0030] An omnidirectional fiberglass antenna is connected to the industrial wireless client and is used to send and receive communication signals to and from the industrial wireless AP.

[0031] Furthermore, the shunting locomotive signal transmission system based on industrial wireless WiFi in this invention includes: a ground communication unit, a shunting locomotive-end communication control unit, and a central control adapter unit. The three units achieve bidirectional signal transmission through a wireless and wired collaborative link, and the specific structure is as follows:

[0032] 1. Ground Communication Unit: Deployed in a ground fiber optic box, including an industrial PoE switch and an industrial wireless AP; the industrial PoE switch is a 2-fiber 4-electrical full gigabit model (GPEM2006GP), one end connects to the optical cable back to the control room, and the other end connects to the industrial wireless AP via a network cable, while providing 48-56V power to the industrial wireless AP, realizing integrated data transmission and power supply; the industrial wireless AP is model GP-AP1200, with IP67 protection level, anti-electromagnetic interference design, wireless coverage radius ≥80m, and diffraction capability adapted to the wall obstruction scenario in the shunting locomotive operation area.

[0033] 2. Shunting locomotive communication control unit: Installed on the shunting locomotive body, it includes an industrial wireless client, an omnidirectional fiberglass antenna, an S7-200smart PLC, and a relay isolation module. The industrial wireless client is model GP-AG1000, with industrial-grade protection (IP40), anti-electromagnetic interference, and a wireless receiving radius ≥50m. The omnidirectional fiberglass antenna has a built-in fixing clamp to enhance signal reception strength in obstructed areas such as doorways. The S7-200smart PLC is connected to the shunting locomotive's hook open, hook closed, hook lifting, and hook lowering signals via the relay isolation module. It is configured as a PROFINET intelligent device with an IP address of 192.168.0.15, a station name of sr20, and a 4-byte input / output module (transmission area start address 1152). The program maps the shunting locomotive signals to the transmission area and generates a GSDML file. The shunting locomotive's photoelectric encoder is directly connected to the industrial wireless client's network port without additional software configuration.

[0034] 3. Central Control Adaptor Unit: For Zhejiang Central Control System, after importing GSDML file, complete slave station configuration, IP address matching, and tag number strategy configuration to realize real-time data exchange with shunting locomotive.

[0035] Based on the above system, the present invention also provides a shunting locomotive signal transmission method based on industrial wireless WiFi, comprising the following steps:

[0036] 1. System Setup Phase:

[0037] (1) Install industrial POE switches and industrial wireless APs in the ground fiber optic box, connect the industrial POE switches to the optical cables, and connect the industrial wireless APs to the industrial POE switches to complete the ground wireless coverage deployment.

[0038] (2) Fix an industrial wireless client, an omnidirectional fiberglass antenna and an S7-200smart PLC on the shunting locomotive. Connect various status signals of the shunting locomotive to the PLC through a relay isolation module. Connect the photoelectric encoder to the network port of the industrial wireless client.

[0039] (3) Configure the communication parameters of S7-200smartPLC, generate GSDML file and import it into Zhejiang Zhongkong system, complete slave station addition, IP address matching, tag number configuration and compilation download, start debugging mode to confirm that the configuration is effective.

[0040] 2. Signal transmission stage:

[0041] (1) When the shunting locomotive is running, the status signal is transmitted to the S7-200smartPLC after being isolated by the relay. The PLC maps the signal to the preset transmission area and converts it into a communication signal.

[0042] (2) The industrial wireless client receives signals through an omnidirectional fiberglass antenna and wirelessly transmits them to the ground industrial wireless AP;

[0043] (3) The ground-based industrial wireless AP transmits the signal to the Zhejiang Zhongkong system in the control room via an industrial POE switch and optical cable;

[0044] (4) After processing the signal, the Zhejiang central control system outputs control commands, which are transmitted to the shunting locomotive PLC via the aforementioned reverse link to achieve precise control of the shunting locomotive. Simultaneously, the position signal from the photoelectric encoder is synchronously transmitted to the central control system to assist in control decision-making. Furthermore, both the industrial wireless AP and the industrial wireless client employ frequency hopping anti-interference technology to avoid interference from electromagnetic signals in the industrial environment. Furthermore, the S7-200smart PLC program includes a signal verification module to perform integrity verification on the transmitted signal, ensuring accurate signal transmission. Furthermore, the Zhejiang central control system incorporates a signal redundancy mechanism; when the main transmission link signal is lost, it automatically switches to a backup communication channel to ensure transmission continuity.

[0045] The process of the present invention will be further described below with reference to specific embodiments:

[0046] The shunting locomotive signal transmission system based on industrial wireless WiFi of the present invention is as follows: Figure 1 As shown, at the shunting locomotive end: equipped with a GP-AG1000 industrial wireless client, responsible for receiving signals from the GP-AP1200 industrial wireless AP, achieving omnidirectional wireless coverage within an 80-meter radius. At the ground transmission end: the GP-AP1200 is connected to the GPEM2006GP industrial PoE switch via a network cable. This switch simultaneously powers the AP and transmits data. At the control room end: utilizing the already laid fiber optic cables, data from the ground fiber optic box is transmitted back to the control room, enabling remote monitoring and control. The specific deployment operation is as follows:

[0047] 1. Ground Communication Unit Deployment: First, select a ground-based fiber optic box that can cover the shunting locomotive's operating area. After opening the box, fix a 2-fiber, 4-electrical gigabit industrial PoE switch (GPEM2006GP) inside. Connect the pre-laid fiber optic cable back to the control room to the switch's optical port. Next, connect the industrial wireless AP (GP-AP1200) to the electrical port of the industrial PoE switch via a network cable, with the switch providing 48V power. The industrial wireless AP should be installed at a height of 2.5m above the ground to ensure its wireless signal can cover the entire operating trajectory of the shunting locomotive, with a coverage radius within 80m.

[0048] 2. Deployment of the communication control unit at the shunting locomotive end: Secure the S7-200smart PLC and relay isolation module within the electrical cabinet of the shunting locomotive. The PLC's input terminals are connected to the shunting locomotive's hook open, hook closed, hook lifting, and hook lowering position sensors via the relay isolation module. Fix the industrial wireless client (GP-AG1000) to the top of the shunting locomotive, equipped with an omnidirectional fiberglass antenna. This antenna has a built-in clamp for mounting on the roof railing. The industrial wireless client connects to the S7-200smart PLC's Ethernet port via a network cable. The photoelectric encoder on the shunting locomotive is directly connected to the industrial wireless client's spare network port, requiring no additional driver configuration.

[0049] 3. Deployment of the Central Control Adapter Unit: In the Zhejiang Central Control system in the control room, import the GSDML file generated by the S7-200smart PLC using PNCon software, then close and restart the software. In the PN bus configuration interface, drag the "SR20[6ES7288-1SR20-0AA1]" slave to the bus, set the device name to "sr20", and the IP address to "192.168.0.15", which must be consistent with the PLC's IP address. Update and save the configuration in VFIOBuilder software, enter the tag configuration interface to add a communication tag strategy, select no status code, scan the newly added tag, and complete the compilation and download. Enable the debug mode of the PNCon software. When the interface displays a green indicator light, it indicates that the system configuration is successful and communication is ready.

[0050] like Figure 2 As shown, to achieve data interaction between the PLC and the host controller, the following transfer areas need to be defined: Transfer Area 01: Configured as an input type, address IB1152, length 4 bytes, used to receive control commands from the host controller. Transfer Area 02: Configured as an output type, address QB1152, length 4 bytes, used to feed back the status data of the shunting locomotive to the host controller. GSDML file export: Export the configuration as GSDML-V2.34-#Siemens-PLC200smart_SR20-20251204-215006.xml, import it into STEP7-Micro / WINSMART or a third-party engineering tool to complete the equipment configuration.

[0051] Specifically as follows:

[0052] 1. System initialization: Start the ground communication unit, shunting locomotive communication control unit and central control adapter unit. The industrial wireless AP and industrial wireless client will automatically establish a wireless connection. After the S7-200smart PLC completes its self-test, it establishes a communication link with the Zhejiang central control system. The signal verification module starts running, and the redundant communication channel is in standby mode.

[0053] 2. Signal uplink transmission (shunting locomotive → control room) such as Figure 2 When the shunting locomotive is running, status signals such as hook open and hook closed positions are collected by sensors and transmitted to the relay isolation module. After isolating external electromagnetic interference, the signals are output to the S7-200smart PLC. To enable data interaction between the PLC and the host controller, the following transmission areas need to be defined: Transmission Area 01: Configured as an input type, address IB1152, length 4 bytes, used to receive control commands from the host controller. Transmission Area 02: Configured as an output type, address QB1152, length 4 bytes, used to feed back the shunting locomotive's status data to the host controller. GSDML file export: Export the configuration as GSDML-V2.34-#Siemens-PLC200smart_SR20-20251204-215006.xml, import it into STEP7-Micro / WINSMART or a third-party engineering tool to complete the equipment configuration. The PLC maps the status signals to the preset transmission area, i.e., bytes 1152-1155 of the input module, through its internal program. After the signal verification module verifies the integrity, the signals are converted into PROFINET communication signals. The communication signal is transmitted to the industrial wireless client via network cable, and then wirelessly transmitted to the ground-based industrial wireless AP by an omnidirectional fiberglass antenna. The ground-based industrial wireless AP forwards the signal to the industrial PoE switch, and then transmits it to the Zhejiang Central Control System in the control room via optical fiber. The Central Control System analyzes the signal and updates the shunting machine status display.

[0054] 3. Downlink Signal Transmission (Control Room → Shunting Locomotive): The Zhejiang Supcon system generates traction, push, and stop control signals based on production instructions, which are transmitted to the industrial wireless AP via fiber optic cable and industrial PoE switch. The industrial wireless AP wirelessly transmits the control signals to the industrial wireless client at the shunting locomotive end, using frequency hopping technology to avoid electromagnetic interference during transmission. The control signals are then transmitted to the S7-200smart PLC via network cable. After parsing the signals, the PLC drives the output terminals to operate, controlling the motors, solenoid valves, and other actuators of the shunting locomotive. If packet loss occurs in the main transmission link, the system automatically switches to a redundant communication channel to ensure continuous transmission of control signals and avoid operational interruptions.

[0055] 4. Anomaly Handling: When the encoder signal is abnormal, the central control system calibrates using the synchronization signal of the photoelectric encoder; if the wireless link is temporarily interrupted, the PLC will temporarily store critical signals and automatically retransmit them after the link is restored to prevent data loss. This invention achieves highly stable and low-cost wireless transmission of shunting machine signals through a customized system architecture and standardized transmission methods, solving many pain points of existing technologies. It can be widely applied in tippler systems, port transfer equipment, industrial mobile robots, and other scenarios.

[0056] According to specific embodiments of the present invention, the following technical effects are disclosed:

[0057] 1. Innovative solution to the problem of adapting to industrial scenarios: By selecting customized industrial-grade wireless equipment (IP67 / IP40 protection, anti-electromagnetic interference), enhancing signal reception in obstructed areas with omnidirectional fiberglass antennas, and combining frequency hopping anti-interference technology, the bottleneck of general wireless technology in complex industrial environments is overcome, and stable communication is achieved when the shunting locomotive is in motion.

[0058] 2. Significantly improved transmission stability and accuracy: The transmission links have been simplified from 7 to 3, and vulnerable wired components have been eliminated, resulting in a near-zero failure rate. Through triple protection of relay isolation, signal verification modules, and redundancy mechanisms, signal transmission is ensured to be free of packet loss and distortion, meeting the control accuracy requirements of shunting locomotives.

[0059] 3. Outstanding economic benefits: Annual savings of 105,000 yuan in cable replacement and fault repair costs, with a system setup investment of only 8,500 yuan and a short payback period; installation and maintenance do not require disassembly of related equipment, significantly reducing the workload of operation and maintenance.

[0060] 4. High replicability of the method: The signal transmission method of the present invention can be quickly adapted to the signal transmission needs of shunting locomotives of different specifications and similar industrial mobile equipment through standardized equipment configuration, PLC programming and central control configuration process, and has high promotion value.

[0061] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A shunting locomotive signal transmission system based on industrial wireless WiFi, characterized in that, include: The ground communication unit includes an industrial PoE switch and an industrial wireless AP; wherein, one end of the industrial PoE switch is connected to the industrial wireless AP and the other end is connected to the optical cable for backhaul control room, and the optical cable is connected to the central control adapter unit. The shunting locomotive communication control unit is installed on the shunting locomotive body and includes an industrial wireless client, a PLC controller, and a relay isolation module. The relay isolation module is connected to both the shunting locomotive and the PLC controller to transmit various status signals of the shunting locomotive to the PLC controller. The PLC controller is connected to the industrial wireless client to wirelessly transmit communication signals to the industrial wireless AP to complete communication with the central control adapter unit.

2. The shunting locomotive signal transmission system based on industrial wireless WiFi according to claim 1, characterized in that, Also includes: An omnidirectional fiberglass antenna is connected to the industrial wireless client and is used to send and receive communication signals to and from the industrial wireless AP.

3. The shunting locomotive signal transmission system based on industrial wireless WiFi according to claim 1, characterized in that, Also includes: The photoelectric encoder is connected to the industrial wireless client for communication.

4. The shunting locomotive signal transmission system based on industrial wireless WiFi according to claim 1, characterized in that, The industrial PoE switch is model GPEM2006GP.

5. A shunting locomotive signal transmission system based on industrial wireless WiFi according to claim 1, characterized in that, The industrial wireless AP model is GP-AP1200.

6. A shunting locomotive signal transmission system based on industrial wireless WiFi according to claim 1, characterized in that, The PLC controller is an S7-200smart PLC.

7. A shunting locomotive signal transmission system based on industrial wireless WiFi according to claim 1, characterized in that, The industrial wireless client selected is model GP-AG1000.

8. A shunting locomotive signal transmission method based on industrial wireless WiFi, applied to the shunting locomotive signal transmission system based on industrial wireless WiFi as described in any one of claims 1-7, characterized in that, include: Configure the communication parameters of the S7-200smart PLC, generate the GSDML file and import it into the central control adapter unit, complete the addition of slave stations, IP address matching, tag number configuration and compilation download, and start the debug mode to confirm that the configuration is effective; When the shunting locomotive is running, its various statuses are transmitted to the S7-200smart PLC via a relay isolation module. The S7-200smart PLC then transmits the signals to the industrial wireless client. The industrial wireless client transmits wirelessly to the industrial wireless AP via an omnidirectional fiberglass antenna. The industrial wireless AP transmits the signal to the central control adapter unit via an industrial PoE switch and optical cable. After receiving the signal, the central control unit outputs control commands and transmits them to the S7-200smart PLC to control the shunting machine.

Images