Siemens PLC fault diagnosis simulation device for WD-320 power stabilization vehicle

Abstract

The utility model discloses a Siemens PLC fault diagnosis simulation device for a WD-320 power stabilization vehicle, and solves the problem of lack of a special simulation facility. A television, a touch screen, a switching power supply, a human cloud module, a switch, a 1200 PLC module, an ET200 expansion module, a motor push rod, photoelectric sensors, a motor, an encoder, a voltage generator and a temperature and humidity sensor are installed on the backboard, and the ET200 expansion module is connected with a plurality of photoelectric sensors II; the number of the motor push rods is two, angle steel is installed between the two motor push rods, the angle steel is matched with the multiple photoelectric sensors I, the motor and the encoder are connected into the 1200 PLC, and the motor and the encoder are matched to act and mechanically connected through a coupler. The voltage generator is electrically connected with the 1200 PLC; and the temperature and humidity sensor is electrically connected with the 1200 PLC. Communication fault simulation can be simulated through the device.

Description

Technical Field

[0001] The present technology relates to a set of fault diagnosis simulation devices, in particular to a WD-320 power stabilizer Siemens PLC fault diagnosis simulation device, and belongs to the field of innovative technology of practical training equipment for large-scale railway maintenance machinery. Background Art

[0002] The operating principle of the WD-320 power stabilizer is to use two excitation devices to force the rail and the roadbed to produce lateral horizontal vibration and transmit vertical static pressure to the roadbed. The ballast is rearranged and filled with each other to achieve density, so that the track can sink evenly in a controlled manner under vibration without changing the original geometry and accuracy of the line, thereby improving the lateral resistance of the operating line and the overall stability of the roadbed, and effectively reducing the limiting conditions for train speed limit operation after line maintenance. The WD-320 power stabilizer is operated strictly in accordance with the WD-320 power stabilizer line maintenance operation instructions.

[0003] At present, new sensors, analog quantities, human-machine interaction (HMI), etc. are gradually replacing old relay circuit board control circuits, which improves the level of intelligence. For example, the control system in the WD-320 power stabilizer has been updated to the Siemens S7 PLC electrical control system. However, on-site technicians and operators do not understand the principles and characteristics of the Siemens S7 PLC system, especially when the PLC electrical control system fails, the relevant personnel do not know how to deal with it, which leads to delays in construction and even affects driving safety. Therefore, it is necessary to carry out skills training for relevant personnel. Due to technical needs, the control modules in the WD-320 power stabilizer cannot be disassembled one by one, and training can only be carried out using text and graphics, which is inefficient and not intuitive enough. Summary of the invention

[0004] In order to solve the above problems, a Siemens PLC fault diagnosis simulation device for WD-320 power stabilizer vehicle was developed according to the logic control signal table and electrical schematic diagram. It is a simulation device that can simulate various actions and conditions in the WD-320 power stabilizer vehicle, solving the problem of lack of such special simulation facilities.

[0005] The technical solution is:

[0006] WD-320 power stability vehicle Siemens PLC fault diagnosis simulation device, the device includes a backplane and a TV, a touch screen, a switching power supply, a human cloud module, a switch, a 1200 PLC module, an ET200 expansion module, a motor push rod, a photoelectric sensor I, a photoelectric sensor II, a motor, an encoder, a voltage generator, and a temperature and humidity sensor installed on the backplane. It is characterized in that the switch is a network cable connection collection point and a synchronous network cable connects the TV, the human cloud module, the 1200 PLC module, the touch screen, and the ET200 expansion module, and the 1200 PLC module is integrated with a PROFINET communication module and establishes an electrical connection with the ET200 expansion module, the touch screen, and the switch;

[0007] The ET200 expansion module is connected to multiple photoelectric sensors II, which respectively simulate the left limit of the front stabilizing head rising of the stabilizing car, the right limit of the front stabilizing head rising, the locking of the middle measuring trolley, the locking of the front stabilizing head, the locking of the rear stabilizing head, the locking of the rear measuring trolley, the locking of the front measuring trolley, the locking of the positive vector trolley, and the driving clutch of the active shaft operation;

[0008] There are two motor push rods, and an angle steel is installed between the push rods of the two motor push rods. The angle steel simulates the chassis of the stable vehicle body. The angle steel cooperates with multiple photoelectric sensors I. The number of the photoelectric sensors I is six, and they respectively simulate the actions of the front stable vehicle head descending to the left, the front stable vehicle head descending to the right, the rear stable vehicle head descending to the left, the rear stable vehicle head descending to the right, the middle measuring vehicle descending to the left, and the middle measuring vehicle descending to the right;

[0009] The motor and encoder are connected to the 1200 PLC, the motor and encoder cooperate with each other and are mechanically connected through a coupling;

[0010] The voltage generator is electrically connected to SM1231 in the 1200 PLC;

[0011] The temperature and humidity sensor is electrically connected to SM1231 in the 1200 PLC.

[0012] Furthermore, the angle steel is arranged perpendicular to the movement direction of the electric push rod, and the angle steel is arranged perpendicular to the sensing direction of the photoelectric sensor I.

[0013] Furthermore, the motor push rod is arranged horizontally.

[0014] Furthermore, the back plate is a structure with a hollow structure and is configured with an aluminum alloy profile frame.

[0015] Furthermore, a DIN rail and a wire groove are provided on the back panel.

[0016] Furthermore, the number of input and output of the 1200 PLC module is: ≥8; the input type includes analog input and digital input, the power supply voltage is 24V DC, the network type is Ethernet, and the communication port type is Ethernet.

[0017] Furthermore, the power supply voltage of the ET200 expansion module is 24V DC.

[0018] Furthermore, the number of the indicator lights is sixteen.

[0019] The beneficial effects of the utility model are:

[0020] (1) It can simulate control system alarms. When the system alarms, such as hardware module damage, signal module channel short circuit, open circuit, communication interruption, temperature or pressure exceeding the set range, this alarm screen will appear, displaying the alarm number, alarm time, and alarm content, prompting the operator to take measures to eliminate safety hazards.

[0021] (2) It can simulate communication failures. According to the indicator lights and analog and digital status displays of the Siemens CPU module of the system, it can be determined whether the communication failure is caused by a communication cable or hardware module failure.

[0022] (3) Simulation of intelligent fault diagnosis function of stable vehicle. The input and output status of each logical relationship can be directly demonstrated on the touch screen, realizing on-site intelligent fault diagnosis simulation of Siemens PLC.

[0023] (4) With 4G remote function. The human cloud module communicates with the PLC through the switch, which can realize the remote transmission and monitoring of PLC data. By logging in through the computer and mobile phone, you can remotely monitor the operating data of the PLC, realize remote guidance of fault handling, and realize the simulation of the remote control function of the Siemens large machine on site. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a structural diagram of the utility model.

[0025] Figure 2 This is the power supply circuit diagram of the switching power supply.

[0026] Figure 3 This is the circuit diagram of the 1200PLC main module.

[0027] Figure 4 This is the circuit diagram of the ET200 expansion module.

[0028] Figure 5 Connect the network cables to the switch.

[0029] Figure 6 This is the network cable interface of the switch.

[0030] Figure 7 This is a diagram of the connection port for Profinet communication.

[0031] In the figure:

[0032] 00 back panel,

[0033] 01TV,

[0034] 02Touch screen,

[0035] 03Switching power supply,

[0036] 04 Human cloud module,

[0037] 05Switch,

[0038] 06 1200 PLC module,

[0039] 07 ET200 expansion module,

[0040] 08 motor push rod, 081 angle steel,

[0041] 09 Photoelectric sensor Ⅰ,

[0042] 10 Photoelectric sensor Ⅱ,

[0043] 11 motors, 111 speed regulators,

[0044] 12 encoders,

[0045] 13 voltage generator,

[0046] 14 temperature and humidity sensors,

[0047] 15 indicator lights. DETAILED DESCRIPTION

[0048] refer to Figure 1 The device consists of a back panel and a TV 01, a touch screen 02, a switching power supply 03, a human cloud module 04, a switch 05, a 1200 PLC module 06, an ET200 expansion module 07, a motor push rod 08, a photoelectric sensor I 09, a photoelectric sensor II 10, a motor 11, an encoder 12, a voltage generator 13, a temperature and humidity sensor 14, an indicator light 15, a cable, a signal line, etc. The above-mentioned multiple modules are modularly and quickly installed and connected for easy assembly, wherein,

[0049] The back panel 00 is a hollow structure, and the frame is made of aluminum alloy profiles to form the installation base of the device. The back panel is provided with DIN rails and wire grooves, and the DIN rails provide installation points for the above-mentioned functional modules and are installed one by one. The wire grooves are used to bundle and constrain the cables and signal lines, which are neat and beautiful.

[0050] The 1200 PLC module 06 integrates and adds PROFINET communication function, which can communicate with the ET200 expansion module of the distributed IO module for PROFINET communication, and establish Profinet communication between the 1200 PLC module, touch screen, and switch. Figure 7 .

[0051] Furthermore, the number of input and output of the 1200 PLC06 module 06 is: ≥8; the input type includes analog input and digital input, the power supply voltage is 24V DC, the network type is Ethernet, and the communication port type is Ethernet.

[0052] Furthermore, the power supply voltage of the ET200 expansion module is 24V, DC, the DI module is 16×24V, DC, and the D0 module is 16×24V, DC.

[0053] The TV 01 is used to simulate and display the operation steps and operation status of the stabilization vehicle. It is preferably an LCD screen. The TV is mounted on the top of the back plate through fasteners to facilitate the operator's horizontal observation. Figure 1 , electrical connection with the switch for signal transmission.

[0054] Touch screen 02 is used to simulate various buttons of the stable car. Various functions are realized by clicking and operating various buttons. It is a touch control functional component. The touch screen matched with Siemens is preferred. The touch screen is installed at the top of the back plate through fasteners to facilitate the operator's horizontal observation. Figure 1 The touch screen 02 is connected to the switch through a signal line and performs corresponding electrical control.

[0055] Preferably, the touch screen 02 and the TV 01 are located at the same height. Figure 1 shown.

[0056] Switching power supply 03 is used to supply power to the simulation platform equipment. The power supply connection is as follows: Figure 2 As shown in the figure, the switch power supply 03 is powered by two independent power supplies. One power supply supplies power to the TV, touch screen, switch, 1200 PLC module, and ET200 expansion module and makes electrical connections. The other power supply supplies power to the motor, motor push rod, encoder, and photoelectric sensor and makes electrical connections. Figure 2 shown.

[0057] The user cloud module 04 is used to upload data to the cloud, which is convenient for mobile phones and PCs to view; the user cloud module 04 uploads the operating status data to the cloud for easy viewing, realizing wireless monitoring, and the switch 05 makes the data interaction of the stable car simulation system easier. The system information, operations, etc. can be monitored in real time by mobile phones and remote computers. The user cloud module is equipped with a mobile phone traffic card, and wireless monitoring can be realized in any signal location.

[0058] Switch 05 is used to connect the collection point via network cable; synchronously connect the above-mentioned TV, human cloud module, 1200 PLC module (CPU1212), touch screen 02, and ET200 expansion module to the switch through network cable electrical connection. The network connection is as follows Figure 5 and Figure 6 As shown, data transmission and exchange are realized.

[0059] 1200 PLC06 is a centralized controller for stabilizing vehicles. As the general control module of the simulation system, it plays a role in statistically arranging data in the entire system, controlling the equipment to run simulations, and enabling the equipment to run normally when conditions are met. The main module circuit diagram is shown in the figure below. Figure 3 As shown;

[0060] ET200 expansion module 07 is used to expand PLC points. Since the points of PLC are fixed, the excess points need to use ET200 modules to read the status and control the operation. The circuit diagram of this module is as follows Figure 4 As shown, ten photoelectric sensors II are connected to simulate the actions of ten cylinders of a stable vehicle.

[0061] The motor push rod 08 and the photoelectric sensor Ⅰ09 are used to simulate the descent of the stable vehicle and determine the closed state of the vehicle head and body, and simulate whether the descent is in place when the equipment is running. If it is not in place, an alarm needs to be issued and the subsequent action needs to be stopped. Among them, the number of the above-mentioned photoelectric sensors Ⅰ09 is 6, representing the front stable vehicle head descending left, the front stable vehicle head descending right, the rear stable vehicle head descending left, the rear stable vehicle head descending right, the middle measuring vehicle descending left, and the middle measuring vehicle descending right. Figure 3 .

[0062] like Figure 1As shown, the WD-320 power stabilization vehicle Siemens PLC simulation system is equipped with two motor push rods (also called small electric push rods). The forward and reverse relays can control the extension and retraction of the push rods in the small electric push rods. When the push rods are extended to the position of the photoelectric sensor Ⅰ, the extension stops. The extension of the stabilization cylinders in different parts of the stabilization vehicle can be simulated. When the small electric push rod is extended, but the push rod is not in place and is not sensed by the photoelectric sensor Ⅰ, it is used to simulate the extension of the stabilization cylinder in the stabilization vehicle. The system alarms (marking a fault), that is, the simulation of the extension working state of the stabilization cylinder is realized through the combination of the small motor push rod and the photoelectric sensor Ⅰ.

[0063] Furthermore, there are two small electric push rods, which respectively simulate the two directional stabilizing cylinders that control the descending action of the stabilizing vehicle, and the push rods of the two small electric push rods are connected by an angle steel 081, so that the angle steel simulates the chassis of the stabilizing vehicle body, and the angle steel 081 cooperates with the above-mentioned multiple photoelectric sensors Ⅰ09 for sensing. Specifically, the arrangement of the angle steel is perpendicular to the movement direction of the above-mentioned electric push rod, and the arrangement of the angle steel (length direction) is perpendicular to the sensing direction of the photoelectric sensor Ⅰ.

[0064] Furthermore, the two small electric push rods are horizontally arranged to overcome the influence of gravity, but it is also feasible to arrange the two small electric push rods horizontally.

[0065] During the simulation, the extension length of the two small motor push rods is controlled to control the inclination angle of the angle steel, thereby simulating the tilt state of the chassis of the stable vehicle body. The descent of the front stable vehicle head, the rear stable vehicle head and the middle measuring vehicle are simulated through the induction of six photoelectric sensors Ⅰ, and corresponding teaching guidance is provided.

[0066] The motor 11 is used to simulate the forward and running speed of the stable car, that is, the motor is used to simulate the forward and movement speed and other motion control limits of the stable car. The motor 11 cooperates with the encoder 12, and the two are mechanically connected through a coupling, and the motor 11 is configured with a speed regulator 111. Specifically, the working principle of the motor speed regulation and encoder simulation PWM (pulse width modulation) speed regulator is based on the mutual conversion between digital signals and analog signals to achieve the speed regulation of the motor or other loads. In digital systems such as single-chip microcomputers, the I / O port can usually only output high level (5V) or low level (0V). In order to simulate voltages of different sizes, PWM technology is required. The PWM speed regulator can effectively control the analog voltage by changing the duty cycle in the digital signal, thereby achieving accurate speed regulation of the motor or other loads. The PWM speed regulator configured in the Siemens PLC simulation system of the WD-320 power stable car can adjust the motor speed. The encoder is configured at the front end of the motor to monitor the motor speed information in real time and simulate motor control. The acquisition of the encoder signal simulates the distance pulse information of the stable car.

[0067] The voltage generator 13 is used to measure and test the voltage response capability and accuracy of circuit components, electrical equipment or systems. The voltage generator 13 is electrically connected to the SM1231 in the 1200 PLC. It can generate signals of different amplitudes and frequencies to simulate the voltage signals of the stable vehicle in different application scenarios, such as motor voltage. Figure 6 The WD-320 power stabilizer car Siemens PLC simulation system is equipped with a voltage regulator that can generate 0-10V voltage. Through PLC conversion, it can be used to simulate the wiring conversion program of motor speed, stabilizer car speed, current and other signals. The analog wiring diagram is as follows Figure 7 shown.

[0068] The temperature and humidity sensor 14 is electrically connected to the SM1231 in the 1200 PLC to simulate the signal acquisition of the on-site temperature and humidity. Its role in the stable vehicle is to simulate the wiring and signal changes of the temperature and humidity sensor.

[0069] Photoelectric sensor II 10, the number is ten, the photoelectric sensor II converts the light signal into an electrical signal through the photoelectric effect, the magnitude of the current is proportional to the intensity of the light, and then through circuit processing and amplification, finally outputs the corresponding signal. The above ten photoelectric sensors II are respectively marked as: front stabilizing head rising left limit, front stabilizing head rising right limit, middle measuring trolley locking, front stabilizing head locking, rear stabilizing head locking, rear measuring trolley locking, front measuring trolley locking, positive vector trolley locking, active shaft operation drive clutch, spare, and the above ten photoelectric sensors II are digitally numbered for reference Figure 4That is to say, the ten photoelectric sensors II mentioned above are used to simulate the extension and retraction signals of each positioning cylinder of the stabilizing vehicle. The specific operation demonstration process is that the operator holds a metal sheet and approaches any of the above photoelectric sensors II carefully. When metal approaches the corresponding photoelectric sensor II, the corresponding input signal receives a signal and gives the PLC host computer an in-place indication. For example, when a metal sheet is used to approach the photoelectric sensor II represented by the left limit of the front stabilizing head, the corresponding indicator light will light up.

[0070] Furthermore, the number of indicator lights 15 is sixteen. In different programs, the sixteen indicator lights are used to simulate signal output and the meaning of each output indicator light can be customized according to the program. The operation process is that the eight indicator lights on the left are signal output functions, and the eight indicator lights on the right can control the lighting speed according to voltage regulation to achieve the effect of lighting up the colored lights in a cycle.

[0071] The above-mentioned photoelectric sensors Ⅰ and Ⅱ have the following indicators:

[0072] Power supply voltage: 24V, DC

[0073] Sensing distance: 4MM

[0074] Ambient temperature: -25℃-+65℃

[0075] In this embodiment, Profinet communication is an industrial communication protocol widely used by Siemens control systems. It is a relatively new industrial communication protocol based on Ethernet. The physical interface used by Profinet is a standard RJ-45 Ethernet socket. For example, two S7-200Smart PLCs can achieve wireless Profinet communication with the help of the European and American PLC wireless communication terminal DTD418M. Use a communication line, connect one end to the RJ45 interface of DTD418M, and the other end to the RJ45 interface of S7-200SMART, to achieve wireless Profinet communication.

[0076] The WD-320 power stabilizer car Siemens PLC fault diagnosis simulation system is equipped with Siemens 1200 series and remote ET200s modules. The two use Profinet communication to realize data exchange. When the communication between the two is abnormal, such as network cable disconnection, poor contact, power failure of any device, etc., the red alarm light of the module itself will light up, and the host computer will also generate a communication failure prompt, such as Figure 7 shown.

[0077] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements to the present invention by relevant technical personnel in the field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. WD-320 power stabilization vehicle Siemens PLC fault diagnosis simulation device, the device includes a back panel and a TV, a touch screen, a switching power supply, a human cloud module, a switch, a 1200 PLC module, an ET200 expansion module, a motor push rod, a photoelectric sensor I, a photoelectric sensor II, a motor, an encoder, a voltage generator, and a temperature and humidity sensor installed on the back panel, characterized in that: The switch is a network cable connection collection point and a synchronous network cable connection TV, human cloud module, 1200PLC module, touch screen, ET200 expansion module, and the 1200PLC module is integrated with a PROFINET communication module and establishes an electrical connection with the ET200 expansion module, touch screen, and switch; The ET200 expansion module is connected to multiple photoelectric sensors II, which respectively simulate the left limit of the front stabilizing head rising of the stabilizing car, the right limit of the front stabilizing head rising, the locking of the middle measuring trolley, the locking of the front stabilizing head, the locking of the rear stabilizing head, the locking of the rear measuring trolley, the locking of the front measuring trolley, the locking of the positive vector trolley, and the driving clutch of the active shaft operation; There are two motor push rods, and an angle steel is installed between the push rods of the two motor push rods. The angle steel simulates the chassis of the stable vehicle body. The angle steel cooperates with multiple photoelectric sensors I. The number of the photoelectric sensors I is six, and they respectively simulate the actions of the front stable vehicle head descending to the left, the front stable vehicle head descending to the right, the rear stable vehicle head descending to the left, the rear stable vehicle head descending to the right, the middle measuring vehicle descending to the left, and the middle measuring vehicle descending to the right; The motor and encoder are connected to 1200PLC, the motor cooperates with the encoder and the two are mechanically connected through a coupling; The voltage generator is electrically connected to SM1231 in the 1200 PLC; The temperature and humidity sensor is electrically connected to SM1231 in the 1200 PLC.

2. The WD-320 power stabilizer vehicle Siemens PLC fault diagnosis simulation device according to claim 1, characterized in that: The angle steel is arranged perpendicular to the movement direction of the electric push rod, and the angle steel is arranged perpendicular to the sensing direction of the photoelectric sensor I.

3. The WD-320 power stabilizer vehicle Siemens PLC fault diagnosis simulation device according to claim 1, characterized in that: The motor push rod is arranged horizontally.

4. The WD-320 power stabilizer vehicle Siemens PLC fault diagnosis simulation device according to claim 1, characterized in that: The back plate is a structure with a hollow structure and is configured with an aluminum alloy profile frame.

5. The WD-320 power stabilizer vehicle Siemens PLC fault diagnosis simulation device according to claim 4, characterized in that: The back panel is provided with a DIN rail and a wire pressing groove.

6. The WD-320 power stabilizer vehicle Siemens PLC fault diagnosis simulation device according to claim 1, characterized in that: The number of input and output of the 1200 PLC module is: ≥8; the input types include analog input and digital input, the power supply voltage is 24V DC, the network type is Ethernet, and the communication port type is Ethernet.

7. The WD-320 power stabilizer vehicle Siemens PLC fault diagnosis simulation device according to claim 1, characterized in that: The power supply voltage of the ET200 expansion module is 24V DC.

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