Bucket wheel machine network control communication redundancy configuration

Abstract

The utility model discloses a bucket wheel machine network control communication redundancy configuration, and relates to the technical field of bucket wheel machine communication configuration, in particular to the bucket wheel machine network control communication redundancy configuration. Comprising a master station, a CPU, a master station CNB, a master station IO module, a master station EN2TR, a slave station, a slave station CNB, a slave station IO module, a slave station EN2TR, an upper computer, a touch screen, a switch, a host and a display. In the utility model, two paths of ControlNet bus redundancy configurations and two paths of six-type network cable redundancy communication configurations are included. In the communication redundancy switching process, through newly-added logic switching of the newly-added upper computer, redundancy communication of two paths of ControlNet buses and redundancy communication display of two paths of category 6 network cables can be achieved, and normal use of the bucket wheel machine is not affected. The occurrence rate of original communication faults is reduced from 50% to 4.17%, and faults and damage of field equipment caused by interruption of any communication mode are prevented.

Description

Technical Field

[0001] The utility model relates to the technical field of bucket wheel stacker-reclaimer communication configuration, and specifically relates to a redundant configuration for the network control communication of a bucket wheel stacker-reclaimer. Background Art

[0002] Existing bucket wheel stacker-reclaimer network control systems usually use a single ControlNet bus for communication. When the communication is interrupted, the equipment cannot operate normally, seriously affecting production efficiency and safety. Although the ControlNet bus has certain redundancy functions, it still cannot completely avoid the risk of single-point failures. To improve the reliability and stability of the system, multiple redundant communication configurations need to be introduced. However, traditional redundant designs are complex, with high implementation costs and difficult maintenance. An existing communication configuration method, device, and equipment (publication number: CN110719180A) has the following drawbacks and needs further improvement.

[0003] 1. Limitations of single communication mode: Traditional bucket wheel stacker-reclaimer network control systems use a single ControlNet bus for communication. This design has obvious limitations and risks. If the single communication mode, the ControlNet bus, fails, the entire system will not be able to operate normally. In this case, the production efficiency and safety of the equipment will be affected, and the shutdown of the bucket wheel stacker-reclaimer will cause the entire production line to come to a standstill. In addition, the fault recovery time of the single communication mode is relatively long, requiring professional technicians to conduct on-site inspections and repairs, increasing the maintenance cost and prolonging the equipment downtime, further affecting the production schedule. Therefore, there is an urgent need for a bucket wheel stacker-reclaimer redundant configuration with a dual redundant communication mode.

[0004] 2. Singularity and non-expandability of hardware modules: Traditional equipment has a single design in hardware module, lacking flexibility and expandability. Previous control systems mainly relied on a single communication module inside the PLC and could not support the flexible switching of multiple communication modes. The limitations of the hardware design reduce the adaptability of the system and increase the difficulty of maintenance and upgrade. The PLC communication card in the traditional system cannot support Ethernet communication, making the system unable to utilize modern network technologies for data transmission and remote monitoring. The hardware module design of traditional equipment is a fixed configuration, lacking the modular design concept. As a result, when it is necessary to add or replace a communication module, the entire system must be extensively modified. This increases the cost and also causes long-term downtime. There is an urgent need for a bucket wheel stacker-reclaimer redundant configuration with a design for adding hardware modules.

[0005] 3. Complexity and inefficiency of software configuration: The software configuration of the traditional bucket wheel stacker-reclaimer control system is complex and lacks flexibility. Such a system relies on specific control software and communication drivers. Once configured, it is difficult to adjust and optimize the system. The traditional upper computer software and lower computer software use fixed versions, making it difficult to achieve cross-version compatibility and optimization. In addition, the data exchange driver configuration in the traditional system is cumbersome and requires professional technicians to manually configure and debug, increasing the complexity of the initial installation and the technical difficulty in daily maintenance. There is an urgent need for a bucket wheel stacker-reclaimer redundant configuration with optimized software configuration design. Summary of the Invention

[0006] The main purpose of the present utility model is to provide a redundant configuration for the network control communication of a bucket wheel stacker-reclaimer, which can effectively solve the problems in the background technology.

[0007] To achieve the above purpose, the technical solution adopted by the present utility model is as follows: There is a redundant configuration for the network control communication of a bucket wheel stacker-reclaimer. A slave station is installed below the master station, an upper computer is installed below the slave station, a switch is installed below the slave station, a host is installed below the switch, and a display is installed on one side of the host.

[0008] Preferably, a CPU is installed inside the master station, a master station CNB is installed on one side of the CPU, a master station IO module is installed on one side of the master station CNB, and a master station EN2TR is installed on one side of the master station IO module.

[0009] Preferably, a slave station CNB is installed inside the slave station, a slave station IO module is installed on one side of the slave station CNB, and a slave station EN2TR is installed on one side of the slave station IO module.

[0010] Preferably, a touch screen is installed inside the upper computer.

[0011] Compared with the prior art, the present utility model has the following beneficial effects:

[0012] This utility model adopts a dual-redundancy communication method. Through the combination of the ControlNet bus and Category 6 network cables, it ensures that when any communication fails, the system can automatically switch to the backup line to maintain the continuous operation of the equipment. It effectively avoids the problem of the entire system shutdown caused by the interruption of a single communication method, and improves the reliability and stability of the system. The dual-redundancy design enables the system to automatically switch to the backup line when detecting a communication failure, without waiting for professional technicians to conduct on-site troubleshooting and repair, shortening the fault recovery time. It reduces the equipment downtime, lowers the maintenance cost, and improves the production efficiency. This utility model adds an EN2TR Ethernet module, enabling the system to support flexible switching of multiple communication methods and having stronger adaptability. The introduction of modern network technology allows the system to use Ethernet for data transmission and remote monitoring, expanding the application scope of the system. Adopting a modular design, the addition and configuration of hardware modules such as the EN2TR Ethernet module are more flexible. Modules can be easily added or replaced when needed without large-scale transformation of the entire system. It reduces the difficulty of maintenance and upgrade, decreases the cost and downtime, and improves the maintenance efficiency of the system. This utility model uses the latest versions of the upper computer and lower computer software, enabling the system to achieve a more efficient and intuitive operation interface, enhancing the operation and monitoring capabilities of the bucket wheel stacker-reclaimer. The optimized software configuration design enables the system to quickly respond to changes in production requirements. The standardized configuration of the IGS drive makes the data exchange between the upper and lower computers more efficient and stable. The configuration process is simplified, reducing the cumbersome steps of manual configuration and debugging, lowering the complexity of initial installation and the technical difficulty of daily maintenance. It improves the overall efficiency of the system, enhancing the flexibility and usability of the system. Description of the Drawings

[0013] Figure 1 It is a schematic diagram of the overall structure of this utility model;

[0014] Figure 2 It is a schematic diagram of the main station structure of this utility model;

[0015] Figure 3 It is a schematic diagram of the slave station structure of this utility model;

[0016] Figure 4 It is a schematic diagram of the upper computer structure of this utility model.

[0017] In the figure: 1, main station; 101, CPU; 102, main station CNB; 103, main station IO module; 104, main station EN2TR; 2, slave station; 201, slave station CNB; 202, slave station IO module; 203, slave station EN2TR; 3, upper computer; 301, touch screen; 4, switch; 5, host; 6, display. Detailed Implementation Manner

[0018] In order to make the technical means, creative features, achieved purposes and effects realized by the present utility model easy to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0019] In the description of the present utility model, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "inner", "outer", "front end", "rear end", "both ends", "one end", "the other end", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present utility model. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0020] In the description of the present utility model, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "provided with", "connection", etc. should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific situations.

[0021] Embodiment

[0022] Please refer to Figures 1-4 , the present utility model provides a technical solution:

[0023] A redundant configuration for the network control communication of a bucket wheel stacker-reclaimer. A slave station 2 is installed below the master station 1, an upper computer position 3 is installed below the slave station 2, a switch 4 is installed below the slave station 2, a host 5 is installed below the switch 4, and a display 6 is installed on one side of the host 5.

[0024] The following are the specific embodiments of the components of the present utility model:

[0025] 1. Master station

[0026] 101. CPU:

[0027] The CPU is the core processing unit of the master station PLC, responsible for executing the control program and processing various input / output signals. The CPU module is installed in the first slot of the master station PLC to ensure its normal connection and communication.

[0028] 102. Master station CNB:

[0029] The CNB module is used for communication on the ControlNet bus. Install the CNB module in the designated slot of the master station PLC and connect it to the ControlNet bus through a coaxial cable to achieve data transmission between the master station PLC and the slave station PLC.

[0030] 103. Master station IO module:

[0031] The IO module is used to process input and output signals. Install the IO module in the designated slot of the master station PLC and connect various sensors and actuators to ensure accurate signal acquisition and effective execution of control instructions.

[0032] 104. Master station EN2TR:

[0033] The EN2TR module is used for Ethernet communication. Install the EN2TR module in the designated slot of the master station PLC and connect it to the switch through a network cable to achieve Ethernet communication with the slave station PLC and the upper computer.

[0034] 2. Slave station

[0035] 201. Slave station CNB:

[0036] The slave station CNB module is also used for communication on the ControlNet bus. Install the slave station CNB module in the designated slot of the slave station PLC and connect it to the ControlNet bus through a coaxial cable to ensure normal communication with the master station PLC.

[0037] 202. Slave station IO module:

[0038] The slave station IO module processes the input and output signals of the slave station. Install the IO module in the designated slot of the slave station PLC and connect the relevant sensors and actuators to ensure the accuracy of signal acquisition and control.

[0039] 203. Slave station EN2TR:

[0040] The slave station EN2TR module is used for Ethernet communication. Install the EN2TR module in the designated slot of the slave station PLC and connect it to the switch through a network cable to achieve Ethernet communication with the master station PLC and the upper computer.

[0041] 3. Upper computer

[0042] 301. Touch screen:

[0043] The touch screen serves as the display and control interface of the upper computer. Install the touch screen at the operation position and connect it to the switch through a network cable to achieve data exchange with the PLC system. Software runs on the touch screen to display real-time data and control the operation of the bucket wheel stacker reclaimer.

[0044] 4. Switch

[0045] The switch is used to connect all Ethernet devices. The master station EN2TR, slave station EN2TR, and touch screen are connected to the switch via network cables to achieve data communication and network management among devices.

[0046] 5. Host

[0047] The host is used to run the upper computer software and monitor system operations. The host is connected to the switch to communicate with the PLC and touch screen via network cables. Software is installed on the host for data monitoring and system control.

[0048] 6. Display

[0049] The display is used to display the operation interface of the host. The display is connected to the host to display real-time data and system status through software, assisting operators in monitoring and control.

[0050] The following is the specific technical logic implementation of the innovation points of this utility model:

[0051] 1. Technical logic implementation of dual redundant communication mode

[0052] This utility model realizes a highly reliable communication system by introducing a dual redundant communication mode and combining the ControlNet bus and Category 6 network cables. First, the master station PLC and the slave station PLC are connected through the ControlNet bus. The specific implementation method is to install ControlNet communication card modules CNB in the master station and slave station PLCs respectively and connect them through coaxial cables. The ControlNet bus serves as the main communication path and undertakes most of the data transmission tasks. When the ControlNet bus is working properly, the system realizes real-time data exchange between the master station PLC and the slave station PLC through the CNB module. In addition, the system is also configured with Category 6 network cables as the backup communication path. To achieve this, EN2TR Ethernet modules are installed in the master station and slave station PLCs respectively and connected through Category 6 network cables and switches. The introduction of the EN2TR module enables the PLC to communicate through Ethernet and supports high-speed data transmission and remote monitoring. When the ControlNet bus fails, the system can automatically detect the communication interruption and quickly switch to the Category 6 network cables to continue data transmission. Such a design ensures that when any communication path fails, the system can maintain continuous operation, avoiding production line downtime. The whole process does not require the intervention of professional technicians, greatly shortening the fault recovery time, reducing the maintenance cost, and improving the reliability and stability of the system through the automatic switching mechanism.

[0053] 2. Technical logic implementation of the increased design of hardware modules

[0054] The utility model significantly improves the flexibility and adaptability of the system by adding an EN2TR Ethernet module. The design of the hardware module adopts the concept of modularization and standardization, enabling the system to support flexible switching between multiple communication methods. The specific implementation method is to install EN2TR modules in the racks of the master and slave PLCs respectively, configure appropriate IP addresses and slots, so that each module can work properly. The EN2TR module transmits data through Ethernet to achieve the functions of high-speed communication and remote monitoring. Through this design, the system can not only communicate traditionally through the ControlNet bus, but also use modern Ethernet technology for data transmission and monitoring. Another advantage of the modular design lies in the simplicity of maintenance and upgrade. Since the hardware modules are standardized, when adding or replacing communication modules, there is no need to carry out large-scale transformation of the entire system. Engineers only need to simply add or replace the modules and perform corresponding configurations to complete the upgrade or maintenance work. This not only reduces the difficulty of maintenance and upgrade, but also reduces costs and downtime, and improves the maintenance efficiency of the system. Through the flexible design of the hardware module, the system can easily adapt to different production requirements and environmental changes, enhancing the overall adaptability and flexibility.

[0055] 3. Technical Logic Implementation of Software Configuration Optimization Design

[0056] The utility model optimizes the operation interface and monitoring ability of the system by using the latest versions of the upper computer and lower computer software, significantly improving the overall efficiency. The specific implementation methods include installing the IFIX5.8 software version on the upper computer to provide an intuitive operation interface and real-time monitoring function; installing the RSLogix5000V20.03 software version on the lower computer to be responsible for handling specific control logic and data processing tasks. The optimized design of the software configuration enables the system to quickly respond to changes in production requirements and ensure the efficiency and stability of the production process. To achieve efficient data exchange, the system introduces the IGS driver with version 7.58. The standardized configuration of the IGS driver makes the data exchange between the upper and lower computers more efficient and stable. The specific configuration process includes creating new channels and devices, setting corresponding IP addresses and slots, and importing point tables to achieve data exchange. The standardized configuration process simplifies the cumbersome steps of manual configuration and debugging, reducing the complexity of initial installation and the technical difficulty of daily maintenance. In addition, the system also manages the communication settings of the PLC through the RSLinkx software to ensure the stability and efficiency of Ethernet communication. Through the optimized software configuration, the system can achieve a more efficient and intuitive operation interface, improving the operation and monitoring ability of the bucket wheel stacker reclaimer. Overall, the optimization of the software configuration not only improves the overall efficiency of the system, but also enhances the flexibility and usability of the system, ensuring the continuity and stability of the production process.

[0057] The following is the working process of the utility model:

[0058] 1. System Startup and Initialization

[0059] When the system starts up, the master station PLC first conducts self - inspection and initialization to ensure that all hardware modules and communication lines are normal. The master station PLC establishes ControlNet and Ethernet communications through the CNB module and EN2TR module respectively. Correspondingly, the slave station PLC also conducts initialization to ensure that its communication channel with the master station PLC is properly established. The upper computer and the host are connected to the network through a switch, start the IFIX5.8 software, and load the operation interface and monitoring program.

[0060] 2. Routine Operations and Data Transmission

[0061] During normal operation, the master station PLC and the slave station PLC conduct major data transmission and control instruction exchange through the ControlNet bus. The IO module is responsible for processing input signals from sensors and sending control signals to actuators to ensure the normal operation of the bucket wheel stacker - reclaimer. At the same time, the EN2TR module is connected to the switch through a Category 6 network cable to achieve Ethernet communication. The upper computer and the host monitor the real - time status of the system through the IFIX5.8 software, and display the data of each sensor and the operation status of the PLC.

[0062] 3. Fault Detection and Switching

[0063] The system continuously monitors the communication status of the ControlNet bus and the Category 6 network cable. When a fault is detected in the ControlNet bus, the master station PLC and the slave station PLC can automatically switch to Ethernet communication. The specific implementation method is as follows: The master station PLC establishes a communication channel with the EN2TR module of the slave station PLC through its own EN2TR module to continue data transmission and control instruction exchange. After the upper computer and the host detect the network switch through the switch, they automatically adjust the communication settings to ensure that data monitoring and control operations are not affected. In this way, through the redundant communication method, the system can maintain the continuous operation of the equipment and avoid production stagnation when any one communication fails.

[0064] 4. Data Recording and Remote Monitoring

[0065] Throughout the working process, the upper computer and the host record all operation data and sensor readings through the IFIX5.8 software to form a log file. These data are used for production analysis, fault troubleshooting, and maintenance optimization. At the same time, through the EN2TR module and Ethernet connection, the system supports remote monitoring and control. Engineers can connect to the host and the upper computer through a remote computer to view the system status in real - time, adjust control parameters, and conduct fault troubleshooting. This function greatly improves the maintenance efficiency and response speed of the system, ensuring the high - efficiency and safety of the production process.

[0066] 5. Maintenance and Upgrade

[0067] When the system needs maintenance or upgrade, the modular design enables engineers to easily add or replace hardware modules, such as the EN2TR Ethernet module. The maintenance personnel connect to the host and the upper computer through a switch and use the IFIX5.8 and RSLogix5000 software for configuration and debugging. Through the software, engineers can set and manage the communication of the PLC to ensure the normal operation of all modules and devices. The modular and standardized hardware design, combined with the optimized software configuration, greatly simplifies the maintenance and upgrade process, reducing the downtime and cost.

[0068] A new upper computer is designed, which has the same touch screen function as the original upper computer, but the internal logic design of the new upper computer has changed to ensure that after the original ControlNet bus fails, the driver of the new upper computer can be enabled in time to solve the actual equipment operation problem within a short time and ensure the normal use of the bucket wheel machine.

[0069] The above shows and describes the basic principles, main features and advantages of the present utility model. Those skilled in the art should understand that the present utility model is not limited by the above embodiments. The above embodiments and the descriptions in the specification only illustrate the principles of the present utility model. Without departing from the spirit and scope of the present utility model, the present utility model will have various changes and improvements, and these changes and improvements all fall within the scope of the present utility model claimed. The scope of protection claimed by the present utility model is defined by the appended claims and their equivalents.

Claims

1. A redundant configuration for network control communication of a bucket wheel stacker-reclaimer, including a master station (1), characterized in that: A slave station (2) is installed below the master station (1), a host computer position (3) is installed below the slave station (2), a switch (4) is installed below the slave station (2), a host (5) is installed below the switch (4), and a display (6) is installed on one side of the host (5).

2. A redundant configuration for the network control communication of a bucket wheel stacker-reclaimer according to claim 1, characterized in that: A CPU (101) is installed inside the master station (1), a master station CNB (102) is installed on one side of the CPU (101), a master station IO module (103) is installed on one side of the master station CNB (102), and a master station EN2TR (104) is installed on one side of the master station IO module (103).

3. A redundancy configuration for network control communication of a bucket wheel stacker-reclaimer according to claim 1, characterized in that: A slave station CNB (201) is installed inside the slave station (2), a slave station IO module (202) is installed on one side of the slave station CNB (201), and a slave station EN2TR (203) is installed on one side of the slave station IO module (202).

4. A redundant configuration for the network control communication of a bucket wheel stacker-reclaimer according to claim 1, characterized in that: A touch screen (301) is installed inside the host computer position (3).

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