The central management system scheme of Guangxi Yu

2022-08-06
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Guangxi Yuchai engine assembly workshop central management system scheme

introduction: the engine test bench, AGV running trolley and pre installed roller conveyor line in Yuchai engine assembly workshop generally adopt the typical mode of "centralized monitoring and decentralized control". According to this principle, we divide the entire electronic control system into three levels, namely, the computer central monitoring system, For equipment level PLC control system and fieldbus control system, different network structures and software and hardware configurations are used in each level to achieve different functions. The system is used for information exchange among the bench, AGV trolley and roller conveying system, as well as unified monitoring and dispatching management of the three systems. At the same time, the production information of these three parts is incorporated into the ERP and QAS systems of the whole plant to realize data sharing and accept unified dispatching management

key words: AGV centralized monitoring PLC information ERP QAS data sharing

I: composition of central control system:

the central control system is constructed by using industrial computer network technology, PROFIBUS field industrial bus technology and iFIX industrial configuration software SCADA (data acquisition and monitoring control system). The computer central monitoring system adopts the client/server structure. The server is specially responsible for the data communication with each field controller (PLC), directly receiving the effective information sent from the field controller (PLC) and establishing the monitoring system database. At the same time, the system can be developed and the system database can be changed; As the client node, the equipment operator station reads the information in the database from the server, establishes the display interface and monitors the running status of the equipment in real time; In addition, a monitoring data management station is set, whose main function is to read the relevant data in the SCADA server database, process them, count and save them

II: composition of the system network

1: the upper information management network is shown in figure 1

Figure 1: the structure of the upper information management network

a) operation management machine: through the application software on the operation station, the on-site equipment can be centrally monitored and dispatched. It exchanges data with the on-site PLC through the industrial Ethernet to realize the information exchange between PLC and management system, as well as between PLC and PLC. There are three operation management machines to supervise and manage the three systems of AGV, bench and pre assembly line

b) data server: the data server is used to store and store mixed materials containing low-level long carbon fiber reinforced materials, which will be much cheaper than all carbon long fiber reinforced composites (Figure 1). It manages production data, including real-time production data and basic data. On the one hand, it records and saves production data in real time, and on the other hand, it synchronizes with the company's management system to update basic production data at any time. In order to improve the data security and ensure the real-time and reliability of the system operation, the system is configured with two data servers, one for use and one for standby

2.. Equipment selection

2.1 operation management machine

3 Dell commercial workstations

configuration: P4 2.8g/256k/40g/card/17 inch crt/speaker

configuration software (running version) 3 sets of

model: iFIX 1024 point running version

application software 3 sets of

operating system 3 sets of

model: Windows 2003 Professional

2.2 data server

dell special server 2 sets of

configuration: P4 2.8g/512k/80g/card/17 inch crt/speaker

database development platform: orace9.2 workgroup Level 2 sets/p>

operating system: Windows 2003 advanced server 2 sets

2.3 Replacement

3com switch 1 set, 16 ports, 10/100m adaptive

2.4 printer

hpa3 color ink jet printer 1 set

3: the bottom device control network is shown in Figure 2

Figure 2: the bottom device control network structure figure

the bottom device control network is mainly used to control the actions of the whole AGV trolley, roller conveyor line and experimental bench through the Profibus network of the field industrial bus The PLC of the roller conveyor line and the test bench controls the corresponding equipment actions respectively according to the control instructions sent by the upper information management network. At the same time, each PLC sends its own status information to the relevant PLC through the network on the one hand, and receives the status information of other PLCs through the network on the other hand to determine the next action. In this way, the actions of various equipment controlled by each PLC can cooperate, contact and coordinate with each other

III: system function

3.1. centralized display monitoring function

can conduct real-time centralized monitoring on the working conditions and positions of field equipment and workpiece to be tested

3.2. centralized operation function

can centrally operate field equipment through computer for centralized production

3.3. scheduling function

unified production management and scheduling can be carried out in the control room through data sharing and exchange between management machines and PLCs

3.4. remote programming and monitoring function

each PLC on the site can be programmed and debugged through the PLC programming software on the computer

3.5. data storage management function

the system uses a special data server for production data management and storage, It can save and update real-time production data and basic data, realize data sharing and synchronization within the system and the ERP and QAS systems of the whole plant

3.6. data query

it is convenient to query production historical data on the operation management machine

3.7. report generation function

the operation management machine can automatically generate shift, day Monthly and annual production reports

3.8. centralized alarm function

field equipment failures can be centrally reflected on the management machine through the network, so that the production management personnel can take measures in time

3.9. network expansion

the system adopts tcp/ip Industrial Ethernet, which is compatible with commercial Ethernet while improving communication reliability

IV: system features

4.1 high system reliability

is reflected in the following aspects:

1) Industrial Ethernet is adopted, and its own network communication is very reliable

2) at the same time, all three operation management machines can access the existing PLC, so in fact, the three management machines can be redundant to each other

3) two data servers are used for redundant configuration, which improves the reliability of the system

4) iFIX industrial configuration software of intelligence company is used, which can reliably communicate with the following PLC

4.2. easy to operate

the computer uses graphical monitoring images to conduct real-time dynamic monitoring on the site, and animation can be used to simulate the actual work process on the site, so the monitoring operation is extremely convenient

4.3. high data security

the data is backed up in real time by dual servers, and the multiple security access mechanisms of windows and database platform ensure that the data will not be accidentally damaged or lost

V: information processing of the system

1: the functions to be realized by the central management system and the process flow of the whole system are as follows:

engine from the pit (with two-dimensional positive moment code) → preassembled material points on the roller conveyor line. After manually scanning the engine information, the central management system database stores the model, quantity and The machine to be tested and its location → at the lower line of the pre installed roller conveyor line, manually scan the engine information and tell the central management system that this type of engine will be tested. The central management system coordinates the AGV trolley through the network to prepare for receiving → after docking with the AGV trolley, the AGV trolley will send the engine to the test bench, The engine on the AGV trolley required by the test bench shall be coordinated by the central management system according to the requirements of the empty and important vehicle sent by the test bench (where to send it?) → the AGV trolley is connected to the test bench → the engine test is carried out manually → after the test is completed, the engine test results are manually entered (through the human-computer interface), and the vehicle delivery request is sent. The central management system stores the engine test results, Coordinate the AGV trolley to prepare for receiving → connect the AGV trolley with the test bench → send it to the AGV trolley → connect the AGV trolley with the loading point of the roller conveyor line → after the connection is successful, the loading point will manually scan the information of the engine → after some station operations, enter the conveying roller conveyor and the lower line of the conveyor line → after manually scanning the information of the engine at the lower line, the central management system will confirm whether the engine is offline to the analog line, If the engine is unqualified, enter the repair area → send the unqualified engine to the repair area by the crown block → at each repair station, after manually scanning the engine information, the man-machine interface will display the unqualified condition of the engine, and the worker will carry out corresponding manual repair according to the displayed information → after the repair is completed, the worker will manually input the repair condition on the man-machine interface and send it to the pre installed roller conveyor line by the crown block, Conduct engine test

2: the monitoring screen

runs iFIX on the three operation management machines in the central control room. Its main function is to collect the status information of each process equipment of AGV trolley, test bench and roller conveyor line in real time, and generate the precision level of the experimental machine in the form of graphics and text to display the working conditions of each line in real time. The manager can monitor and manage the production in the central control room according to the process conditions. The central control room of the system is equipped with three operation management machines, which respectively display the operation of AGV trolley, test bench and roller conveyor line

1) monitoring screen of pre installed roller conveyor line system

a) system main screen: the stop and start of the whole system can be operated on the screen, and the system can automatically complete in time sequence. The screen shows the process flow of the whole line, the number, model and various engine parameters of each station; Working status of each lifting table and rotary table

b) main screen of engine identification system: display the real-time data information of each engine identification station on the line (read QR code information and reading time)

c) shift system statistics: display the hourly production, working time timing, target production, actual production and total downtime of each shift system in days

d) control cabinet status screen: displays the working status of the control cabinet on the line body, such as automatic, manual, alarm and the working status of the operation button station on the line body

e) alarm summary screen: display the alarm signal of the equipment on the whole line

2) AGV trolley system monitoring screen

a) system main screen: the stop and start of the whole system can be operated on the screen, and the system can automatically complete in time sequence. The screen displays the running status, location, where to go, the model of the engine carried by the three AGV trolleys on the line and their relevant information

b) interface between AGV trolley and pre installed roller conveyor line and test bench

c) control cabinet status screen: displays the working status of the control cabinet on the line body, such as automatic, manual, alarm and the working status of the operation button station on the line body

d) alarm summary screen: display the alarm signal of the equipment on the whole line

3) test bench system monitoring screen: display the working conditions of each test bench, such as whether the test bench has an engine under test, the model of the engine to be sent and to be sent, whether it is qualified or not, which trolley to be sent to, which trolley to be received, and which engine model

VI: system information maintenance

system information maintenance mainly includes the following aspects:

a) equipment information maintenance/query