CN102566512B - Based on automatic bearing cutting production line dedicated control circuit and the system of figure programming - Google Patents

Abstract

The invention discloses a special control circuit and system for a bearing cutting automatic production line based on graph programming. The control circuit includes an automatic production line scheduling module, a power supply module, a graph programming interface module, an I/O interface module and a communication module, and the system using the control circuit It includes an engine driver generation module, a diagram editing module, a compilation generation module, a download module, and an online debugging and diagnosis module. The engine driver generation module generates a system engine corresponding to each module of the control circuit according to the architecture of the control circuit, including system initialization. Programs, drivers, scheduling programs, etc., provide interfaces for control algorithms. The invention provides support for bearing equipment manufacturers to reduce the production cost of control systems and develop control systems with independent intellectual property rights. It is more convenient and easy to modify the control of the current bearing processing system , Easy to expand the needs.

Description

Special control circuit and system for bearing cutting automatic production line based on graph programming

technical field

The invention relates to a control circuit of an automatic bearing cutting production line, in particular to a special control circuit and system for an automatic bearing cutting production line.

Background technique

As an important part of the machinery and equipment industry, the machine tool industry plays a pivotal role in the development of the entire national economy. From the perspective of the industry as a whole, my country's machine tool industry is currently in the best period of development since 1992, and the market is showing a good situation where supply exceeds demand. Especially since entering a new growth period in 1999, the output value of my country's machine tool industry has increased year by year, the product structure has been continuously adjusted, and the product quality has been improving day by day.

Although my country's machine tool industry has made great progress in recent years, under the current situation of extremely fierce competition in the domestic and foreign machine tool markets, my country's machine tool industry appears to be less competitive, mainly because my country is a big machine tool consumer. It is not a machine tool powerhouse, the number of machine tools is large but the level is low, the product composition is still backward, the product innovation ability is poor, and the reliability of machine tools needs to be improved. The use of rolling bearings on machine tools is mainly used in the following three parts: main shaft, ball screw and general transmission shaft. Rolling bearings are the basic accessories of machine tools, and their performance directly affects the speed, rotation accuracy, rigidity, anti-vibration and vibration cutting performance, noise, temperature rise and thermal deformation of the machine tool, which in turn affects the precision and surface quality of machined parts. Therefore, high-performance machine tools must be equipped with high-performance bearings.

． Status of bearing production equipment

Precision machine tool bearings have high technical content, high added value, and difficult processing. All major bearing companies in the world have invested a lot of energy in the development and development of precision machine tool bearings. At present, foreign manufacturers of precision machine tool bearings mainly include German FAG, French SNF, Japanese NSK, Swedish SKF, and Japanese NTN.

There is a big gap between the overall level of my country's bearing industry and developed countries, especially in the development and development of precision bearings. Due to the limitations and constraints of processing equipment, manufacturing processes and related technologies, at present, domestic batches and supporting production of precision bearings The manufacturers of machine tool bearings are only a few companies such as Luoyang Shaft Research Technology Co., Ltd. and Harbin Bearing Group Corporation.

． Current status of bearing equipment controller

1) PLC

Programmable Logic Controller (PLC) is a new microprocessor-based industrial control device developed gradually in the late 1960s. It is a new product that applies computer technology to the field of industrial control. In recent years, PLC technology has been widely used in various industrial process control, production automatic line control and various mechanical and electrical integration equipment control. However, as a product with a large volume and a wide range, it has certain defects in control accuracy, function and price; with the advancement of technology, more and more equipment has begun to use dedicated controllers to achieve the best cost performance.

2) Dedicated controller

The research on the domestic bearing production and processing control system is still in its infancy. There are very few companies that develop and produce the entire control system. At present, the design of the controller and the development of the control mechanical system in the market are separated. Due to this situation, the bearing equipment control Due to the uncoordinated development of system technology, there is still a big gap compared with foreign products.

． Current status of controller program development

At present, the special controller program for bearing equipment generally adopts a closed development mode. The core control algorithm is written in high-level languages such as C and VHDL. When the controller leaves the factory, it is solidified in media such as EEPROM or Flash. The control algorithm cannot be customized according to the special needs of end customers. When a new demand arises, the bearing equipment manufacturer will transmit the demand information to the controller manufacturer, and the controller manufacturer will write the corresponding algorithm program according to the demand. In this mode, since there is no standardized logic language component, it is difficult to efficiently and reliably develop corresponding control algorithms during the development of programs, especially when new controllers and new application modes are generated. For the disadvantages of rapid response to the market, the market urgently needs an efficient and reliable development model. In addition, under the current development mode, the intellectual property rights of the controller are in the hands of the controller developer, and the bearing equipment enterprises do not have intellectual property rights, which is unfavorable for the construction of the bearing processing control system's own brand and market competition with similar foreign products Influence.

Contents of the invention

Aiming at the low technical content of current bearing equipment manufacturers, the lack of technology with independent intellectual property rights, the long product update cycle, the inability to adapt to the rapidly changing market needs and the special performance requirements of customers, and to make full use of the hardware conditions in the development process of embedded systems , to achieve the purpose of less components and high reliability, combined with the current development trend of bearing control system, a special control circuit and system for bearing cutting automatic production line based on graph programming is proposed.

In order to solve the problems of the technologies described above, the technical solution of the present invention is as follows:

A dedicated control circuit for bearing cutting automatic production line based on graph programming, including an automatic production line scheduling module, a power supply module, a graph programming interface module, an I/O interface module and a communication module, the graph programming interface module and I/O interface module are respectively connected to the automatic The production line scheduling module is connected, and the communication module realizes the data transmission between each module and the communication with the circuit and the external RS232 serial port; the automatic production line scheduling module adopts an embedded programmable chip, executes the control program to control the production line, and completes the data processing , signal processing, task scheduling, and system control work; the graphic programming interface module provides human-computer interaction functions and supports online configuration technology, and the display content and method can be selected according to needs; the I/O interface module adopts a fully isolated The input and output interface mode; the power supply module provides working power for the whole circuit.

Further, the power supply module supplies power to the circuit in the way of double isolation and voltage stabilization. The method of double isolation and voltage stabilization is that the input voltage of the voltage stabilization module is 24V + 20%, and a stable 5V is generated, and a layer of Isolated regulator module.

The system applying the above-mentioned control circuit includes an engine driver generation module, a diagram editing module, a compile generation module, a download module and an online debugging diagnosis module, and the engine driver generation module generates corresponding The system engine of the system, including system initialization program, driver program, scheduler, etc., provides an interface for the control algorithm;

The graph editing module adopts a graphical program development method, provides a custom component generation method, and provides a basis for subsequent product development, application debugging, and maintenance; the compilation and generation module compiles and generates the graphics program edited by the graph editing module The special-purpose machine language corresponding to the control circuit module is embedded in the engine driver generation module to form a system operating program; the download module downloads the program code generated by the compilation generation module to the system hardware platform; the online debugging diagnosis module can be used for all On-line debugging and diagnosis of the above-mentioned system.

Further, the system implements control algorithm design through a graphical algorithm design environment, and all graphic components are provided to the designer in the form of controls, and users drag and drop controls on the designer to edit the ladder diagram.

Further, the overall program of the system can be designed in a component-based way to debug correct control algorithm functions.

The beneficial effect of the present invention lies in: using cutting-edge technologies such as embedded SOC controller chip, dedicated controller PLC and intelligent control technology, to develop an intelligent control system in line with the current market trend, and to develop an open control system software and hardware platform, At the same time, study the design method of mechanical equipment that meets the needs of bearing processing, provide support for bearing equipment manufacturers to reduce the production cost of control systems and develop control systems with independent intellectual property rights, and adapt to the current needs of more convenient control, easy modification, and easy expansion of bearing processing systems .

Description of drawings

Fig. 1 is a control circuit block diagram;

Fig. 2 is a block diagram of the system;

FIG. 3 is a schematic diagram of a conventional power module;

4 is a schematic diagram of a power module of the present invention;

Fig. 5 is a schematic diagram of the graph programming technique of the present invention;

Fig. 6 is an evolution diagram of the development mode of the control program of the present invention.

Detailed ways

The present invention will be further described according to the drawings and specific embodiments below.

The special control of bearing cutting automatic production line based on graph programming includes two components: hardware system and software system. The hardware system takes the intelligent controller chip as the core, combined with peripheral functional components, constitutes the main board of the bearing automatic production line controller, completes the operation of the control program of the bearing production line, and at the same time forms the production line control system through the production line mechanical device. The present invention improves the control circuit and the application control circuit system based on the existing technology. The software part is the programming and debugging tool of the automatic production line controller, and completes the development of the control program, the debugging of the program, and the monitoring and running functions. Through this technology, electrical engineers can conveniently realize the programming of the operation logic of the production line on the designed production line, and complete the control requirements for different processing processes required by different bearing components. The content of system development is as follows:

1. control system hardware

The main board of the production line controller is the main part of the controller and is responsible for the execution of the automatic production line scheduling program. There are five parts in the communication module.

(1) Automatic production line scheduling module

This module is the core module of the whole system. It adopts the embedded programmable smart chip as the core, executes the control program to achieve the purpose of controlling the safe and reliable operation of the whole production line, and mainly completes the data processing, signal processing, task scheduling and system control of the whole system. Work, specifically including logic signal processing, analog signal processing, communication data processing, graphic display data processing, production line operation management, etc.

(2) Power module

Provide the working power of the whole system. Different from ordinary industrial control systems, bearing machinery belongs to precision machining machinery. Each functional part is expensive and easily damaged if improperly operated. The control system requires a high-reliability power supply. Therefore, when designing a power supply module, the power supply between each module needs to be isolated to improve The anti-interference ability of the system should also pass EMC tests such as cycle drop and group pulse to effectively ensure the effective, reliable and stable operation of the entire control system. The system adopts single 24V power supply mode and anti-reverse connection circuit to ensure the convenience and safety of on-site use.

(3) Graphic programming interface module

Provide system human-computer interaction, including system working status, signal display, parameter setting, alarm prompt and other functions. This module supports online configuration technology. Users can choose the display content and method according to their needs. They can directly enter the configuration environment and modify the configuration to make the modified configuration take effect directly without exiting the system operation. The source code of the software program does not need to be modified when the application system is suitable for one's own needs.

(4) I/O interface module

The system adopts a fully isolated input and output interface mode. Even if the IO equipment works abnormally in the case of large impact and strong interference, it will not affect the work of the core control module, ensuring that there will be no unpredictable factors when there are uncertain factors in the periphery. working condition.

(5) Communication module

It mainly realizes data transmission between the system and external RS232 serial communication, and supports common communication protocols.

The above 5 modules constitute the main body of the controller main board of the bearing automatic production line, providing the hardware operation platform of the entire production line system, through the reasonable matching design of smart chips and peripheral components, effectively ensuring the safe and reliable operation of the system, and providing field programmable hardware operating environment.

control system software

The structural block diagram of the system software platform is shown in Figure 2:

(1) Engine driver generation module

According to the architecture of the system hardware platform controller, the corresponding system engine is generated through this module, including system initialization program, driver program, scheduler, etc., to provide an interface for the control algorithm.

(2) Figure editing module

The platform adopts a graphical program development method. Using graph programming is more intuitive and convenient than using traditional C language or assembly language development, and it is not easy to make mistakes. It can be mastered by ordinary electrical engineers, thus bringing great benefits to on-site modification and debugging. Great convenience. Provides the generation method of custom components to provide the basis for subsequent product development, application debugging, and maintenance.

(3) Compile and generate modules

The graphics program edited by the graphics editing module is compiled to generate a special machine language corresponding to the hardware platform controller, which is embedded into the engine module to form a system running program.

(4) Download module

Through a dedicated protocol, the protocol can be existing, or can be programmed according to one's own needs, and the program code generated by the compilation and generation module can be downloaded to the system hardware platform.

(5) Online debugging diagnostic module

Engineers can use this module to conduct on-site debugging and diagnosis of the control program, so as to effectively ensure the correctness and reliability of the program.

Technical key: 1. Power Module Design

For traditional mechanical equipment controllers, the power supply method usually uses a switching power supply to provide 24V as the working power supply for I/O, and 5V as the working power supply for the system CPU and its peripheral components. The working mode of its power supply is shown in Figure 3:

In the figure, the switching power supply, as an AC to DC component, plays the role of isolating 220V and DC 24V and 5V, but the output stability of the switching power supply directly affects the performance of the system, especially the fluctuation of the 5V power supply signal will cause the system to work in confusion , causing system damage in severe cases. The controller adopts double isolation and voltage stabilization to supply power to the system, as shown in Figure 4. For this circuit, the input voltage of the isolation voltage stabilization module is within the range of 24V + 20%, and it can generate a stable 5V, which is enough to ensure that the switching power supply When the output voltage fluctuates due to poor power supply, the system CPU can work normally. In addition, an additional layer of isolation voltage regulator module can effectively improve the system's ability to resist power supply interference. This method can effectively ensure the reliability of the chip operation, thereby ensuring the correctness and stability of the communication data. Through the actual measurement surface of the project team, the controller composed of this circuit can guarantee the EMC group pulse test level 4.

In addition, in this power supply mode, because of the single power supply mode, it provides great convenience for the selection of switching power supply.

． Design and generation of software engine for automatic production line controller

Due to the diversity of embedded chips, it is difficult to transplant user programs. After replacing the embedded chips, the control program needs to be developed repeatedly, which makes the development efficiency low. Therefore, in order to customize the controller for different application fields, flexibly select the required CPU, and quickly complete the system development, it is necessary to provide a method to use the same development method for the system composed of different CPUs, abstracting different CPUs. specific implementation details. The abstract CPU model is instantiated after selecting a specific CPU. The Cotex-M3 chip series can be used as an entry point, and the engine structure can realize the description of the general engine, including initialization, timer, interrupt, communication, etc. The general engine includes the common attributes and frameworks of various CPUs, providing a unified structure for the engine construction of a specific CPU. The characteristics of different CPUs realize the interaction between commonality and characteristics through the engine characteristic interface. After successful research and development, when the equipment changes and other types of chips are required, the same method can be used to quickly realize the generation of the engine.

． Graph programming technology

For traditional special controllers for bearing production lines, because the program is solidified by the special controller manufacturer when it leaves the factory, and it is in a closed program development mode, bearing equipment manufacturers cannot modify the program for different processing techniques, thus limiting the development of new products. The bearing-specific controller developed by the present invention adopts an open design concept to meet the secondary development control algorithm of bearing equipment manufacturers. Through the design method of combining software and hardware, the system software platform can be used to conveniently carry out on-site program changes, Download, expansion, debugging and other functions, so as to meet the individual requirements of customers and the special needs of special occasions. In addition, through the software platform or operator developed by the project, the on-line diagnosis of the on-site control program is realized. In order to meet the possibility of damage to some I/O points after improper maintenance or long-term work, it is possible to change the function of abnormal logic input or output points to backup points on site without re-modifying the program, thereby greatly improving maintenance efficiency and shortening maintenance time. The system software platform realizes the control algorithm design through the graphical algorithm design environment. All diagram components are provided to the designer in the form of controls, and users can drag and drop controls on the designer to design ladder diagrams. The system application mode is shown in Figure 5 below:

4. Component Graphical Program Development Model

Traditional special-purpose controllers basically use C, VHDL and other languages to develop control programs. There are problems such as troublesome debugging and difficulty in finding hidden bugs in the programs. Especially after the introduction of pointer operations, the problems are even more serious. The invention adopts graph as the basic logic component to realize the basic logic control. Graph logic components are tested repeatedly during platform design to ensure correctness. When programming, the user realizes the editing of the ladder diagram by dragging and dropping the control, only needs to care about the logic of the control algorithm, and does not need to worry about whether there is a BUG problem in the program. In addition, the overall program of the system can adopt the component-based design method to debug the correct control algorithm function. Users can easily form a functional component through the component-based design method provided by the platform, which brings convenience to subsequent product development, debugging and maintenance. Figure 6 shows. At present, this project has realized the design of the ladder diagram and the generation of the il instruction. The ladder diagram design is realized by dragging and dropping the control. The design result can be debugged and run with breakpoints, and the registers can be monitored.

． Field Programmable Diagnostic Technology

Through the system software platform, on-site program download, change, expansion, debugging and other functions can be conveniently performed, thus realizing the on-line diagnosis of on-site program. For example, when an input or output point is abnormal, the abnormal logic can be debugged and changed on site. The input or output point achieves the purpose of maintenance, thereby greatly improving maintenance efficiency and shortening maintenance time.

The dedicated control with innovative architecture and technology makes the structure of the product more compact and reduces intermediate links. Reduce the cost of the current controller by 20% to 30%. Assuming that 500 production lines are used every year, each production line needs 4 controllers, and the average cost of each controller is 500 yuan, it can save the production cost of about 1 million yuan for the enterprise every year.

The system has on-site programmable debugging and diagnosis functions. Maintenance engineers can solve most of the faults through debugging on site, so as to solve problems quickly and improve maintenance efficiency. The annual maintenance cost of each controller can be reduced by 40% to 50%. Based on the calculation that 500 units need to be maintained each year and the maintenance cost of each controller is 500 yuan, it can save about 250,000 yuan in maintenance costs for the enterprise every year; The field programmable diagnostic technology brings a new concept.

The above is only a preferred embodiment of the present invention, it should be pointed out that for those of ordinary skill in the art, without departing from the concept of the present invention, some improvements and modifications can also be made, and these improvements and modifications should also be considered Within the protection scope of the present invention.

Claims (4)

1. The special control circuit for bearing cutting automatic production line based on graph programming is characterized in that it includes two components: hardware system and software system; the hardware system takes the intelligent controller chip as the core, combined with peripheral functional components to form the bearing automatic production line controller The main board completes the operation of the control program of the bearing production line, and at the same time forms the production line control system through the production line mechanical device. The hardware system includes an automatic production line scheduling module, a power supply module, a graphic programming interface module, an I/O interface module and a communication module. The interface module and the I/O interface module are connected with the automatic production line scheduling module respectively, and the communication module realizes the data transmission between each module and the communication between the circuit and the external RS232 serial port; the automatic production line scheduling module adopts an embedded programmable chip , execute the control program to control the production line, complete data processing, signal processing, task scheduling, and system control; the programming interface module of the diagram provides human-computer interaction functions, and supports online configuration technology, and can select display content and methods according to needs; The I/O interface module adopts a fully isolated input and output interface mode; the power supply module provides working power for the entire circuit; the dedicated control circuit includes an engine driver generation module, a diagram editing module, a compilation generation module, a download module and online debugging Diagnosis module, the engine driver generation module generates a system engine corresponding to each module of the control circuit according to the architecture of the control circuit, including a system initialization program, a driver program, and a scheduler, and provides an interface for the control algorithm; The graph editing module adopts a graphical program development method, provides a custom component generation method, and provides a basis for subsequent product development, application debugging, and maintenance; the compilation and generation module compiles and generates the graphics program edited by the graph editing module The special-purpose machine language corresponding to the control circuit module is embedded in the engine driver generation module to form a system operating program; the download module downloads the program code generated by the compilation generation module into the system hardware platform; Conduct on-site online debugging and diagnosis; The dedicated control circuit also includes an automatic production line controller software engine, which instantiates the abstract CPU model after selecting a specific CPU; the engine structure realizes the description of the general engine, including initialization, timer, interruption, communication; the general engine includes The common attributes and frameworks of various CPUs are provided to provide a unified structure for the engine construction of a specific CPU. The characteristics of different CPUs realize the interaction between commonality and characteristics through the engine characteristic interface; when the device changes and other types of chips are required, The same method can be used to quickly realize the generation of the engine. 2. The special control circuit for bearing cutting automatic production line based on graph programming according to claim 1, characterized in that, the power supply module supplies power to the circuit by means of double isolation and voltage stabilization, and the method of double isolation and voltage stabilization is stable The input voltage of the voltage module is 24V + 20%, which generates a stable 5V, and a layer of isolation voltage regulator module is added after it. 3. The special control circuit for bearing cutting automatic production line based on graph programming according to claim 1, characterized in that the control algorithm design is realized through a graphical algorithm design environment, and all graph components are provided to the designer in the form of controls. The user can drag and drop controls on the designer to edit the ladder diagram. 4. The special control circuit for bearing cutting automatic production line based on graph programming according to claim 1, characterized in that the overall program adopts a component-based design method to debug correct control algorithm functions.