A kind of on-line monitoring digital control system of framework Network Based
Technical field
The invention belongs to manufacturing CNC technology field, particularly relate to on-line monitoring, failure diagnosis, Based Intelligent Control and the networked remote maintenance of digital control system.
Background technology
The advanced manufacturing technology field makes on-line monitoring, state identification and intelligent control technology as high-precision digitlization processing basis highlight its importance to the raising that workmanship requires.On digital control system, building soft, the hardware platform of on-line monitoring, is to carry out the early warning of multiple processing physical state, control, and then realizes the basis of lathe complete machine performance maintenance.Present conventional online monitoring diagnosis system; The Siemens ePS [1] that comprises the Machine Tools Electric system that to realize, the fault detect of switching value type; FANUC 18i series [2] and as the cutting force of Switzerland Kistler company monitor [3], the tool monitorings of German ARTIS [4] etc. are towards the monitoring diagnosis system of individual event functional part.The subject matter of its existence has; Traditional on-line monitoring equipment exists because mounting complexity and the external property of the equipment characteristics that the volume restriction causes; And there are defectives such as R&D cycle length, open difference and monitoring function are single in the special-purpose embedded monitoring modular of customization, is difficult to adapt to high-grade digital control system open architecture and the reconfigurable growth requirement of functional module.To the problems referred to above; Many physical messages state warning function with lathe complete machine fault; Having the exploitation of reconfigurability and open function modoularization embedded intelligence TT&C system simultaneously concurrently, is one of key technology of needing to be resolved hurrily of domestic and international diagnosing faults of numerical control machine field.
[1] .ePS Network Services, SIEMENS, www.automation.siemens.com/SIEMENS website.
[2] the long-range and fault diagnosis system of 16i/18i/2li, www.bj-fanuc.com.cn/ Fa Nake website.
[3] .Kistler cutting tools monitoring, www.kistler.com/cn_cn-cn/441_CuttingToolMonitoring/Cutti ng-Tool-Monitoring.html/Kistler tool monitoring website.
[4] .SINUMERIK 810D powerline, the www.automation.siemens.com/SIEMENS website.
Summary of the invention
Defective based on above-mentioned prior art existence; The present invention proposes a kind of on-line monitoring digital control system of structure Network Based; Through the exploitation general-purpose interface; On digital control system in open type framework and the seamless mutual basis of the embedded monitoring means information of modular reconfigurable; The Digit Control Machine Tool machine system that has in machine monitoring and intelligent maintenance function that constructs Network Based has realized that integratedly the state of high-grade, digitally controlled machine tools can show, fault is diagnosable, performance can be forecast, the embedded-type condition monitoring diagnostic system of remote monitoring.
In order to achieve the above object, the technical scheme of the present invention's employing is:
A kind of on-line monitoring digital control system of framework Network Based; Comprise Digit Control Machine Tool, embedded on-line monitoring unit, remote fault diagnosis center and standard interface; Wherein, Said embedded on-line monitoring unit has independent central processing unit and independently is arranged in this system, and this unit comprises PC/104 bus, signal condition module, data collecting card and system's on-line monitoring module:
Said signal condition module is used to carry out the amplification and the filtering operation of sensor output voltage, electric current, with the noise reduction precision that satisfies the output analog signal and the requirement of A/D acquisition chip;
Said data collecting card is used to realize the A/D data transaction of multichannel voltage and electric current;
Said system on-line monitoring module, the digital signal that is used for that A/D is collected show in real time with the corresponding failure diagnosis algorithm under warning and on-line monitoring); And
Said embedded on-line monitoring unit makes up the transfer of data that weak coupling is connected with said Digit Control Machine Tool through the standard interface that the TDNC-Connect host-host protocol provides; Said on-line monitoring unit is connected with the remote fault diagnosis center through standard interface, adopts the TDNC-Connect host-host protocol to carry out the fault data transmission; And said Digit Control Machine Tool realizes being connected employing TDNC-Connect host-host protocol realization information interaction through standard interface with said remote fault diagnosis center; The TDNC-Connect host-host protocol is the lightweight communications protocol based on software that is based upon on the universal network communication agreement basis; This agreement will be transmitted content and form and be divided into failure diagnosis information data flow transmission agreement and machine tooling status information data flow host-host protocol according to the feedback information to the digital control system machining state; The data flow transmission agreement of failure diagnosis information adopts the state information describing method of " factory-monitoring means-measuring point-monitoring variable "; In embedded on-line monitoring unit, digital control system and long distance control system software, make up the monitoring information database, realize that the measuring point information of state information type data is accurately located; This agreement mainly comprises following 4 partial contents: (1) monitoring initial data section: identify the initial of Monitoring Data, comprise monitoring date, monitoring time; (2) monitoring global data section: provide getting parms of state that information is set, comprise the parameter setting of analysis frequency, sampling number, gain, overall channel number, passage; (3) monitoring information data segment: the concrete conditions of machine tool signal, the waveform that monitor; (4) ED identification section: the end of sign Monitoring Data bag; Machine tooling status information data flow host-host protocol is the host-host protocol of setting up to Fault Identification information in the conditions of machine tool feedback information process; Its connection object comprises waveform, frequency spectrum display type data message, comprises following 4 partial contents: (1) facility information data segment comprises: lathe numbering, title, position, workshop, time of failure and lathe administrative staff information; (2) Monitoring Data achievement data section: the machining state monitoring location is surveyed period, Monitoring Data maximum and alarm threshold value; (3) failure mechanism is analyzed data segment: abort situation, generation reason and probability of happening; (4) breakdown maintenance report data section: the concrete scheme of breakdown maintenance, maintenance project, maintenance form.
Said standard interface adopts Ethernet digital control system on-the-spot bus, Internet network or USB, serial mode.
Said embedded on-line monitoring unit is applicable to that simultaneously the dual-cpu structure of DSP master's process chip and FPGA coprocessor is embedded.
This system also comprises host computer, the considerable task of failure diagnosis, intelligent maintenance is transferred to host computer realize, remedies the restriction of on-line monitoring unit operation disposal ability.
Compared with prior art; The embedded on-line monitoring unit that the present invention adopts has the central processing unit that is independent of digital control system; Can Guarantee Status monitoring function module in the actual course of processing and numerical control command function module independent operating separately; Improved the information processing capability of numerical control, TT&C system, guaranteed that the numerical control instruction is implemented and the real-time of observing and controlling on-line monitoring function; Simultaneously, the general calling interface of TDNC-Connect information interaction that the present invention adopts has stressed the opening of digital control system to have the portable excellent characteristics of numerical control unit; The TDNC-Connect host-host protocol has been realized the information interaction at embedded on-line monitoring unit and remote fault diagnosis center, the considerable task of failure diagnosis, intelligent maintenance is transferred to host computer realize, has remedied the restriction of on-line monitoring unit operation disposal ability; Above-mentioned key element has constructed fast to be had general-purpose interface, can realize digital control system and the seamless mutual Digit Control Machine Tool complete machine monitoring platform of the embedded monitoring means information of restructural; And, realize that integratedly the state of high-grade, digitally controlled machine tools can show, fault is diagnosable, performance can be forecast, remote monitoring with its node or terminal as the facility information net.
Description of drawings
Fig. 1 is the on-line monitoring digital control system structure chart of a kind of framework Network Based of the present invention;
Fig. 2 is a kind of embedded on-line monitoring unit hardware structure chart of on-line monitoring digital control system of framework Network Based;
Fig. 3 is a kind of telecommunication network system architecture sketch map of on-line monitoring digital control system of framework Network Based;
Among the figure: 1; Backup server 2; Expert system 3; Internet/intranet 4; Remote fault diagnosis center 5; Main control unit 6; Lathe n 7; Lathe 28; Lathe 19; Fault message 10; Bus/netting twine/USB 11; Embedded on-line monitoring unit 12; Signal condition unit 13; Data collecting card 14; PC/104 bus 15; The CF card; Hard-disk interface 16; Display interface 17; Serial ports 18 embedded main boards 19; USB interface 20; Network interface 21 backup servers 22; Fire compartment wall 23; Www server 24 remote fault diagnosis centers 25; The expert 26; The ERP of enterprise 27 device management information nets 28; Equipment condition monitoring and diagnosis net 29; Embedded on-line monitoring unit 30; Digital control system 31; HUB
Embodiment
In order further to understand technical scheme of the present invention; In conjunction with the practical implementation of the great special project of national science and technology (2009ZX04014-101-05)-" fault of numerical control machine tool early warning diagnostic techniques reaches the restructural monitoring diagnosis system based on functional part " sub-problem " based on the lathe complete machine monitoring, diagnosing experiment porch of autonomous digital control system " project, the execution mode that the conjunction with figs. explanation is concrete:
Among Fig. 1 to Fig. 3, the on-line monitoring digital control system structure of framework Network Based of the present invention comprises: embedded on-line monitoring unit 11 with have the independently Digit Control Machine Tool main control unit 5 of central processing unit.In the on-line monitoring process; Embedded monitoring means 11 is through data collecting card 13 and many physical quantity transducers such as signal condition 12 external vibrations, power, electric current; Realize the real-time monitoring of lathe complete machine state, and then carry out storage, the demonstration of Monitoring Data through PC/104 bus 14, CF card, hard-disk interface 15, display interface 16.Embedded monitoring means is connected with main control unit 5, HUB 31 through serial ports 17, usb 19, network interface 20; Through the general invocation protocol of TDNC-Connect information interaction, realize tripartite communication based on the digital control system-embedded on-line monitoring unit-remote network monitoring system of Monitoring Data and fault message.
The embedded on-line monitoring unit diagnosis system architecture that has the modular reconfigurable characteristics under the digital control system in open type: have the central processing unit that is independent of digital control system; In the on-line monitoring of the course of processing; Status monitoring function module and numerical control command function module be independent operating separately, to guarantee that the numerical control instruction is implemented and the real-time of observing and controlling on-line monitoring function.
Embedded on-line monitoring unit is connected with digital control system: adopt the general calling interface of monitoring information based on multiple transmission technologys such as Ethernet digital control system on-the-spot bus, Internet network, USB and serial ports; Realize that online monitoring means and digital control system real-time transmission of information with mutual, have made up the high speed information transport frame under the weak coupling seamless link condition.The transfer of data real-time has been stressed in the utilization of this information interaction mode, has measurement and control unit opening, portable excellent characteristics.
Embedded on-line monitoring unit is connected with remote network monitoring system: the Monitoring Data that adopts Internet to carry out status monitoring diagnostic system under embedded on-line monitoring unit and the network architecture is uploaded and the less demanding information interaction of real-time such as DTC download.Status monitoring and diagnostic system towards the complex device management under the network architecture adopt the mixed architecture of C/S and B/S to build; This system provides multiple common network data storehouse selective (like Sql Server; Oracle etc.); The whole system framework can be divided into three-layer network, comprises based on the equipment condition monitoring of C/S model and failure diagnosis net, based on the device management information net and the enterprise network of B/S pattern, and finally is structured in the ERP system of enterprise.
The Data Transport Protocol of embedded on-line monitoring unit and digital control system and long distance control system: with digital control system, embedded monitoring means, long distance control system is host-host protocol service object's TDNC-Connect host-host protocol, is the lightweight communications protocol based on software that is based upon on the universal network communication agreement basis.This agreement will be transmitted content and form and be divided into failure diagnosis information data flow transmission agreement and machine tooling status information data flow host-host protocol according to the feedback information to the digital control system machining state.The data flow transmission agreement of failure diagnosis information adopts the state information describing method of " factory-monitoring means-measuring point-monitoring variable "; In embedded on-line monitoring unit, digital control system and long distance control system software, make up the monitoring information database, realize that the measuring point information of state information type data is accurately located.This agreement mainly comprises following 4 partial contents: (1) monitoring initial data section: identify the initial of Monitoring Data, comprise monitoring date, monitoring time etc.(2) monitoring global data section: provide getting parms of state that information is set, like the parameter setting of analysis frequency, sampling number, gain, overall channel number, passage.(3) monitoring information data segment: the concrete conditions of machine tool signal, the waveform that monitor.(4) ED identification section: the end of sign Monitoring Data bag.Machine tooling status information data flow host-host protocol is the host-host protocol of setting up to Fault Identification information in the conditions of machine tool feedback information process; Its connection object is that real-times such as waveform, frequency spectrum require relatively low display type data message, mainly comprises following 4 partial contents: (1) facility information data segment: lathe numbering, title, position, workshop, time of failure and lathe administrative staff information etc.(2) Monitoring Data achievement data section: the machining state monitoring location is surveyed period, Monitoring Data maximum and alarm threshold value etc.(3) failure mechanism is analyzed data segment: concrete failure diagnosis conclusions such as abort situation, generation reason and probability of happening etc.(4) breakdown maintenance report data section: the concrete scheme of breakdown maintenance, maintenance project, maintenance form etc.This data exchange agreement has 2 kinds of connected modes: point-to-point connection is realized in (1) on the exclusive data interface basis of Ethernet netting twine transmission, realize the weak coupling seamless link of digital control system and embedded monitoring means.(2) on conventional data Fabric Interface bases such as network, USB, serial ports, realize one (embedded monitoring means), make up embedded machining center on-line monitoring remote maintenance system based on the digitlization manufacturing environment to many star-like connections.
The structure of embedded on-line monitoring unit: comprise the independently embedded industrial control mainboard of PC104 PLUS bus architecture; Signal condition module, the data collecting card of independent development, be installed in embedded OS XPE and on-line monitoring software on the CF card; The on-the-spot end of Digit Control Machine Tool application platform as equipment monitoring running state, advanced signal processing, failure diagnosis, intelligent maintenance function and remote monitoring; Realized its hardware capability design (data acquisition module, with the digital control system interface, with the remote fault diagnosis hub-interface etc.) and software function (data acquisition software, on-line monitoring software, with the digital control system communications protocol, and remote fault diagnosis center communications protocol etc.) integrated; Measurement and control unit obtains platform to the power, vibration, noise, the temperature integrated monitoring information that on Digit Control Machine Tool, make up; Merge the method for multiple signal processing and failure diagnosis; Realize diagnosis and the intelligent maintenance under the multi-sensor information, guaranteed the operation of Digit Control Machine Tool high-precision high-efficiency.Simultaneously; Network interface and TDNC-Connect host-host protocol through measurement and control unit or digital control system; Make the digital control system become intelligent node or terminal in the factory automation network, realized the realization of many digital control system in open type and the information interaction of failure diagnosis net, networked data management, expert system and Remote Diagnosis System.