I. Introduction
The German SCHULER 6000KN large-scale automatic press line introduced by Shanghai Volkswagen Automotive Co., Ltd. is mainly used to produce medium-sized stamping parts such as 4 doors and 2 covers of PASSAT car, with an average stroke of 6.7 times per minute. The SCHULER press line is mainly composed of 6 press units and 6 mechanized units. The press unit is mainly used for sheet metal stamping. The mechanized unit mainly uses the suction cup method to remove the material and transfer the material between the presses.
The control equipment of SCHULER automatic press line adopts advanced Siemens control equipment. The whole automation control network is divided into two levels. The first level is the basic automation network, which mainly includes the SIEMENS programmable controller SIMATIC H1 network and the operator workstation WINCC. Network; the second level is the server control management network.
The entire industrial control network network system of the SCHULER press line is complex, and is composed of an industrial control network of three topological types: a ring topology, a star topology, and a bus topology.
Second, the basic automation network
2.1 Field layer network
The field layer control of the SCHULER press line is controlled by PLC and PROFIBUS fieldbus. Each press unit and mechanized unit are controlled by independent PLC. The PLC adopts Siemens S5-115U programmable controller. The whole press line uses 12 PLCs for control.
2.1.1 PLC H1 Network
The server communicates with the field layer PLC using SIMATIC H1 Ethernet network, CSMA/CD protocol, optical cable medium, communication speed of 10Mbps, ring topology. Each unit PLC is equipped with CP1430 communication module, through the corresponding OLM (optical conversion module) to communicate online, the server built-in CP1413 communication module communicates with PLC H1 network through the first unit OLM module. In this server, the upload/down function of parameters is performed, and the data exchange between it and the PLC is performed by DDF (Dynamic Data Exchange).
The use of fiber optic network not only satisfies the high-speed and large-capacity data exchange, but also greatly enhances the resistance to external electromagnetic field interference and leakage resistance. The advantage of the ring structure is that communication can be maintained once the fiber-optic network link breaks; in addition, it completely The potential is operated independently, without the need for expensive equipotential bonding costs, and greatly enhances the reliability of the network.
2.1.2 PROFIBUS bus
The communication between PLC and field device adopts Siemens PROFIBUS-DP field bus. PROFIBUS-DP bus is a fully distributed fieldbus type field control network. It realizes two-way between ET200 distributed input/output system and field devices. Serial multi-node digital communication. A single distributed field device is connected through a PROFIBUS bus into a network system and a control system that can communicate information with each other and perform control tasks together, forming a fully distributed network integrated new control system with control functions completely decentralized to the site, which greatly simplifies field wiring and Save on installation costs.
The ET200 distributed input/output system uses a master stack and a slave stack structure. The master stack sends data to the slave stack on the bus and requests data from the stack. The slave stack can only exchange data with the master stack when the master stack makes a request.
In the PROFIBUS field bus of the control system, the PLC of the built-in bus interface control board IM308-C is used as the main stack of the bus, the ET200 input/output module is used as the slave stack of the bus, the bus transmission medium is the shielded twisted pair, and the PLC passes the PROFIBUS- DP implements control of field devices.
2.2 Operator workstation WinCC network
The operator workstation communication network adopts 10BASE-T Ethernet, TCP/IP open protocol, optical cable medium, communication rate of 10Mbps, ring topology, and the specific configuration is as follows: each press unit is provided with two operator workstations before and after, SCHULER There are 12 operator workstations in the automatic press line. The built-in 3COM network card of the workstation communicates with the Ethernet through the TPTR (Ethernet interface) and the corresponding OLM (Optical Conversion Module) module. The OLM module of the first unit passes through the twisted pair and the HUB ( The central hub is connected, and the built-in 3COM network card of the server is connected to the HUB, thereby realizing communication between the server and the operator workstation Ethernet.
2.2.1 WinCC Configuration Software
The screen configuration of the man-machine interface of the operator station is carried out using the SIMATIC WinCC 4.0 software configuration software from Siemens. SIMATIC WinCC (Windows Control Center) is a 32-bit distributed automation control configuration software developed by Siemens. WinCC as a monitoring configuration software has powerful functions and high openness, enabling users to design interfaces with good functions and functions. Monitoring system; and because it can take advantage of the convenience features of Windows in the Windows standard environment, it can greatly shorten the time to develop the process package. The WinCC software mainly includes two basic functions of data acquisition and data management. Data acquisition refers to the collection of data from the field and corresponding processing. The acquisition is mainly done by the PLC as the field control station. Data management is to process the data obtained from the scene and send it to the server's database and read the data by the database access function and then send it to the application.
2.2.2 WinCC Network
In this system, the server acts as the server of WinCC, and also as the SQL (Structured Query Language) Server (database server), which includes the running database and the engineering database. The field data is sent to the WinCC through the PLC for collection and management. After processing, it is sent to the running database of the server; all the mold and production data are stored in the engineering database of the SQL server, and the SQL server is connected to the production line via Ethernet. On the WinCC operator station, mold production data and field data are graphically displayed on the server or operator station for monitoring. At the time of production, after the mold job is selected, the WinCC operator station receives the production data required for the mold production from the SQL server and then starts the production process. The database can store 1000 sets of mold data in total, which can be retrieved at any time.
The operator can monitor the working status and fault alarm display of each press unit and mechanized unit through the WinCC human-machine interface of 12 operator stations located on the six press units of the press line, and can perform mold data conversion and Production data settings and other operations.
Third, control the management network
The press line server is connected to the management management star network through a 10BASE-T central hub (HUB) and router (ROUTER) and operator station Ethernet and PMS (press production management system).
3.1 network operation platform
The server communicates with the operator station using a server/client network structure. The operating platform of the server is WinNT Server 4.0 Chinese operating system, and the operating platform of the operator station is Win NT Workstation 4.0 Chinese operating system. WinNT operating platform has the characteristics of security, reliability, multi-tasking, etc., and has good software compatibility, supports most Windows application software, and provides great convenience for users' work.
3.2 Network Security Technology
As the backbone of the SCHULER press control network, server security is of great significance to ensure the safety of the entire press line industrial network. The server uses hardware RAID (disk array) technology.
Fourth, the conclusion
The industrial control network of the SCHULER automatic press line uses many newer technologies. Since the normal production of the press line, the network operation is very stable, ensuring efficient production of the press line. The industrial network technology of SCHULER press automation line also has many references for the construction and application of domestic industrial networks.
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