The overall frame design system composition of the automotive painting network control system is based on different areas and equipment in different process processes. The entire car painting production line control system is divided into 12 sets of independent control systems: pre-processing control system. Phosphate control system, electrophoresis control system, electrophoresis drying control system, PVC drying control system, top coat room control system, circulation pool control system, grinding room control system, repair line control system, etc. Due to the relatively complex process control, there are not only a large number of I/O discrete points, but also a large number of pump flow, flow rate, various types of regulating valves, solenoid valves, various fan, motor speed, drying process PID control such as temperature. Therefore, each process control system uses a powerful PLC programmable controller with PID control to control the process. In addition to the above-mentioned process control system, in order to strengthen the control flexibility of the system and meet the characteristics of the mixed-flow production line, the coating production line control system adds a vehicle body identification system. The function of AVI system: (1) Real-time collection of statistics, quality monitoring data and information of different production data.
(2) Make full use of the system's network functions, and transfer related process information (models, colors, batches, etc.) to each process control system for flexible coordination of the production process. (3) Using position sensors distributed on the production line to monitor the position of the vehicle body in real time. (4) Intelligent routing decision function.
AVI system data acquisition can use barcode recognition system or RFID system, but due to the harsh environment of the coating production line, requiring production equipment with corrosion resistance, high temperature characteristics, plus bar code in the production process can not store any other information, so AVI The system tends to be an RFID system.
The AVI system process: from the upper line of the coating shop, collects the process information for each vehicle body, and transmits this information to the real-time database; uses the position sensors distributed on the production line to track the vehicle body in real time, and implements monitoring; In the production process, the detection information of the quality inspection points distributed on the production line is transmitted to the real-time database and intelligent routing decision system through the AVI's on-site HMI subsystem, and related routing decisions are made to optimize the entire process process; Database, manufacturing information of the bottom workshop can be used by upper MES and ERP systems. In view of the large amount of information processed by the AVI system and the high real-time requirements, multiple large PLC programmable controllers are generally used for control.
The frame structure of the system (1) The longitudinal frame accesses all equipment on the car painting production line to the fieldbus network through a standardized interface module. The so-called interface module is to implement protocol conversion. Simply speaking, the data format in the underlying smart device is converted into a fieldbus protocol frame format. Such as CM11 module on DeviceNet; CM31 module on ProfiBus. Programmable controller PLC through its own fieldbus control module to the underlying equipment for data acquisition or instruction issued. There is a large amount of implicit data, such as I/O or state mutation, transmitted between the controller and the field device. The amount of data transmitted is relatively small, but the real-time and deterministic requirements are extremely high. Data exchange with the monitoring layer HMI via OPC server or various middleware. Of course, in some processes, due to the adopted DCS structure, data exchange with the HMI is directly performed through serial communication or hard wiring. The on-site AVIHMI is responsible for collecting the process information of the car body, the initialization of the car body information at the upper line, and the collection of quality information during the production process. The AVIHMI in the central control room is responsible for the routing decision function of the car body; in addition, it also has the function of interacting with the planning floor of the MES workshop, writing process-manufacturing information related to the car body to the real-time database for use by the MES, and also from the real-time The database reads instructions from the upper MES workshop planning level. Since the control system is mainly integrated with the enterprise information network, real-time requirements are not as severe as the first two parts, but the amount of data transmission is large, and in order to achieve remote management, the routing function and transmission distance of this part of the network will be There are higher requirements.
(2) Horizontal Frame The horizontal frame of the car painting production line control system refers to the communication between each process system and the AVI system, which is mainly reflected in the communication between the PLC controllers in each system. The amount of data transmitted is greater than that of the field devices. Large, it can transmit implicit data such as I/O and interlocks, as well as explicit data that is not demanding on time.
The network system of the car painting and controlling system is based on the Ethernet technology. The two-layer network structure TCP/IP protocol has become an industrial standard for automation in the future and will replace the field bus technology. Therefore, the network architecture of the company is now completely etheric. The structure of the net is affected. However, because Ethernet technology in the field of industrial control is not mature enough, it cannot achieve true Ethernet control network system from top to bottom.
The multi-layered distributed network structure cannot be completely replaced by the Ethernet control network system. In a complex process control system, multiple controllers and human-machine interfaces require a large amount of data transmission, and the control network is indispensable. Data exchange can enhance the transmission speed of the network. However, in situations where multiple controllers do not require coordinated control, the control network can be simplified, which makes the control simple and easy to maintain. The use of a communications controller can replace the status of the control network, and the fieldbus is directly hooked up to the network architecture on the Ethernet through the communications controller. This can effectively reduce cost, achieve effective network control, reduce the network architecture, and enhance the system's openness.
The main network structure of coating control system coating production line control system is composed of pre-treatment control system, electrophoresis control system, phosphating control system, top paint control system and other control systems, each control system corresponds to the corresponding process process. Because the objects to be controlled in various processes are different, for example, the electrophoresis control system controls more continuous quantities such as pumps and valves, whereas the AVI system in contrast has more control over discrete points, which affects the control systems from a certain extent. Layout, structure, etc.
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