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Process Data Acquisition – PLC-PDA -- Detailed
analysis of quality manage&industrial big data sources |
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56 PDA
system scheme for converter, RH furnace, LF furnace in steel plant |
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64 S7-1200 as both a PROFINET IO Controller and an
IO Device |
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2
S7-400 Ethernet high speed fixed period 2ms
It can be used when the collection points are not many, but the acquisition period is very fast, the acquisition period can be 2ms, the data source type is 0, to attention to fill in the CPU slot number, CPU may be with or without Ethernet ports. Add a specifical Profinet network card for data acquisition can significantly shorten the sampling period. Recommend using siemens's upgraded network card such as 6GK7 443-1EX20-0XE0, its performance is much higher than 6GK7 443-1EX11-0XE0. The curve is interrupted
occasionally if the PLC Ethernet card load is too heavy, you may change the It cannot be simulated by Step7 5.5 + S7-PLCSIM + NetToPLCSim. When single PLC acquisition points is not much or sampling period is not very short, PDA network may be the PLC programming and monitoring network.
Figure 2.1 Shared Ethernet Template Communication Set up an independent network of PDA system by adding a separate ethernet module to every PLC that can improve the single PLC collection points and shorten the sampling period.
Figure 2.2 Independent Ethernet Template Communication 2.3 Install the PLC controller system 1. Copy OB80、OB81、OB82、OB83、OB84、OB85、OB86、OB87、OB88、OB121、OB122 to project, do not replace if it is repeat. 2. Copy SFB37、SFC1、SFC20、SFC37 to project, do not replace if it is repeat. 3. Copy DB500、DB501、DB502、UDT501、FC501、FC502 to project. 4. Place FC501 and FC502 into
OB block such as OB35 or OB38, its scan cycle determines the sampling time of
PDA system, It is recommended that no other function blocks should be called
by the 5. Analog and digital quantities defined by FC501 must be same as Config.csv. 6. Modify FC501 and write rapid acquisition signal of analog and digital at the corresponding position.
Figure 2.3 PDA Communication Function Block in CPU of S7-400 7. FC501 example of 60INT+128BIT project as below: SET SAVE = L 0.1 L 1000
// be same as T DB501.DBW 2 L 12.345
// real L 100.0
*R //
real with 2 decimal places RND
// convert to an integer T DBW 12
// AI1 L L#123456789
// DINT retain the low 2 byte T DBW 14
// AI2 L L#123456789
// DINT DTR
// convert to real L 0.00001
*R
// cut off last 5 digit RND
//
convert to an integer T DBW 16
// AI3 ...... L 59 T DBW 128 // AI59 L 60 T DBW 130 // AI60 AN M 1.0 = DBX 132.0 // DI1 AN M 1.0 = DBX 132.1 // DI2 A M 1.0
= DBX 132.2
// DI3 …… A M 1.0
= DBX 147.6
// DI127 A M 1.0
= DBX 147.7
// DI128 SAVE BE 8. Below is an example for 16INT+16BIT with 2ms of period and slot 3 of CPU, 1000 must be same as identification code of PLC sample program. [1000,32CH,2.000ms,192.168.1.24,0S,CMO,192.168.1.216,3] No, Name
,Adr/note,Unit,Len,Offset
,Gain ,Type CH1=, 波形曲线给定 ,
,mm ,2 ,0.000000,0.010000,INT CH2=, 左缸实际位移 ,
,mm ,2 ,0.000000,0.010000,INT CH3=, 右缸实际位移 ,
,mm ,2 ,0.000000,0.010000,INT CH4=, 左缸上腔压力 ,
,KN ,2 ,0.000000,0.010000,INT CH5=, 左缸下腔压力 , ,KN ,2 ,0.000000,0.010000,INT CH6=, 右缸上腔压力 ,
,KN ,2 ,0.000000,0.010000,INT CH7=, 右缸下腔压力 ,
,KN ,2 ,0.000000,0.010000,INT CH8=, 浇铸速度
,
,mpm ,2
,0.000000,0.010000,INT CH9=, 两缸位移差
,
,% ,2 ,0.000000,0.010000,INT CH10=,左缸伺服阀给定 ,
,% ,2 ,0.000000,0.010000,INT CH11=,右缸伺服阀给定 ,
,% ,2 ,0.000000,0.010000,INT CH12=,左缸伺服阀阀芯反馈,
,% ,2 ,0.000000,0.010000,INT CH13=,右缸伺服阀阀芯反馈,
,% ,2 ,0.000000,0.010000,INT CH14=,两缸出力和
,
,KN ,2 ,0.000000,0.100000,INT CH15=,两缸出力差
,
,KN ,2 ,0.000000,0.010000,INT CH16=,SPARE
,
,mm ,2 ,0.000000,1.000000,INT CH17=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH18=,SPARE
,
,Bool,1 ,0.000000,1.000000,BIT CH19=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH20=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH21=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH22=,SPARE
,
,Bool,1 ,0.000000,1.000000,BIT CH23=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH24=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH25=,左缸锁定阀打开 ,
,Bool,1
,0.000000,1.000000,BIT CH26=,右缸锁定阀打开 ,
,Bool,1
,0.000000,1.000000,BIT CH27=,故障停机
,
,Bool,1
,0.000000,1.000000,BIT CH28=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH29=,SPARE ,
,Bool,1
,0.000000,1.000000,BIT CH30=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH31=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT CH32=,SPARE
,
,Bool,1
,0.000000,1.000000,BIT 2.4 Data communication of multiple CPU The multiple S7-400 CPUs can be inserted in a frame; Data may be exchanged between CPUs by the Global Data. Right click the MPI network in the network configuration. Define the content of communications between CPU by "Define Global Data".
Figure 2.4 Data communication network configuration between multiple CPUs
Figure 2.5 Data Exchange between CPUs |
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Apparatus test&Fault diagnosis&Quality analysis |
Millisecond data sampling Real-time data compression Capture signal instantaneous mutation |
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