[Mcgs Embedded Configuration Software 12
Amancio Mccrae
This monitoring system combines configuration technology with computer technology to realize monitoring in both industrial fields and remote environments. Industrial site workers quickly and directly operate the loom through the on-site touch screen. Enterprise management personnel centrally manage the loom through remote means. Therefore, the system is convenient for different types of users in the enterprise.
The industrial field monitoring system has comprehensive functions and friendly interface operation, which realizes the comprehensive monitoring and operating parameter setting of each link of the loom production. It can also meet functional requirements such as fault alarm and debugging and maintenance.
The use of the cloud platform and other technologies to achieve remote monitoring of the loom, breaking through the geographical restrictions. It is possible to log in to the remote system anytime and anywhere to monitor the running status and production information of the loom, which also provides convenience for later maintenance and upgrades.
With the acceleration of structural adjustment and upgrading of China's textile industry, loom enterprises are developing in the direction of informatization, less labor, and intelligence. At present, the loom equipment in our country has realized automated production initially, with many controlled objects and complex mechanical structures. However, its monitoring method still adopts the traditional mechanical button and touch screen method, and the touch screen can realize the use of a single function, and the interface design is simple. The original monitoring system lacks effective and convenient unified management of equipment, and the factory manager cannot timely inquire about the working status of the loom. In the case of loom failure, it is impossible to find out the reason for loom failure quickly, and only manual inspection can be carried out, which seriously affects production efficiency due to the tedious process [1]. Moreover, the traditional monitoring method is limited by the geographical space, which is only suitable for operation in the industrial field and lacks an effective network management method. Given the above shortcomings, a monitoring system that can be used in both industrial fields and remote networks is designed.
From the function point of view, the whole system can be divided into two parts: loom monitoring system and control system. The control objects of the loom control system are select the weft and selvage, let-off and take-up, main motor, brake clutch, and so on. Because of its complex mechanical structure and decentralized process, a distributed modular design method with one main control center and several sub-controls is adopted. This design can not only meet the control requirements but also avoid the whole system damage caused by the failure of a single system. In this paper, the loom monitoring system is independent as a subsystem and performs data interaction with the main control board of the control system through the industrial bus. The management and operation of each module are concentrated in the loom monitoring system, and the control work is completed by other corresponding functional modules. The overall structure of the loom system is shown in Fig. 1.
The chip of the main control module in the control system is STM32F407ZET6. The touch screen and the RS485 communication module of the main control system realize data interaction through Modbus RTU communication protocol.
The design of the main control window, equipment window, user window, real-time database, and strategy script is completed in MCGS Pro configuration software, so that the industrial field system can realize the functions of real-time monitoring, parameter setting, color editing, fault diagnosis and alarm, machine repair and debugging, etc. Fault diagnosis is a fault tree diagnosis method based on the theory of the expert system.
The main control module transmits the collected data to the wireless module through the serial port and then uses the TCP/IP communication protocol based on the Socket interface for data transmission to the cloud platform server. TCP has two working modes: Client and Server. In this system, the WIFI module is set as TCP Client, and the Socket Server is set as TCP Server.
The cloud platform is the core organization of the remote system, which mainly includes a Socket server, a data processing module, a database, and a Web server [2]. The data processing module saves the processed data files into the database as historical parameters and sends them to the Web server. The Web server mounts HTML pages and sends data files to the WEB client through Ajax. In this way, the client can quickly refresh device data [3].
The carrier of the field system adopts Kunlun touch screens, and the RS485 bus is adopted to communicate with the hardware of the main control system. The remote system can simultaneously satisfy enterprise users to monitor multiple looms and select WIFI as the wireless communication mode of the remote system. The wireless module ESP8266 is adopted to realize communication and interaction between on-site devices and the Internet. Figure 3 shows the PCB board of the main control module.
With the rapid development of industrial buses, more and more industrial sensors, instruments, and equipment adopt industrial buses. RS485 industrial bus is one of them, which often combines with Modbus and other communication protocols for communication detection and control [4]. In this system, STM32F407ZET6 is used as the main control module MCU. Because the main control chip of this system uses the RS485 communication mode to transmit data with the touch screen, only the RS485 module circuit is introduced here, and other hardware circuits of the main control module are not involved. Figure 4 shows the schematic diagram of the circuit designed according to the RS485 chip manual.
Before designing and developing the touch screen in the industrial field, it is necessary to clarify the detailed functional requirements and actual operation steps and then plan and design the entire interface structure of the industrial field system. This monitoring system uses MCGS Pro embedded configuration software to design all functional interfaces of the industrial field system. It needs to meet the requirements for real-time monitoring of the working status, parameters, and production data of the loom. This system adopts MCGS Pro embedded configuration software to design all functional interfaces of the industrial field system. It needs to meet the requirements of real-time monitoring of the working status, parameters, and production data of the loom and the recording of loom failure and tension fluctuation information. The staff can modify the operating parameters of the loom through the touch screen interface to realize the control of the loom equipment. The industrial field system should implement the following specific functional tasks:
This monitoring system mainly designs the device window, user interface, real-time database, script strategy, etc. Each part corresponds to different characteristics; especially in the interface design process, the rationality and friendliness of the user operation engineering should be fully considered [5]. The specific implementation steps are as follows:
The main control module and the touch screen communicate with each other using a serial port. Therefore, in the device window, the "general serial port parent device" is added, and the touch screen communicates with the external device using the "Modbus RTU" communication method.
The real-time database is the core hub of the monitoring system for data conversion. The data sent or retrieved between each part of the monitoring system through the real-time database finally realizes the monitoring of the loom. The device window connects the main control module to the system and reads or writes data from the main control module to the real-time database. After that, the data in the real-time database and the data objects designed by the personal computer interaction interface are correlated with each other, and the data is processed by the operation strategy.
The MCGS Pro configuration software has good logic scripting capabilities, but the hardware computing capabilities cannot support some fault diagnosis methods. Therefore, the fault tree diagnosis method with strong logic and a simple structure is adopted to realize the fault diagnosis function. The expert system fault diagnosis method based on fault tree diagnosis is combined with a real-time database to establish related fault logic and knowledge base. And this monitoring system uses MCGS Pro configuration software to design a logic script program to complete knowledge acquisition and fault interpretation expression and finally realize the fault diagnosis function of the industrial field system.
Expert system has been widely used. However, to better establish a clear and concise logical relationship between the various detection parameters of the loom and the related fault phenomena, the fault tree diagnosis method is also referred to [9]. The basic idea of the fault tree diagnosis method is shown in Fig. 6: Three failure events occurred, namely event 1, event 2, and event 4. According to the logical relationship, it is inferred that the final cause of the failure is event 6.
The fault diagnosis of the loom field system must have multiple fault trees, and the sub-events in these fault trees will overlap each other, which leads to repeated operations on multiple fault trees and makes the fault knowledge base redundant. Because the phenomenon of concurrent faults in the loom system rarely occurs, the fault tree can be simplified. Sub-events involving intersections are set as reference relationships, and different fault trees can refer to the same sub-event. As shown in Fig. 7, the complex fault tree is simplified according to the logical relationship between events.
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