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Profinet EIP EtherCAT
EGD UDP RFM RtEthernet Tc-net S7 Modbus OPC iso Ads Siemens
AB,GE,Mitsubishi,Beckhoff,MOOG,Schneider,ABB,Alstom,Driver,Domestic
PLC,Special Board QDR quality data
recording (digital steel coil) centimeter and millisecond level, supports
32+clients online Equipment testing, fault
diagnosis, quality analysis, ikoPDA CHPDA PLC-PDA, Full-stack Self-developed |
3rd PDA formats &
Rich proprietary features Global Standards,
Exceptional Value Simplified for Full Customization &
OEM with Open APIs Proven by Hundreds of |
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Process Data
Acquisition – CHPDA -- Detailed analysis of
quality manage & industrial big data sources -- Full stack develop & Fully intellectual property
owned |
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6 DCC - Digital Coil Conversion and full process quality management |
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20
Comprehensive data acquisition system for steelmaking plants |
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21 A
large amount of S7 communication causes network instability |
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11
HDP - High frequency density and speed Data Platform construction |
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12 HDC - Hot rolled high-frequency high-density
Digital steel Coil |
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26
Research Form for PDA System Config in the Steel Industry |
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27 MCP - Millisecond & Centimeter level information
Platform |
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11 HDP - High frequency
density and speed Data Platform construction
High frequency refers to sampling time, high density refers to space, and high speed refers to the speed of accessing the platform. The PDA system supports multiple methods such as Modbus TCP, telegrams, OPC UA, memory access, MQTT, etc., providing the platform with data at millisecond, second, centimeter, and meter levels. 1.1
One-time high-frequency acquisition and multi-frequency dynamic distribution
Figure 11.1 High-speed forwarding of multiple data paths 11.2
High-speed data forwarding
The PDA server is equipped with multiple network cards. In principle, data required by other systems is not directly connected to the L1 controller, but is instead forwarded and obtained through the PDA. Different network segments are forwarded through different network ports.
Figure 11.2 High-speed forwarding of data collected by PDA to other systems 11.3 High speed data forwarding -
connection
This task is executed by PDAServer.exe, it may achieve millisecond level forwarding. The PDA server adds a multi port network card. In principle, the data required by other systems is not directly connected to the L1 controller, but is obtained through PDA forwarding. Different network segments are forwarded through different network ports, which can save a lot of PLC resources. The first forwarding method is set through Config.csv, as shown in the figure below, with the forwarding IP, forwarding destination IP, and forwarding cycle set. This method can only forward to one place.
Figure 11.3 Setting up high-speed data forwarding to a location The second method is set through toIP. ini, which allows for high-speed forwarding to up to 10 locations, forward the received data at once when the forwarding cycle is 0. 11.4
High speed data forwarding - hybrid
This task is executed by PDAServer\PDA\Retransfer.exe, the forwarding period is an integer multiple of 10ms. Retransfer.ini is the configure file. Type 0: Combine data from different connection channels and send to the destination IP using UDP. The configuration example is as follows, the period is used to set the period (ms). Type 1: Retransfer all data of the connection, the efficiency is lower than the previous method. The connection port number is the port number of the first valid variable. The forwarded INT occupies 2 bytes, and the REAL occupies 4 bytes, Boolean occupies one bit of WORD, 16 Boolean occupy one complete WORD. [ToL2] style=0,挑变量转发 WithTimeStamp=1,是否带时间戳如 targetIP=192.168.0.220 targetPort=3010 period=20 1=1000,1 2=1000,2 3=1000,3 4=1000,36 5=1000,37 6=1000,4 7=2000,3 8=2000,8 9=2000,32 10=3000,12 11=3000,20 12=4000,2 13=4000,3 [ToL3] style=0,挑变量转发 WithTimeStamp=0 targetIP=192.168.0.221 targetPort=3020 period=25 1=1000,10 2=1000,20 3=1000,30 4=1000,22 5=2000,31 6=2000,2 7=2000,32 8=3000,11 9=3000,20 10=4000,1 11=4000,2 [ToQuality] style=1,转发整个连接 WithTimeStamp=0 targetIP=192.168.0.222 targetPort=3050 period=50 1=1000 [ToDevice] style=1,转发整个连接 WithTimeStamp=0 targetIP=192.168.0.223 targetPort=3060 period=50 1=3000 11.5
Modbus Tcp interface of A railway data teletransmission system
The control system of a certain railway station is S7-200smart, and the railway bureau needs to collect signals from it, but only supports the ModbusTcp protocol. The ModbusTcp protocol of S7-200smart is relatively troublesome. PDAServer communicates with PLC through the S7 protocol, and the collected real-time data is mapped to the Modbus register. The railway bureau can communicate with ModbusTcpServer, and the following figure is a schematic diagram of a railway data remote transmission system.
Figure 11.4 Schematic diagram of PDA data remote transmission network for a certain railway station 11.6
Database Interface - Millisecond-level High-speed Data Collection for the
Entire Plant
PDA supports data acquisition
of 30,000 points within 10 milliseconds, and uniformly stores slow or
triggered signals from the entire factory at high speed. If the number of
points exceeds 30,000, multiple PDA servers can be utilized. PDAServer
down-converts the acquired signals and writes them into multiple relational
databases such as SQLServer, MySQL, and ORACLE. Millisecond-level signals are
written into time-series databases such as
Figure 11.5: Data collected by PDA is saved to the database 11.7
Opc Ua Interface
The PDA maps the collected data to Opc Ua tags, allowing third-party platforms to directly scan the tag information and collect data.
Figure 11.6 Opc Ua Data Interface 11.8
MQTT Interface
The data format can be customized according to third-party platforms. 11.9
Traditional - Data Platform
Based on databases, it is basically in seconds. 11.10
High frequency - Data Platform
There is a huge market demand for secondary analysis and development based on high-resolution data, but the threshold is high. Currently, data analysis is mostly done in seconds, and upgrading the data platform to High Density Data Platform is an ideal choice. If the platform's rich analysis methods and close connection with business can be integrated with high-resolution data, it will definitely create a domestically unique high score and high density platform, achieving a sudden rise. 11.11
High
Frequency and High Density - Data Platform
As a transitional platform, it can store high-frequency and high-density data without requiring access speed. It is easy to build a conventional platform in combination with PDA. Advantages: There are no special requirements for platform hardware performance, which can remain unchanged, with almost no additional costs, minimal workload, and no technical bottlenecks. Disadvantage: There will be no improvement in access speed.
Figure 11.7 Data Flow of High Frequency and High Density Data Platform 11.12
High
Frequency High Density High Speed - Data Platform
This is the ultimate goal, which can store high-frequency and high-density data, and the access speed requires a return result in seconds. All applications must establish a result time of 3 seconds, otherwise the user experience will be poor. For example, if a search command on Google, Baidu, or Taobao produces results in 10 seconds, it will be difficult to promote. These are civilian applications, and industrial high-frequency and high-density data platforms should have higher standards. For data at the second, minute, and meter levels, if it meets business requirements, it should still be retained. However, the platform performance has changed, and such applications can produce results in less than one second. The cost should be appropriate, the plan should be carefully selected, and the technology should be optimized. 11.13
Implementation
method
The full installation of PDA in each project will lay a solid foundation for a high-resolution data platform, which can form centimeter level, millisecond level, or even microsecond level data platforms in the short term. By fully utilizing and exploring the super strong capabilities of PDAs that are very suitable for processing large amounts of data, it will form a strong competitive advantage in domestic and international markets. High resolution and high-density data platform is a practical requirement for data analysis. Once a high resolution and high-density high-speed data platform is formed, it will be able to establish technological advantages, and the threshold for a second level data platform is relatively low. As long as fully open PDAs are popularized in every project, such a platform will have a foundation and can be developed smoothly. 11.14
B/S architecture
(1) All PDA data files and analysis templates from each production line should be saved to the company-level data center Ø Millisecond-level data Ø Second-level data Ø 10-second-level data Ø 60-second data (2) The B/S server establishes indexes for all data files Ø PDA system opens relevant field content of dat file (3) Develop a webpage for selecting the scope of data files (4) High-speed download the data file selected by the client browser to the local Ø The download speed impacts the user experience Ø Do not download duplicate files (5) Quickly download the analysis template to the local (do not download duplicates) (6) When a browser webpage is opened, the PDA analysis tool is launched in the background Ø Load downloaded data files (PDA system open interface) Ø Load analysis template (PDA system open interface) (7) Use the PDA tool to generate a .dat file in PDA format from statistical or third-party data Ø PDA system opens conversion function interface
Figure 11.8 Signal flow of B/S architecture 11.15
Cooperation
with the outside world
High performance controllers
in For many years, our R&D
team has been dedicated to the exploration of communication protocol research
and development, field bus analysis, high-speed data acquisition, real-time
data compression, massive data storage, online data analysis, and other
technologies. We have devoted infinite energy and enthusiasm, worked
tirelessly, and finally achieved some breakthroughs. We hope to share and
encourage with everyone, and make some modest contributions to improving the
production and quality of industrial products, equipment testing, fault diagnosis,
Industry 4.0, and big data quality analysis in Some high-speed data collection systems in foreign countries are becoming increasingly closed, with layers of encryption. As a strategic partner, it is necessary to require unconditional open data interfaces. In order to significantly reduce the cost of high-frequency data collection, we have made unremitting efforts and launched major customer systems, annual package systems, etc., laying the foundation for the widespread popularity of PDAs. This way, the cost of each project can be basically ignored, and installing several sets of high-frequency data collection for each project will not be a problem, laying a solid foundation for high-resolution data platforms. PDA is only responsible for
basic data collection, storage, and analysis functions, and all subsequent
tasks are done by the platform, including rapid exchange, conversion,
storage, analysis, calculation, display, and interaction between the platform
and high-frequency data. PDA provides underlying support, which will be a
milestone and revolution for the data platform, with profound strategic significance.
We hope to shine a light on the construction of platforms in |
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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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