Process Data Acquisition – PLC -- Detailed analysis of quality manage&industrial big data sources	高速数采方案 High speed data acquisition scheme		系统 System	Contact us
1 Background and significance		12 HDC - Hot rolled high-frequency high-density Digital steel Coil
2 PDA - data acquisition and analysis system		13 CDC - Cold rolled Digital steel Coil
3 LTA - Long historical Trend Analysis system		14 DSP - Digital Steel Plate
4 HDS - open time series high frequency Historical database		15 DTP - Digital Steel Pipe
5 DBU - Database system and Upgrade tools		16 CDS - Continuous casting Digital Slab
6 DCC - Digital Coil Conversion and full process quality management		17 TDA - Typical high-speed Data Acquisition scheme
7 CFS - Coil Fast Search and statistics system		18 QMS - Quality Manage and analysis System
8 DSO - Device diagnostic Synchronous Oversampling system		19 Common debugging tools and development board
9 RSA - Roll Spalling Alarm and Quick Stop System		20 Project performance and typical project application
10 RCM - Roller Current Monitoring system		21 Research Form for PDA System Configuration in the Steel Industry
11 HDP - High frequency density and speed Data Platform construction

2 PDA - data acquisition and analysis system

PDA (Process Data Acquisition) system is an industrial real-time platform with high speed data acquisition compression storage and analysis, online and offline analysis is its basis function, it's also a high performance general product at same time, it is a basic platform of industry 4.0 and big data.

(1) Provide equipment test method for the equipment manufacturing factory

(2) Provide effective methods of fault diagnosis and status detection for operation and maintenance of production plant

(3) Provide a convenient tool for the analysis of dynamic process

(4) provides the accurate basis for objection to the quality of product identification

(5) Provide strong data support for the development of new products

(6) Intelligent unmanned data recorder, radar, image recognition, speech recognition, deep learning, laser ranging, path planning, driving instruction, navigation and location, and equipment status

2.1 Overview of PDA system

The system can collect multiple units of PLC or controller data, the sampling period can be down to 0.05ms, the sampling points up to 100000 points, used to support the mainstream PLC, network, bus, hardware interface module, Multi-server and multi-client mode are supported, PDA drive may be developed cooperatively for special equipment, User specific analysis functions can be customized.

Figure 2.1 application interface

2.2 Fields of application

Figure 2.2 Application fields

Figure 2.3 application fields of PDA systems

2.3 System functionality and performance

Open, compatible, universal Millisecond data sampling Acquire 100000 points Effective real time data compression Microsecond time resolution Support for commonly used mainstream PLCs Support the reflective memory network Support the field bus and the hardware IO Wireless data acquisition Take client / server architecture Support multiple master multiple slave multi window Dedicated board, dedicated network Develop cooperatively PDA driver for special equipment Signal search, layering, grouping Export signal tree Config with Excel Telegraph message(mixed type taxis) Packeted data acquisition Analysis data export History data export Logical virtual signal Real-time trend Historical trend Dynamic playback Multi-column view Dual x-axis marks Dual y-axis marks Dynamic y-axis mark Auto scale Alignment Time sequence analysis 2D view 3D view Curve fit 3D surface view Surface fit Profile analysis Frequency chart Phase analysis Energy analysis Acceleration analysis Same compare analysis View navigator Roller span Roller zoom Span trend chart Zoom Adjust area height Data statistic Export statistic data Data dictionary Digital filter

Video synchronous analysis Absolute and calculative time base Analysis strategy X-Y convert Digital meter Curve annotation Fault diagnosis To capture transient signals Event note Expert system System alarm Database upgrade Data remote transmission Quality data report QDR-Quality data recording Judge the quality of questions Calculation of bearing oil film Mill stiffness measurement Mill stiffness trace report Performance test report of large hydraulic cylinder Dynamic running record and meter reading system Dynamic energy report To configure flexibly collection signal Acquiring state indication Wireless model configure Oscilloscope waveform analysis History data interface Compatible with third-party data formats Plugins Video synchronization analysis interface Online data interface Data file generation completion interface Fully open real-time data interface Oracle Database real-time interface Quality management system and big data interface HMI Interface High speed data forwarding ModbusTcpServer interface OpcUaServer / OpcUaClient KafkaServer / KafkaClient mqttServer / WebSocketServer Ftp Server / Http Server Whole process quality management and data analysis Customizing special analysis function Develop cooperatively for special board PLC Communication protocol service of data platform Distributed data acquisition Secondary day data file Minute grade year data file Big Data Office Cloud synchronizing Chinese / English / Any language

2.4 Technology parameters

PLC field bus and intelligent devices are supported.

2.4.1 Data type

String: LSTRING[Length]: 2 + Length bytes are occupied, the first byte is max string length,

the second byte is actual string length

STRING[Length]: 1 + Length bytes are occupied, the first byte is actual string length

CHAR[Length]: Length bytes are occupied

Analog: SINT: signed char, int8, smallint

INT: short, int16, shortint

DINT: long, int32, longint, integer

BYTE: USINT, unsigned char, uint8

WORD: UINT, uint16, unsigned int, DATE, S5TIME

DWORD: UDINT, unsigned long, uint32, longword, cardinal,

ulong, TIME,TIME_OF_DAY

REAL: FLOAT, single

DOUBLE: LREAL, DateTime

Digital: BIT(BOOL, Boolean)

Mixed arrangement

2.4.2 Sampling period

0.05ms level(0.05ms, 0.2ms, 0.8ms......50.0ms)

1ms level (1.0ms, 2.5ms, 3.6ms......50.0ms)

10ms level (10ms, 11ms, 12ms......50ms)

2.4.3 Data compression

Realtime compression: focus on real-time and efficiency.

Efficient compression: high compression ratio, pay attention to compression ratio.

No compression: pay attention to openness.

2.4.4 Collection points

More than 100000, As the acquisition cycle becomes shorter, it may be less and depends on the computer performance.

2.4.5 PLC data source connection number

Less than or equal to 80

2.4.6 Data acquisition mode

Industrial Ethernet, Profibus-DP, RFM and other network acquisition.

Hardware interface module.

PLC forwardly sends data, PDA server receives them.

PDA server directly reads data from PLC.

Data packet transmitted.

2.4.7 System clock

Calculated clock

Real time clock (wide area synchronization)

2.4.8 Data interface

Dos, Windows32/64, Linux32/64, Android, Mac OS, iOS and other platforms are supported.

Fully open real time data interface

Oracle or other database realtime interface

Fully open historical data interface

Fully compatible with third party data

Quality management system and big data interface(Memory pointer + data file)

HMI interface(Memory pointer + data file)

Video synchronous data interface

Plugins

Data file generation completion interface

ModbusTcp interface

2.4.9 System device

To take general equipment and protocols as possible.

To discard special interface module and network.

2.4.10 Distributed data acquisition

Local ethernet clock synchronization error is less than 1ms.

GPS and other clock synchronization is supported.

Figure 2.4 PDA Data Collection Server Distribution

2.5 System structure and network topology

Real time data of controller is collected at high speed by bus or network or interface module, the following analysis functions are provided: Selection of drawing mode(X axis based time, X axis based on length, ordinary view, 2D view, 3D view); Statistics function(calculation of the selected area maximum, minimum, instantaneous, mean, standard deviation, variance); Color control; View navigation; Signals arithmetic operations(addition, subtraction, multiplication, division, square, square root, the four operations of common mathematical functions); Various filters (Low pass, high pass, band pass, band stop); fast Fourier transform and so on.

The system is mainly composed of data acquisition server, data acquisition and analysis software, network configuration as shown below.

Figure 2.5 System network configuration and topology

2.6 PLC, field bus and vendors

□ Collect mainstream PLC data □ Collect Intelligent controller data □ Field bus data acquisition □ Signal acquisition for remote AI, DI module □ Wireless data acquisition □ Acquisition of reflective memory network □ Acquisition of PC data □ A variety of multiple PLC, infinite point □ Develop cooperatively PDA driver for special equipment □ Acquisition AI, DI signal of hardware card (orders) 0~5V / 0~±5V / 1~5V / 0~10V / 0~±10V 0~10mA / 0~±10mA / 4~20mA / 0~±20mA 0~1A / 0~5A / 0~±1A / 0~±5A mV weak signal 16Bit A/D conversion, PDA time base 1~255ms 16 channel analog non-isolation 16 channel analog : 3000VDC full isolation 32 channel digital input Channel may be grouped according to the type of signal Module can be extended to hundreds of points by series □ Thermal resistance Pt100/Cu50 □ Thermocouple J/ K/ T/ E/ R/ S/ B □ Angular displacement, electronic scale □ potentiometer, Frequency signal □ SSI synchronous serial interface The communication rate:250KHz, 500KHz, 1MHz, 2MHz Data length:16 / 32 bit □ Realtime data file □ Siemens S7-400 / FM458 Sampling period may be 2ms, Point to point □ Siemens S7-300 S7-1200 S7-1500 □ Siemens TDC, S7-200smart □ GDM(Global data memory) □ Simotion SCOUT □ Mitsubishi

□ Electric energy meter DL/T645-2007 □ PowerPC、VxWorks □ GE PACSystem □ GE 9070/9030 □ ALSTOM HPCi □ ABB AC500/AC31 □ BECKHOFF □ WAGO MOOG □ OPC □ LogiCAD TCS CoDeSys IsaGraF □ Modicon 984/Quantum/Premium/ Momentum/M340 □ Rockwell Automation/Allen-Bradley MicroLogix 1000, 1100, 1200, 1500 SLC 500 CompactLogix FlexLogix PLC-5 ControlLogix SoftLogix 5800 RSLogix □ Westinghouse WDPF □ Ethernet UDP □ Ethernet TCP □ S7 Ethernet TCP、iso □ Profinet □ Beckhoff Realtime Ethernet □ EtherCAT □ Beckhoff Ads □ MPI / DP □ Profibus-DP □ Modbus, ModbusTCP □ RS232 / RS485 □ CANopen DeviceNet □ EGD □ EtherNet/IP □ Reflective memory □ Inverter and so on □ Other special bus

2.7 PLC protocol service of data platform

2.7.1 Automation bus protocol classification

The automation system bus and protocol types are numerous, some are open, and some are dedicated.

The following table is classified according to the communication medium.

No.	Media	Speed	PDA data acquisition scheme		Example
			hardware	Software protocol
1	RS-232		Common serial port	PDA integrated	Modbus
2	RS-485	<=115200bps	Convert to RS-232	PDA integrated
3	RS-485	>115200bps	Special network	PDA integrated API/OPC gateway Third party interface
4	Special RS-485		Special network	PDA integrated API/OPC gateway Third party interface	Profibus-DP CAN DeviceNet
5	Ethernet	fast	Common ethetnet	PDA integrated	Profinet
6	Ethernet	faster	Special network	PDA integrated API/OPC gateway Third party interface	EtherCAT
7	Reflective Memory network	faster	Special network	PDA integrated API/OPC gateway Third party interface	GE Reflective Memory Siemens GDM TMEIC TC-net
8	other

PDA differently treats the different protocol understand for the same vendor in different periods or different manufacturers.

No program is needed for some PLC, Read directly data according to the variable address or symbol.

The real-time data interface is fully opened for the third party data platform which is convenient for the users to carry out data storage or processing neatly and diversely.

PDA system with a perfect communication protocol software development template may quickly develop unknown and future protocol.

2.7.2 Mainstream automation protocols

2.7.2.1 Process automation

AS-interface • BSAP[Bristol Standard Asynchronous Protocol] • CC-Link Industrial Networks • CIP[Common Industrial Protocol] • CAN bus[Control Area Network](CANopen • DeviceNet) • ControlNet • DF1 • DirectNET • EPA Ethernet for plant automation • EtherCAT[Ethernet for Control Automation Technology] • EGD[Ethernet Global Data, GE/ALSTOM HPCi] • Ethernet Powerlink • EtherNet/IP[Rockwell ControlLogix/CompactLogix/MicroLogix] • FIP[Factory Instrumentation Protocol] • FINS • FF[FOUNDATION fieldbus](H1 • HSE) • GDM[Siemens Global Data Memory] • GE RFM[Reflective Memory, 5565/5576 VxWorks LogiCAD CoDeSys IsaGRAF]• GE SRTP[Service Request Transport Protocol, GE Fanuc 90/VersaMax/PACSystems] • HART Protocol • Honeywell SDS • HostLink • INTERBUS • IO-Link • Lightbus • Lonworks • MECHATROLINK • MelsecNet • Modbus/Modbus Tcp[Schneider-Modicon 984/Quantum…] • MP-bus[Modular Power Bus]• Optomux • PieP • Profibus • PROFINET • RAPIEnet[Real-time automation protocol for industrial ethernet] • Realtime Ethernet[Beckhoff] • SafetyBUS p • SERCOS interface • SERCOS III • Sinec H1 • Symotion • SynqNet • TMEIC TC-net • TTEthernet[Time-Triggered Ethernet] • WorldFip.

2.7.2.2 Industrial control system

EtherNet/IP-backplate[Rockwell ControlLogix/CompactLogix/MicroLogix] • GE SNP/SNPX • MTConnect • OPC[OLE for Process Control] • Profibus-MPI/DP • S7 Ethernet Tcp/iso[Siemens S7-400/S7-300/TDC/FM458].

2.7.2.3 Building automation

1-Wire • BACnet • C-Bus • CC-Link • DALI[Digital Addressable Lighting Interface] • DSI[Digital Signal Interface] • Dynet • Enocean • FIP • Idranet • KNX[EIB/BatiBus/EHSA] • LonTalk • Modbus • Modbus/Tcp • oBIX • VSCP • X10 • xAP[xAP Home Automation protocol] • xPL • ZigBee.

2.7.2.4 Power-system automation

CDT[Cyclic Digital Transmission] • IEC 60870 • (IEC 60870-5-101 • IEC 60870-5-102 • IEC 60870-5-103 • IEC 60870-5-104 • IEC 60870-6) • DNP3 • FIP • IEC 61850 • IEC 62351 • Modbus • Profibus.

2.7.2.5 Automatic meter reading

ANSI C12.18 • IEC 61107 • DLMS/IEC 62056 • DL/T645[Multi-function watt-hour meter communication protocol] • M-Bus • Modbus • ZigBee.

2.7.2.6 Automobile / Vehicle

AFDX[Avionics Full-Duplex Switched Ethernet] • ARINC 429 • CAN bus(ARINC 825 • SAE J1939 • NMEA 2000 • FMS) • FIP • FlexRay • IEBus • IDB-1394 • J1587 • J1708 • KWP2000[Keyword Protocol 2000] • SMARTwireX • UDS[Unified Diagnostic Services] • LIN[Local Interconnect Network] • MOST • VAN[Vehicle Area Network].

2.8 Data acquisition and analysis view

Figure 2.7 Operation interface of data acquisition software

Figure 2.6 ~ Figure 2.23 is for operation interface of analysis software.

Figure 2.8 Main interface of analysis software and Multi column display of curves

Figure 2.9 System configure

Figure 2.10 Dual x-axis mark

Figure 2.11 Dynamic y-axis and dual y-axis mark

Figure 2.12 2D 3D view analysis

Figure 2.13 Height adjustment view

Figure 2.14 3D surface view and surface fitting

Figure 2.15 FFT- spectrum analysis

Figure 2.16 Data statistics

Figure 2.17 Logic signal - Expression

Figure 2.18 X-axis wheel trend figure translation

Figure 2.19 Y-axis wheel zoom and span

Figure 2.20 Digital table

Figure 2.21 X-Y convert and align

Figure 2.22 Curve annotation

Figure 2.23 Stiffness measurement of rolling mill

Figure 2.24 QDR Report of quality data record

Figure 2.25 Performance test of large hydraulic cylinder

2.9 WinCC-PDA FTView-PDA Web-PDA

Figure 2.26 Call PDAClient.ocx in C#

Figure 2.27 WinCC calls PDAClient.ocx

Figure 2.28 Call PDAClient.ocx in the browser

Figure 2.29 FactoryTalk View calls PDAClient.ocx

2.10 Using PDAClient under Linux

Connect to the Internet under Ubuntu and sudo apt install wine64 to install a 64 bit Windows emulator.

Copy PDAClient.exe to Linux, enter the directory where PDAClient.exe is located, right-click Open in Terminal, and run wine PDAClient.exe to directly open the PDAClient analysis tool.

Figure 2.30 Using PDAClient.exe in Linux

2.11 pdaCloud

pdaCloud in Config.csv specifies whether pdaCloud.exe starts automatically.

pdaCloud.exe may gengeate ①day file list file, ②day second level data file, ③appropriate data file found and copy them and ④log file to the cloud synchronization folder specified by CloudDir of Config.csv.

pdaCloud.exe sends ①the day list file and ②log file to the Email specified by Config.csv.

Figure 2.31 Prepare data for pdaCloud

2.12 Millisecond level high-speed data acquisition for the entire factory

PDA supports data collection of 30000 points within 10 milliseconds. Slow or trigger signals in the entire factory can be saved at a unified high speed. If the data exceeds 30000 points, multiple PDA servers can be used. PDA servers reduce the frequency of the collected signals and write them to multiple relational databases such as SQL Server, MySQL, and ORACLE. Millisecond level signals are written to temporal databases such as InfluxDB. Other subsystems require real-time data to be forwarded by PDA servers at a high speed or reduced frequency.

Figure 2.32 Data collected by PDA saved to database

2.13 High speed data 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.

Figure 2.33 Setting up high-speed data forwarding to multiple locations

Apparatus test&Fault diagnosis&Quality analysis

Millisecond data sampling

Real-time data compression

Capture signal instantaneous mutation

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