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

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1 S7-1500 and slave drop data collection scheme

31 Beckhoff Ads

2 S7-400 Ethernet high speed fixed period 2ms

32 EtherCAT

3 S7-300 Ethernet high speed fixed period

33 RS232 / RS485

4 Profinet

34 Rockwell AB PLC

5 S7-400/300/TDC/FM458 Ethernet Variable Access

35 OPC / OPC Ua

6 Standard Ethernet UDP

36 Auxiliary transmission S120

7 Standard Ethernet TCP

37 Main driver system SL150

8 S7 PLC Tools for program debugging - pdaTools

38 B&R - Robot

9 S7-400/300/TDC/FM458 Symbol Variable DB block

39 MITSUBISHI MC protocol - format 4

10 S7-400/300 iso(MAC address)

40 MITSUBISHI MELSECT – QnA 3E

11 S7-300/400 standard ethernet

41 MITSUBISHI Q-Series UDP

12 TDC Ethernet

42 Smart meter DL/T645-2007 protocol

13 S7-1500/1200

43 S7-200 smart

14 MPI/DP variable access

44 Automobile CAN-bus

15 Profibus-DP

45 Alstom HPCi VMIVME 7750 - UDP

16 RFM(Reflective Memory)

46 Collecting KEPServer data through Opc Ua

17 CoDeSys

47 Collecting S7-1500 data through Opc Ua

18 Interface Module

48 Listen to all data on the Profibus bus and collect it

19 Simotion D

49 ABB main drive ACS6000

20 EGD(Ethernet Global Data)

50 Collecting PCI/PCIe card data

21 Modbus Register address

51 Collect TC-net network data

22 Modbus TCP Memory block

52 Collect UDP data forwarded by Tc-net

23 Modbus TCP Register address

53 Collect domestic PLC data

24 FM458 Profibus-DP gateway

54 Other data collection methods

25 GE Fanuc SRTP/ SNPX

55 High speed data forwarding

26 Wago

56 PDA system scheme for converter, RH furnace, LF furnace in steel plant

27 MOOG PLC

57 Continuous Casting Hydraulic Vibration PDA System

28 ABB PLC

58 Hot rolling TDC GDM.PDA system renovation

29 Beckhoff Ethernet

59 USB HID

30 Bechhoff Realtime Ethernet

60 AnyControl

11 S7-300/400 standard ethernet

11.1 Define DB and assign values in PLC

Assign gathered data to a DB in PLC, send the whole to the PDA server, as follows.

Create Book1.csv with Excel, and establish the STL corresponding assignment statement with the last table, copy the content into the PLC function block.

L ,65,,

T,DB1000.StringA[1],// DB1000.StringA[1],// CH1

 

L,1,,

T,DB1000.IntA[1],// DB1000.IntA[1],// CH2

 

L,2,,

T,DB1000.IntA[2],// DB1000.IntA[2],// CH3

 

……

 

AN,M1.6,,

=,DB1000.BoolB[15],// DB1000.BoolB[15],// CH73

 

AN,M1.7,,

=,DB1000.BoolB[16],// DB1000.BoolB[16],// CH74


11.2 S7-400 Redundant PLC configuration

UR2-H Redundant frame is needed.

if the Ethernet port is not available after power on, It will be normal if you wait 20 minutes.

11.3 CPU with integrated PN port(S7-300/400)

UDP communication protocol is used, the type of data source is 25, which supports the following or higher version CPU.

CPU

Version

UDP

Local_Device_ID

315/317(F)-2PN/DP

V2.5

1472 Bytes

16#2

319-3PN/DP

V2.4

1472 Bytes

16#3

319-3PN/DP

V2.5

1472 Bytes

16#3

412-5H PN/DP

V6

1472 Bytes

16#5

414-3PN/DP

V5

1472 Bytes

16#5

416-3PN/DP

V5

1472 Bytes

16#5

Please ask for the example of the collection process "PDA S7-400 With PN UDP.rar" if needed, Multiple connections can be created in one CPU.

The following is configuration and program for collection of 1472 bytes, 10ms sampling period, rising edge triggered, OB35 program cycle is set to 5ms.

Copy OB35, OB100, FB65, FB66, FB67, FB68, FB500, FC95, FC96, DB1, DB500, UDT65, UDT66 to user’s program, FB65, FB66, FB67, FB68 are system function blocks, rename the block with name conflict.

PDA program use 3 global BOOLs, M0.1, M0.2 and M0.3 are used in this example, DB1 is the data to be collected.

OB100 procedures are as follows.

OB35 procedures are as follows.

FB500 procedures are as follows.

 

LOC_PORT must be same as REM_PORT.

 

 

FC95 procedures are as follows.

FC96 procedures are as follows.

Place the below ladder to a OB to trigger the sending function block.


11.4 6GK7 343/443-1EX20-0XE0 and above Ethernet card

UDP communication protocol is used, Each connection can collect at most 1452bytes, Sampling period is about 10~20ms, the other CPU in the same rack besides the first send data to CPU1, CPU1 collects data together, see 4.5.4 section, Network configuration is as below.

Network adapter property settings.

Connection property settings.

 

 

 

PLC procedures are as follows,  FC53 is used to send data.

DB99 defines 300 REAL.

PDAServer configuration for 300REAL/10ms is as follows, pay attention to swap byte.

[2000,300CH,10.000ms,192.168.0.100,25S,Note,192.168.0.216]

No,    Name,Adr/note,Unit,Len,Offset  ,Gain    ,Type,ALM,HH   ,HI   ,LO   ,LL   ,Opr,FFS

CH1=,      ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

CH2=,      ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

CH3=,      ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

CH4=,      ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

CH5=,      ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

CH6=,      ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

……

CH300=,    ,        ,    ,4  ,0.000000,1.000000,REAL,0  ,0.000,0.000,0.000,0.000,0  ,  

The Tcp protocol is similar.

In order to ensure the data consistency, the pdaData function block is located before the transmission function block. The hardware address of PIxxx PQxxx from DP network should not be put into the pdaData which prevent CPU failure due to DP and other network disconnection, they may be converted in OB1.

With the increase of the number of PLC Ethernet communication connections or the amount of communication, the transmission speed and the number of bytes used for PDA communication will slow down and decrease. please select Profinet mode to collect more data or for less collection cycle, see section 4.7 for detail, Application example: slab yard and heating furnace area of some Hebei 1580 hot rolling mill, 5 PLCs(416-2XN05-0AB0+443-1EX30-0XE0), PLCs update data per 15ms, PDA Server collects data per 8ms, 100REAL+100INT+512BOOL(712points/664bytes) are collected by per PLC. There are three hydraulic stations, 156REAL+112INT+1312BOOL(1580points/1012bytes) are collected by per PLC. There are four lubricant stations and four S7-300, PLCs refresh data about 6ms, 192 pointes are collected by per PLC.

11.5 6GK7 343/443-1EX11-0XE0 and the following Ethernet cards

Udp protocol: S7-PLC directly send data block to PDA server by FC5 or FC50(>240bytes), the network configure is below, the other is same as section 4.3.

Tcp protocol: S7-PLC directly send data block to PDA server by FC5 or FC50 (>240bytes), S7-PLC acts as tcp client, the network configure is below, the other is same as section 4.4.

11.6 Export comment of S7 DB block to grid

 

 

 

 

 

 

 


11.7 CFC programming notes

LAD programming is used by the PDA FC block, there will be a mixed programming of CFC and LAD if the user main program is CFC, S7-PLC supports this way, the PDA blocks effective range should be paid attention to, see below, otherwise they will be covered when CFCs are compiled or cause system conflict, More memory space is occupied because a large number of DB and FC are produced after CFC are compiled, to ensure CF card is sufficient to no compression program for download, otherwise "The interface of block has changed Please reimport" error will appear when you download CFC, you may decrease the PDA FC block number, it is priority to be downloaded to the CF card, the error may be not appeared, To replace CF card with large capacity is the fundamental solution.

11.8 About "upload"

The address related to Id may be changed when PLC Ethernet network configuration is uploaded, so the project configuration should be consistent with the actual PLC hardware, Do not have to use the upload network configuration.

 

Apparatus test&Fault diagnosis&Quality analysis

Millisecond data sampling

Real-time data compression

Capture signal instantaneous mutation

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