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Process Data Acquisition – CHPDA -- 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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36
Auxiliary transmission S120
S120 is a new generation frequency converter launched by Siemens, with DP and PN interfaces. CU320-2 PN (control unit 6SL3 040-0MA01-0AA0+memory card 6SL 3054-0EJ01-1BA0), CU320 (control unit 6SL3 040-0MA00-0AA1+memory card 6SL 3054-0CG00-1AA0). 36.1
PDAServer as Profinet master
PDAServer, as Profinet master station, can collect data from several CU320 slave stations at high speed. this is the fastest way to collect data without interference from A/D and D/A conversion. the data source type is 40. You may use the CU320 self PN port or add CBE20 network card, the speed is lower than self PN.
The CPU 315-2 PN/DP hardware configuration can be referred to in the following figure.
The hardware configure of
devices and networks is below in CPU
View version number and assign
IP address and Profinet device name to CU
The configuration in Scout is as follows:
CBE20 is automatically allocated to IF1, DP is automatically allocated to IF2, DP is automatically allocated to IF1 if CBE20 is not inserted.
To configure the data to CU320 sent by PDAServer.
To configure the data to PDAServer sent by CU320.
36.2 PDAServer
as Profinet Master Station Bus Time Division Multiplexing
Add Ethernet board CBE20 to each CU320 to form a dedicated data collection PN network. Indicator: CU: 25Word, Supply: 10Word ±, each Drive: 20Word ±, data refresh cycle up to 1 millisecond, Profinet bus time division multiplexing method can collect more data, (CU: 25Word, Supply: 10Word ±, each Drive: 20Word ±) * 3 data refresh cycle up to 3 milliseconds. Advantages: Fast collection speed, no modification required for automated L1 software, isolated from the automated L1 system. Disadvantages: CU320 requires the addition of CBE20, CU320 parameters need to be modified, and separate networking is required.
The following figure shows the CFC program diagram for collecting CU: 75Word with a PDA side data refresh cycle of 3 milliseconds. If CU only collects 25Word, there is no need for the CFC program.
36.3
Transfer the CU320 data to PLC or D455
As a DP or PN slave station, CU320 transmits data to the master station, and the master station collects data, the comprehensive acquisition speed is slower than that of the previous scheme. 36.4
PDAServer reads directly by r or p parameter address
The data source type is 27 or 21, and the comprehensive collection speed is slower than the previous two schemes, but it is convenient. The CPU slot number is determined as shown in the following figure.
Rules for setting variable addresses: DB [parameter number] DBB [1024 * device number+parameter index] corresponds to int8 and uint8 DB [parameter number] DBW [1024 * device number+parameter index] corresponds to int16 and uint16 DB [parameter number] DBD [1024 * device number+parameter index] corresponds to int32, uint32, and float The device number is determined as shown in the following figure. Parameter subscripts refer to the subscripts of array elements, such as 0, 1, 2, 3, etc. In a PDA connection, the same array can only have one of its elements. To read multiple elements of the same array, multiple PDA connections must be established.
Method 1: Use the PN network composed of existing X150 to read the P and r parameters. Indicator: Read 50 parameters with a refresh cycle of approximately 10 milliseconds. Advantages: Hardware and network, L1 software, and CU320 parameters do not require any modifications.
Method 2: X127 monitoring port networking, reading P and r parameters through the monitoring port. Indicator: Read 50 parameters with a refresh cycle of approximately 10 milliseconds. Advantages: The automated L1 software does not require any modifications. Disadvantage: The IP of the CU320 monitoring port needs to be modified and networked.
36.5 Comprehensive
data acquisition plan for company level main and auxiliary transmission
systems
In order to isolate from the automated L1 system, signals with a sampling period of less than 10ms are collected through a dedicated PN network formed by CBE20. If there are no special requirements for the sampling period, data is read from S120 through standard Ethernet using Siemens internal communication protocol. The PDA system saves the collected signals as. dat files and can also be saved to relational and temporal databases such as InfluxDB, making it convenient for various automatic reports and big data analysis such as Power BI, Sailsoft, and Grafana. Multiple PDA servers need to be set up based on the geographical location of each branch and the number of transmission systems.
36.6 Method
of Importing Scout Free Messages in Portal
The onboard PN port X150 serves as IF1 to communicate with automation L1, while CBE20 serves as IF2 to communicate with PDA. Free messages are used for communication with PDA. If there are no free messages in the chart, the configured IF2 communication messages need to be exported as gsd from Scout. Since Scout can only export IF1, IF1 and IF2 should be exchanged first. After the following operations are completed, the settings of IF1 and IF2 should be restored. Prepare two sets of files, such as GenerateGsdmlFile_ V2_ 2_ 0 and GSDML-V2.34-Siemens Sinamics_ S_ CU3x0-20181115.xml.
Finally, generate these two files.
Load in Portal.
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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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