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《面向数控系统的EtherCAT主站设计与实现》一、引言随着工业自动化技术的不断发展，数控系统作为制造业的核心设备之一，其性能和效率的提升显得尤为重要。
EtherCAT （Ethernet for Control Automation Technology）作为一种高性能、高实时性的工业以太网通信协议，被广泛应用于数控系统中。
本文将详细介绍面向数控系统的EtherCAT主站设计与实现，旨在提高数控系统的性能和效率。
二、背景及意义EtherCAT协议以其高实时性、高带宽和易扩展性等优点，在数控系统中得到了广泛应用。
然而，传统的数控系统主站设计往往存在通信效率低、实时性差等问题，无法满足现代制造业对高精度、高效率的要求。
因此，设计并实现一种面向数控系统的EtherCAT主站，对于提高数控系统的性能和效率具有重要意义。
三、EtherCAT主站设计（一）总体设计思路EtherCAT主站设计主要包括硬件设计和软件设计两部分。
硬件设计主要涉及主站控制器的选择和电路设计；软件设计则包括EtherCAT协议栈的实现、通信任务的调度等。
设计过程中需充分考虑实时性、可靠性和可扩展性等因素。
（二）硬件设计硬件设计是EtherCAT主站设计的基础。
首先，选择一款性能稳定、实时性强的主站控制器，如工业级FPGA或高性能微处理器。
其次，根据实际需求，设计合理的电路，包括电源电路、通信接口电路等。
此外，还需考虑硬件的抗干扰能力和散热性能，以确保主站的稳定运行。
（三）软件设计软件设计是实现EtherCAT主站的核心。
首先，需实现EtherCAT协议栈，包括网络初始化、节点管理等功能。
其次，设计通信任务的调度策略，以确保实时性要求。
此外，还需实现错误处理机制和日志记录功能，以便于问题的排查和解决。
四、实现过程（一）协议栈实现EtherCAT协议栈的实现是EtherCAT主站设计的关键。
首先，需深入了解EtherCAT协议的原理和特点，然后根据实际需求，编写相应的代码实现协议栈的功能。
设计题目：基于工业以太网的控制系统设计与实现
1.设计任务：
本设计的主要任务是利用工业控制网络实验室的设备，设计并实现基于工业以太网的控制系统。
此系统的基本模式为对等模式，每一站点可以选择该实验设备的任一模块作为受控模块，站点个数为3个（含3个）以上一样。
采用计算机作为主站，通过在计算机上发出指令，使从机上的模块可以真确运行。
2.设计要求：
（1）从站采用配备S7-200系列的PLC，被控端采用实验设备所提供的模块。
可选模块包括液位控制系统，交通灯控制系统，变频调速系统，立体仓库系统，电梯运行系统，工业机械手等模块。
（2）主站采用安装有WINCC系统的PC机。
（3）要求参照模块使用说明，编写PLC的控制程序。
（4）调试工业以太网网络使之正常运行。
（5）使用WINCC编写上位机控制程序，要求多个控制程序可以相互切换，要求控制程序能正确运行。
（6）设计报告书需参照《徐州工程学院毕业论文（设计）》模板规定的格式撰写。
要求内容翔实连贯，数据准确可靠，突出技术细节。
3. 设计计划安排：
4.参考资料
[1] 工业自动化网络实验指导书
[2] 现场总线及工业控制网络技术
[3] WINCC组态软件教程
[4] 电气控制与PLC教程
[5] 电机与拖动教程
[6]《自动控制原理》教材
[7] 自行查找的资料。
基于工业以太网的网络数控系统设计及实现1 引言从企业实际需求来看,对于制造业,目前企业的MIS 和ERP 仅仅局限于通常的管理、设计开发等上层部分的信息化,是远远不够的,工厂、车间的最底层数控机床不能够连成网络,就必然成为制约制造业企业信息化的瓶颈,不能充分提高生产效率。
对于面临全球化竞争的现代制造工厂,数控机床必须达到一定的数量或比例;其次就是把所拥有的数控机床组建成一个双向、高速的制造体系,彻底解决信息孤岛问题,构成数字化车间,以保证信息流在工厂、车间的底层之间及底层与上层之间通讯的畅通无阻。
2 网络数控技术的发展2.1 DNC 系统及网络结构DNC(Direct Numerical Control, DNC)系统是指多台数控机床由一台计算机统一分配控制程序和进行管理。
现在的DNC 系统从内容和意义上已发展成为分布式数字控制(Distributed Numerical Control, DNC)系统。
从数控技术的发展分析,分布式数控系统是由直接数控系统发展而来的,是针对当时数控设备内存小、处理能力弱而产生的。
以后出现的计算机数控(Computer Numerical Control, CNC)设备使DNC 系统增加了程序编制和编辑功能,并且有一定的通讯能力。
随着局域网、数据库、工作站的发展以及零件加工系统发展的需要,出现了分布式数控系统,它是针对车间的生产计划、技术准备、加工操作等基本作业的集中监控与分散控制相结合而产生的车间生产控制系统。
系统的目标任务通过局域网分配给各子系统,子系统之间信息相互交换以协调完成任务。
这种系统的优点是易于扩充、灵活、可靠性高,具有良好的开放性。
基于实时以太网EtherCAT的数控系统研发的开题报告摘要：以太网在各个领域中的广泛应用，如工业、家庭、医疗等，不断推动着其技术的发展和完善。
在工业领域中，以太网作为实时控制的通信手段得到了越来越广泛的应用。
而EtherCAT则是基于实时以太网技术的一种开放式高性能工业网络通信协议。
本文主要研究基于实时以太网EtherCAT的数控系统，通过对EtherCAT协议、数控系统的基本原理和相关技术的研究，提出一种基于EtherCAT协议的数控系统设计方案，为数控系统实时通信的研究提供一定的参考。
关键词：以太网，EtherCAT，数控系统，实时通信一、研究背景数控系统是现代机械制造行业中必不可少的系统之一，其能够通过计算机程序控制机床进行高精度、高效率、高灵活性的加工。
然而，传统的数控系统通常采用RS232、RS485等串口通信手段，通信速度慢、稳定性差，无法满足实时性要求。
而随着以太网技术的发展，以太网逐渐成为了数控系统实时通信的有力替代品。
EtherCAT是一种基于实时以太网技术的网络通信协议，采用Master-Slave架构，具有通信速度快、实时性好、支持大规模节点、可实现高精度的同步等特点，已经被广泛应用于工业控制、自动化等领域，成为实时以太网技术的一种代表。
二、研究目的和意义本文旨在研究基于实时以太网EtherCAT的数控系统，通过对EtherCAT协议和数控系统基本原理进行研究，提出一种基于EtherCAT协议的数控系统设计方案，使其能够满足实时通信的要求，并能够与传统数控系统互通。
三、研究内容和方法1. EtherCAT协议研究① EtherCAT协议的概念、特点和架构；② EtherCAT主站和从站的通信机制；③ EtherCAT数据帧结构和传输方式。
2. 数控系统研究①数控系统基本原理；②数控系统实时通信的要求；③数控系统通信协议。
3. 基于EtherCAT协议的数控系统设计①数控系统的硬件和软件平台；② EtherCAT网络的拓扑结构设计；③ EtherCAT主站和从站的程序设计；④数控系统实时通信的测试和性能分析。
摘要电梯作为现代高层建筑最常用的垂直运输工具，广泛应用于社会活动的各个角落，如何保证每台电梯都能够可靠运行，已成为提高物业管理水平和电梯技术进步的关键所在。
电梯运行质量直接由控制系统的功能决定，而控制系统软件又直接决定着控制系统运行的好坏。
本文介绍了基于工业以太网（EPA）现场总线控制系统的模拟电梯控制的组态设计的整个过程。
文中首先对课题的研究背景及意义做了明确的说明，其次对基于EPA现场总线控制系统设计及组态控制设计所需用到的各种硬件及软件设施做了一定的说明，然后设计了基于工业以太网（EPA）现场总线控制系统的模拟电梯控制，最后使用组态设计实现对模拟电梯的控制。
系统采用PLC_Config进行编程，通过PEC系列模块实现对模拟电梯的控制，使模拟电梯运行起来。
组态设计是采用力控ForceControl6.1，力控是我国较早出现的组态软件之一。
最近几年，力控得到了长足的发展，最新版本的组态软件在功能、特性、易用性、开放性和I/O驱动数量上都得到了很大的提高。
关键词：电梯；EPA；编程；组态；控制基于工业以太网（EPA）现场总线控制系统的组态控制设计（模拟电梯控制）AbstractLift the most commonly used as a modern high-rise building vertical transportation, social activities are widely used in every corner, how to ensure reliable operation of each elevator can have a lift to improve property management and the key to technological progress. Quality elevator control system functions directly from the decision and control system software and directly determines the quality control system operation. In this paper based on Industrial Ethernet (EPA) field bus control system configuration of the analog design of elevator control the entire process. In the first part of the background and significance of the subject made a clear statement, followed by the EPA based on field bus control system design and configuration control design used in all the necessary hardware and software facilities to do a certain amount of description, and then designed based on Industrial Ethernet (EPA) field bus control system simulation, elevator control, the final design and implementation of simulation using the configuration of the elevator control. Programming system uses PLC_Config by PEC series of modules on the simulation of the elevator control to simulate the elevator up and running. Configuration design is the use of force control ForceControl6.1, power control is the emergence of the configuration software of the earlier one. In recent years, power control has been considerable development, the latest version of the configuration software in functionality, features, ease of use, openness, and I / O-driven number have been greatly improved.Keywords: elevator; EPA; programming; configuration; control- 1 -基于工业以太网（EPA）现场总线控制系统的组态控制设计（模拟电梯控制）目录摘要 ··························································································································· - 0 - 目录 ··························································································································· - 2 - 第一章绪论···················································································································· - 4 -1.1基于工业以太网（EPA）现场总线控制系统的研究背景及意义········································· - 4 -1.1.1 研究背景及意义 ·························································································· - 4 -1.1.2 创新之处 ··································································································· - 5 -1.2电梯控制设计的要求······························································································· - 5 -1.2.1设计目的···································································································· - 5 -1.2.2 设计要求 ··································································································· - 5 -1.2.3 控制要求 ··································································································· - 5 -1.3 电梯的简介·········································································································· - 6 -1.3.1 电梯的起源 ································································································ - 6 -1.3.2 电梯的定义与分类 ······················································································· - 6 -1.3.3 电梯电气控制发展 ······················································································· - 7 -1.3.4 电梯的国内外发展状况 ················································································· - 7 -1.4 EPA的简介 ·········································································································· - 9 -1.4.1 EPA的起源································································································· - 9 -1.4.2 EPA控制系统······························································································ - 9 -1.4.3 EPA取得的成果··························································································- 10 -1.4.4 EPA的特点································································································- 10 -1.4.5 EPA的研究现状··························································································- 12 -1.4.6 EPA的发展方向··························································································- 12 - 第二章基于工业以太网EPA及力控的开发环境····································································- 14 -2.1 EPA可编程控制器产品介绍及特点 ···········································································- 14 -2.2 基于IEC61131-3编程标准的PLC_Config编程软件 ·····················································- 16 -2.2.1 PLC_Config编程软件 ··················································································- 16 -2.2.2 PLC_Config编程指令介绍 ············································································- 17 -2.3 EPA可编程控制器硬件安装 ····················································································- 18 -2.3.1电源连接如图2.2 ·······················································································- 18 -2.3.2 编程线缆连接 ····························································································- 18 -2.4力控ForceControl6.1 ······························································································- 19 -2.4.1力控ForceControl6.1概述···········································································- 19 -2.4.2力控ForceControl6.1主要特点·····································································- 19 - 第三章电梯控制系统的软件设计 ·······················································································- 21 -3.1 四层电梯的主电路································································································- 21 -3.1.1 四层电梯曳引机及门电机电路图····································································- 21 -3.1.2 电梯控制PLC外部I/O接线图·······································································- 22 -3.1.3 电梯控制PLC I/O点数的估算·······································································- 23 -3.2 现场总线的三级控制模式·······················································································- 24 -3.3 电梯控制的系统框图·····························································································- 24 -- 2 -基于工业以太网（EPA）现场总线控制系统的组态控制设计（模拟电梯控制）3.4 电梯控制的程序图································································································- 27 -3.4.1 PLC编程语言·····························································································- 27 -3.4.2 程序设计常用编程方法 ················································································- 27 -3.4.3 外召唤信号登记及消除 ················································································- 28 -3.4.4内指令信号登记及消除·················································································- 29 -3.4.5电梯的平层信号处理····················································································- 31 -3.4.6选层定向及反向截梯····················································································- 31 -3.4.7内指令外召唤信号的保持··············································································- 33 -3.4.8各楼层停车信号··························································································- 34 -3.4.9 手动及自动开关门 ······················································································- 35 - 第四章组态控制设计 ······································································································- 36 -4.1绘制组态图并定义相关变量 ····················································································- 36 -4.2 组态设置············································································································- 38 -4.2.1设置I/O点的地址并保存··············································································- 38 -4.2.2设置本机IP地址 ························································································- 38 -4.2.3 对设备（PEC8000）进行配置 ········································································- 39 -4.3组态调试·············································································································- 40 -4.4最终实时组态效果·································································································- 40 - 参考文献 ·······················································································································- 41 - 附录 ·····························································································································- 42 - 附录A 参数说明·······································································································- 42 - 附录B 从设备资源和特性···························································································- 44 - 附录C 端子排布及指示灯说明·····················································································- 46 - 谢辞 ·····························································································································- 48 -- 3 -。
基于交换式以太网的网络化数控系统研究【摘要】交换式以太网推动了以太网在网络控制系统中的应用和发展,成为网络控制系统新的发展方向,对于数控系统这种特殊的控制系统来说也不例外。
本文提出了一种面向多对象和多用户的网络数控服务系统体系结构,论述了系统各组成部分,重点讨论了网络数控服务系统中各通信任务的协调设计,并通过实验证明了设计方案的有效性和稳定性。
【关键词】交换式以太网数控服务引言数控系统必须满足网络化的要求,数控设备的形态已逐步发展为整个企业网络中的一个能进行感知、处理、传输并自动执行的节点,本文的研究就起源于交换式以太网技术应用于数控系统中所面临的实际问题。
当交换式以太网的拓扑结构和交换机的情况已经确定时,除了各端节点的通信带宽分配策略,在实际的网络系统设计中,另一个影响系统性能的因素就是主节点(如主控单元、核心服务器)上各通信任务的协调[1]。
在应用层面,数据的产生和通信的发起是随机的,所以在这一层面也需要考虑多个通信任务对信道的共享问题,另外各类任务之间也存在对主节点计算资源的共享问题。
本文以工业控制中的一个典型应用——网络数控服务系统为对象,有针对地对实时系统设计与实现过程中各通信任务之间以及通信任务与其他任务之间的协调设计问题进行分析。
2 系统结构网络数控服务系统体系结构如图1所示。
每个机床配备有少量的、必须的、功能简单且单一的控制器,如运动控制、伺服驱动、PLC等,它们通过现场总线、网络构成了机床的基本数控单元(但非完整系统),这些基本数控单元通过交换式以太网与功能丰富、提供更强处理能力的数控服务系统相连,从而获得机床加工所需的完整数控功能[2-3]。
对机床的操作,由远程数控客户端(专用客户端或通用浏览器)通过交换式以太网连接到数控服务系统进行。
整个系统主要包括如下几个控制模块:(1)面向多控制对象的数控服务系统(NC service system, NCSS),负责多台机床的数控操作管理和业务处理。
基于工业以太网的网络数控系统设计及实现3梁志锋1,解翔2,唐小琦2(1 广东省机械研究所,广州510000;2 华中科技大学国家数控中心,武汉430074)摘要 在分析网络数控技术发展历史基础上,重点介绍工业以太网的网络数控系统硬件平台和软件平台的设计与实现,具有很强的实际应用性。
关键词:网络数控 工业以太网 DNC中图分类号:TP39119;TH16 文献标识码:A 文章编号:1671—3133(2006)01—0038—03Design o f the netw orked num erical control system b ased on industrial E thernetLiang Zhifeng1,X ie X iang2,T ang X iaoqi2(1 G uangdong Machinery Research Institute,uangzhou510000,CH N;2 National NC system Engineering Research Center,Huazhong University of Science&T echnogy,Wuhan430074,CH N)Abstract The netw orked numerical control system based on industrial E thernet has already become the development trend of numerical control system.Has explained the design and implementation netw orked numerical control system based on industrial E thernet in the view of practical application.A fter analyzing the development history of the netw orked numerical control technology,explains the design and realization of hardware platform and s oftware platform of netw orked numerical control system based on industrial E thernet especially, with very strong actual using value.K ey w ords:Netw orked numerical control Industrial E thernet DNC1 引言从企业实际需求来看,对于制造业,目前企业的MIS和ERP仅仅局限于通常的管理、设计开发等上层部分的信息化,是远远不够的,工厂、车间的最底层数控机床不能够连成网络,就必然成为制约制造业企业信息化的瓶颈,不能充分提高生产效率。
对于面临全球化竞争的现代制造工厂,数控机床必须达到一定的数量或比例;其次就是把所拥有的数控机床组建成一个双向、高速的制造体系,彻底解决信息孤岛问题,构成数字化车间,以保证信息流在工厂、车间的底层之间及底层与上层之间通讯的畅通无阻。
2 网络数控技术的发展211 DNC系统及网络结构DNC(Direct Numerical C ontrol,DNC)系统是指多台数控机床由一台计算机统一分配控制程序和进行管理。
现在的DNC系统从内容和意义上已发展成为分布式数字控制(Distributed Numerical C ontrol,DNC)系统。
从数控技术的发展分析,分布式数控系统是由直接数控系统发展而来的,是针对当时数控设备内存小、处理能力弱而产生的。
以后出现的计算机数控 广东经贸委项目(0612A2003040Π5) 开放式、网络化已成为当代数控系统发展的主要趋势。
通过网络进行大系统的集成,便于实现车间自动化。
参考文献:[1] 向华,陈吉红,周云飞.基于PC数控实时检测系统建模方法研究[J].中国机械工程,2003,14(20):1777-1779.作者简介:向华,工学博士,主要从事精密测量、数控技术方面的研究。
收稿日期:200520922883 现代制造工程2006年第1期数控加工技术(C om puter Numerical C ontrol ,C NC )设备使DNC 系统增加了程序编制和编辑功能,并且有一定的通讯能力。
随着局域网、数据库、工作站的发展以及零件加工系统发展的需要,出现了分布式数控系统,它是针对车间的生产计划、技术准备、加工操作等基本作业的集中监控与分散控制相结合而产生的车间生产控制系统。
系统的目标任务通过局域网分配给各子系统,子系统之间信息相互交换以协调完成任务。
这种系统的优点是易于扩充、灵活、可靠性高,具有良好的开放性。
图1 传统DNC 结构 一般DNC 系统通常具有两级计算机分级结构形式,即主控计算机加C NC 系统群组成(见图1)。
对于通信距离短、组成DNC 系统的数控机床数量少的小型系统可采用这种方式联接。
该联接方式结构简单,但连线多、易出故障、通信距离短(RS 2232通讯距离一般为15m 以内),不适宜较大范围的DNC 系统。
212 现场总线系统及网络结构图2 基于总线的DNC 结构 鉴于以上通信方式存在的缺陷,一些研究单位提出了基于现场总线技术(主要有BitBus 和C AN 总线)的改进型DNC 通信系统,可实现远距离通信,具有操作方便、开放性好的特点,其网络拓扑结构如图2所示。
每台数控机床配备一台通信前端单元,各通信前端单元与DNC 主控计算机间采用现场总线进行连接。
通信前端单元与数控系统集成在一起,可靠性高。
系统具有良好的扩展性,设备更灵活,但是车间级网络是总线协议,工厂上层网络都是基于TCP ΠIP 的以太网,这样还不能方便地实现信息共享。
3 工业以太网普通以太网(Ethernet )是为IT 应用而开发的,在工业自动化领域只得到有限的应用,这是由于:1)以太网采用CS M A ΠC D 碰撞检测方式,在网络负载较重(大于40%)时,网络的确定性(Determinism )不能满足工业控制的实时要求:2)Ethernet 所采用的接插件(connector )、集线器(hub )、交换机(switches )和电缆等是为办公室应用而设计的,不符合工业现场恶劣环境的要求;3)以太网抗干扰性能较差;4)以太网满足本安型应用有一定的难度等。
随着工业以太网技术的发展,上述问题正在迅速得到解决。
工业以太网是基于IEEE 80213(Ethernet )的强大的区域和单元网络,工业实时以太网对普通以太网作了如下改进:1)采用交换式以太网,仅在发送站和接收站之间直接交换信息,克服了时延和碰撞,提高了实时性;2)采用全双工(Full 2duplex )网络,端口上媒体段的长度不受CS M A ΠC D 的制约,可以延伸距离;3)网络速度的提高(已全面从10M 过渡到100M ,甚至1000M ),使以太网能提供足够的带宽,又减少了冲突;4)所采用的接插件(connector )、集线器(hub )、交换机(switches )和电缆等已有为工业环境而设计的。
至于以太网存在的不确定性和实时性能欠佳的问题,已由于智能集线器的使用、主动切换功能的实现、优先权的引入以及全双工的布线等,基本上得到解决。
通过提高数据传输速率,仔细地选择网络的拓扑结构及限制网络负载等,可将发生数据冲突的概率降到最低。
工业以太网经过上述改进措施后,典型的工业应用中,10M Ethernet 峰值负载为10%,100M Ethernet 峰值负载为015%,而Ethernet 只有当负载达40%以上时才会有明显的延时现象;在100M Ethernet 网中,发送一个信息包延时超过2ms 的状况五年也不会发生一次,美国电力研究院(EPRI ,Palo Alto.,Calif )的实验结果表明,可保证延时在4ms 以内。
网络数控就是建立在上述工业以太网的基础之上,而且采用工业以太网作为网络数控的底层有多方面的优势:1)成本低。
因普遍应用所形成的硬件、软件资源和广泛的支持,Ether 2net 是世界上应用最多的网络,超过93%的网络节点为Ethernet 。
2)为了促进Ethernet 在工业领域中的应用,国际上成立了工业Ethernet 协会(Industrial Ethernet Ass ociation )。
美国电气工程师协会(IEEE )正着手制定现场装置与Ethernet 通信的新标准。
3)全球主要自动化厂商和组织加强了工业Ethernet 的实现,如德国SI 2E ME NS 公司于1998年发布了工业Ethernet 白皮书,于2001年发布了其工业Ethernet 规范,称为ProfiNET.2004年奥迪(Audi )、宝马(BMW )、戴梅勒克莱斯勒(DaimlerChrysler )和大众(Volkswagen )四家主要的德国汽车公司一致同意支持ProfiNET 工业以太网标准。
4 基于工业以太网的网络数控网络数控系统(Netw orked C om puter Numerical C on 293 数控加工技术现代制造工程2006年第1期trol System)是网络控制系统的一个分支。
近几年国内比较高端先进的数控系统上都配备了标准以太网的接口,比如华中数控的世纪星系统,这样可以方便地进行联网,即使没有标配以太网接口的数控系统,由于都有RS2232接口,笔者也提出了RS2232到以太网的转换解决方案,专用通信单元用AT89S8252单片机和AT24C512Serial EEP2ROM,以支持Internet应用。
此通信单元还有数据缓冲的功能,可以解决老式数控系统内存太小,不能一次装下复杂加工程序的问题,这样就解决了加工停顿的问题,此装置也符合工业标准,安装方便。
本文以华中数控系统为例,说明基于工业以太网的网络数控系统的实现。
华中数控系统具有开放化、模块化的优点,支持Micros oft Netw ork Client V310for MS-D0S,Micros oft Netw ork Client V310,包含了TCPΠIP 协议、DHCP功能,使构建数字化车间非常地便利和稳定,每台华中数控系统都采用TCPΠIP协议,如图3所示,各车间H UB采用交换式集线器,再通过交换机联到服务器,其中交换机高速接口联到服务器端。
系统开机以后,远程的服务器自动分配给数控机床一个固有的IP地址,出于网络安全的考虑,此IP地址是私网地址,一个网段内可以容纳254台数控机床,如果数控机床数量多,可以划分几个网段,可以为每台数控机床设置各自的名称,由于采用DHCP技术,避免了设备冲突,可以很便利地增加或减少数控机床。
