CN106094763A - A kind of restructural polycarboxylate water-reducer automated production controller based on FPGA - Google Patents

Abstract

The invention discloses a reconfigurable polycarboxylate water reducer automatic production controller based on FPGA. After the serial port data receiving module, instruction verification module and instruction analysis processing module are sequentially connected in series, the instruction analysis processing module is connected with the register. And carry out data entry; after the entered data is processed by the register, the register is connected to the response command framing module, and the response command framing module, response command buffer module, and serial port data transmission module are connected in series in sequence for data output. The switch processing module, the sensor data acquisition module, the dropping control module, the feeding control module and the discharging control module are connected in parallel on the register. The register consists of three groups of modules: control adjustment, data processing, and status display. After the Flash drive module is connected with the SD card read-write module, the Flash drive module is connected with the register; the present invention can realize seamless switching, and is easy to expand and more flexible to update.

Description

An FPGA-based automatic production controller for reconfigurable polycarboxylate superplasticizer

technical field

The invention relates to the field of industrial control, and more specifically relates to a reconfigurable polycarboxylate superplasticizer automatic production controller. Use FPGA dynamic reconfiguration technology to realize seamless switching of industrial controller communication protocols.

Background technique

Polycarboxylate superplasticizer is a kind of cement dispersant in the application of cement concrete, and cement concrete is the most basic substance in construction, so polycarboxylate superplasticizer is required to have high product quality, which requires polycarboxylate The production process of acid superplasticizer must be stable, efficient, high quality and safe.

The production process of polycarboxylate superplasticizer is controlled by an automatic production controller, which is connected upward to the industrial control software running on the industrial computer to receive the commands sent by the user through the industrial control software; downward to various industrial instruments to collect real-time data from the production site All kinds of data, such as reactor temperature, material quality, material pH value, etc.

The automatic production controller communicates with industrial control software and various instruments through a specific communication protocol. The communication protocols used vary with the types and manufacturers of industrial control software and various instruments. At present, there are hundreds of fieldbus protocols.

The control core of the automatic production of polycarboxylate superplasticizer is the control of the chemical reaction process. Factors affecting product quality include the type, quality, addition speed, temperature of the chemical reaction process and so on of the materials involved in the chemical reaction. These factors are related to the content of the user's control command and the data collected by the controller in real time. Therefore, the controller uses the correct communication protocol to communicate with industrial control software and industrial instruments is the key to obtain correct data. There are more and more types of communication protocols. In order to ensure the correct and uninterrupted production process, all possible communication protocols have to be implemented on the controller at the same time as much as possible, so as to realize online switching of protocols. In a single production job, only a part of the protocols may participate in the actual work. This greatly increases the power consumption, cost and complexity of the controller system, while reducing the integration and resource utilization of the controller system.

Contents of the invention

Aiming at the defects of existing designs, the present invention proposes an FPGA-based automatic production controller for reconfigurable polycarboxylate superplasticizers.

The controller includes a serial port data receiving module, an instruction verification module, an instruction analysis processing module, a response instruction framing module, a response instruction buffer module, a serial port data transmission module, a switch processing module, a sensor data acquisition module, a dropping control module, and a feeding module. Control module, material discharge control module, Flash driver module and SD card read-write module.

After the serial port data receiving module, instruction verification module, and instruction analysis processing module are connected in series, the instruction analysis processing module is connected to the register and performs data entry; after the entered data is processed by the register, the register is connected to the response command framing module, and the response The instruction framing module, the response instruction buffer module, and the serial port data sending module are serially connected in sequence for data output.

The switch processing module, the sensor data acquisition module, the dropping control module, the feeding control module and the discharging control module are connected in parallel on the register.

The register consists of three groups of modules: control adjustment, data processing, and status display. After the Flash driver module is connected with the SD card read-write module, the Flash driver module is connected with the register.

The FPGA-based reconfigurable polycarboxylate superplasticizer automatic production controller communicates with the industrial computer through the RS-232 bus, and the serial port instruction data receiving module is responsible for receiving serial port instructions; the instruction verification module judges the current communication protocol type and analyzes the instructions The processing module and the response instruction framing module are dynamically reconstructed; the instruction analysis processing module is responsible for parsing the instructions, thereby triggering the corresponding task execution; the response instruction framing module is responsible for assembling according to the communication protocol and the current status of all devices and the execution status of tasks Response command; the response command cache module buffers the assembled response command; the serial port data sending module reads the response commands from the response command cache module and sends them one by one; the switch processing module is responsible for controlling the switch of the connected valve device and reading the feedback status of the device; the sensor The data acquisition module is responsible for identifying the type of communication protocol used by the connected sensor, automatically and dynamically reconstructing the protocol and completing the correct collection of various sensor data; the dropping control module includes a PID adjustment function, and is responsible for completing the delivery of materials according to the specified speed and time according to the instruction requirements. Dropping; the feeding control module is responsible for completing the feeding of materials of specified quality according to the instructions; the discharge control module is responsible for completing the discharge of materials of specified quality according to instructions; the Flash driver module is responsible for reading and writing of Flash, and the SD card reading and writing module Read the configuration file for reconstruction from the SD card, and write it into the Flash through the Flash driver module, so that the configuration file can be loaded from the Flash when the FPGA is reconfigured.

The beneficial effects of the present invention are: (1) Reconfigurable function: the use of FPGA reconfigurable technology makes it unnecessary to realize all communication protocols on a single chip at the same time, but which protocol needs to be reconfigured into a different protocol functions. (2) Seamless switching: Using FPGA partial dynamic reconfiguration technology, there is no need to power off and reset when switching communication protocols, and non-reconfigurable modules will not be affected and can maintain uninterrupted work. (3) Easy to expand: When a new communication protocol needs to be added, it is only necessary to realize the part of the new communication protocol and generate the configuration file of this part, without considering program merging. (4) Flexible update: use SD card to store configuration files, and the system will automatically load when refactoring, so users do not need to learn to use complicated download software, just copy the update files to the SD card.

Description of drawings

Fig. 1 is the general block diagram of the system of the present invention.

Fig. 2 is a curve diagram of the reaction kettle temperature for updating the controller program using the common power-off method.

Fig. 3 is a curve diagram of the reaction kettle temperature using dynamic reconfiguration to update the controller program.

detailed description

The present invention will be described in further detail below in conjunction with the accompanying drawings and specific embodiments.

As shown in Figure 1, the present invention is an FPGA-based reconfigurable polycarboxylate superplasticizer automatic production controller, including a serial port data receiving module, an instruction verification module, an instruction analysis and processing module, a response instruction framing module, Response command cache module, serial port data sending module, switch processing module, sensor data acquisition module, dropping control module, feeding control module, discharging control module, Flash drive module and SD card reading and writing module.

The user operates on the software of the industrial computer, and the command is sent to the controller through RS232 and other protocols, and enters the FPGA through the GPIO interface. The command is received by the serial port data receiving module, and the command verification module identifies the type of the current command and verifies the legality of the content, and generates a reconstruction signal if the protocol needs to be switched. The command parsing module is responsible for parsing the command content and triggering corresponding tasks, including switching valves, executing or terminating dripping tasks, executing or terminating feeding tasks, executing or terminating discharging tasks, querying valve status, querying sensor values, querying dripping task status, Query the status of feeding tasks and query the status of discharging tasks. The response command framing module assembles the corresponding response command for the query command type, puts it into the response command buffer, and the serial port data sending module reads the command from the response buffer and sends it. The Microblaze soft core implemented inside the FPGA acts as a controller for dynamic reconfiguration and is connected to other modules through the PLB bus. The software program written on it will read the reconstruction signal, and when reconstruction is required, it will read the corresponding configuration file in the Flash to complete the reconstruction. The SD card read-write module is responsible for reading the configuration files stored in the SD card and loading them into Flash for use during reconstruction.

Figures 2 and 3 are the reaction kettle temperature curves for updating the controller program by using the traditional common power-off method and the reactor temperature curve diagram for updating the controller program by using the dynamic reconfiguration method during the dropping process of a material respectively.

An ordinary reactor unit is generally composed of A metering tank, B metering tank, alkali metering tank, and reactor; the dropping process means that the materials in A metering tank and B metering tank are dripped into the reactor at a preset speed, The alkali metering tank does not participate in the work during a dropwise addition process. The temperature sensor on the reactor is used to collect the temperature of the chemical reaction in real time, and the temperature is controlled and adjusted manually or by industrial control software. The temperature of the chemical reaction during the dropwise addition process will be directly affect product quality.

If it is necessary to replace the load cell used in the alkali metering tank with a load cell from another manufacturer during a drop-adding process, it is necessary to update the communication protocol used in the corresponding part of the controller program. The alkali metering tank does not participate in the dripping process, so modifying the alkali metering tank should not affect the normal operation of the dripping.

When using the traditional program update method, the controller needs to be powered off and reset when the program is downloaded, which will cause the interruption of the dropping process. As shown in Figure 2, the middle section is a temperature drop, which represents the power-off reset process of the controller program in the corresponding period. At this time, the temperature of the reactor may be out of control during this period, which will affect the product quality.

Using the dynamic reconfiguration method to update the program does not require a power-off reset, so it will not cause interruption of the dropping process and realize seamless switching of communication protocols, as shown in Figure 3.

Claims (2)

1. a restructural polycarboxylate water-reducer automated production controller based on FPGA, it is characterised in that:

This controller includes serial data receiver module, instruction check module, instruction dissection process module, response instruction framing mould Block, response instruction cache module, serial data sending module, switch process module, sensor data acquisition module, dropping control Module, charging control module, discharging control module, Flash drive module and SD card module for reading and writing；

After serial data receiver module, instruction check module, instruction dissection process module are contacted mutually, instruct dissection process mould Block is connected with depositor and carries out data inputting；The data of typing are after depositor processes, and depositor instructs framing with response Module connects, and response instruction framing module, response instruction cache module, serial data sending module are sequentially connected in series, and carry out data Output；

Switch process module, sensor data acquisition module, dropping control module, charging control module, discharging control module are also It is associated on depositor；

Depositor has control and regulation, data process, state shows three groups of module compositions；Flash drives module and the read-write of SD card After module connects, Flash drives module to be connected with depositor.

A kind of restructural polycarboxylate water-reducer automated production controller based on FPGA the most according to claim 1, its It is characterised by:

Restructural polycarboxylate water-reducer automated production controller based on FPGA and industrial computer are by RS-232 bus communication, string Mouth director data receiver module is responsible for receiving serial ports instruction；Instruction check module judges current communication protocol type, to instruction Dissection process module and response instruction framing module carry out dynamic restructuring；Instruction dissection process module is responsible for solving instruction Analysis, thus trigger corresponding tasks carrying；Response instruction framing module is responsible for according to communications protocol and current all device shapes The execution state assembly response instruction of state and task；The response instruction that response instruction cache module caching assembles；Serial data Sending module will read response instruction from response instruction cache module and send one by one；Switch process module is responsible for controlling associated valve The switch of door equipment and reading equipment feedback states；It is logical that sensor data acquisition module is responsible for identifying that connected sensor uses News protocol type automatic dynamic reconstruct agreement and complete the correct collection of various kinds of sensors data；Dropping control module comprises PID regulatory function, is responsible for completing material according to command request and drips by fixing speed and time；Charging control module is responsible for The charging of the material of definite quality is completed according to command request；Discharging control module is responsible for according to the thing having instructed definite quality The discharging of material；Flash drives module to be responsible for realizing the read-write of Flash, and SD card module for reading and writing reads for reconstruct from SD card Configuration file, is driven in module write Flash by write Flash so that can load configuration from Flash during FPGA reconstruct File.