Research and Application of Fieldbus Technology in Textile Production Control Systems
2026-04-06 05:58:36··#1
With the development of computer technology, communication technology and control technology, fieldbus technology has been widely used in industrial control systems and has also begun to be applied in the textile industry. This article introduces the basic principles of fieldbus, compares several existing fieldbuses, and, based on the analysis and summary of the new characteristics of the development of digital textile production control systems, introduces the current situation of fieldbus application in the domestic and foreign textile industries. 1 Introduction With the continuous and rapid development of China's textile industry, modern textile technology will be dominated by electronic information technology and characterized by intelligent production [1]. At present, the development of domestic textile machinery and equipment control systems focuses on realizing the automation of textile process performance of single equipment, enclosing the advanced functions of the machine in a single machine system, while ignoring the network structure of the system. As a result, the structure of the machine (especially its control system) will become more and more complex, making the machine an "island" in the automation system of textile enterprises. Since the 1990s, fieldbus technology and control systems based on it have attracted significant attention both domestically and internationally, becoming a hot topic in automation technology development worldwide. It integrates microprocessor technology, network technology, communication technology, and automatic control technology, embedding microprocessors into field control devices to enable digital computing and communication capabilities. This not only improves the accuracy of signal measurement, control, and transmission but also creates conditions for remote transmission. In the process of the textile industry's transformation from traditional to modern industry, fieldbus-based control technology provides an opportunity for the development of textile industry control systems towards decentralization, networking, and intelligence. This paper introduces the basic principles of fieldbus, compares the characteristics and applications of several commonly used fieldbuses, and constructs a framework model of a digital textile production system based on fieldbus control technology. 2. Basic Principles of Fieldbus Fieldbus is the intersection of current 3C (Computer, Communication, Control) technologies, as well as process control technology, automation instrumentation technology, and computer network technology. It is a concentrated manifestation of the development of information technology and network technology in the control field and an inevitable result of the extension of information technology and network technology to the field. According to the standards of the International Electrotechnical Commission (IEC) and the Fieldbus Foundation (FF), fieldbus is a digital, bidirectional, multi-branch communication network that connects intelligent field devices and automation systems [2]. Fieldbus technology incorporates dedicated microprocessors into traditional measurement and control instruments, enabling them to have digital computing and digital communication capabilities, and to become network nodes capable of independently undertaking certain detection, control, and communication tasks. A network system is formed by connecting multiple measurement and control instruments, computers, etc. as nodes through ordinary twisted-pair cables; using open and standardized communication protocols, data transmission and information sharing are realized between multiple microcomputerized measurement and control devices located in the production control field, as well as between field instruments and remote computers used for monitoring and management, forming various automatic control systems that meet actual needs. Fieldbus is mainly oriented towards process control. In addition to transmitting direct information of digital and analog signals, it can also transmit control information. The data unit exchanged in the network is a frame. Compared to Distributed Control Systems (DCS), Fieldbus Control Systems (FCS) offer advantages such as higher reliability, better security, interchangeability and interoperability, openness, and decentralization. In summary, a fieldbus is a real-time control communication network that interconnects the lowest-level field controllers and intelligent field instruments in automation. It follows all or part of the communication protocols of the ISO/OSI Open Systems Interconnection Reference Model. 3. Several Common Fieldbus Technologies Since the 1980s, major international companies have successively launched several industrial fieldbuses and field communication protocols. Currently popular ones include FF (Fieldbus Foundation), Profibus (Process Fieldbus), CAN (Controller Area Network), LonWorks (Local Operation Network), and WorldFIP (Factory Instrumentation Protocol). The main technical differences and applicable scenarios are as follows: 3.1 FF Fieldbus: The Foundation Fieldbus is based on the ISO/OSI Open Systems Interconnection model, taking its physical layer, data link layer, and application layer as the corresponding layers of the FF communication model, and adding a user layer on top of the application layer. FF has two communication rates: low-speed H1 and high-speed H2. H1 has a transmission rate of 1.25 kbit/s, a communication distance of up to 1900 m (extended with repeaters), supports bus power supply, and supports intrinsically safe explosion-proof environments. H2 has two transmission rates: 1 Mbps and 2.5 kbit/s, with communication distances of 750 m and 500 m respectively. The physical transmission medium supports twisted-pair cable, optical fiber, and wireless transmission. The protocol conforms to the IEC11582 standard, and the transmission signal of the physical medium uses Manchester encoding. It is mainly used in process automation fields, such as chemical, power, oil field, and wastewater treatment. 3.2 Profibus Fieldbus The Profibus series consists of three compatible parts: Profibus-DP, Profibus-FMS, and Profibus-PA. Profibus adopts the physical layer and data link layer of the OSI model, which form a subset of its standard part one. Profibus has a transmission rate of 9.6 kbit/s to 12 Mbit/s, with a maximum transmission distance of 100m at 12 Mbit/s and 400m at 1.5 Mbit/s, which can be extended to 10km using repeaters. Its transmission medium can be twisted-pair cable or optical fiber. Main application areas include: DP type is suitable for applications in manufacturing automation, such as pharmaceuticals, cement, food, power, power generation, and power transmission and distribution; FMS is suitable for general manufacturing automation such as textiles, building automation, programmable logic controllers (PLCs), and low-voltage switchgear; PA type is a bus type used for process automation. 3.3 CAN Fieldbus The CAN network design adopts a three-layer structure model conforming to the ISO/OSI network standard model: physical layer, data link layer, and application layer. The functions of the physical and data link layers are completed by the CAN interface devices, while the functions of the application layer are completed by the processor. Communication features outstanding reliability, real-time performance, and flexibility; it uses a short frame structure, resulting in short transmission time and strong anti-interference capabilities; nodes are assigned different priorities to meet different real-time requirements. Its transmission medium can use twisted-pair cable, coaxial cable, or optical fiber, with a maximum communication rate of 1 Mbit/s (40m) and a maximum direct transmission distance of 10km (5kbit/s). Major application areas include: automotive manufacturing, robotics, hydraulic systems, distributed I/O, machine tools, and medical devices. 3.4 Lonworks Fieldbus LonWorks adopts a 7-layer protocol structure similar to the OSI reference model. The core of LonWorks technology is the Neuron chip, which has communication and control functions. The Neuron chip implements the complete LonTalk communication protocol of LonWorks, allowing peer-to-peer communication between nodes. LonWorks offers communication rates from 78K bit/s to 1.25M bit/s, supporting various physical media including twisted-pair cable, fiber optic cable, coaxial cable, power line carrier, and wireless communication. It also supports multiple topologies, allowing for flexible networking. Its main application areas include industrial control, building automation, data acquisition, and SCADA systems, demonstrating superior performance in building distributed monitoring networks. 3.5 WorldFIP Fieldbus: The WorldFIP fieldbus architecture is divided into three levels: process, control, and monitoring. Its protocol consists of a physical layer, a data link layer, and an application layer. Communication rates include 31.25K bit/s, 1M bit/s, 2.5M bit/s, and 25M bit/s. Shielded twisted-pair cable and fiber optic cable are used as transmission media. It can meet various user needs and is suitable for centralized, distributed, and master/slave application structures. A single WorldFIP bus can meet the needs of process control, factory manufacturing, and various drive systems. Main application areas include: power industry, railway, transportation, industrial control, and building systems. 4. Textile Production Control System Based on Fieldbus Technology The informatization of the textile industry is a key pursuit and construction focus for textile factories in the coming years, and a digital textile production system is an indispensable foundation. It will comprehensively improve the management level of textile factories and have a direct and significant promoting effect on the progress of factory technology, quality, economy, and service. Digitalized textile machinery adopts modern advanced control technology: a CPU-based controller, a new drive technology based on power electronics technology, and network and high-speed data communication technology represented by fieldbus technology. This achieves real-time accurate data acquisition and high-speed transmission, improves distributed, on-site, and anti-interference performance, realizes the automation and intelligence of the production process, and completes the integration of textile machinery with modern advanced control technology, laying a solid foundation for the informatization of textile enterprises from the equipment level. According to the network connection structure, the enterprise network system is generally divided into four layers: control layer, monitoring layer, management layer, and information layer. A textile production informatization system based on fieldbus technology is shown in Figure 1. The fieldbus control layer is the source of various production information. Controllers of various cotton spinning, weaving, and dyeing machinery, provided they have fieldbus communication interfaces, can transmit real-time operational data to the monitoring system through appropriate programming. The fieldbus monitoring layer completes workshop-level equipment detection and control. Utilizing configuration software programming and fieldbus networks, it integrates the control systems of individual machines within the workshop, enabling monitoring of the production status, output, and efficiency of all equipment in the workshop through a clear and user-friendly human-machine interface. It also allows for unified setting of equipment process parameters, fault alarms, parameter recording, display of historical trends and real-time curves, and generation and printing of various production reports. The management layer is a factory-level information management system. Control systems can establish databases through various buses and industrial networks according to user needs, processing and classifying data before sending it to various management departments for data querying, statistics, analysis, and reporting. The fieldbus information layer integrates control processes, information management, and communication networks, enabling data sharing. Relevant personnel can log into the web server to monitor the operation of equipment on the production floor according to their respective permissions. 5 Application Cases Due to its unparalleled advantages in reliability, openness, economy, and fully digital transmission, fieldbus technology meets the needs of modern textile industry for high-quality, low-cost, small-batch, multi-variety, rapid response, high-efficiency, low-consumption, and clean production. Currently, fieldbus technology is widely used in textile machinery and equipment in spinning, chemical fiber, weaving, knitting, dyeing and finishing, and garment manufacturing to simplify production system structure, create flexible production systems, ensure product quality, reduce production costs, and promote computer-integrated production in the textile industry. In foreign-made chemical fiber, weaving, and dyeing and finishing equipment using fieldbus technology, modular field devices from different manufacturers are distributed across various parts of the machine. These are then assembled into a dedicated system using control network integration technology, simplifying system hardware design and reducing wiring costs. For example, the G6300 rapier loom from Sulze Textile in Switzerland uses servo motors for weft insertion, warp feeding, take-up, and selvedge weaving. The main controller is a 32-bit multiprocessor architecture. All field devices in the loom are connected via a CAN fieldbus to form a control network. Fabric specification weaving conditions and control data conversion can be remotely controlled or set on-site. The AIRFLOW AFT piece dyeing machine from THEN in Germany uses the THEN-DYNET (TDN) control system, based on a LonWorks fieldbus control network structure. Actuators such as airflow control valves, inlet and outlet water valves, and heat exchanger control valves, as well as sensors for dye liquor temperature and fabric speed, are all autonomous field devices connected to the upper-level PLC controller as nodes in the overall control network. my country began researching fieldbus technology in 1993 and officially listed it as a key national science and technology project during the Ninth Five-Year Plan period in 1996. By 1998, some incomplete fieldbus OEM new products had been launched. Domestic textile machinery manufacturers have seized the opportunity to actively introduce advanced fieldbus technology, focusing on the system integration of fieldbus products in conjunction with the functional characteristics of various textile machinery. For example, Shanghai No. 2 Textile Machinery Co., Ltd. has developed a four-motor driven roving frame using a CAN bus. Large-capacity polyester spinning and post-processing production lines all use Profibus. Shanghai Pacific Electromechanical Group, in developing a complete set of equipment for an annual production of 30,000 tons of polyester staple fiber, has developed a fieldbus-based control system, reaching the advanced level of similar international products. 6. Conclusion Fieldbus technology is one of the hottest development topics in the field of automation today. Its emergence has brought about revolutionary changes to the traditional control system structure, propelling automatic control systems towards intelligence, digitalization, informatization, networking, and decentralization, forming a new type of network-integrated fully distributed control system—the fieldbus control system. As a development direction for industrial automation, the fieldbus control system provides excellent opportunities for the automation field of China's textile industry. With the widespread use of fieldbus products, the digestion of R&D costs, and the reduction of production costs, fieldbus products will be widely applied to textile industrial automation systems, and fieldbus system technology will be widely used and develop significantly in textile automation. References [1] Mei Ziqiang. Vigorously promote the modernization of textile technology in China. Shanghai Textile Science and Technology, 2004, 32 (4): 1-4. [2] Yang Xianhui. Fieldbus technology and its application [M]. Beijing: Tsinghua University Press, 1999. [3] Bai Yan, Wu Hong, et al. Distributed control system and fieldbus control system [M]. Beijing: China Electric Power Press, 2002. [4] Jean Pierre Thomesse. A review of the fieldbuses [J]. Annual reviews in control, 1998, 22: 35-45 [5] Fieldbus tutorial [Z]. SMAR Company, 1999. [6] Profibus specification, Edition 1.0 [Z]. PNO, 1998. [7] Ling Zhihao, Wu Qinqin. Current status and prospects of fieldbus technology [J]. 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