Design of a Workshop Digital Equipment Intelligent Control System Based on Industrial Ethernet
2026-04-06 06:38:13··#1
Abstract: This paper analyzes the application status and characteristics of digital equipment in workshops of discrete manufacturing enterprises in China, examines the functional requirements of intelligent centralized control of digital equipment in the production field, proposes an open, modular, and distributed intelligent control system topology, and presents a design scheme for directly applying industrial Ethernet to the intelligent control of workshop digital equipment. Keywords: Industrial Ethernet, Digital Equipment, Intelligent Control 1. Current Status of Network Information Integration Systems in Manufacturing Enterprises To cope with the increasingly fierce global competition in the manufacturing industry, discrete manufacturing enterprises must vigorously develop internal control network construction and strengthen the control and management of production systems. The workshop is the foundation of the network information integration system of manufacturing enterprises, undertaking the task of dynamically reorganizing and integrating workshop resources based on existing workshop digital equipment resources, and transmitting various management and production control information in real time using network technology. It is a crucial link in promoting enterprise informatization and improving enterprise productivity. Due to different development speeds and production conditions, the current forms of workshop automation control systems mainly include computer centralized control based on serial communication, distributed control systems (DCS), and fieldbus. Fieldbus is currently the most commonly used communication network between workshop-level devices, providing a communication technology platform for the integration of workshop-level device information and production process information. Different industry applications have led to the development of different bus systems, and conflicting economic interests have resulted in severe incompatibility between various fieldbus standards, significantly hindering the interconnection of devices from different manufacturers and limiting the widespread adoption of multi-fieldbus applications. Traditional control systems, from network to control system backplane design, are all master-slave based, and different application layer protocols at different levels make cross-layer access difficult. Enterprise-wide Supervisory Control and Data Acquisition (SCADA) and factory-level electronic operator interfaces also suffer from inconsistent software development and inconsistent upper-level and lower-level databases. Therefore, the control of low-level equipment in the workshop has become a bottleneck for enterprise informatization and factory automation. To address this situation, Siemens has adopted the PROFINET automation bus standard based on component technology to achieve transparent links between distributed field devices and industrial Ethernet via PROFINET; DigiIntemational has adopted device server technology to achieve links between industrial devices with serial ports and industrial Ethernet. Domestic institutions such as Zhejiang University, Zhejiang University Control System, Shenyang Institute of Automation of the Chinese Academy of Sciences, Tsinghua University, Dalian University of Technology, and Chongqing University of Posts and Telecommunications, with the support of the National 863 Program, have researched key technologies for the application of Ethernet technology in communication between field devices in industrial measurement and control, and drafted the EPA (Ethernet for Public Automation) national standard. Professor Fei Minrui and others from Shanghai University developed a "new measurement and control platform supporting industrial Ethernet and multi-protocol conversion technology." These studies mainly target the process industry. This paper mainly studies the correlation information between workshop digital devices in discrete manufacturing enterprises, analyzes the functional requirements of its distributed intelligent centralized control, and proposes to utilize industrial Ethernet technology and adopt a unified network structure to construct an intelligent centralized control system for workshop digital devices. 2 Industrial Ethernet Industrial Ethernet uses Ethernet as a control network platform for field devices. It has been widely used not only in office automation but also in industrial automation. Many devices such as controllers, PLCs, intelligent instruments, actuators, and DCS systems already have Ethernet interfaces, indicating that industrial Ethernet has become the development direction of truly open and interconnected industrial networks. Industrial Ethernet, based on traditional Ethernet technology, utilizes technologies such as full-duplex communication, switching, and information prioritization. This allows for transparent forwarding of communication between stations with real-time requirements through switches, eliminating contention issues caused by channel sharing. It also facilitates priority queuing mechanisms, ensuring the fastest possible transmission of urgent information. Using Ethernet hubs can control real-time data latency within 200ms, and by incorporating real-time functionality into the Ethernet protocol, high-speed backplane switching or microprocessor switching provides deterministic response times, sufficient to meet the real-time control requirements of most 2005/V applications. Industrial Ethernet is low-cost and offers speeds up to 1Gb/s. Therefore, Industrial Ethernet will play a crucial role in the control of field equipment in workshops, significantly impacting the networked control model of digital equipment in workshops. 3. Intelligent Control System and Functional Design of Digital Equipment Workshop digital equipment refers to equipment or instruments with digital control functions used in discrete manufacturing enterprises, such as CNC machine tools, coordinate measuring machines, programmable logic controllers (PLCs), intelligent instruments, and intelligent actuators (industrial robots). Currently, the use of digital equipment in Chinese discrete manufacturing enterprises has the following characteristics: digital equipment exists from different manufacturers, with different production times, or different CNC systems; most enterprises use online programming methods based on different processing objects for their CNC equipment; single equipment uses centralized control, resulting in a high degree of automation; centralized control is mostly not achieved between equipment, and information transmission between them is limited; Fieldbus Control System (FCS) is currently the main method used for distributed control of workshop digital equipment. With the needs of modern management, the amount of data exchanged between workshop digital equipment and control systems is increasing, such as: uploading and transmitting process measurement and control data, uploading alarm information, downloading and transmitting configuration information, and downloading and transmitting modified control parameter data. This requires the use of intelligent theory and intelligent sensing technology to acquire information, store it in dynamic and static databases, and utilize relevant intelligent scheduling and control strategies to analyze, process, optimize, and control data information to achieve coordinated and unified management and control of workshop digital equipment, thereby optimizing the production process. However, neither completely local control nor completely global control can achieve optimal results. Following the principle of centralized management and distributed control, a distributed centralized intelligent control method must be adopted for workshop digital equipment, with its main modules and functions described below. (1) Equipment configuration and status management includes workshop equipment file management and query; workshop production equipment operation data collection and equipment operation statistics query; task-based (equipment) resource dynamic combination: reallocate and combine equipment according to production tasks, processed workpieces and other changes; equipment command protocol customization function: customize equipment protocol for different attributes of monitored objects, ensure the consistency of console and equipment protocol, and ensure the correct interpretation and execution of control commands. (2) Intelligent maintenance management establishes a digital equipment information database and spare parts database, records the operation quality of various digital equipment, provides predictive maintenance information for production, supports predictive maintenance plans, avoids unplanned downtime, conducts safety management and fault analysis, tracks and guides equipment and tool maintenance activities to ensure the progress of production and scheduling, and also provides emergency problem response, such as alarms, and maintains historical information to support problem diagnosis. (3) Process management mainly includes digital equipment resource tracking (accessing the equipment resource database, querying and tracking equipment status information), production process tracking (including workpiece process tracking, part quality information tracking and part completion number tracking), and quality monitoring (including part quality statistical analysis and key component quality tracking). (4) Process management: maintenance of part process information, such as processing steps, processing time, etc., and automatic correction of process information to meet workshop production and temporary process changes. Process planning and management mainly include data management, product structure (BOM) management, and process planning. Among them, data management includes document receiving, document updating, document borrowing, document distribution, document query and stub management; product structure management includes project code definition, material list management and dynamic maintenance, such as production operation completion registration, and determining the next process of the part according to the part's process information and recording it in the process information table to facilitate the tracking of part logistics information; process planning includes interactive process design, process query and retrieval, tooling proposal management, process exception handling, processing process card compilation and temporary process card compilation. (5) Data collection/acquisition and processing: including the description model of manufacturing information, acquisition and processing of workshop on-site manufacturing information, considering the process flow, used to correct the processing parameters of subsequent processes or to automatically adjust subsequent processing steps, thereby improving processing efficiency while ensuring processing accuracy. (6) Component management includes the description of equipment components and control components models, the establishment and management of component libraries, component reconstruction, component input/output mechanism, and dynamic scheduling and configuration of components. (7) SCADA function SCADA includes data acquisition through various communication protocols, storage, classification, comprehensive analysis and display of various real-time data; direct browsing and operation of field equipment or controllers without the need to write special monitoring software. Real-time monitoring and automatic status diagnosis of workshop equipment operation, and automatic correction function can be realized. 4 Architecture of intelligent control system based on industrial Ethernet The topology of intelligent control system based on industrial Ethernet is shown in the figure. The functions of each main part of the system are as follows. (1) The intelligent controller completes the program management and dynamic scheduling of digital equipment in the production field. It acquires information of each control device and downloads the configuration information to each digital device; it receives periodic process measurement and control data issued by each digital device, monitors the field digital devices, and at the same time, these data are also transmitted to the database server to establish a real-time database; it receives alarm information issued by field devices, establishes historical alarm information documents, and reminds users to handle them in a timely manner through sound and light alarms. (2) Intelligent Interface Considering the wide variety of equipment control systems and the different control methods of different manufacturers, and the fact that many devices that did not have network connectivity when they were first manufactured are still in use. In this case, an intelligent interface is used to extract field information and control the equipment. Then, the intelligent interface communicates with the intelligent controller and the database, as well as with the digital devices. It realizes the conversion between multiple protocols; downloads software components or data to the field digital devices; realizes the collection and processing of the working parameters and status parameters of the field devices, and realizes the exchange of control information, status information and I/O data with the intelligent controller. (3) Web Server The measurement and control information in the processing process is used to refresh dynamic web pages. Users can remotely monitor the production site in real time through general browsers such as IE and Netscape (without special monitoring software). (4) Database Server Includes dynamic database server and static database server. It realizes the input and output of various data, the establishment and management of database. **5 Conclusion** Research on intelligent control systems for workshop digital equipment based on industrial Ethernet is an important aspect of workshop manufacturing process management. Its purpose is to achieve transparent communication from resource planning to underlying equipment control, and to solve coordination problems under autonomous conditions of workshop digital equipment. This has positive significance and practical value for improving the utilization rate of resources in China's manufacturing industry, enhancing the core competitiveness of enterprises, and promoting the development and application of networked manufacturing. **References:** 1. Chen Haisong. PROnNEI - An Ethernet Fieldbus Solution for the Future of Automation [J]. Modern Manufacturing, 2004, (12): 34-37. 2. Marketing Department, Digi International (Hong Kong) Co., Ltd., USA. Managing Traditional Industrial Equipment via Ethernet [J]. Modern Manufacturing, 2004, (22): 46-47. 3. Zhao Lianxiang. Research and Application of Industrial Control Systems Based on Ethernet [D]. Zhejiang University, 2004. (Click to download: Design of Intelligent Control System for Workshop Digital Equipment Based on Industrial Ethernet; Editor: Chen Dong)