Abstract: This paper, from the perspective of industrial control, combines the latest wireless communication technology and Internet technology to introduce the application of an intelligent communication box based on an ARM processor in remote network control and data acquisition.
I. Overview
With the acceleration of my country's industrialization, the widespread use of automated equipment has played a significant role in improving productivity and reducing the labor intensity of workers, making it a key piece of equipment in production. Problems with this equipment can severely impact subsequent processes, making its maintenance and upkeep increasingly important. However, for most users, the knowledge required to maintain automated equipment is too complex, and fully understanding all the performance characteristics and principles of different equipment is unrealistic. The reality is that equipment needs to be repaired as quickly as possible to restore normal production. When users cannot quickly resolve faults, they request repairs from the equipment manufacturer. This puts a strain on the manufacturer's after-sales service, creating an urgent need for remote monitoring and diagnostic capabilities to quickly resolve user issues and improve service efficiency.
II. Implementation Methods of Remote Monitoring
1. Installing industrial cameras on the equipment to monitor its on-site operation, then networking these cameras and connecting them to the equipment manufacturer's control terminal via the Internet, allowing the manufacturer to monitor the equipment's status and perform remote diagnostics. This is the most primitive method. It requires dedicated equipment, dedicated communication lines, and leased broadband from a telecom operator to connect to the equipment manufacturer. It is time-consuming and labor-intensive, and due to the limited field of view of the cameras, it is impossible to observe the entire equipment, making accurate judgments impossible when analyzing problems. This method has many drawbacks and cannot solve the user's problems, so it quickly faded into history. This was the beginning of remote monitoring.
2. Using a controller with an Ethernet module, remote monitoring is achieved by assigning each device an independent public IP address via the Internet. This also requires setting up communication lines and applying for static public IP addresses from a network service provider (independent static IP addresses are expensive resources, difficult to apply for and maintain, and costly). This limits the applicability of this method to critical equipment and prevents large-scale adoption. In situations where various devices are concentrated in a specific area, this model can be modified by leasing a telecommunications operator's network and using VPN technology to create a large local area network (LAN). Each device is then assigned a LAN IP address for centralized monitoring. Some cities initially used this method for constant pressure water supply equipment and centralized heating heat exchange stations to achieve unattended operation and automatic alarms.
3. With the rapid development of 4G networks, the connection speed and stability of wireless networks have seen a qualitative leap compared to 3G/2G, making it possible for various devices to connect to the internet via 4G. ARM chips have also developed rapidly with the upgrading of smartphones, and their performance is sufficient to support the normal operation of connected devices. Therefore, manufacturers quickly developed a powerful 4G-based networking tool—the smart box + cloud platform—based on market demand. Using a client/server architecture, it only requires a single 4G SIM card to easily connect devices to the internet, eliminating the hassle of setting up lines, renting networks, and applying for public IP addresses, making it extremely convenient. The following explanation uses Fbox, a product from FanYi Company, as an example.
III. Features and Uses of Fbox
Fbox is an industrial internet intelligent transmission terminal device within the Industrial Internet of Machines System (IMS) platform. It provides an internet solution for industrial equipment, and combined with a powerful cloud platform, it can achieve the following functions:
Connecting a large number of industrial devices to a remote network eliminates the need to consider network deployment.
Equipment historical data query
Acquire and set remote data for the device
Equipment after-sales information maintenance management
Try sending and querying alarm information.
Remote downloading and monitoring of PLC programs (VPN pass-through)
Remote shutdown
The interface is open, supporting OPC interface, which users can configure themselves; it also provides HTTP interface and SDK interface, allowing users to program themselves.
Supports Windows platform and Android mobile platform
IV. How to use the Fbox client in Windows environment
Launch the client, register an account, and then add the device using the SN and password on your Fbox.
(1) Management Box
Adding/Removing Boxes: After logging into the client with your registered account, you can add the boxes you need by entering the box's ID and corresponding password. You can also delete boxes you've added or boxes shared with you by others. Sharing and Saving Boxes: Boxes you've added can be shared with everyone on other accounts. Those who receive the box can then log in with their own account to view the shared box information. You can also save boxes; saved boxes can be viewed on the favorites page. And so on.
(2) Data monitoring
For added boxes, the client can monitor/modify all data of the controllers connected to the box. If the box belongs to the account, entries for the connected controllers that need to be monitored/modified can also be added or deleted. (Shared)
The items monitored by the box cannot be added or deleted.
(4) Alarm function
Alarm conditions and details can be pre-registered. When an alarm occurs, the client can view the alarm details and time.
In addition, alarm notifications can be sent by binding an account through a WeChat official account. You can also specify a mobile phone number, and when an alarm occurs, the mobile phone of that specified number will receive an alarm message.
(5) Remotely download the connected controller program
This client allows you to download programs from the PLC connected to the box. There are two main download methods: "recorded download (virtual serial communication port)" and "transparent download (VPN)".
(6) Historical data
It enables functions such as setting and viewing historical data, displaying trend charts, and performing statistical analysis on historical data.
V. Examples
This demonstration uses the Schneider TM241 as an example to showcase remote control and remote shutdown functions. The TM141 has an Ethernet port; its address is set to 85.16.1.12, and the subnet mask to 255.0.0.0. The Fbox's LAN IP is set to 85.16.1.253, and "Use 4G remote connection" is selected. The specific remote shutdown settings are as follows:
Figure 1
The remote control settings are as follows:
Figure 2
The control code for TM241 is:
PLC_START_DELAY(IN:=SM400,PT:=T#55S,Q=>,ET=>);
CONNECT_DELAY(IN:=YX<>PRODUCT_MOUNT,PT:=T#120S,Q=>,ET=>);
WORKING_R(CLK:=WORKING,Q=>);
IFWORKING_R.QTHEN
IFPRODUCT_MOUNT<65535THEN
PRODUCT_MOUNT:=PRODUCT_MOUNT+1;
END_IF
END_IF
RELEASE_LIMIT:=REMOTE_COMMAND=1;
IFPLC_START_DELAY.QTHEN
ALLOW_TEST_RUN:=REMOTE_COMMAND=0ANDPRODUCT_MOUNT<65530ANDNOTCONNECT_DELAY.Q;
END_IF
ALLOW_AUTO_START:=RELEASE_LIMITORALLOW_TEST_RUN;
As can be seen from the code above, setting REMOTE_COMMAND=1 will shut down the device. The device will also shut down if the box is removed or the connection is lost for more than 1 minute.
VI. Conclusion
As can be seen from the examples above, Fbox, as a relatively mature industrial equipment networking solution, is simple to use and powerful in function. It can easily realize remote interconnection, remote downloading, and remote maintenance of field devices, and is a promising solution.
