Description
8310N2 TRICONEX nput/output communication card
8310N2 TRICONEX nput/output communication card
Module Clips Drive controller servo motor
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Application of IO Link in Industrial Automation
This article mainly introduces the overall solution of ST IO Link communication master station used in industrial systems, including the following 5 aspects:
Firstly, the application of IO Link in industrial automation; The second is the introduction of ST IO Link main station transceiver; The third is the introduction of our ST”s IO Link main site evaluation board; The fourth is an introduction to the reference design scheme of the IO Link main station; The fifth is a demonstration of the IO Link master station reference design.
The industrial automation system can be said to be composed of many levels. The top level is usually industrial Ethernet to transmit data to the upper control center or monitoring center of the factory, while the middle layer is usually some PLC system for specialized process processing, such as controlling a specialized assembly line or production line. At the bottom, there are usually many industrial sensors, such as temperature sensors, pressure sensors, flow sensors, or proximity sensors, as well as some actuators, such as valves, moving lights, relays, or contactors, which are used for collecting and controlling physical quantities.
Between these levels, there will also be some modules or gateways for conversion and processing work. Therefore, in traditional industrial systems, there are many different level standards and communication protocols on site, resulting in poor modularity and versatility. Because there are both analog signals on site, such as a 4 to 20 mA current loop and analog voltage signals, as well as digital signals. In such an environment, analog signals are particularly susceptible to interference from harsh on-site environments. At the same time, sensors or actuators for analog transmission cannot perform on-site remote configuration or calibration 8310N2 TRICONEX nput/output communication card diagnosis work. In order to solve the transmission of the last segment of data to sensors and actuators in industrial field environments, as described earlier, we have introduced a specialized digital interface IO Link to achieve fully digital transmission between the interface modules of sensors and industrial field buses. The bidirectional data transmission makes it possible to parameterize the interaction of on-site data, diagnose and transmit information. By using this technology, remote condition monitoring and predictable maintenance of terminal equipment can be achieved, thereby effectively alleviating the problem of production line downtime.
Its advantages include:8310N2 TRICONEX nput/output communication card
Firstly, whether it is a pure digital sensor, an analog sensor after digital quantization, or different types of actuators, unified access can be achieved, thus achieving a simplified and standardized system architecture. Secondly, the transmission of digital signals will have stronger anti-interference ability than the transmission of analog signals, so the reliability of the system will also be stronger. Thirdly, through the bidirectional transmission of digital signals, more intelligent and advanced actuators or sensors can be used, making it easier to achieve status monitoring and system diagnostic protection functions. In this way, any issues and status of the production line can be monitored and maintained in real-time, ensuring the reliability, maintainability, and upgradability of the entire production line, thereby ensuring the minimum downtime.
The following is the specific content about IO Link technology
Firstly, the definition of the IO LINK standard enables data transmission, processing, configuration, and diagnostic information exchange between sensors or actuators and control systems. Secondly, this is a simple peer-to-peer communication architecture, where a master port is connected to a device port. Then, it can achieve compatibility with existing communication architectures, such as reusing cables and interfaces. At the same time, the IO Link system also has backward compatibility upgrade capability, as the master end of the system uses digital binary serial communication to interact with devices, and vice versa.
It can be said that IO link makes the system simpler:
Firstly, this is a universal standard communication method that complies with IEC61131-9. Secondly, IO Link is an intelligent communication system that solves the digital information exchange and transmission of the last distance from the control host to the terminal device. Thirdly, IO Link is simple to use and can be said to be plug and play, compatible with some existing system devices.
Some related products and solutions provided by ST in IO Link communication solutions
Firstly, in this communication system, the IO Link Master, which connects to the upper computer controller, is one of the main key solutions that will be mentioned later. Secondly, ST can provide some communication chips on the IO Link Master project, such as L6360. On the other side of the sensor or actuator end, namely the IO Link Slave end, ST can provide communication chips L6362A and L6364 on this IO Link Slave slave project. According to standards, this three-wire point-to-point communication method is easily compatible with some existing sensor actuators” standard ports, such as M12 standard industrial connectors and M12 standard connector wires. In addition, its advantages include the ability to achieve point-to-point bidirectional signal transmission within a single cable, as well as the general power supply requirements of the master end to the sensor actuator. According to the general requirements of the current industry, the maximum length of this cable is 20 meters, and the three wires inside are 24V, 0V, and data cables. The L+of this chip can support up to 500 milliamperes. If greater current is needed, there are also other L+drivers, including Load Switch IPS and other products, which can provide greater current or can be applied externally. The IO Link communication speed can generally reach a baud rate of 230.4K per COM3, and it also has functions such as status indication and detection.
For some specific application characteristics of IO Link, the communication transceiver system composed of L6360 and L6362A can support three standard data types of IO Link, namely COM1 (4.8k), COM2 (38.4K), and COM3 (230.4K) modes. This communication system can meet the requirements of all modern standards, industrial sensors, and actuators: firstly, it can quickly and very easily configure or reconfigure sensors or actuators. Secondly, it can be widely applied to various standardized sensors or systems that execute information. Thirdly, as a digital communication system, compared to traditional analog signal transmission systems, it can reduce power consumption and improve system efficiency. Fourthly, it has complete diagnostic and protection functions, which can improve the reliability of related systems. Therefore, it can be widely used to drive various digital sensors and actuators, as well as input and output modules of PLC, in order to achieve and meet various requirements of Industry 4.0.
How to Determine the Interference Problem of PROFINET IO Communication
Preliminary Diagnosis of PROFINET Interference Problems
1. Overview
When debugging PROFINET IO communication, it is common to encounter communication failures. One of the reasons for communication failures is interference. PROFINET IO communication equipment often operates in complex industrial electromagnetic environments, and incorrect shielding grounding or non-standard installation may lead to communication interference problems. Since optical signals are not affected by electromagnetic interference, this article only introduces interference problems with electrical signals.
2. How to determine interference issues
If PROFINET IO communication is affected by electromagnetic interference, a simple judgment can generally be made through the following aspects:
2.1. Judging the communication status through PROFINET IO
If the following communication phenomena are found during PROFINET IO communication debugging or operation, it may be affected by electromagnetic interference:
① Occasionally, communication is interrupted and restored.
② When certain on-site devices or specific operations are turned on, communication is interrupted, and on the contrary, communication returns to normal.
2.2. By using STEP7 online diagnostic information to determine and view the diagnostic buffer information of the IO controller, how to detect the presence of frequent communication failures and recovery information between the IO controller and IO devices in the diagnostic buffer, as shown in the following figure, may be affected by electromagnetic interference:
14 STEP7 Device Diagnostic Buffer Information
3. How to troubleshoot and solve interference problems
If a suspected electromagnetic interference causing PROFINET IO communication failure is found, how should we troubleshoot and solve it? The following will be introduced from the following aspects:
3.1 Increase PROFINET IO communication watchdog time
Due to PROFINET IO communication failure occurring during watchdog time, the IO controller did not provide input or output data (IO data) to the IO device, and watchdog time=the number of update cycles allowed for IO data loss × The refresh time is usually automatically calculated and allocated by the IO controller. This time value is generally small. If electromagnetic interference is encountered, the probability of communication failure occurring within the automatically calculated watchdog time will increase. At this time, we can appropriately increase the PROFINET IO communication refresh time or the number of update cycles allowed for IO data loss to increase the watchdog time. However, this method may not solve serious electromagnetic interference problems, and it is recommended to eliminate and solve them through subsequent methods.
What exactly does embedded development do?
Embedded development is a technology similar to programming, but our understanding of the scope of programmers is to do computer software, web development, and also to do apps.
The majority of embedded development is intelligent electronic products, which are designed for hardware programming. This hardware can be understood as a circuit board, usually composed of a controller (processor) chip and different circuits.
The specific program and circuit are generally determined by the product function. For example, an electronic clock product is usually composed of a digital tube and a microcontroller (controller), and then written in C language to download it to the microcontroller to achieve clock display.8310N2 TRICONEX nput/output communication card
Of course, there are far more products that can be developed in embedded systems, including smartphones, wearable devices, drones, robots, mice and keyboards, and so on.
The knowledge system of embedded development and design is also very diverse, and different products require different learning contents.
So, if we want to enter embedded development, we must first understand several directions of embedded development, otherwise you will never find a starting point.
The general mainstream directions are microcontroller development, ARM+Linux development, and FPGA/DSP development.
I have been working on microcontroller development for the past 10 years of my career.
Microcontrollers can be said to be the foundation of all directions. If you have strong microcontroller development capabilities, then ARM+Linux, or FPGA/DSP are easy for you to get started.
The development of microcontrollers is also one of the directions with the lowest threshold for embedded systems. Initially, I was self-taught in electrical engineering and transferred there. It took me about four months from the beginning of my studies to finding a job.
However, at that time, the threshold was still very low, and you could basically find a job by working on a small project with a 51 microcontroller.
If it”s the current situation, you only know these things and have little competitiveness. Nowadays, the main focus of enterprises is on whether you have project experience, rather than what kind of microcontroller you know.
The project experience can be accumulated through practical projects with endless microcontroller programming, which can be said to be the closest to actual development at present.
At present, the salary of single-chip microcontrollers is not low, and it is normal for them to start at 8K in first tier cities, and they can reach 15K after working for 2-3 years.
There are many industries covered by embedded systems, and in the later stage, based on work, we will only focus on one direction. From a macro perspective, we will divide it into embedded software development and embedded hardware development. Software development is mainly based on application software development on systems (Linux, VxWorks, WinCE, etc.), and hardware development includes motherboard design, system porting, cutting, and writing low-level drivers
My personal experience started with microcontrollers. Firstly, I studied C and C++, digital and analog electronics, power electronics, circuit design, microcontroller principles, FreeRTOS, data structures, and computer operating systems. Later, due to work requirements, I relearned university automation control theory, signals and systems, complex functions, linear algebra, calculus, statistics, and compiler principles. These are all basics, and it is important to understand and thoroughly study them, This will bring help to the later research and development work, and there is also a need for more drawing board, drawing board, and practical operation. Without practicing optics, the efficiency is very low, and knowledge is repetitive. Only by repeatedly looking and using can we understand. We can buy some development boards to assist in learning. Now that the internet is developed, network resources can improve our learning efficiency.
Embedded development refers to developing under an embedded operating system, commonly used systems include WinCE, ucos, vxworks, Linux, Android, etc. In addition, develop using C, C++, or assembly; Using advanced processors such as arm7, arm9, arm11, powerpc, mips, mipsel, or operating systems also belongs to embedded development.
1. Basic knowledge:
Purpose: I can understand the working principles of hardware, but the focus is on embedded software, especially operating system level software, which will be my advantage.
Subjects: Digital Circuits, Principles of Computer Composition, and Embedded Microprocessor Architecture.
Assembly Language, C/C++, Compilation Principles, Discrete Mathematics.
Data structure and algorithms, operating systems, software engineering, networks, databases.
Method: Although there are many subjects, they are all relatively simple foundations and most of them have been mastered. Not all courses may be taught, but elective courses can be taken as needed.
Main books: The C++programming language (I haven”t had time to read it), Data Structure-C2.
2. Learning Linux:
Purpose: To gain a deeper understanding of the Linux system.
Method: Using Linux ->Linxu system programming development ->Driver development and analysis of the Linux kernel. Let”s take a closer look, then the main topic is principles. After reading it a few times, look at the scenario analysis and compare it deeply. The two books intersect, with depth being the outline and emotion being the purpose. Analysis is version 0.11, suitable for learning. Finally, delve into the code.
Main books: Complete Analysis of Linux Kernel, Advanced Programming in Unix Environment, Deep Understanding of Linux Kernel, Scenario Analysis, and Source Generation.
3. Learning embedded Linux:
Purpose: To master embedded processors and their systems.
Method: (1) Embedded microprocessor structure and application: Direct arm principle and assembly are sufficient, without repeating x86.
(2) Embedded operating system class: ucOS/II is simple, open source, and easy to get started. Then delve deeper into uClinux.
(3) Must have a development board (arm9 or above) and have the opportunity to participate in training (fast progress, able to meet some friends).
Main books: Mao Decao”s “Embedded Systems” and other arm9 manuals and arm assembly instructions.
Application of Data Acquisition IO Module in Thermal Power Plant System8310N2 TRICONEX nput/output communication card
The Ethernet IO module is a data acquisition and control device. It uses Ethernet as a communication method to transmit data from various industrial control sensors and actuators to computers or other devices for management and monitoring. As a modern energy supply base, thermal power plants need to widely apply various intelligent control technologies to improve operational efficiency, reduce costs, and improve safety. In this context, the application of barium rhenium Ethernet IO modules is particularly important.
In the application of thermal power plants, the main function of the barium rhenium Ethernet IO module is to achieve real-time monitoring and control of the production process. By connecting to various sensors and actuators, the barium rhenium Ethernet IO module can collect real-time environmental parameters, machine operation status, and other data of the thermal power plant. By analyzing and processing these data, commanders can understand the operation of the thermal power plant and make corresponding adjustments. Compared to traditional automatic control systems, the barium rhenium Ethernet IO module has the advantages of stronger flexibility, faster reaction speed, and higher accuracy, which can greatly improve the operational efficiency and reliability of thermal power plants.
The real-time monitoring and control of thermal power plants require many capabilities of barium rhenium Ethernet IO modules. Here are several common application scenarios:
Firstly, the barium rhenium module can monitor parameters such as gas flow and water flow in thermal power plants. These parameters are crucial for ensuring the normal operation of the thermal power plant. Once these parameters undergo abnormal changes, the DO channel can be connected to the barium rhenium Ethernet IO module, and the alarm signal will immediately sound to remind the command personnel to handle it. Meanwhile, due to the fact that the barium rhenium Ethernet IO module can collect these data in real-time and transmit it to the monitoring system for recording, it can provide better technical support for quality management in thermal power plants.
Secondly, the barium rhenium Ethernet IO module can also monitor the operating status of mechanical equipment in thermal power plants. This includes parameters such as temperature, pressure, vibration, etc. By monitoring and analyzing these parameters, the barium rhenium Ethernet IO module can detect machine equipment faults in a timely manner, thereby avoiding the expansion of losses. In addition, during machine equipment maintenance, historical data recorded by the barium rhenium Ethernet IO module can be used to develop more scientific and reasonable maintenance plans, reduce maintenance costs, and improve maintenance efficiency.
Finally, the barium rhenium Ethernet IO module can also help thermal power plants achieve distributed control. We can remotely control and monitor multiple areas of the thermal power plant by connecting multiple barium rhenium modules to a network. This not only reduces the on-site debugging of equipment, but also strengthens the evaluation of equipment reliability.
In summary, the barium rhenium Ethernet IO module has unique advantages in real-time monitoring and control of thermal power plants. It can help command personnel monitor machine data in real-time, discover abnormal information, take timely measures to avoid impacts, and improve production efficiency and safety.
Remote IO modules based on Ethernet communication are widely used in the field of industrial IoT
With the development of IIOT (Industrial IOT) industrial Internet of Things technology, many traditional assets need to be connected to the internet to achieve unified data collection, analysis, processing, and storage, breaking the traditional phenomenon of device information silos. Therefore, the MQTT Ethernet IO acquisition module M160T, which supports the Internet of Things protocol, is able to unleash its potential by being compatible with existing devices and able to connect to IoT platforms. The MQTT Ethernet IO acquisition module will be widely used in industrial IoT, such as smart property, smart parks, smart factories, smart transportation, smart water conservancy, smart agriculture, smart campuses, smart communities, smart distribution, smart water conservancy, and many other industries.
Ethernet communication technology is a mature communication technology that has been widely applied. Therefore, Ethernet communication is the first choice for enterprises to connect various assets to the Internet of Things platform. Its reasons are stable and reliable, mature technology, fast transmission speed, and fast construction wiring.8310N2 TRICONEX nput/output communication card
For traditional various assets, such as low-voltage distribution rooms, air compressor rooms, property and living pump rooms, street light control, liquid level collection, temperature and humidity collection, etc., through the MQTT Ethernet IO collection module, they can be quickly connected to the Internet of Things platform.
So, what characteristics do MQTT Ethernet IO modules need to have when used in IoT solutions? The details are as follows:
1. Actively connect to cloud platforms:
Based on the characteristics of Ethernet communication networking, the Ethernet IO acquisition module must support the TCP Client function, which is not only the TCP client function, so that the Ethernet IO module can actively connect to the IoT platform without the need for complex settings such as peanut shells;
2. Compatible with existing systems:
Support TCP Server and Modbus TCP protocol functions, which can be compatible with traditional upper computer systems or device access of HMI”s TCP client;
3. Access to IoT platforms:
Supports standard MQTT protocol and Modbus TCP protocol, and can be connected to various MQTT protocol IoT platforms such as Huawei Cloud and Alibaba Cloud, or traditional SCADA and DCS systems;
4. Rich IO interfaces and scalability:
There are various types of data to be collected on site, and it is necessary to support the collection of various devices such as 4-20Ma, RS485, DI, DO, etc. At the same time, it is also necessary to have the ability to read RS485 device instrument data or expand the functions of the IO acquisition module;
5. Easy installation method:
The volume of the control box is very limited, so it is necessary to use directly inserted and unplugged wiring terminals, as well as a rail installation method.
6. Industrial grade design
The industrial environment is harsh, and the Ethernet IO module must adopt an industrial grade design to ensure continuous and stable operation in harsh environments.
Through the MQTT Ethernet IO acquisition module, there is no need to replace various existing enterprise assets and the digital transformation of accessing IoT platforms can be quickly achieved. Therefore, the MQTT Ethernet IO acquisition module will be widely used in industrial IoT, such as smart properties, smart parks, smart factories, smart transportation, smart water conservancy, smart agriculture, smart campuses, smart communities, smart power distribution, smart water conservancy, and many other industries.
What are the characteristics of a demonstration system based on IO Link slave stations
IO Link is an industrial communication interface that is independent of any fieldbus and suitable for simple sensors and actuators at the lowest level of industrial control. The IO Link system includes IO Link devices (such as sensors and actuators), IO Link master stations, and cables for standard sensors. The system structure is shown in Figure 1. For example, when a remote IO module compatible with EtherNet/IP serves as the master station, in addition to standard I/O signals, the module sends and receives configuration data, diagnostic data, or enhanced process data through a pulse modulation process, which is then packaged into EtherNet/IP data packets and finally transmitted to the network master station, usually a PLC. In the above applications, the connection between remote I/O and IO Link devices remains the same as that of traditional discrete devices. The advantage of IO Link mainly lies in its greater information exchange capability, which was previously impossible to achieve with standard I/O devices. Another advantage of IO Link is that it does not rely on any fieldbus, and through any I/O module that complies with the IO Link protocol (including local I/O and remote I/O), IO Link sensors or actuators can be integrated into any fieldbus system.
In order to further study the architecture, communication mechanism, and development application of the IO Link system, an IO Link slave toolkit can be designed and developed, including a universal development module for IO Link, an IO Link analysis tool, and an IO Link slave protocol stack. The IO Link universal development module is the foundation for this work and also serves as a bridge between the IO Link master station and equipment signals. The IO Link analysis tool can help developers and testers analyze communication details to identify and solve problems. The IO Link slave protocol stack is a firmware library that provides a hardware abstraction layer and application program interface, allowing developers to easily and quickly develop IO Link slave products on various microprocessor platforms. The IO Link slave station studied in this article only focuses on digital (button) signal input and digital signal output (indicator light). The design of the IO Link universal development module only needs to be expanded on this basis to have the ability to process analog signals.
The IO Link Master module used in this article, USB IO Link Master, can connect IO Link devices to a PC, which can be configured and tested through the IO Link Device Tool software or demonstrated device functionality. IO Link devices must be described through a device description file (IODD file), which includes a set of XML text files and PNG graphic files, which contain information about device identification, communication characteristics, parameters, process data, and diagnostic data. The portion within the elliptical dashed line in Figure 2 is an IO Link three wire cable, with L+/I – being a 24 V DC power supply and C/Q being a signal line used to transmit process data, diagnostic data, configuration data, etc. The IO Link universal development module is mainly composed of data transceivers and microprocessors. It can process input signals from sensors and transmit information to the IO Link master station. It can also receive and process data information from the master station and transmit it to the actuator. The IO Link analysis tool can help developers view, record, analyze data, and understand communication details. This part of the design is not discussed in this article.
Introduction to IO Link Communication Mode8310N2 TRICONEX nput/output communication card
IO Link devices can operate in SIO mode (standard I/O mode) or IO Link mode (communication mode). After power on, the device always operates in SIO mode. The port of the main station has different configuration methods. If configured in SIO mode, the main station considers the port as a standard digital input. If configured in communication mode, the main station will automatically identify the communicable devices for communication.
2.1 Data Types8310N2 TRICONEX nput/output communication card
The three basic data types for IO Link communication are periodic data (or process data PD), non periodic data (or service data SD), and event.
The process data (PD) of the device is transmitted periodically in the form of a data frame, while service data (SD) is only exchanged after the master station issues a request. Figure 3 shows a typical IO Link message structure. When an event occurs, the “event flag” of the device is set, and the main station reads the reported event (service data cannot be exchanged during the reading process) upon detecting the setting. Therefore, events such as pollution, overheating, short circuits, or device status can be transmitted to the PLC or visualization software through the main station
2.2 Parameter data exchange
Since service data (SD) must be transmitted through PLC requests, SPDU (Service Protocol Data Unit) is defined. In the main station, requests for read and write services are written to SPDU and transmitted to devices through the IO Link interface.
The general structure of SPDU is shown in Figure 4, and its arrangement order is consistent with the transmission order. The elements in SPDU can take different forms depending on the type of service. SPDU allows access to data objects that are intended for transmission, while Index is used to specify the address of the requested data object on the remote IO Link device. In IO Link, there is a term called direct parameter page, which stores parameter information such as minimum cycle time, supplier ID, and master station commands. The data objects accessible in the direct parameter page can be selectively provided through SPDU.
HMT7742 is an IO Link slave transceiver chip that serves as a bridge between the MCU of external sensors or actuators and the 24V signal line that supports IO Link communication. When the IO Link device is connected to the master station, the master station initializes communication and exchanges data with the MCU. HMT7742 serves as the physical layer for communication.
Due to the fact that the three indicator lights (rated voltage 24 V) controlled by the output port of the MCU are powered by the IO Link power cord, it is necessary to monitor the current on the power cord in order to trigger appropriate corrective measures when the current exceeds a set threshold, such as removing the indicator lights from the IO Link power cord. The current monitoring module uses an INA194 current detection amplifier. As a high detection current detector, INA194 is directly connected to the power supply and can detect all downstream faults. It has a very high common mode rejection ratio, as well as a large bandwidth and response speed. It can amplify the voltage on the induction resistor 5O times and output it to the forward input terminal AIN0 of the MCU internal voltage comparator. When the voltage value of AIN0 exceeds the threshold set at the reverse input terminal, By controlling the low level output of PB0, the indicator LAMP can be cut off from the IO Link power line to achieve overcurrent protection function. This part of the circuit is shown in Figure 6.
1.Has been engaged in industrial control industry for a long time, with a large number of inventories.
2.Industry leading, price advantage, quality assurance
3.Diversified models and products, and all kinds of rare and discontinued products
4.15 days free replacement for quality problems
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