Development of Automatic Downloads System for Slub Yarn Parameters Based on MODBUS/TCP

Yue-gang Liu, Chong-qi Ma, Han-ming LvSchool of textile, Tianjin Polytechnic University, Tianjin, China

(lygtjpu@163.com, tjmcq@tjpu.edu.cn, lv_hanming@yahoo.com.cn)

Abstract - In order to solve the issue of laborious and time-consuming caused by excessive parameters manual inputting during slub yarn production, a system was developed to realize the database management and automatic downloads of slub yarn parameters included slub length, base length and multiple . This invention relates to slub yarn controller with human machine interface (HMI) and programmable logic controller (PLC). It’s a configuration system based on MODBUS/TCP communication protocol between King View and HMI that saves time and reduces the mistakes for the operators. The system realizes integrate controlling, which improve the automatic level.

Keywords - slub yarn, configuration, HMI, MODBUS/TCP

I. INTRODUCTION

Nowadays, most of slub controllers were controlled by PLC and HMI, quite a few production parameters must be set up, and it is arduous and more mistakable to operate for workshop operators. Moreover, it’s hard to organize network in workshop because of the PLC without Ethernet port. By contrast, the touch screen with Ethernet port could be easily accepted rather than PLC network module on cost. A configuration system was developed to answer current difficulties. This configuration was connected to the slub yarn controller, more particularly to means for controller with PLC and HMI. It is a system of the present invention to provide parameters downloads for slub yarn which presented an unusual appearance and can be employed in manufacture of varieties of fabrics used as upholstery, draperies, clothing and the like [1-3]. Most of our adoption of producing slub yarn system is to change the draft or feed a little sliver [4-6]. Due to the machine precision and locale's environment, the characterization of production necessarily was not match with the pre-set parameters of slub yarn. For the reason mentioned above, what we need to do is to fine-tune the pre-set parameters. In this pattern the clicking of the mouse can easily transfer all parameters, which take place of moving around workshop.

II. SYSTEM COMPOSITION

The system hardware is composed of industrial personal computer (IPC), database server, HMI and PLC. HMI is highly praised in industry for its complete product ranges,

stable and reliable hardware as well as user-friendly configuration software and high cost performance. HMI can provide network interface and supported the standard MODBUS, so that the network can be formed easily. The system structure is illustrated in Fig.1.

Figure1. System structure

The main software of system includes king view6.53 and SQL server2008. The SQL functions of king view6.53 that run on IPC can realize storage, read, deletion and other types of operation. The slub yarn parameters stored in database and collected by King View are distributed to scattered touch screen and then be transmitted to PLC. The overall systems architecture is implemented based on Ethernet which is versatile enough to be employed in new and various fields of application. As the superior of system, IPC was communicated with subordinate HMI through MODBUS/TCP protocol [7-8]. RS-485 communication standard is used for the communication between HMI and PLC.

Ⅲ. ACCESS TO SQL SERVER

Data preservation inquiry, updating and other operations were easily to realize as the convenient way to access SQL server provided by King View which includes SQL access manager and SQL function. King view SQL access manager including form templates and record body was mainly used to build relationship between database column and king view variables [9]. Corresponding database must be defined to realize data transmission in open database connectivity (ODBC) data source. Open the 32-bit ODBC data manager of windows

control panel and then choose SQL Server. Fill data source name, server name and requested address of SQL server in corresponding column. The allocation was achieved after completing the process mentioned above. The grammar can be depicted as below: [Result Code=] SQL Connect (Device ID, "dsn=;uid=;pwd=") [10]. The Device ID means connect number; the value of below attribute is the data resource name; Login ID, password and database was named in proper order.

Ⅳ. COMMUNICATION BETWEEN KING VIEW AND HMI

MODBUS/TCP is a TCP/IP variation of MODBUS protocol which encapsulates slightly modified MODBUS serial frames into TCP segments. The pattern of the network communication is CLIENT/SERVER model, and the circulation process of MODBUS/TCP protocol is illustrated in Fig.2 [11-13].

Figure2. The circulation process of MODBUS/TCP

Build up a MODBUS/TCP device after open the Touch Explorer of King View by following the instruction of wizard. A uniqueness logical name was assign for the device in the engineering, and a fictitious serial port was chosen. Then the address for the device should be set. The MODBUS/TCP device was completed after the recovery interval and the longest recovery time were set finally. Device address required special explanation. Address format: IP [: Port] Address [/Timeout], and three formats in common use of TCP was introduced as below.<1>219.243.53.173：502 1/50 219.243.53.173 IP Address: Port separator502 Port number1 Station number/ Network timeout separator50 Delay time<2>219.243.53.173 1 The default of port and network timeout was 502 and 50, respectively.<3>219.243.53.173 1/30

Format <2> is the style used most frequent, and <3> is the best choice as device break [14].Open EV5000 that is editing software for HMI, and creating a touch screen project. Screen model and Ethernet should be chosen from the component window firstly. And then the device number, IP address, port number, communication protocol and station number should be set. There is no doubt that the protocol should be MODBUS/TCP slave. The subnet mask and default gateway should be allocated at last.

Ⅴ. REGISTER EXCURSION

HMI provided bit and word address, which separately corresponds to registers 0 and 4 of King View in MODBUS/TCP. The address excursion should be noticed as the address in HMI started from 0 which was different with that from 1 in the King View. For instance, 01 correspond LB0 and 41 correspond to LW0. What’s more, the screen system reserved some LW, LB and RW address for some particular purposes [15]. These registers should be used by following introductions. Acquisition frequency should be set to 0 in King View for write-only register. Secondary channel must be set up separately represented the high-order word and the low-order word as reading byte data. For example, 41.0 stand for the low byte, and 41.1 represent the high byte. Additionally, byte data can be only read. Short or Ushort data must be redefined if the data need to be written. The instance of x.y will be cited to illustrate the string data: x indicated the start address and y presented the length of data. The register of king view was shown in table 1.

Table 1 Register of King View

Name Form Channel range Read-write

Data type

0 0dd 1 ~ 65535 read-write

Bit

4 4dd dd: 1 ~ 65535

read-write

Ushort/short/BCD/Long/LongBCD/float/Byte/String

4dd.xx dd: 1 ~ 65535 xx: 0-1

read

4m.n m: 1 ~ 65535 n: 0-127 m+n<=65535

read-write

Ⅵ.WORK PROCESS OF SYSTEM

Parameters were divided into several strings with same length as the fugitive loops and cycle length before stored on a database. Consequently, the parameters can be cited according to slub yarn serial number with the help of abundant database functions. Letter I is set to circulation of variable as much data repeat transmission. The original set was to OFF for flag bit, which was defined to guarantee reliable data transmission. The supervisory computer started to transfer as the system started up. Flag was set to ON to order the lower position machines receiving data. Flag is set to OFF after one receipt, then next until end. The working process of the system is

illustrated in Fig.3.

Figure3.The working process of the system

All parameters have been stored in the HMI register after the end of circle. Then the system stimulates the data transmission component, transferring data to PLC. The production begins as soon as the basic parameters matched.

Ⅶ. CONCLUTION

This paper reported a configuration system to realize automatic downloads of slub yarn parameters based on MODBUS/TCP protocol. A method of downloading the main parameters of slub yarn included slub length, base length and multiple was proposed and a determination software system compiled by king view 6.53 was developed. Database access is achieved through not only IPC but also HMI, which enhanced the flexibility of the designing system. In this system, slub yarn parameters were stored in the database through the SQL access manager and the quick, effective and practical data message management was realized through SQL functions. IPC could communicate with corresponding HMI by entering machine serial number on the user-friendly interface of system. Supervision appearance configuration of multiple devices was facility with the help of structure variable application. An operator can not operating multiple devices at the same time was thing of the past. Hence it’s easy to set the basic parameters including the adjustment coefficient, roller speed and others. After lab test and onset installation test, it is proved that the slub yarn parameters can be effectively transmitted by the system.

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