The hottest Rockwell is based on DeviceNet

2022-08-14
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Rockwell automobile assembly production based on DeviceNet Fieldbus

DeviceNet Fieldbus is a world-class automation control and information solution supplier that can be used for a long time in the temperature range of (4) 0 ℃ to 85 ℃ - the bottom network of NetLinx, the best industrial control network technology launched by Rockwell Automation in the United States. DeviceNet has the advantages of openness, low price, reliability and efficiency, and is especially suitable for the bottom control of industrial sites with high real-time requirements

devicenet has become the International Standard IEC () low voltage switchgear and control equipment controller device interface, and has also been listed as the European standard en50325. In addition, DeviceNet is actually a device standard in Asia and the Americas. DeviceNet has been supported by many manufacturers around the world. There are thousands of registered products that comply with DeviceNet specifications, and millions of DeviceNet node devices have been actually applied. In North America and Japan, DeviceNet has the highest market share among similar products, and also shows a strong development momentum in other parts of the world

Although DeviceNet entered China relatively late, it has been highly valued by relevant departments and units in China because of its outstanding advantages. On October 8th, 2002, DeviceNet was approved as China's national standard gb/t18858.3-2002 and was implemented on April 1st, 2003, which further promoted the promotion and application of DeviceNet Fieldbus Technology in China

devicenet can be widely used in all walks of life. Taking China's automotive industry as an example, DeviceNet has been applied to the welding and assembly production lines of Audi A6, Bora A4 and Jetta of FAW Volkswagen Co., Ltd., the welding and assembly production lines of Zhangjiagang Mudan Automobile Factory, the coating production line of Qingdao Yizhong automobile factory, and the bogie coating line of Changchun Bus Factory, Zhou Shaoxiong, the welding student of Hafei Automobile factory and the deputy chief engineer of China Steel Research Technology Group Co., Ltd., pointed out the production line, coating production line, final assembly production line, and so on. This paper introduces the application of DeviceNet in FAW Volkswagen Bora A4 assembly line

II. Design objective of the final assembly production line

FAW Volkswagen Bora A4 final assembly plant the design of the technical production line of tension machine accessories you need to know is a project of technical transformation of the equipment and control system of the original final assembly production line according to the development plan of China First Automobile Group Corporation. The design objective is to meet the requirements of mixed production of Bora A4 and Jetta models, so as to achieve a production rate of 90s/vehicle and an annual production capacity of 150000 vehicles. The process design of the final assembly line adopts the internationally advanced modular process assembly technology and the flexible production line technology of mixed production of various models, and is equipped with an efficient, reliable and convenient maintenance control system to improve the assembly quality of the whole vehicle

The process flow of Bora A4 production line is composed of storage area, workpiece assembly area, lifting area, maintenance area, testing area and offline area. The mechanized production line system includes the whole vehicle assembly line (process chain, driven by multiple motors), body conveyor line (stacking chain), reserve line (stacking chain), elevator, etc. Among them, there are 22 stoppers, 10 pushers and 6 turnouts; Frequency conversion speed regulation is required for motor drive and control; The number of on-site controlled equipment is large and highly decentralized: there are about 2600 i/o points with a length of 3000m

in order to meet the design requirements of the production line and save costs as much as possible, on the premise of making full use of the original equipment and lines, the original conveying system is re arranged more reasonably; A pusher is installed at the turning line between the lines to avoid the turning line fault; The new balance rail system makes the operation classification and performance of the production line stable and reliable, and reduces the labor intensity of workers; The car profile rail offline is changed to the elevator offline, which adds two stations to the whole car assembly line; The manipulator assembly station is added

the original control system of the production line was designed many years ago, using the traditional PLC centralized control, which has low control accuracy and inconvenient operation; All digital and analog i/o points are wired from the PLC cabinet. The large amount of wires, complex wiring and high failure rate have brought many inconveniences to the on-site maintenance, seriously affected the production, and have not met the production requirements of modern enterprises. Therefore, it is necessary to design a new type of control system with excellent performance, which is the key to ensure that the production line reaches the predetermined design goal

2.1 control system

after analyzing and comparing various control schemes, it is decided to adopt the fieldbus control system with DeviceNet as the underlying network, as shown in Figure 1. Input devices connected to DeviceNet Network include buttons, emergency stop switches, proximity switches, photoelectric switches, travel switches, etc., and output devices include indicator lights, control valves, frequency converters, etc. The system realizes the mutual communication between different PLCs through ControlNet, and completes the monitoring, control, fault alarm, management information exchange and other functions in the central control room

Figure 2 shows the hardware configuration of Rockwell Automation plc-5/80c used in the system (it has built-in remote i/o (Rio) and ControlNet interface). Due to the large number of points and long lines controlled in the system, six 1771-sdn scanners are used, and a total of 12 DeviceNet networks are connected to the controlled equipment. The 12 DeviceNet networks are named 1dn1, 1dn2, 2DN, 2dn2, 3DN, 3dn2, 4dn1, 4dn2, 5dn1, 5dn2, 6dn2 and 6dn2 respectively. Among them, 1dn1 controls all 14 frequency converters on the production line; 1dn2 controls all flexi/o nodes on the production line. Most of the devices connected to flexi/o are devices on the original assembly line that cannot be directly connected to DeviceNet Network; 2DN control body conveyor line (stacking chain); 2dn2 control reserve line (accumulation and release chain); 3dn1 and 3dn2 control another reserve line (accumulation and release chain); 4dn1 to 6dn2 control the whole vehicle assembly line (process chain). The process of the whole vehicle assembly line is very complex, consisting of 153 stations. The main control functions include process emergency stop, interlocking with other equipment, etc; The main equipment includes chassis marking machine, skylight assembly manipulator, gluing manipulator, assembly manipulator, windshield gluing robot, driving system control module, powertrain, detection device, etc. There are more than 200 nodes in the system

the working status, working parameters and fault information of all on-site production equipment are transmitted to the controller in the central control room through DeviceNet Network; All kinds of controls implemented by the controller on the field production equipment are also carried out through the DeviceNet Network. The configuration software RSV is applied to the monitoring computer connected to the Ethernet in the system

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