Inernet+OTSK New concept of service

Tangshan Outstanding science and technology CO.LTD

Jia Lei, Wang Shouxiong, Zhou Heng

1. Program background

The 21st century is a society of information explosion, science and technology develop by leaps and bounds, especially in the middle of the last century after the invention of the computer, great changes have taken place in the whole world, composed of a computer network (Internet) has been all over the world every corner of the entertainment on the Internet, shopping on the Internet, network has been deep into the each person's life.

"Internet +" is the Internet thinking further practice of the results, it represents a kind of advanced productivity, promote the evolution of the economy form. Thereby it gives impetus to the vitality of social economic entity, for providing the vast network platform of reform, development and innovation. Generally speaking, the "Internet +" is the "Internet + various traditional industry", but this is not a simple combination, but the use of information communication technology and the Internet platform, the Internet and traditional industries to depth of fusion, create new development.  

Although Kiln DRI process has a great leap in the digestion and absorption based on foreign advanced technology, it still remain in the level of the PID control mode dispersion control and PLC logic control, though it can meet the needs of normal production on the way, the aftermarket services are difficult to meet the satisfaction of customers: Firstly, problems of the kiln production process is difficult to feedback to the furnace manufacturer timely and accurately, which affects the normal production order; second, furnace manufacturer cannot receive feedback timely and accurately, and space constraints increase the impact of the furnace manufacturer's service level. Thus, it is necessary for the rapid development of network technology to find out a new control method to solve these problems, based on this, we propose "Internet + OTSK" kiln control technology to this new research topics.

Based on the rapid development of the Internet, the use of computer automatic control technology, network communication technology, simulation technology, multimedia technology and network database technology and Web technology of remote advanced control system on the net, solve the problem of network remote control, engineering device for higher engineering implementation in the Internet remote provides a complete set of solutions.

2. The purpose of the implementation

 (1) Change the current situation of DRI production line control level, provide strong technical support for the DRI production line.

 (2) Provide users with fast, high quality and efficient after-sales service, to solve the problem on the user device the first time, to minimize the loss of customers.

 (3) To provide the most effective technical support for the user's normal production.

(4) Minimize service costs.

(5) Maximize OTSK service level and competition ability.

3. Feasibility analysis

 For the Feasibility analysis of this system we can take the WinCC Web Navigator as example to give the following analysis.

(1) PLC remote hardware structure design

Based on PLC remote hardware consists of the following sections: Visual unit, control unit, monitor server, experiment server, as well as the router. Based on the design of remote simulation factory the actual network topology and its hardware structure was shown in figure 3.1.1. In order to simulate an enterprise with multiple factories and workshops in the same place or different places, the system designs a multilayer network structure. The function of each part is briefly described as follows: 

（1）Control unit： As shown in the figure 3.1.1 is the SIMATIC S7 series of PLC, which is located in the automation network. The role of the PLC series S7 is to process control, to provide process data for the visualization unit, and to receive control commands from the visual unit.

（2）Monitor server： It has two functions, one of which is the function of conventional monitoring system on-site monitoring software running, it and connected in the fieldbus or industrial Ethernet experimental device object communication, on-site monitoring work, and the necessary test data, statistical data and deposit number database; another function is as a monitoring server. It receives commands and parameters to remote clients, and of these commands are interpreted and executed, would be required for the remote client data or command execution results feedback to remote clients.

（3）Experiment server：As shown in the figure 3.1.1 they are the Web server and database server which are located in the laboratory network. Among them, the web server is to provide users with remote experiment service function of web server, when the need for remote operation remote users, through the authentication is logged on to the site, download the corresponding page, can be remotely operated. Database server function is to store the real time data and historical data for the operation of laboratory equipment.

（4）Network equipment： That is the network interconnection between the hierarchical network in figure 3.1.1. The switch is used to connect to the office network based on the commercial Ethernet and the laboratory network based on industrial ethernet. Routers are used to connect local networks and remote networks.

（5）Visual unit： That is the Web client located in the remote network in figure 3.1.1. They are personal computers with a Web browser, without the need to install any professional software, just download the corresponding monitoring interface, you can carry out remote experiments.

2. PLC telecommunication

（1） Communication between client and server

For the upper communication of WinCC Web Navigator provides two network server WinCC Web Navigator client and WinCC Web Navigator server. They can accomplish the function of network communication in the client and server separately. In a network that supports the TCP/IP protocol, either LAN or WAN, any client can install the Web Navigator Client WinCC, which can communicate with the remote server.

（2） Communication between control network and host computer

The control network and computer communication is mainly used WinCC provide SIMATIC protocol suite (communication driver), this driver supports multiple network protocols and communication type, with a variety of SIMATIC S7-300 and S7-400 PLC communication through his channel unit. Select the specific channel unit, you need to configure different communication networks. Web Navigator WinCC based remote laboratory design uses two different channel units: Industrial Ethernet and Soft, PLC TCP/IP. The industrial Ethernet and TCP / IP is used to communicate with the PLC Laboratory, and soft PLC is to S7-PLCSim simulation software communication, so the S7-PLCSim simulation software can be extended laboratory control network.

4. System planning

According to the reduced iron production line control technology and associated control equipment production status and imitation of the controls system from primary to senior three steps implementation.

The computer and PID regulator constitute an interactive device for microcomputer control system, and can realize remote monitoring function by INTEMET.

(2) Intermediate

Remote monitoring based on primary.

(3)Senior

Remote monitoring and controlling system for the reduction of iron production line and the remote diagnosis and treatment of the soft fault in the control system.

Technical support:

①    related equipment control software has been successfully developed;

②    the application of network technology has been quite mature;

③ control system development of related equipment has been conducted (for advanced control mode).

5. System function

A. Main configuration

（1）    control interface（Fig 5.1.1）

（1） to achieve real-time monitoring of the equipment operation process.

（2） the temperature (thermocouple) of the tunnel kiln is detected.

（3） friendly interface can provide convenient man-machine conversation function.

（4） can provide users with multi-level menu modification.

（5） authorized by INTERNET to achieve remote monitoring or monitoring.

（2）Real-time data curve diagram（Fig 5.1.2）

（1） the temperature of each point in the kiln is described in a graphic way, and the difference between the actual temperature and the set temperature is reflected (in different color curves).

（2） all control valves for real-time monitoring

(3) Historical alarm data interface（Fig 5.1.3）

（1） has the right temperature alarm function.

（2） has the function of the report and the graphics output.

（3） can view the historical data at any time and print.

B. System software function（Tunnel kiln）

C. The function Description:

Kiln-site control equipment via the relevant module parameters transferred to the main control room, information input for analysis of on-site computer control system, information after treatment, combining conventional PID regulator to jointly implement the monitoring function of each device.

General Manager's Office of the user can monitor the computer system in the main control room and emergency treatment failure through LAN.

OTSK Technical Service Center (authorized person) monitor the main control room computer， through internet control monitoring the computer control system. Implement its system maintenance functions in time, when the furnace operational failure, system software can perform troubleshooting and provide furnace maintenance program in the first time.