Development trend of industrial computer

The development of IPC and its application is closely related to the development of informatization, digitalization, intelligent world trend and computer technology, control technology, network technology, display technology (especially Fieldbus and control network). 2000 the World Industrial control computer market for $30.04 trillion, of which DCS60 billion, embedded system $607 billion, FCS20-30 billion, IPC70-80 billion, PLC70-80 billion, CNC $708 billion. And grow at a rate of every year. 1, DCS (Distributed control System)Although Fieldbus-based FCS develop quickly and eventually replace the traditional DCs, FCS development has a lot to do, such as unified standards, instrument intelligence and so on. 　　But the traditional control system maintenance and transformation also need DCs, so FCS completely replace the traditional DCs have a longer process. The current industrial control computer is still based on large systems, scattered objects, continuous production processes (such as: Metallurgy, Petrochemical, power), the use of distributed system structure of decentralized control system is still developing. Due to the development of open structure and integration technology, the sales of large-scale decentralized control systems have been increased. DCS1997 Annual sales of $4.5 billion, 2000 to $6 billion. 　　The world's major DCS suppliers are: Honeywell, Bailey, Westing, House, ABB, Foxboro, L&n, Siemens, EuRo, Yokogawa, Japan Mountain Wu Honnavire and so on. DCS is one of the most affected and fastest reaction in computer industry. 　　The main development trend of DCS is as follows: (1) The development of DCs to comprehensive direction, due to the development of standardized data communication link and network, a variety of single (multi) loop regulator, PLC, industrial pc, NC and other industrial equipment constitute a large system to meet factory automation requirements, and adapt to the trend of openness. (2) DCs to the direction of intelligent development, due to the development of database systems, reasoning functions, especially the Knowledge Base system (KEB) and expert system (ES) applications, such as self-learning control, remote diagnosis, self-seeking excellence, AI will be implemented at DCS level. 　　Similar to FF Fieldbus, microprocessor-based smart devices such as intelligent I/O intelligent PID Control, intelligent sensors, transmitters, actuators, intelligent human-computer interfaces, programmable regulators have emerged. 　　(3) DCs industrial PC, from the IPC composed of DCs become a major trend, PC as DCs operating station or node machine has been very common, PC-PLC, PC-STD, PC-NC and so is Pc-dcs pioneer, IPC became the hardware platform of DCs. 　　(4) DCs specialization, DCs for more suitable for the application of the corresponding fields, it is necessary to further understand the professional process and application requirements, to gradually form such as nuclear power DCs, substation DCs, Glass DCs, Cement DCs and so on. Now the DCS manufacturer's new products have the following characteristics: System open, control integration and has advanced control software. DCS manufacturers are also engaged in research and development of FCS, production and application work. 2. CNC Device 　　Since the 80 's, in order to adapt to FMC, FMS, CAM, cims development needs, numerical control device using large-scale, VLSI, improve the flexibility, function and efficiency. (1) PC: By the high development of VLSI manufacturing technology, the PC hardware structure is very small, the CPU is running faster and higher, and the storage capacity is very large. The large-scale production of PC, the cost is greatly reduced, the reliability keeps improving. The openness of the PC, the application of Windows, the application of more technicians and the development of software make the software of PC extremely rich. PC function has been very strong, CAD/CAM software has been from the minicomputer, workstations transplanted to the PC, three-dimensional graphics display and process data has been established on the PC. 　　Therefore, PC has become an important resource and way to develop CNC system. (2) AC servo: AC servo system constant power range has been achieved 1:4, the speed range can reach: 1:1000, the basic and DC servo equivalent. 　　The AC servo is small in size, low in price, high in reliability, and widely used. 　　(3) High-function CNC system to the direction of integrated automation: In order to adapt to FMS, CIMS, unmanned chemical plant requirements, the development of robots, automatic car, automatic diagnosis and tracking monitoring system, and so on, the development of control and management integration System, has become the direction of the international numerical control system. 　　(4) Easy to use: Improve human-computer interface, simplify programming, operation panel using symbolic keys, as far as possible to use the dialogue, such as to facilitate the user. (5) Flexibility and systematization: At present, the CNC system adopts modular structure, its function coverage is large, from the three-axis two-linkage machine to up to 24-axis flexible processing unit. Since the 80 's, various types of flexible production systems based on CNC machine tools have emerged. 　　According to its specifications, automation and control methods, can be divided into flexible manufacturing unit, flexible manufacturing system, flexible assembly line, independent manufacturing Island, computer integrated manufacturing system and intelligent manufacturing system. 　　(6) Miniaturization: Because of the high integration of semiconductor circuits, three-dimensional packaging, circuit board interpolation three-dimensional, so that the NC device further miniaturization, in the NC device operating unit with TFT (thin film transistor) color LCD display, touch screen replace CRT, thickness only 1/4 of the CRT. (7) High-speed: the so-called three-high is the high spindle speed, high speed of rapid movement and high tool change speed. 　　To achieve high-speed machining, the spindle must be high-speed, AC spindle motor at the highest speed of 180000 rpm, the maximum feed speed of 120 m/min, tool change speed of 1s, acceleration 2g. (8) High efficiency: the key to achieving efficient machining, shortening the non-cutting time and machining cycle is to improve the processor of the PMC (Programmable machine Controller), and as the processing content is complicated, the PMC programming language becomes a problem, although the C language and Pascal have been applied, but for the replacement of the ladder diagram language, You also need to use a view in the same language as the straight-flow flowchart (SFC).　　(9) High precision: Improve machining accuracy, high resolution rotary encoder is essential. In order to achieve 0.001 micron accuracy in ultra-precision machining, it is necessary to develop an ultra-high resolution coding, 0.0001 micron minimum set of NC units. Control and robust (r0bust) control is also required for the performance of the servo system in the process, even when the load is changed. In the control of servo system, high-speed microprocessor is used, which is based on the Feedforward control of modern cybernetics, the control of two degrees of freedom and the learning control. 　　The tracking error of its digital control system does not exceed 2 microns. (10) Mechanical Intelligence: in the field of NC is a new technology, the so-called mechanical intelligence function, refers to the machine itself can compensate for temperature, mechanical load and other mechanical deformation caused by the function. This requires the detection of the spindle load, the spindle and frame deformation of the sensor and processing the sensor output signal circuit. The sensor itself has the function of signal processing, so it is called intelligent sensor. 　　AI will be useful in PMC for processing signals. (11) Intelligent diagnosis and maintenance: fault diagnosis and maintenance is an important NC technology. Fault diagnosis based on AI expert system has existed, and now it is mainly to establish a database for diagnosing faults. The NC device is connected with the central computer through the intranet and the Internet, so that it has the function of long distance diagnosis. 　　Further development is the maintenance system, which is a system that replaces the components that will fail before they occur, and it needs to be realized through intelligent sensors, high-speed PMC and large databases. (12) Compounding becomes the mainstream of machine tool development. The so-called composite processing multitaskmachining can be defined as a processing capability capable of completing a variety of machining processes without manual intervention. It has a workpiece once installed for turning, drilling, tapping and milling functions, from one process to another process of workpiece transfer is automatic, in the process of the workpiece assembly is also automatic. It has many advantages. 3, PLC (Programmable controller)At present, there are about 200 plc manufacturers around the world, producing more than 300 varieties. The number of Global PLC shipments in 1998 was 14.56 million, 1999 was 16.2 million, 2000 reached 17.78 million. In the PLC shipped in 1995, by end-user points: The car accounted for 23%, grain processing accounted for 16.4%, chemical/pharmaceutical 14.6%; metal/mine accounted for 11.5%; pulp/paper accounted for 11.3%; 　　Because of CIMS, engineering automation and process control and other large systems and complex application requirements, the main development trend of PLC is: (1) high-function, high-speed, large capacity, increase the direction of the development of analog, the formation of DCs with the large system of resistance. (2) Network and communication enhancement communication capability is the important development direction of PLC. 　　Network Aether has been very successful, and notice the development of Fieldbus. (3) Programming language diversification Iec61131-3 provides 5 programming languages: Ladder diagram (LD discrete us, day), sequential function chart (SFC batch, mechanical Europe), function block diagram (FBD process Europe), structure text (ST) and instruction table (il de, th). 　　It is possible to use multiple programming languages in the same PLC program to suit the requirements of different application situations and different countries. (4) Plc and other industrial computer joint, PLC and other control systems between the blurring of the line, in the application has also appeared similar situation. The most popular combination of PC technology, PLC increasingly accelerated infiltration into the DCS, PLC into the territory of CNC. PLC self-control is also decentralized. In the situation where the real-time requirement is not too high, soft PLC software is used to realize PLC function. Relative to PC-based control, the advantage is on a small plc. According to the data, the sales of i/o64 points accounted for 31% of the 47%,i/o64~256 point of the PLC, and the sum of the two was 78%. 　　In the use of Mature plc in the United States, 350,000 small enterprises only 30% use PLC, this situation shows that the development potential of small plc is still very large, and the OEM form of the formation of the electromechanical integration gradually increased. (5) EIC (electric drive, instrument, computer) integration, realize electric drive control, instrument control and computer control integration, this is the iron and steel industry automation use more and much needed control system. This is also the most important development trend of PLC. Well-known foreign PLC manufacturers have: A-B Company, Siemens, GE-FANUC, Modican Electronics company, France TE Company, Mitsubishi Electronics company, Omron Electronics company. 4. IPC (industrial PC)Because of the PC hard, rich software resources, large production, low price, for the vast number of technical personnel familiar with and recognition. Home computers are becoming increasingly popular. At present, PC computer accounts for more than 95% of general-purpose computers. This is the foundation of industrial PC heat. Industrial experts and technicians naturally want to give the PC bus a higher mission, it is intended to make it in Process control, manufacturing automation, building automation and other aspects play an important role. As with DCs, PLC into tripod IPC Market is expanding, especially in China. IPC will be better developed due to the better solution of real-time operating system, programming language and so on. The main performance of the IPC is as follows: (1) The major plc manufacturers, such as Siemens, Rockwellautomation, GEFANUC, Mitsubishi Electric have introduced their own brand of IPC products, which shows that these PLC giants have accepted the IPC technical route. 　　Authorities pointed out that "the PLC era must have passed" although the function of PLC is still retained, but the form may change; (2) Microsoft WindowsCE into the embedded OS market this is undoubtedly an iconic event for the industrial automation market. (3) Embedded PC computer: "Embed" (enbeded) to the inside of the device, provide the user interface, manage the data input, output, and instruct the machine to work. 　　The definition of embedded system: application-centric, computer-based, software hardware can be cut, adapt to the application system to function, reliability, cost, volume, power consumption requirements of the dedicated computer. In China at present, the most used in embedded design is still 80386 and 80486, this CPU performance price ratio, with In-tel, IBM, Cyixs, AMD and Ti and other famous CPU manufacturers support. 　　Rich software (including operating system, development tools and application software) support. The embedded PC can work reliably in harsh environments such as high temperature, humidity and vibration. The average fail-free time (MBTE) for embedded PCs is 100,000-150,000 hours, while desktops are only 10,000-15,000 hours. hardware, software and industrial PCs are similar. 5, the development trend of the sensor 　　Sensing, communication, computer technology constitute the three foundations of modern information, the 80 's is a personal computer, 90 is a computer network, is expected in 21st century the first 10 hot spots are likely to be sensing, implementation and detection. 　　The main function of the sensor is to obtain information, it is information technology (1) High function, high speed, large capacity, increase the development direction of analog quantity, and form a big system that fights with DCs. (2) Network and communication enhancement communication capability is the important development direction of PLC. 　　Network Aether has been very successful, and notice the development of Fieldbus. (3) Programming language diversification Iec61131-3 provides 5 programming languages: Ladder diagram (LD discrete us, day), sequential function chart (SFC batch, mechanical Europe), function block diagram (FBD process Europe), structure text (ST) and instruction table (il de, th). 　　It is possible to use multiple programming languages in the same PLC program to suit the requirements of different application situations and different countries. (4) Plc and other industrial computer joint, PLC and other control systems between the blurring of the line, in the application has also appeared similar situation. The most popular combination of PC technology, PLC increasingly accelerated infiltration into the DCS, PLC into the territory of CNC. PLC self-control is also decentralized. In the situation where the real-time requirement is not too high, soft PLC software is used to realize PLC function. Relative to PC-based control, the advantage is on a small plc. According to the data, the sales of i/o64 points accounted for 31% of the 47%,i/o64~256 point of the PLC, and the sum of the two was 78%. 　　In the use of Mature plc in the United States, 350,000 small enterprises only 30% use PLC, this situation shows that the development potential of small plc is still very large, and the OEM form of the formation of the electromechanical integration gradually increased. (5) EIC (electric drive, instrument, computer) integration, realize electric drive control, instrument control and computer control integration, this is the iron and steel industry automation use more and much needed control system. This is also the most important development trend of PLC. Well-known foreign PLC manufacturers have: A-B Company, Siemens, GE-FANUC, Modican Electronics company, France TE Company, Mitsubishi Electronics company, Omron Electronics company.