PDA高速數據採集分析系統應用指南——詳盡解析質量管理及工業大數據來源

目 錄
第1 章 PDA 高速數據採集分析系統概述 ····································································.1
1.1 解決的應用問題 ·························································································.2
1.2 應用領域 ··································································································.2
1.3 應用界面 ··································································································.2
1.4 主要功能特點 ····························································································.3
1.5 系統性能指標 ····························································································.5
1.6 支持的PLC、現場總線和廠商 ·······································································.6
1.7 典型網絡拓撲圖及解決方案 ··········································································.9
第2 章 PDA 高速數據採集分析系統的安裝、卸載及維護 ··············································.11
2.1 原版Windows 的安裝 ·················································································.11
2.2 Windows 設置 ···························································································.14
2.3 PDAServer 的安裝 ······················································································.23
2.4 PDAClient（客戶端系統）的安裝和卸載 ·························································.28
2.5 其他子系統的安裝及卸載 ············································································.28
2.6 系統維護 ·································································································.28
第3 章 PDA 高速數據採集分析系統之系統文件說明及系統組態 ·····································.30
3.1 系統文件說明 ···························································································.30
3.2 系統組態 ·································································································.43
3.3 PDA 服務器啟動後自動進入數據採集狀態 ······················································.49
3.4 PDA 服務器啟動後自動進入在線監控狀態 ······················································.50
3.5 PDA 接口模塊的組態 ·················································································.50
第4 章 PDA 高速數據採集分析系統的數據採集及通信協議 ···········································.52
4.1 自動化總線和自動化通信協議分類 ································································.52
4.2 常用自動化通信協議 ··················································································.53
4.3 通過標準以太網UDP 通信協議採集數據 ·························································.55
4.4 通過標準以太網TCP 通信協議採集數據 ·························································.55
4.5 通過以太網高速定周期採集S7-400 PLC 控制器數據 ··········································.56
4.6 通過以太網高速定周期採集S7-300 PLC 控制器數據 ··········································.60
4.7 基於PROFINET 通信協議的數據採集方式 ······················································.61
4.8 通過以太網採集S7-400/S7-300/TDC/FM458 控制器數據 ·····································.72
4.9 通過pdaTools 工具調試S7 系列PLC 數據採集方式 ···········································.72
4.10 通過以太網採集S7-300/S7-400/TDC/FM458 符號表、變量表、DB 塊中的數據 ······.81
4.11 通過ISO 協議採集S7-400 PLC 數據 ·····························································.81
4.12 通過標準以太網協議採集S7-300/S7-400 PLC 數據 ···········································.83
4.13 通過以太網採集西門子TDC 控制器數據 ·······················································.96
4.14 西門子S7-1500 PLC 數據採集方式 ·······························································.99
4.15 西門子S7-1200 PLC 數據採集方式 ·····························································.111
4.16 通過MPI 網絡採集數據 ···········································································.111
4.17 通過PROFIBUS-DP 網絡採集數據 ·····························································.113
4.18 內存映象網數據採集方式 ·········································································.118
4.19 CODESYS 編程軟件中的PDA 通信程序開發 ················································.120
4.20 採集硬件接口模塊數據 ············································································.121
4.21 西門子SIMOTION D 控制器的數據採集方式 ················································.126
4.22 基於以太網全局數據通信協議的數據採集方式 ··············································.132
4.23 基於Modbus 寄存器地址的數據採集方式 ····················································.138
4.24 基於Modbus TCP 內存塊的數據採集方式 ····················································.140
4.25 基於Modbus TCP 寄存器地址的數據採集方式 ··············································.149
4.26 通過PROFIBUS-DP 網關方式採集FM458 數據 ·············································.149
4.27 通過CAN 總線採集數據 ··········································································.150
4.28 基於Ethernet/IP 通信協議的數據採集方式 ···················································.150
4.29 基於Ethernet/IP-backplate 通信協議的數據採集方式 ······································.155
4.30 基於Ethernet/IP-backplate block 通信協議的數據採集方式 ·······························.156
4.31 基於SRTP 通信協議的GE Fanuc 系列PLC 數據採集方式 ·······························.159
4.32 基於 SNPX 通信協議的GE Fanuc 系列PLC 數據採集方式 ······························.161
4.33 WAGO PLC 的數據採集方式 ·····································································.161
4.34 MOOG PLC 的數據採集方式 ·····································································.166
4.35 ABB PLC 的數據採集方式 ········································································.169
4.36 基於Beckhoff Ethernet 通信協議的數據採集方式 ···········································.171
4.37 基於Beckhoff Realtime Ethernet 通信協議的數據採集方式 ·······························.184
4.38 基於Beckhoff ADS 通信協議的數據採集方式 ···············································.189
4.39 基於EtherCAT 通信協議的數據採集方式 ·····················································.192
4.40 通過RS232/RS485 採集數據 ·····································································.197
4.41 基於OPC 通信協議的數據採集方式 ···························································.197
4.42 西門子輔傳動S120 系列變頻器的數據採集方式 ············································.212
4.43 西門子主傳動SL150 系列變頻器的數據採集方式 ··········································.227
4.44 貝加萊（B＆R）PLC 的數據採集方式 ·························································.233
4.45 基於三菱MC 通信協議的PLC 數據採集方式 ···············································.243
4.46 基於三菱MELSECT 通信協議的PLC 數據採集方式 ······································.246
4.47 基於UDP 通信協議的三菱Q 系列PLC 數據採集方式 ····································.249
4.48 基於DL/T645-2007 通信協議的智能電表數據採集方式 ···································.253
4.49 西門子S7-200 SMART 控制器數據採集方式 ·················································.254
4.50 汽車CAN 總線數據採集方式 ····································································.255
4.51 基於UDP 通信協議的阿爾斯通HPCi 系列控制器數據採集方式 ························.256
4.52 通過OPC UA 通信協議採集KEPServer 數據 ················································.257
4.53 通過OPC UA 通信協議採集西門子S7-1500 PLC 數據 ····································.260
4.54 主傳動ACS6000 變頻器的數據採集方式 ·····················································.262
4.55 採集PCI/PCIe 卡數據 ··············································································.263
4.56 通過TC-net 網絡採集數據 ········································································.264
4.57 部分國產控制器的數據採集方式 ································································.266
4.58 其他數據採集方式 ··················································································.267
第5 章 數據採集及在線監控 ·················································································.268
5.1 開始與停止採集數據 ················································································.268
5.2 採集邏輯信號 ·························································································.268
5.3 工具欄按鈕和快捷鍵 ················································································.269
5.4 PDAServer 在線監控 ·················································································.271
5.5 PDAClient（客戶端）在線監控 ···································································.272
5.6 多台PDA 服務器在線監控 ·········································································.273
5.7 開始與停止在線監控 ················································································.274
5.8 結束當前數據文件 ···················································································.274
5.9 在線修改組態信息而不重啟PDAServer·························································.275
5.10 高速轉發一個連接通道的全部數據 ······························································.275
5.11 高速轉發選擇的數據 ···············································································.276
5.12 系統文件目錄設置建議 ············································································.278
第6 章 歷史數據查詢及數據導出 ···········································································.279
6.1 打開一個數據文件 ···················································································.279
6.2 同時打開多個數據文件 ·············································································.279
6.3 通過快捷菜單打開數據文件 ·······································································.280
6.4 獨立打開多個數據文件 ·············································································.281
6.5 打開以逗號分隔的數據文件 ·······································································.281
6.6 打開Excel 的csv 格式數據文件 ··································································.282
6.7 打開PDA 導出的Excel 的csv 格式數據文件 ··················································.283
6.8 打開實時Excel 的csv 格式數據文件 ····························································.284
6.9 打開第三方自定義格式數據文件 ·································································.285
6.10 創建並打開模擬數據文件 ·········································································.285
6.11 創建並打開第三方開放式不壓縮數據文件 ····················································.286
6.12 打開數字示波器數據文件 ·········································································.286
6.13 按時間段導出分析數據 ············································································.287
6.14 導出所有分析數據 ··················································································.288
6.15 導出符合條件的分析數據 ·········································································.289
6.16 從打開的數據文件導出數據 ······································································.289
6.17 導出同比數據 ························································································.291
6.18 按日期範圍合並秒級數據 ·········································································.291
第7 章 分析功能使用說明 ····················································································.293
7.1 分析軟件的窗口佈局 ················································································.293
7.2 信號樹的查找功能 ···················································································.293
7.3 創建、合並、移動、刪除顯示區 ·································································.294
7.4 調整顯示區變量的位置 ·············································································.298
7.5 保存分析文件 ·························································································.303
7.6 打開分析文件 ·························································································.303
7.7 新建分析文件 ·························································································.304
7.8 定義邏輯信號 ·························································································.305
7.9 數據統計表格 ·························································································.306
7.10 曲線的多欄顯示 ·····················································································.307
7.11 改變顯示區底色和曲線顏色 ······································································.308
7.12 即指即查 ······························································································.309
7.13 雙X 軸標記 ···························································································.310
7.14 動態Y 軸及雙Y 軸標記 ···········································································.310
7.15 數字表 ·································································································.311
7.16 單個顯示區曲線Y 軸自動定標 ···································································.312
7.17 所有曲線Y 軸自動定標 ············································································.313
7.18 所有曲線Y 軸自動定標功能選擇 ································································.314
7.19 設置顯示區Y 軸最大最小值 ······································································.315
7.20 頻譜分析 ······························································································.316
7.21 能譜分析 ······························································································.317
7.22 X-Y 轉換和對齊 ······················································································.318
7.23 數據擬合 ······························································································.319
7.24 三維曲面視圖及曲面擬合 ·········································································.320
7.25 軸承油膜厚度的計算 ···············································································.321
7.26 軋機剛度的計算 ·····················································································.322
7.27 基於FIR、IIR 的數字濾波器設計 ·······························································.323
7.28 基於FFT 的數字濾波器設計 ·····································································.324
7.29 信號的平滑、微分分析 ············································································.324
7.30 毫秒級報警 ···························································································.325
7.31 添加多條曲線 ························································································.326
7.32 質量報表 ······························································································.327
7.33 軋機剛度跟蹤報表 ··················································································.328
7.34 標註 ····································································································.331
7.35 專家系統 ······························································································.332
7.36 二維視圖分析 ························································································.332
7.37 三維視圖分析 ························································································.333
7.38 滾輪X 軸縮放 ·······················································································.333
7.39 X 軸趨勢圖平移 ·····················································································.334
7.40 滾輪X 軸趨勢圖平移 ··············································································.335
7.41 滾輪Y 軸縮放 ························································································.336
7.42 Y 軸趨勢圖平移 ·····················································································.336
7.43 調整視圖高度 ························································································.337
7.44 視圖導航 ······························································································.338
7.45 按條件對齊 ···························································································.338
7.46 設定時間長度 ························································································.339
7.47 設置無線串口模塊參數 ············································································.340
7.48 設置2AI 串口模塊參數 ············································································.340
7.49 設置FFT 參數 ·······················································································.341
7.50 同比分析 ······························································································.341
7.51 毫秒級同比分析及數據導出 ······································································.342
7.52 長時間段同比分析及數據導出 ···································································.343
7.53 曲線標註 ······························································································.344
7.54 大型液壓缸性能測試 ···············································································.345
7.55 功率譜分析 ···························································································.352
7.56 在信號樹中隱藏備用變量 ·········································································.354
7.57 FFT-頻譜分析 ························································································.354
7.58 復制視圖 ······························································································.355
7.59 同時復制視圖和統計表格 ·········································································.356
7.60 查找數據 ······························································································.357
7.61 設備信號分組 ························································································.357
7.62 模擬量按位拆分 ·····················································································.359
7.63 搜索其他數據文件 ··················································································.359
7.64 啤酒廠的CO2 回收及產量預測分析 ····························································.360
7.65 設置字體及選擇字符集 ············································································.361
7.66 語言選擇 ······························································································.362
7.67 幫助 ····································································································.363
第8 章 數據接口 ································································································.364
8.1 歷史數據接口 ·························································································.364
8.2 秒級傳輸實時數據接口 ·············································································.378
8.3 毫秒級傳輸實時數據接口 ··········································································.392
8.4 視頻同步分析應用接口 ·············································································.393
8.5 兼容第三方數據格式 ················································································.404
8.6 插件 ·····································································································.405
8.7 HMI 系統接口 ·························································································.414
8.8 質量管理系統及大數據接口 ·······································································.414
8.9 新的數據文件名接口 ················································································.416
8.10 ModbusTcp 接口 ·····················································································.416
8.11 MQTT 接口 ···························································································.417
8.12 WebSocket 接口······················································································.417
8.13 OPC UA 接口 ························································································.418
8.14 用於WinCC-PDA、FTView-PDA 和Web-PDA 的OCX 控件接口 ······················.421
第9 章 PDA 雲——pdaCloud ················································································.425
9.1 發送實時數據到雲端 ················································································.425
9.2 騰訊微雲 ·······························································································.426
9.3 百度網盤 ·······························································································.428
9.4 微軟OneDrive ·························································································.429
9.5 專用雲 ··································································································.429
9.6 移動端App ····························································································.429
第10 章 數字鋼捲轉換計算系統及全流程質量管理 ····················································.431
10.1 數字鋼捲轉換計算系統架構 ······································································.432
10.2 數字鋼捲轉換計算 ··················································································.432
10.3 計算流程 ······························································································.433
10.4 長度、時序和設備診斷數字鋼捲 ································································.435
10.5 長度數字鋼捲數據統計及降頻 ···································································.436
10.6 時序數字鋼捲數據統計及降頻 ···································································.437
10.7 設備診斷數字鋼捲的特徵值統計及降頻 ·······················································.438
10.8 對齊 ····································································································.441
10.9 實時數字鋼捲計算 ··················································································.441
10.10 帶鋼性能指標預報 ················································································.442
10.11 數字鋼捲各版本功能劃分 ·······································································.442
10.12 數據分層分組 ······················································································.442
10.13 信號的搜索 ·························································································.447
10.14 熱軋數字鋼捲計算示例 ··········································································.447
10.15 數字鋼捲 ····························································································.451
10.16 數字鋼管 ····························································································.453
10.17 全流程質量管理 ···················································································.454
10.18 數字鋼捲分析工具 ················································································.454
10.19 數字鋼捲應用 ······················································································.458
第11 章 數字鋼捲快速搜索統計系統 ······································································.464
11.1 CFS 與傳統系統的不同 ············································································.464
11.2 實施方案 ······························································································.465
11.3 切片指標的搜索統計 ···············································································.465
11.4 特殊特性識別 ························································································.467
11.5 特殊特性識別——指導應切除帶鋼位置 ·······················································.467
11.6 搜索下載主題切片原始數據 ······································································.468
第12 章 PDA 子系統 ··························································································.469
12.1 長期趨勢分析系統 ··················································································.469
12.2 開放式高頻時序數據庫HDServer ·······························································.472
12.3 數據庫升遷工具及大數據BigOffice ····························································.481
12.4 設備診斷同步過採樣系統 ·········································································.485
12.5 軋輥剝落預警及快停系統 ·········································································.487
12.6 輥道電流監測系統 ··················································································.488
12.7 高頻高密高速數據平臺的構建 ···································································.490
第13 章 應用案例分析 ························································································.492
13.1 某熱軋廠平整機高速數據採集 ···································································.493
13.2 基於IGBT 柔性直流斬波電源的綠色智能超級電弧爐高速數據採集 ···················.493
13.3 某鋼廠特厚板坯（鑄坯）連鑄機結晶器液壓振動高速數據採集 ························.494
13.4 某熱軋控制系統高速數據採集 ···································································.495
13.5 氣力輸送系統高速數據採集 ······································································.496
13.6 某機組作業時間統計報表 ·········································································.496
13.7 鋼管軋制高速數據採集 ············································································.497
13.8 電能管理系統高速數據採集 ······································································.498
13.9 其他數據採集系統的改造 ·········································································.500
13.10 某鐵路站與鐵路局之間的數據遠傳 ···························································.500
13.11 動態運行記錄及抄表系統高速數據採集 ·····················································.501
13.12 無人機車及智能鐵水運輸系統高速數據採集 ···············································.501
13.13 全天候碼頭少人化管理 ··········································································.502
13.14 電液伺服控制系統高速數據採集 ······························································.503
13.15 汽車監控系統高速數據採集 ····································································.504
13.16 某啤酒廠高速數據採集及點圖分析 ···························································.505
13.17 統計過程控制指標計算 ··········································································.506