Since the advent of fieldbus technology in the late 1980s, there have been standards advocated by different entities, typical representatives are: Foundation LONWOKS, PROFIBUS, CAN, HART, etc. Among them, PROFIBUS is proposed and strongly advocated by Siemens of Germany, and it has become the German national standard DIN19245 and the European standard EU50170 successively. In China, a PROFIBUS field bus professional committee has also been established. This paper takes Siemens PLC as an example and takes the biopharmaceutical engineering as the background to expound some problems solved by the fieldbus technology in the practical application of the biopharmaceutical industry.

1. Fieldbus technology

Fieldbus was formed internationally in the late 1980s and early 1990s. It is used for the realization of two-way serial multi-node digital communication system between the production site and the computerized measurement and control equipment. It is also known as open, digital, multi- The underlying control network for point-to-point communication.

The field bus system FCS is called the fifth generation control system. People generally call the pneumatic signal control system PCS before the 1950s the first generation, the 4-20mA and other electric analog signal control systems are called the second generation, and the digital computer is centralized. The distributed control system is called the third generation, and the distributed control system DCS since the mid-1970s is called the fourth generation. The field bus control system FCS, as a new generation control system, on the one hand, breaks through the limitation of the DCS system using a dedicated communication network, adopts an open and standardized solution, and overcomes the defects caused by the closed system; on the other hand, the DCS system The centralized and decentralized distribution system structure has become a new type of fully distributed structure, and the control function is completely delegated to the site. The emergence of fieldbus technology has realized the interconnection and communication between the field intelligent equipment in the fields of engineering automation, manufacturing automation, information acquisition automation, etc., and realized the interconnection and communication between the production process field control equipment and the higher information management layer. In addition, FCS can also It is connected to the upper management network of the enterprise through the gateway, so that managers can grasp the first-hand information and provide a basis for decision-making. It creates conditions for completely breaking the information silos of automated systems.

1. Classification of field bus PROFIBUS

At present, there are many popular fieldbuses and bus standards in the world. Among them, PROFIBUS fieldbus is a European standard, and its products have been generally accepted in the world market. In China, a PROFIBUS fieldbus professional committee has also been established, which is currently the most successful in the world. one of the fieldbuses.

In the factory automation control system of the vaccine engineering of the Institute of Veterinary Medicine, it does not involve workshop-level communication tasks and intrinsically safe process automation, so PROFIBUS-DP is mainly used.

2. PROFIBUS related products of Siemens S7-300 series PLC.

Siemens PLC provides a variety of CP communication function modules for PROFIBUS communication. According to the specific situation of the foot-and-mouth disease vaccine project of the Institute of Veterinary Medicine, 7 PLC-300s are selected for each area and function, and the CPU is 315-ZDP. The communication processor involved It is a DP slave station ET200M that forms a field-level PROFIBUS; CP342-5 is used for communication between PLCs and man-machine interface; CP-5613 is used for PROFIBUS-PA to PG/PC system interface. It is now described as follows:

1) DP slave ET-200M

ET-200M is a master-slave I/O distributed PLC field bus system with PROFIBUSDPslave.

Because it can be used as the remote distributed I/O of the CPU, the communication distance between the CPU and the CPU through the field bus is as long as 1.2KM, so the specific slave station can be set near the control device according to the actual situation of the site, and then communicate with the central CPU through the bus. connected communication. The biggest advantage of this is that the distance from the field signal to the central control cabinet is greatly reduced, the cost of I/O wiring is reduced, and the construction efficiency is improved. At the same time, because the bus cycle time of PROFIBUS-DP is less than 10ms, its control The real-time performance will never be reduced due to this. In the PLC control system of the vaccine engineering of the Veterinary Research Institute, the cold station and the power station are located at the northernmost end of the production plant. Signals are in the workshop at the southern end of the production plant, such as process temperature, pressure signals, and underground technical interlayers, such as the cold station and 4 cooling water pumps. In order to solve this contradiction, in order to set up the central control cabinet of the PLC CPU in the cold station machine room at the north end, and set up its DP station ET200M in the underground technical mezzanine at the south end of the production plant, send all relevant on-site signals to the DP station for processing. , DP station communicates with the central control cabinet in the cold station through bus connection. The communication distance between them is about 120m, and the on-site signals processed are around 50 points. The ET200M remote distributed I/O is used to solve this problem and greatly reduce the construction cost.

2) CP342-5 communication processor

CP342-5 is a communication processor connecting Siemens S7-300 to PROFIBUS-DP bus system. It can be used as a DP master slave station to provide PROFIBUS-DP, S7 communication, S5 unit communication, programmer and HMI system communication for the system. Function, in the PLC control system of vaccine engineering, it mainly serves for the communication networking between S7-300 and HMI system.

3) CP-5613 communication processor

CP5613 is used to connect SIMATIC PG/PC and AT compatible PC to PROFIBUS under WINDOWSNT4.0 (WINDOWS200) with PCI slot. Since CP5613 operates as a PROFIBUS-DP master, it stores the process image in DPRAM (storage area on the CP), and the hardware handles high-performance data transmission autonomously, so it can reduce the CPU load of the computer host. Improve the performance of the computer host for other computers or network processors. In the PLC control system of the FMD vaccine project of the Animal Research Institute, it is used as the communication processor between the HMI/SCADA system host and the S7300 PLC system.

2. Application of Fieldbus Technology and Industrial Ethernet in Biopharmaceutical Industry

1. System review

The automation network of this project advocates the use of Siemens SIMATICNET series products. The entire network takes Industrial Ethernet (international standard for area and unit networking) and PROFIBUS fieldbus (international standard for field area and unit networking) as an important part, which can complete factory communication, data communication and process/field automation Communication and other complex networking tasks with different levels and different performances.

Application of Siemens SIMATICNET series products based on fieldbus technology in pharmaceutical industry

The network system is divided into three layers, namely: field control layer, process monitoring layer, production management and market management management.

1) Field control layer

PROFIBUS is a field bus technology used for process automation. Its flexible network configuration and bus connection to distributed I/O devices greatly reduce the engineering cost of the control system in terms of wiring, greatly simplify engineering implementation, and make the system reliable. Performance and system functionality are greatly improved.

The communication protocol of PROFIBUS fully meets the requirements of standardization and standardization, and its openness allows standardized components from different manufacturers to be compatible and integrated.

The on-site I/O control of our institute adopts PROFIBUS-DP bus for I/O distributed configuration, which is divided into 8 PLC units. PLC-1~PLC-3 are the control units of the fresh air unit and air conditioning unit of Building No. 52. PLC-4 is responsible for the monitoring tasks of the process cooling station and power station of the air-conditioning cooling station in Building 52. PLC-5 is the control unit for the lighting and power distribution system of Building 52. PLC-6 will monitor the air conditioning units and cooling station in Building 53. PLC-7 is the process equipment control unit of Building No. 52. The main control equipment includes: bottle spinner, sterilizer, drying box, etc. PLC-8 is an energy monitoring unit, which mainly completes the monitoring or control of our air compressor station, pure water treatment station, industrial steam, water tower and other power facilities.

The monitoring or control of the suspension culture, inactivation, emulsification, sub-packaging and other processes will depend on the communication interface status of the process control equipment configured by me, or be integrated on the PROFIBUS-DP bus of PLC-7 (these are required at this time. The interface of the process control equipment meets the PROFIBUS communication protocol), or is integrated on the industrial Ethernet (in this case, the interface of the process control equipment is required to meet the TCP/IP communication protocol).

2) Process monitoring layer

The above 8 control units are all connected to the PROFIBUS bus to complete the communication processing with the upper operating station or each other, thus forming the process monitoring layer of the entire network system.

According to the different functions of the 8 control units, 4 independent operation stations and 1 WINCC server are set up on the PROFIBUS bus. The 4 independent operation stations are: HVAC system operation station, lighting/transformation and distribution system operation station, process equipment control operation station and energy monitoring operation station. HVAC system operation station is for PLC-1~PLC-4, PLC6 these 5 control units, lighting/power distribution system operation station is for PLC-5 control unit, process equipment control operation station is for PLC-7 control unit, energy monitoring system The operator station is for the PLC-8 control unit. These operating stations will install the SIMATIC WINCC Windows Control Center to generate the various SCADA functions required by the user - process graphics, alarm information processing, data sending and receiving, records and curves, chart display, data storage and report generation, print output, etc.

The data information of all 8 control units will be transmitted to the relevant data server of the industrial Ethernet through the WINCC server for the full integration of the system.

Considering the upgrade of my future planning project, the network interfaces of the following systems are reserved on the PROFIBUS bus layer:

New substation network interface

Biosafety Level 4 (BL4) Laboratory Network Interface

Boiler room monitoring system network interface

Existing GMP workshop rebuilds network interface

3) Production and Marketing Management

Our production scheduling, planning, inventory, personnel, finance, sales and market decisions constitute the management of factory information, and realize office automation among these departments.

SIMATICNET is an IT network. Because its data communication adopts the TCP/IP protocol, the main parts of the entire industrial control system can be integrated into the office automation environment through the industrial Ethernet, which realizes the seamless integration of office automation and automation systems in the industrial environment.

Industrial Ethernet (that is, Intranet) is based on the TCP/IP communication protocol, and all monitoring system workstations, fire system workstations, access control system workstations, equipment on-site monitoring workstations and the above-mentioned process monitoring system servers in the project are implemented together. Fully integrated. For this purpose, a database and a network management server will be set up on the Industrial Ethernet.

Email and browsers will be widely implemented as communication tools in the office environment, both now and in the future. According to the network structure of this design, the office automation level of our institute is not limited to the use of e-mails and browsers. At the same time, through the ISDN (Integrated Service Digital Network) and the telephone connection on the Internet, it can realize the connection function with the WAN (Wide Area Network), making the office work in different places. , remote management becomes possible, which will provide fast and accurate global information services for our future market competition.

2. Network system settings and equipment selection

1) Main control room workstation

The network equipment in the main control room includes the fire protection system workstation, the access control system workstation, the equipment on-site monitoring operation station, and the HVAC system operation station, lighting/distribution system operation station and energy monitoring operation station used in the process monitoring layer. The workstation is set up in the technical mezzanine office on the axial (BC)-horizontal (2, 3) of the 52# building for centralized arrangement.

The computer configuration of the above workstation is: Pentium III-500MHZ or above CPU, 64MB or above memory, 4.3Gb or above hard disk, 1.44MB floppy drive, 17-inch or 21-inch color display, with accessories such as mouse and keyboard.

A network printer is set up on the PROFIBUS bus of the process monitoring layer and on the industrial Ethernet. Use a laser printer. The bus printer completes functions such as process alarm recording, process data recording, and chart generation. The network printer completes the process information, monitoring information and management charts output by each network device.

Set up 1 UPS power supply with a capacity of 6KVA, and the emergency time for power failure is not less than 180 minutes.

2) Large screen monitoring room

The large-screen monitoring room is set up in Room J06 of Building 52#. Through the large-screen monitor, you can clearly see the contents monitored by the main network workstations, such as the running status of the fire protection system, the setting status of the access control system, the running status of the on-site process equipment and HVAC system equipment, whether the lighting equipment is turned on or not and Important site information, etc.

3) Sub-control room

The sub-control room is located in Room J05 of Building 52#. The sub-control room is equipped with process equipment monitoring station and field equipment operation status monitor. The process equipment monitoring station monitors the control content of the PLC-7, and the field equipment operation status monitor will display the real-time operation status of the field equipment through a combination of various screens.

4) Production and market management - the setting of the monitor in the director's office

In order to enable the leaders of our institute to observe the video screen of the technological process in time or to look up the relevant production data and management information, a monitor will be set up in the director's office through the network, and equipped with a corresponding host and laser printer, which will be important. The production process parameters, production schedule and other related management information can be printed out and recorded in time. At the same time, the director can issue corresponding management instructions to each workstation on the network in time according to market operation and demand.

5) System maintenance and management - system management engineer monitor settings

The system management engineer must keep abreast of the operation status of each network equipment and conduct regular inspection and maintenance according to the maintenance and management methods of the network equipment. Therefore, a monitor will be set up in the office through the network, so that the system management engineer can check the operation status of each network device at any time, and at the same time, through the monitor computer, the relevant notification or management information of system maintenance can be issued to each network workstation in time.

3. Network structure and communication

The network system adopts an open bus topology. The three-layer bus constitutes the FMCS system of the veterinary clinic.

The field control layer and the process monitoring layer use the PROFIBUS communication protocol, which is the field bus standard of the German national standard DIN19245 and the European standard EN50170.

The factory management layer is composed of industrial Ethernet, and the communication protocol is TCP/IP, which is convenient for system integration and expansion.

The ordering and wiring of network communication equipment are completed by the self-control contractor and our institute. The selected equipment and circuit materials should meet the speed and reliability necessary for system control data exchange, comply with national standards, and leave room for future system expansion.

3. Conclusion

In the biopharmaceutical industry, a real layered and distributed structure can be realized after the fieldbus is adopted. This structure greatly improves the reliability, flexibility and scalability of the entire system, which is in line with the development trend of biopharmaceutical automation.

Fieldbus technology has a very broad application prospect in the biopharmaceutical industry, especially in today's new projects, it can obtain the greatest benefits in many aspects such as reliability, high precision, and economy. With the joint efforts of fieldbus manufacturers and design and research departments at home and abroad, the fieldbus-based control system will gradually replace the existing distributed control system by system and stage. leading equipment. The above system is designed with many sites and a long PROFIBUS bus. It is used in biopharmaceutical companies (to realize analog monitoring, which is more complicated than other industries). Real-time monitoring is rare in China. The main contribution of this paper is to build a control network based on PROFIBUS, and to realize resource sharing and seamless link with IT network. After nearly two years of use, the effect is good, the design requirements are met, and the informatization level and management level of the enterprise are greatly improved.