Research On Ultra-high Speed Cigarette Making Machine Control System Based On EtherCAT And Its Real-Time Performance

With development of cigarette making machine towards high speed, highefficient and low consumption, the performance requirements of control system isincreasing high. The traditional PLC control system is been difficult to meet demandsfor cigarette making process control. Developing new control system of ultra-highspeed cigarette making machine control system is urgent. With high communicationspeed, high Calculating ability and good open, industrial real-time Ethernettechnology and PC-based technology have been widely used in the field of industrialcontrol and provide a new solution for the development of ultra-high speed cigarettemaking machine control system.This paper mainly studies control system based onindustrial real-time Ethernet, and explores the feasibility from real-time perspective.Firstly, The paper gives an overview of the development of control system andintroduced control system structure of main machine models from internationallyrenowned tobacco machinery company. The domestic research situation is alsosummarized. The basic principle of typical industrial real-time Ethernet technologywas analyzed, and some leading industrial real-time Ethernet performance wascompared. Then, the paper choose EtherCAT which developed by Beckhoff.Secondly, the ultra-high speed cigarette making machine control Systemstructure based on EtherCAT was proposed after analyzing key performanceparameters. Then, the paper studied soft PLC control, bus communication structure,oversampling technology. The real-time performance including EtherCAT cycle time,I/O response time was emphasis analyzed. The feasibility of the control systemstructure was analyzed from real-time perspective according to the size of cigarettemaking machine control system.Finally, the experimental platform based on EtherCAT was designed. Thecommunication principles, methods between TwinCAT and host PC was analyzed.TheGUI based on multi-view of single document was designed by VC++6.0. The controlsystem I/O response time, EtherCAT cycle time, relationship between PLC cycle andI/O response time, ADS communication speed, oversampling and Timestamp moduleperformance were tested.