基于嵌入式Linux的自动焊机监控系统的设计与实现
摘要
随着工业技术的发展,自动焊接技术也日益成熟。发达国家的微机控制电子弧焊机已经进入实用化阶段,并朝着多功能、多参数控制、波形控制以及智能化控制的方向发展。而国内的自动焊接设备,特别是自动焊接控制系统正处于刚刚起步阶段,不能满足国家生产建设的需要。
针对我国的这种现状,国内某焊接设备技术有限责任公司着手研发了自动焊接控制系统的新平台。这对加速传统技术的改造,制造可靠、实用和经济的自动焊接控制系统具有重要的现实意义。本课题即来源于此项目。
自动焊接控制系统新平台主要由上位机、中位机(监控系统)以及下位机(DSP检测控制系统)组成。上位机主要负责远程监控,中位机主要负责整体的焊接流程、通信以及人机界面,下位机负责具体参数的采集与控制。其中,监控系统是本文研究的主要内容。它包括人机界面(键盘,LCD显示)、调试接口(JTAG, RS232接口)、与下位机通信(CAN总线)以及与上位机通信(以太网接口)。
本文首先概述了国内自动焊接领域的现状以及焊机的发展方向,通过对自动焊机平台系统的分析,确立了该系统的基本架构,并划分了各部分的主要功能。
其次,文中设计并研究了以S3C2440为核心的嵌入式硬件电路系统(IIC总线电路、RS232接口电路、以太网控制器电路和基于SPI的CAN总线电路)。本系统采用了先进的JTAG调试方式,并以RS232接口为辅助调试通道,从而加强了调试维护的便利性。同时,将工业现场总线CAN(控制局域网络)总线应用于焊机的方案中,并结合处理器的SPI接口,设计了基于SPI接口的CAN总线电路,在实测中体现出了良好的抗干扰性。
由于需要满足实时性与可扩展性的要求,实时操作系统选择了Linux操作系统,并对Linux进行了裁剪和移植。结合硬件电路和Linux操作系统研究了Linux的驱动程序,同时给出了具体的开发流程,符合监控系统控制的实时性与可维护性的要求。系统中的人机界面研究了640*480点阵的彩色液晶显示器与S3C2440的配合应用,并对S3C2440内置的LCD控制器进行了配置,本文以启动画面为例说明了人机界面的实用性。与上位机的通信部分研究了基于TCP/IP协议的以太网硬件电路和软件配置,使远程监控与组网十分容易。
在课题进行时,对CAN总线做了抗干扰性实验；对人机界面做了启动画面操作及显示的实验；对Linux进行了裁剪与移植实验。实验结果表明：监控系统的软硬件系统工作可靠,功能模块装卸方便,信号传输抗干扰性以及实时性均满足实际应用。
Along with the development of technology, automatic welding technology matures. Developed countries of the microcomputer control electronics welder has entered into practical phase, and toward multi-function, many parameters controlling, control and intelligent control of wave direction. While the automatic welding equipment, especially the control system of automatic welding is just the start stage, cannot satisfy the needs of the construction of national production.
Aiming at this kind of situation, a welding equipment technology Co., LTD to developed automatic welding system of the new control platform for welding. To accelerate the transformation of traditional technology, the reliable, practical and economical automatic welding control system has the important practical significance. This topic is derived from the project.
The new control platform, mainly by computer, Intermediate machine (monitoring system) and the test control system (DSP). The computer is mainly responsible for remote monitoring the station of the welding equipment, and the Intermediate machine is mainly responsible for the whole process of welding, communication and man-machine interface, the test control system responsible for the specific parameters for the acquisition and control. Among them, the emphasis of the study is the monitoring system. It includes man-machine interface (keyboard, LCD display), debugging interface (JTAG，RS232 interface), and the communication (the CAN bus) and computer communications (the Ethernet interface).
This paper summarized the domestic automatic welding machine. It established the basic framework of the welding system by the analysis of automatic welding machine platform system.
Secondly, designed and researched the embedded hardware circuit system use the core like S3C2440.its included IIC bus circuit and RS232 interface circuit and Ethernet controller based on SPI circuit and the CAN bus circuit. The circuit of the monitoring system adopted advanced JTAG debug mode, and with RS232 interface for auxiliary debugging channel, it make maintenance convenient. And the CAN bus also use in the monitoring system. The CAN bus designed base on the SPI of S3C2440, and then the good anti-jamming measured in the can bus.
This program should satisfy the requirement of real-time and expansibility. The paper choose the operating system with real-time like Linux, which have been cut and transplanted into the S3C2440. The paper studied the driver for Linux combined with the hardware circuit. In this case, it also presented the details of process of the development, and obtained good results of controllability and maintainability in the real-time monitoring system. The man-machine interface study the cooperation application about chromatic LCD of 640X480 dot and S3C2440, and the paper configures the LCD controller of built-in S3C2440, and illustrates the practicability of the man-machine by the example of the startup display. In the part of communication with the computer studied hardware circuit and software configuration of Ethernet which based on TCP/IP protocol, and made it much easier to remote monitoring and networking.
Studying the thesis, these experiments were made like anti-interference on the CAN bus; operation and display for human-machine interface; cut and transplanted for Linux system. The results show that hardware and software of monitoring system is reliable, and it is convenient about loading and unloading of functional modules. It meets the requirements about anti-interference of signal transmission, and reaches the application level of real time.
针对我国的这种现状,国内某焊接设备技术有限责任公司着手研发了自动焊接控制系统的新平台。这对加速传统技术的改造,制造可靠、实用和经济的自动焊接控制系统具有重要的现实意义。本课题即来源于此项目。
自动焊接控制系统新平台主要由上位机、中位机(监控系统)以及下位机(DSP检测控制系统)组成。上位机主要负责远程监控,中位机主要负责整体的焊接流程、通信以及人机界面,下位机负责具体参数的采集与控制。其中,监控系统是本文研究的主要内容。它包括人机界面(键盘,LCD显示)、调试接口(JTAG, RS232接口)、与下位机通信(CAN总线)以及与上位机通信(以太网接口)。
本文首先概述了国内自动焊接领域的现状以及焊机的发展方向,通过对自动焊机平台系统的分析,确立了该系统的基本架构,并划分了各部分的主要功能。
其次,文中设计并研究了以S3C2440为核心的嵌入式硬件电路系统(IIC总线电路、RS232接口电路、以太网控制器电路和基于SPI的CAN总线电路)。本系统采用了先进的JTAG调试方式,并以RS232接口为辅助调试通道,从而加强了调试维护的便利性。同时,将工业现场总线CAN(控制局域网络)总线应用于焊机的方案中,并结合处理器的SPI接口,设计了基于SPI接口的CAN总线电路,在实测中体现出了良好的抗干扰性。
由于需要满足实时性与可扩展性的要求,实时操作系统选择了Linux操作系统,并对Linux进行了裁剪和移植。结合硬件电路和Linux操作系统研究了Linux的驱动程序,同时给出了具体的开发流程,符合监控系统控制的实时性与可维护性的要求。系统中的人机界面研究了640*480点阵的彩色液晶显示器与S3C2440的配合应用,并对S3C2440内置的LCD控制器进行了配置,本文以启动画面为例说明了人机界面的实用性。与上位机的通信部分研究了基于TCP/IP协议的以太网硬件电路和软件配置,使远程监控与组网十分容易。
在课题进行时,对CAN总线做了抗干扰性实验；对人机界面做了启动画面操作及显示的实验；对Linux进行了裁剪与移植实验。实验结果表明：监控系统的软硬件系统工作可靠,功能模块装卸方便,信号传输抗干扰性以及实时性均满足实际应用。
Along with the development of technology, automatic welding technology matures. Developed countries of the microcomputer control electronics welder has entered into practical phase, and toward multi-function, many parameters controlling, control and intelligent control of wave direction. While the automatic welding equipment, especially the control system of automatic welding is just the start stage, cannot satisfy the needs of the construction of national production.
Aiming at this kind of situation, a welding equipment technology Co., LTD to developed automatic welding system of the new control platform for welding. To accelerate the transformation of traditional technology, the reliable, practical and economical automatic welding control system has the important practical significance. This topic is derived from the project.
The new control platform, mainly by computer, Intermediate machine (monitoring system) and the test control system (DSP). The computer is mainly responsible for remote monitoring the station of the welding equipment, and the Intermediate machine is mainly responsible for the whole process of welding, communication and man-machine interface, the test control system responsible for the specific parameters for the acquisition and control. Among them, the emphasis of the study is the monitoring system. It includes man-machine interface (keyboard, LCD display), debugging interface (JTAG，RS232 interface), and the communication (the CAN bus) and computer communications (the Ethernet interface).
This paper summarized the domestic automatic welding machine. It established the basic framework of the welding system by the analysis of automatic welding machine platform system.
Secondly, designed and researched the embedded hardware circuit system use the core like S3C2440.its included IIC bus circuit and RS232 interface circuit and Ethernet controller based on SPI circuit and the CAN bus circuit. The circuit of the monitoring system adopted advanced JTAG debug mode, and with RS232 interface for auxiliary debugging channel, it make maintenance convenient. And the CAN bus also use in the monitoring system. The CAN bus designed base on the SPI of S3C2440, and then the good anti-jamming measured in the can bus.
This program should satisfy the requirement of real-time and expansibility. The paper choose the operating system with real-time like Linux, which have been cut and transplanted into the S3C2440. The paper studied the driver for Linux combined with the hardware circuit. In this case, it also presented the details of process of the development, and obtained good results of controllability and maintainability in the real-time monitoring system. The man-machine interface study the cooperation application about chromatic LCD of 640X480 dot and S3C2440, and the paper configures the LCD controller of built-in S3C2440, and illustrates the practicability of the man-machine by the example of the startup display. In the part of communication with the computer studied hardware circuit and software configuration of Ethernet which based on TCP/IP protocol, and made it much easier to remote monitoring and networking.
Studying the thesis, these experiments were made like anti-interference on the CAN bus; operation and display for human-machine interface; cut and transplanted for Linux system. The results show that hardware and software of monitoring system is reliable, and it is convenient about loading and unloading of functional modules. It meets the requirements about anti-interference of signal transmission, and reaches the application level of real time.
引文
[1]2007-2008年中国电焊机市场分析与投资咨询报告.北京欧立信经济信息咨询中心.
[2]郑宜庭,黄石生.弧焊电源.机械工业出版社,2002
[3]耿正,陈树君.弧焊电源.中国焊接设备,47-62,2004
[4]陈善本等编.焊接过程现代控制技术.哈尔滨工业大学出版社,2001
[5]杨春利,林三宝.电弧焊基础.哈尔滨工业大学出版社,2003
[6]熊腊森.焊接工程基础.机械工业出版社,2002
[7]陈炯.自动焊接设备在全位置焊中的应用.电焊机,第7期,第34卷,2007
[8]张绮文等.嵌入式常用模块与综合系统设计实例精讲.电子工业出版社,2007.5.
[9]王田苗主编.嵌入式系统设计与实例开发.清华大学出版社,2002
[10]华恒科技HHARM2410开发平台技术手册
[11]周立功,陈明计,陈渝.ARM嵌入式Linux系统构建与驱动开发范例.北京航空航天大学出版社,2006年第一版
[12]田泽.嵌入式系统开发与应用.北京航空航天大学出版社,2005年1月第一版
[13]周立功.ARM嵌入式系统基础教程.北京航空航天大学出版社,2005年1月第一版
[14]马忠梅,马广云,田泽等.ARM嵌入式处理器结构与应用基础.北京航空航天大学出版社,2002
[15]刘淼.嵌入式系统接口设计与Linux驱动程序开发.北京航空航天大学出版社,2006年5月第一版
[16]许昌满,成志峰.基于Linux的嵌入式无线可视门铃系统的设计[J].电子查询网
[17]Samsung Limited. S3C2440X user's manual
[18]孙琼.嵌入式Linux应用程序开发详解.人民邮电出版社,2006年7月第一版
[19]张大波,吴迪,赫军,沙毅,冯新建.嵌入式系统原理设计与运用.北京机械工业出版社,2004.11.
[20](美)Qing Li. Real-Time Concepts for Embedded Systems.2004.
[21]Scott Maxwell. Linux内核源代码分析.机械工业出版社.2002
[22]Alessandro Rubini, Jonathan Corbet, LINUX设备驱动程序,中国电力出版社,2002年11月第一版
[23]徐千洋.Linux C库参考手册.中国青年出版社,2002年1月第一版
[24]毛曙福.Linux C高级程序员指南.国防工业出版社,2001年2月第1版
[25]李玉波,朱自强,郭军.Linux C编程.清华大学出版社,2005年9月第一版
[26]怀石工作室.Linux上的C编程.中国电力出版社,2001年5月第二版
[27]李善平,刘文峰,王焕龙.Linux与嵌入式系统.清华大学出版社,2003年1月第一版
[28]邹思轶.嵌入式Linux设计与应用.清华大学出版社,2002年1月第一版
[29]史兴华译. Linux编程起步.人民邮电出版社,2001年4月第一版
[30]David Pitts, Bill Ball. Red Hat Linux 6.机械工业出版社,2000年5月第一版
[31]John Goerzen. Linux编程宝典.电子工业大出版社,2000年10月第一版
[32]曹源.基于ARM芯片和μ CLinux系统的嵌入式以太网网关的研究.[硕士学位论文],南京：浙江大学,2004：28-46
[33]Labrosse Jean著,邵贝贝译.μC/OS-Ⅱ——源代码公开的实时嵌入式操作系统.中国电力出版社,2001年8月。
[34]沈建华.基于ARM的嵌入式OS研究与移植.[硕士学位论文],上海：华东师范大学,2005：18-33
[35]Atmel's ARM-based Microcontroller-Low Power for Portable Systems,-Atmel Corporation,2008.
[36]ARM Developer Suite Version 1.2, Advanced RISC Machines Ltd,2004.
[37]Multi-ICE Version 2.2 User Guide Advanced RISC Machines Ltd,2005.
[38]ARM 7TDMI Data Sheet, Advanced RISC Machines Ltd,2005
[39]ARM Development Suite, Assembler Guide, Advanced RISC Machines Ltd,2006
[40]嵌入式开发网. http://www.teachersong.com
[41]http://bbs.edw.com.cn
[42]http://www.ucLinux.org
[2]郑宜庭,黄石生.弧焊电源.机械工业出版社,2002
[3]耿正,陈树君.弧焊电源.中国焊接设备,47-62,2004
[4]陈善本等编.焊接过程现代控制技术.哈尔滨工业大学出版社,2001
[5]杨春利,林三宝.电弧焊基础.哈尔滨工业大学出版社,2003
[6]熊腊森.焊接工程基础.机械工业出版社,2002
[7]陈炯.自动焊接设备在全位置焊中的应用.电焊机,第7期,第34卷,2007
[8]张绮文等.嵌入式常用模块与综合系统设计实例精讲.电子工业出版社,2007.5.
[9]王田苗主编.嵌入式系统设计与实例开发.清华大学出版社,2002
[10]华恒科技HHARM2410开发平台技术手册
[11]周立功,陈明计,陈渝.ARM嵌入式Linux系统构建与驱动开发范例.北京航空航天大学出版社,2006年第一版
[12]田泽.嵌入式系统开发与应用.北京航空航天大学出版社,2005年1月第一版
[13]周立功.ARM嵌入式系统基础教程.北京航空航天大学出版社,2005年1月第一版
[14]马忠梅,马广云,田泽等.ARM嵌入式处理器结构与应用基础.北京航空航天大学出版社,2002
[15]刘淼.嵌入式系统接口设计与Linux驱动程序开发.北京航空航天大学出版社,2006年5月第一版
[16]许昌满,成志峰.基于Linux的嵌入式无线可视门铃系统的设计[J].电子查询网
[17]Samsung Limited. S3C2440X user's manual
[18]孙琼.嵌入式Linux应用程序开发详解.人民邮电出版社,2006年7月第一版
[19]张大波,吴迪,赫军,沙毅,冯新建.嵌入式系统原理设计与运用.北京机械工业出版社,2004.11.
[20](美)Qing Li. Real-Time Concepts for Embedded Systems.2004.
[21]Scott Maxwell. Linux内核源代码分析.机械工业出版社.2002
[22]Alessandro Rubini, Jonathan Corbet, LINUX设备驱动程序,中国电力出版社,2002年11月第一版
[23]徐千洋.Linux C库参考手册.中国青年出版社,2002年1月第一版
[24]毛曙福.Linux C高级程序员指南.国防工业出版社,2001年2月第1版
[25]李玉波,朱自强,郭军.Linux C编程.清华大学出版社,2005年9月第一版
[26]怀石工作室.Linux上的C编程.中国电力出版社,2001年5月第二版
[27]李善平,刘文峰,王焕龙.Linux与嵌入式系统.清华大学出版社,2003年1月第一版
[28]邹思轶.嵌入式Linux设计与应用.清华大学出版社,2002年1月第一版
[29]史兴华译. Linux编程起步.人民邮电出版社,2001年4月第一版
[30]David Pitts, Bill Ball. Red Hat Linux 6.机械工业出版社,2000年5月第一版
[31]John Goerzen. Linux编程宝典.电子工业大出版社,2000年10月第一版
[32]曹源.基于ARM芯片和μ CLinux系统的嵌入式以太网网关的研究.[硕士学位论文],南京：浙江大学,2004：28-46
[33]Labrosse Jean著,邵贝贝译.μC/OS-Ⅱ——源代码公开的实时嵌入式操作系统.中国电力出版社,2001年8月。
[34]沈建华.基于ARM的嵌入式OS研究与移植.[硕士学位论文],上海：华东师范大学,2005：18-33
[35]Atmel's ARM-based Microcontroller-Low Power for Portable Systems,-Atmel Corporation,2008.
[36]ARM Developer Suite Version 1.2, Advanced RISC Machines Ltd,2004.
[37]Multi-ICE Version 2.2 User Guide Advanced RISC Machines Ltd,2005.
[38]ARM 7TDMI Data Sheet, Advanced RISC Machines Ltd,2005
[39]ARM Development Suite, Assembler Guide, Advanced RISC Machines Ltd,2006
[40]嵌入式开发网. http://www.teachersong.com
[41]http://bbs.edw.com.cn
[42]http://www.ucLinux.org