Zajem podatkov za napredno diagnostiko s programirljivim logičnim krmilnikom Siemens

Razložnik, Aljaž (author), Mušič, Gašper (mentor)

Rdeča nit diplomske naloge je razvoj in izdelava sistema za zajem podatkov na horizontalni tračni žagi. Sistem je namenjen zajemanju podatkov o delovanju stroja, ki so namenjeni diagnostiki na stroju. Spodaj navajam, zakaj je bila izdelava tovrstnega sistema potrebna. Podjetje Mebor ima lasten oddelek za avtomatizacijo lesno-obdelovalnih strojev, kjer poteka programiranje in testiranje izdelanih strojev. Poleg tega se ukvarja z diagnosticiranjem in odpravljanjem težav na strojih pri kupcu. Glavni problem, s katerim se pri diagnosticiranju težav srečujejo, so nezanesljive informacije, ki jih operaterji strojev posredujejo. Oddaljen priklop na stroj omogoča spremljanje dogajanja le v realnem času. To je zelo neučinkovito, saj morajo hkrati spremljati veliko signalov, ki se v avtomatskem načinu hitro spreminjajo. Izdelava sistema za zajemanje dogajanja na stroju je tako ključna pri učinkovitejšem in hitrejšem diagnosticiranju težav ter posledično odpravljanju težav. Sistem je implementiran na programirljivem logičnem krmilniku Siemens SIMATIC S7-1500 v programskem jeziku SCL. Program ob vklopu zajame določen časovni interval dogajanja na stroju. V tem časovnem intervalu so zajeta stanja vseh vhodnih in izhodnih signalov. Poleg teh podatkov, zajame še ključne informacije o delovanju električnih motorjev na stroju in podatke, ki so potrebni za Industrijo 4.0. To so v tem primeru horizontalne tračne žage: delovne ure stroja, statistika razrezane hlodovine v eni izmeni, število razrezanih desk ipd. Zajeti podatki so nato na zahtevo poslani na industrijski prehod, ki omogoča zbiranje podatkov. Ta zbrane podatke preko protokola MQTT posreduje v podatkovno bazo. Ti podatki bodo nadalje uporabljeni za prikaz v spletni aplikaciji. Končni sistem zajemanja podatkov nam omogoča kasnejšo analizo delovanja stroja v času nastanka težave. Sistem bo pripomogel k učinkovitejšemu odpravljanju težav. Poleg tega bo spletna aplikacija omogočila odpravljanje napak tudi strokovno manj izobraženim sodelavcem. Rezultati so prikazani v programu Excel, kjer so predstavljena stanja vhodnih in izhodnih signalov med žaganjem hlodovine v avtomatskem načinu. Sistem je bil uspešno vpeljan na horizontalno tračno žago, zato upam, da bo poenostavil diagnosticiranje in odpravljanje težav tako meni kot vsem sodelavcem, ki skrbijo za odpravljanje težav na strojih.

• Language: Slovenian
• Keywords: horizontalna tračna žaga, diagnostika, OPC UA, MQTT, Siemens SIMATIC S7-1500
• Work type: Bachelor thesis/paper
• Typology: 2.11 - Undergraduate Thesis
• Organization: FE - Faculty of Electrical Engineering
• Year: 2025
• PID: 20.500.12556/RUL-175180
• COBISS.SI-ID: 266821379
• Publication date in RUL: 20.10.2025

Secondary language

• Language: English
• Title: Data acquisition for advanced diagnostics with a Siemens programmable logic controller

Abstract

The main theme of the thesis is the development and implementation of a data collection system for a horizontal band saw. The system is designed to collect data on machine operation for diagnostic purposes. Bellow, I explain why it was necessary to develop such a system. Mebor has its own automation department for woodworking machines, where the programming and testing of the manufactured machines take place. In addition to that, department also deals with diagnosing and troubleshooting machines at the customer's site. The main problem they encounter when diagnosing problems is the unreliable information provided by machine operators. Remote connection to the machine allows real-time monitoring only. This is very ineffective, as they have to monitor many signals at the same time, which change rapidly in automatic mode. Therefore, creating a system to capture machine events was key to more efficient and faster diagnosis of problems and consequently, problem resolution. The system is implemented on a Siemens SIMATIC S7-1500 programmable logic controller in the SCL programming language. Program captures a specific time interval of machine activity when system is turned on. During this time interval the system captures the states of all input and output signals. In addition to this data, we collect key information about the information about electric motors on the machine and data that is necessary for Industry 4.0. In case of horizontal band saw these are: machine operating hours, statistics of logs cut in one shift, number of boards cut, etc. The captured data is sent to an industrial gateway, which enables data collection, and the collected data is transmitted to the database via the MQTT protocol. This data will be used for display in the web application. The completed data collection system enables us to analyze the machine's operation at the time of the problem. The system will help us to resolve the issues more efficiently. Additionally, the web application will allow less educated colleagues to fix errors as well. The results are shown in Excel, where the status of input and output signals during automatic log sawing is presented. The system was successfully implemented on a horizontal band saw. I hope that this system will simplify the diagnosis and troubleshooting for me and all my colleagues who are responsible for troubleshooting on the machines.

• Keywords: horizontal band saw, diagnostics, OPC UA, MQTT, Siemens SIMATIC S7-1500