1 Introduction

In the design and implementation process of industrial control systems, there are often occasions (such as ship gate control, garbage disposal control, etc.) in addition to industrial monitoring software for process data monitoring, you also need to configure a professional video surveillance system to The monitoring center can intuitively and comprehensively grasp the actual situation on the site, thus achieving safe remote control. Traditionally, an independent analog signal video system is used, such as configuring front-end devices (including cameras, lenses, pan/tilt, decoders, etc.), monitors, and video operating keyboards, or using a separate set of digital signal video. Systems such as front-end devices, computers with video capture cards, and video surveillance software. Since the video system and the industrial control system are independent of each other, they often need to be independently wired at the site, and the monitoring center also needs two sets of monitoring and operating equipment. However, the ultimate goal of these two systems is to achieve remote control, so the operation user wants to see real-time data and images on the same monitoring screen at the same time, in order to quickly operate according to the scene, and reduce the daily operation of multiple devices. And maintenance workload, which can maximize the integration of industrial control systems and video surveillance systems.

This paper comprehensively uses the latest technologies of industrial control and video surveillance in two different professional fields, and designs a complete solution, which can simultaneously transmit data, video and control signals in the same monitoring network, simultaneously in the same picture of the same computer software. Carrying out the work situation and video surveillance, thus realizing the "two networks in one" in the true sense of the industrial control system and the video surveillance system.

2 program design

Industrial Ethernet technology is an application hotspot in the field of industrial control. Commonly used PLC products can generally be configured with Ethernet communication modules. At the same time, common monitoring configuration software can also communicate with PLC through Ethernet, and some powerful configuration software. With a complete programming environment, you can implement general application software functions through high-level language programming. Network camera (or network video server) is a new technology in the field of video surveillance. Its essence is to convert the video signal from the CCD camera to a certain compression standard (such as MPEG4, H.264, etc.) to convert it into an ether. Data packets transmitted on the network, each network camera (or network video server) has a different IP address, the computer on the network can connect to the camera (or server) through TCP/IP protocol, and the data package is decompressed and restored by software to Live image.

The system diagram of this scheme is shown in Figure 1. The SIEMENS S7-300 PLC is used for field device control. It is equipped with CPU module CPU314, Ethernet communication module CP343-1 and various I/O modules. The video surveillance front-end equipment is two sets of CCD camera, auto iris zoom lens, pan/tilt and Decoder, network data processing network video server with two-channel video input, it has RS485 port for communication with the decoder and video input BNC port connected to the camera, the output is RJ45 port that can be connected to Ethernet; monitoring computer adopts High-performance industrial computer, its monitoring software uses GE Fanuc's iFIX3.0 as a development platform. The configuration software supports AcTIveX control, VBA programming and various communication protocols. It is very powerful; the communication network adopts 100M Ethernet switch. Super five twisted pair cables connect computers, PLCs and video servers. The key to the realization of this system is to simultaneously transmit video information and control and data information on the Ethernet, and realize the function monitoring and video monitoring functions in the same configuration software.

Figure 1 System diagram of the "two networks in one" scheme of the industrial control system and the video system

3 The concrete realization of "two networks in one"

(1) PLC configuration and programming

The PLC hardware and network configuration is carried out in SIMATIC STEP7. The IP address of the Ethernet module can be set to 192.168.0.2 and the subnet mask is 255.255.255.0. Create variables for communication with the host computer in the DB block, including BOOL, INT and other data types. Then compile multiple FC control programs and download them to the PLC via the MPI cable.

(2) Video device settings

Video devices mainly include cameras, lenses, pan/tilt, decoders, and video servers. The decoder controls the up and down motion of the pan/tilt and the zoom and focus adjustment of the lens through the standard voltage signal. It communicates with the video server via the RS485 bus. Each decoder should set different communication addresses such as 1 and 2. The video server sets its IP address, subnet mask and other parameters through the setting software. For example, the IP address is 192.168.0.3 and the subnet mask is 255.255.255.0. The image number of the two cameras is determined by the plugged BNC port as 1 or 2.

(3) Comprehensive development of monitoring software

Monitoring software development considers both data monitoring and video monitoring functions, and puts process-related data and images on the same monitoring screen. The user's operations include control of various industrial equipment on the site and control of the pan/tilt and lens. Develop routine process monitoring screens, alarm processing, historical data logging, report query printing, user management and other functions in iFIX Workspace. This part of the development is relatively easy to implement in iFIX, and the development of video monitoring functions is the key.

To implement real-time image monitoring in iFIX, you need to use its AcTIveX technology. The video signal transmitted by the video server to the computer is the encoded compressed data packet, and the decompression is completed by software, so the functions of data decompression, image restoration, control information communication and the like can be integrated into an AcTIveX control, and then the control is called in iFIX. Just fine. Insert the control instance Video1 and a button BtnConnect in the iFIX screen. The button click event is programmed as follows: Video1.connect "192.168.0.3", 1. When the user clicks the button, the control displays an image of the video server 1# channel.

The control of the pan/tilt and the lens is completed by sending a communication command to the decoder through the video server. Currently, there are several commonly used protocol formats, such as Pelco-P, AB, etc., generally including pan/tilt motion, pan/tilt manual/automatic , lens wide angle / close shot, lens focus far / near and other instructions. For example, the pan/tilt up function can be programmed in the corresponding button click event as follows:

Dim command(2) As Byte

Command(0)= Val("&H80")

Command(1)= Val("&H00")

Video1.SetupUart 0, 2400, 8, 1, Asc("O")

Video1.WriteUart 0, command, 2

In addition, by calling the control methods, properties and events, you can also add video recording, playback, capture images, screen segmentation, image quality adjustment and other operations as needed, so that the monitoring software has professional data monitoring and video monitoring functions.

4 application examples

Taking a garbage operation terminal automation monitoring system as an example, the system requires that both the garbage truck in place status and the garbage weight information can be seen on the monitoring screen, and the garbage truck operation status on the port machine can be seen, so that the entry can be accurately entered. The gate at the place is controlled. Using the above-mentioned "two networks in one" scheme, multiple cameras can be set to observe the actual state of the garbage truck and the transport vessel, collect the on-site signals through the PLC and complete the equipment control, and the monitoring computer connects the PLC and the video server through the industrial Ethernet, and has achieved good results. Effect. The software screen of its "two networks in one" monitoring system is shown in Figure 2. The left side of the screen is the monitoring part of the process flow, which displays the monitoring data in real time and realizes the remote process operation. On the right side of the screen is the video monitoring part. The user can see the actual situation of the scene through the real-time image, and can also perform image movement/distance and other operations.

Figure 2 Garbage operation terminal monitoring system screen

5 Conclusion

The "two-in-one" solution of the industrial control system and video surveillance system designed in this paper has the following characteristics:

(1) It is an open system. PLC stations, video monitoring points, and monitoring computers can be added or removed as needed. System expansion does not require structural changes;

(2) The video server, video front-end equipment and PLC control station can be placed on site, as long as one network cable can be connected to the computer of the monitoring center, which greatly reduces wiring;

(3) The monitoring center only needs one computer and one set of monitoring software to realize all monitoring functions, which is convenient for operation and reduces maintenance workload;

(4) The use of video server can more disperse the workload of computer data processing than the use of video capture card, and make the control and video are actually transmitted on the same network, which is more suitable for remote network monitoring;

(5) If you need to integrate the voice/music function, you can also use a video server with audio input/output interface to realize the "triple play" of the control system, video system and audio system.

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