201O 2nd International Conference on Industrial and Information Systems

System Design of Electric Locomotives Operational Safety Monitoring Network

Based on PROFIBUS-DP

2 l
Yang Chenghui 1 WuXiaojun Du Lina
College of Electrical Engineering Gansu Baiyin Tobacco Company College of Electrical Engineering
Northwest University for China National Tobacco Corporation Northwest Univerisity for
Nationalities Baiyin, China730900 Nationalities
Lanzhou, China 730030 yghcklrjxdgy@163.com Lan zhou, 730030,China
yangchenghui36@163.com dulina 003@126.com
_

Ab stract---considering the actual situation and the use system latency effectively, and lay a good foundation for the
requirements of electric locomotive operation readiness in our promotion of railway system. This time we changed the
country, we designed a security network control system based traditional manual operation mode, and we are sure that the
on PROFIBUS-DP. The systems implement the system will have good practical value and promotion
communications between a master class and third-party prospects.
equipment, as well as the interactive operation from PLC and
non-contact IC card to SCM System. We described the Multi­ II. ELECTRIC LCOMOTIVE READINESS OPERATION
task scheduling mechanism and the security of data
communications of Monitoring Network System details. At last, A. RequestAnalysis and worliflow of electric locomotive
we did a perfect laboratory debug to this network control readiness operation.
system, and we got satisfactory results, laid a good foundation
for the promotion and application in railway system.
Control requirements and work flow is the basis of
monitoring network system design, it is also a main reference
Keywords-electric locomotive; PROFIBUS-DP; monitoring when we select the system program, so the analysis and
network; multi-task scheduling mechanism; data security improvement of control requirements and work flow is
particularly important.
The control requirements are as followed:
I. INTRODUCTION
Firstly, before the operations, make sure the isolation
In recent years, electrified railway in China has achieved switch has been divided into gate state, and ground rod
remarkable development and progress, in high-speed and should be grounded immediately after the isolation switch is
overloading fields. But the core technology, design disconnected.
standardization, as well as project management is far from Secondly, to switch on isolation switch, we must ensure
the intemational advanced level, especially the low level of that no maintenance staff is on the roof, grounding rod and
equipment, backward of detection and maintenance methods the earth has been disconnected.
[1]. The workflow of the system is as followed:
So far, the domestic electric locomotives (including Firstly, we should check whether the parking position is
EMU) and reorganization of operating control system has suitable, if it does, we should input the locomotive number,
made a lot of results [2, 3], and all of them used centralized and apply for maintenance. Otherwise, we should continue
digital control system or DCS (Distributed Control System, check the parking position.
DCS)[4], which are traditional. They can centrally manage, Then, the worker will see whether the sub-gate
decentralized control, but these systems are not interoperable conditions are fit, and decide to input the sub-gate command
distributed control system. The closing communication or not. Received the command, maintenance personnel will
networks expensive price, making it difficult to promote climb to the top, and do the repair work. When the work is
these results. finished, the man on duty will check again, if he/she is sure
In order to change the backward situation of detection that the equipment is normal and the maintained personnel
and maintenance methods, and lower the system cost, we has got off, he will hop the switch. Then locomotive be
designed and developed security network control system pulled away, and the stocks road system standby
based on field bus technology electric locomotive readiness
operation, which is open, decentralized and can do digital B. Security of monitoring network model
communication. We used graph theory and constructed a Security of monitoring network system using the
comprehensive analysis of token ring, which will reduce the PROFIBUS-DP, S7-300PLC as its master, and S7-200PLC

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through the EM277 module as its slave, then a class from the
station can communicate with a third party equipment. The
network model is consisted of monitoring layer, control layer
and perform layer. In the monitoring layer, there are
interface of Industrial Ethernet and IPC, they formed the
monitoring system. The control layer is the core of the
system, the use of PROFIBUS-DP, let the operator realize
the centralized management and decentralized control to
each slave station. While the perform layer receive command
from the control layer, implement the functions of each
module.
box can open automatically, maintenance staff can get the
key and do repair work on the roof.
While the other difficulty is, after the locomotive
maintenance, only when we ensure that no one on the roof
and ground rod has been disconnected with the earth, then
isolation switch can be closed. To solve this difficulty, we
use the roof industrial cameras to obtain roof images, then
we can send it to the monitoring machine via Industrial
Ethernet, so the people on watch can understand the roof
situation at any time. The system detects if there people on
the roof any more, and then output the closing command.

III. HARDWARE SYSTEM.SECURITY OF MONITORING IV. SOFTWARE DESIGN OF SAFETY MONITORING

NETWORK NETWORK SYSTEM

A. Composition of safety monitoring network hardware A. Structure design of software

By using the pure master - slave network security
monitoring systems, monitoring network can realizes data
exchange between various module and the host computer.
All the communications include the communication between
Master PLC and PC configuration software, Slave PLC and
non-contact IC card, Slave PLC and SCM.
communication between Master PLC (S7-315-2DP) and PC
configuration software is only used when KingView6.51
definite the equipment, select PLC / Siemens / S7-300 series
(Profi-Bus) DP, and then defined variable as the PLC I / 0
variables in the KingView6.51 data dictionary. By the
communication between Slave PLC and the IC card,
monitoring system can obtain the job Information of the
operator automatically. The communication between the
PLC and SCM can realize the input of a locomotive No. and
voice prompts.
We selected the S7-315-2DP [4, 5] as the master, S7-226
as the slave. The two RS485 communication port of S7-266
are connected to non-contact IC card reader
microcontroller systems. The VO ports of CPU226 are
connected to the implementation motor. Our system uses the
OLM (Optical Link Module) modules and the composition
of the glass fiber with a redundant ring, which enhanced the
reliability of the network. We selected OLM/Gl2 type OLM
module, whose transmission distance is 3000m.. Hardware
configuration and module functions are as follows:
Motorcycle parking position detection module uses two
Software structure design of safety monitoring network
system includes: Master /slave network configuration
module, non-contact type IC card operation management
module, data exchange module between Slave PLC and the
SCM system, control module to the implementation motor.
The The function of master / slave network configuration module
is to realize the data change between master PLC and slave
PLC. While the non-contact type IC card operation
management module includes the authentication of
maintenance staff, operating records, and the close or open
of isolation switch. And the input of locomotive number. ,
LCD display and the voice prompts in the operator steps is
realized by the data exchange module between Slave PLC
and the SCM system. Through the last module, PLC control
"interlock, linkage" of the isolation switch and ground rod.
B. Design of communication protocol [6]
After the configuration of master/slave network, the
and address assignment and data formats is assigned. It is shown
in Table I.
TABLE I MASTER / SLAVE CONFIGURAnON ADDRESS ASSIGNMENT
AND DATA FORMATS
Address and Station
formats
Mas/erPLC SlavePLC J SlavePLC 2

general-purpose limit switch, 1.5m apart in orbit, the Configuration

2 10 11
direction of the installation, when the parking spaces Address
appropriate, the speech output "please stop"; The using of Data Format 30 B/Frame 30 B/Frame 30 B/Frame
80C320 microcontroller and LCD display, can realize the
input locomotive number and operation tips. Got the roof By the communication between Slave PLC and the IC
image by industrial camera, and show it on the control card, the operator can get information on the operation
interface, and it can help to check whether to open or close automatically; its data exchange format is shown in Table 2.
the switch.
TABLE II DATA FORMATS BETWEEN SLAVE PLC WITH ICCARD
B. Analysis of difficulties and implementation
ICCard
The first difficulty is that, before we can ensure the Road No. Name Gender Position Swipe Time
No.
isolation switch has been sub-gated and the ground rod
1 byte 10 byte 8 byte 1 byte 4 byte 4 byte
grounded maintenance personnel's can not reach the top and
do their job. Considering this, we designed a special kind
multi-use key which can open many locks, the key is placed
in the key box on the ground, if the equipment is ok, the key

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 The communication between the PLC and SCM, realized
the input of locomotive number and voice prompts, and its
data exchange formats such as shown in Table 3.
TABLE IlL DATA FORMAT BETWEEN SLAVE PLC WITH SCM
SYSTEM
Road No. L ocomotive No. Voice prompts
1 byte 10 byte Pe nding
C. Design of multi-task scheduling mechanism
Field bus control system; break through the limit of DCS
system which use communications networks, and overcome
the deficiencies caused by a closed system. On the other
hand, it has the new full-distributed architecture [7].
The system adopts the multi-tasking data processing
system, so the safety monitoring network system can meet
more complex real-time data processing requirements. Multi­
task real-time data processing module includes: locomotive
location, roof image data acquisition, data processing, data
storage, control output, take single-stranded channel data
processing for example, the scheduling foundation is shown
in Figure 1.
destroy, even may cause the death of the staff. Both the
PROFIBUS and PROFINET have used the Profligate
security technology. At present, the security level can get to
be SIL3 by using Prophesied, and may exceed this level
Security monitoring network is a pure master - slave DP
network system, the use of with Profi-Bus technology drives
can be realized Profi-Bus-based security technology [11].
This system uses secure input / output module to drive the
implementation motor, in order to ensure the security of data
transmission. Without changing the software, equipment
operate in the VI-paragraph, and the level of security can get
to be SIL2.
E. Testing of system software
Software system testing is essential for the normal
operation of the software. In order to achieve the on-site
installation and testing of monitoring network system, we
have developed a communication simulation program
testing procedures. By accepting the instructions from Host
computer, the module receives operating command from
control procedures. After the operator input directive,
laboratory simulation system will respond to operation. If
the state of communication is off-line, the operator can also
input commands manually. No matter the hardware and
software testing, or laboratory tests, the results were normal
and the stability of the system is very good.

� Monitor the host Return

I»
V. MONITORING SOFTWARE DESIGN
[fl
ct
.... Software architecture designed to reduce software
Control the SCM
--l '"C Return engineering design and realization of the complexity of the
I» r
[fl
'" n software can increase the reliability of the system.
[fl
5' 0 Detection of Return Preparation of the entire electric locomotive safety
:T
;:;: (1)
0.. monitoring network operating system software architecture
E t: Collect data Return
N' � design include: master / slave network configuration
� ....
"0 modules, non-contact ID card operations management
o· ....
:::l 0
Store the data Return
(JQ
module, and from the station PLC SCM system data
....
I» exchange module, the implementation of Station PLC motor
3 Deal with the error Return
control module, and several main modules design.

Figure I. Multi-task scheduling functions
By the master PLC of the interrupt mechanism, we
realized multi-task scheduling. The PLC timer is used as
A. Platform--KingView
Host monitoring software used King view 6.52 [10, 11]
developments, running on windows XP platform. In the
configuration software options, analyzed and compared by
using a Beijing-controlled automation software technology

clock management, and the timer will generate time blocks, company Kingview Configuration software. It is simple and
then the system allocate them to different task. According to flexible operation of the visual interface, real-time, a good
interrupt source of PLC, we can decide the task priority. parallel processing capability, rich multimedia vivid screen,
When the switch is on, the scheduling form will be a sound security mechanism, alarm functions, and more
initialized according to the default. Besides, we can also diversification benefits.
modify the scheduling form by monitoring the system After the adoption of a reasonable configuration,
information, and then realize real-time data processing of the automatic control mode in the mainframe computer in the
entire system. visual display is convenient to observe the entire process of
locomotive maintenance, real-time monitoring and control.
D. Security of monitoring network data [8, 9]
So in the process of introducing industrial control
As a master - slave network system, the security
configuration software is essential, it makes more intuitive
monitoring network is based on PROFIBUS-DP, the
control, and more secure. In the realization of the following
requirements to both real-time and data security is high.
methods to focus on four aspects: Graphics, interface
Isolating switch malfunction may lead the equipment to

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settings, rendering various graphical symbols; Achieve configuration, came up with relevant network
graphics and control interface between the physical state of communication protocol, and conducted a more detailed
the corresponding settings; Dynamically generated database, analysis on real-time data processing and security [12, 13].
historical records, statements, etc.; Realization of real-time Finally, we do a relatively complete functional testing on the
monitoring capabilities. entire software system, and obtained the good results.

B. System configuration REFERENCES

Safety monitoring network systems in order to achieve
the various modules and PC data exchange between related
to the communication are: Main Station PLC and PC
configuration software communications from the station
PLC and non-contact between the IC card communication
from the station PLC and the communication between the
microcontrollers. Main Station PLC (S7-315-2DP) and PC
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Mi, Wang Jian.
[2) Yan-min Huang. The Oesigen of the Servicing Work Safety
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(3) Ming-sheng Ma. Electric locomotive (EMUs) and reorganization of
the operational safety of joint control of computer systems research
practice (0). Central South University, 2005.

configuration software communications only in
Kingview6.52-definition equipment selection PLC
Siemens / S7-300 Series Profibus-DP, and
Kingview6.52 in the data dictionary PLC defined as
variables and the corresponding I / 0 variables.
PLC communication with the main station, the main
station selection S7-300 PLC, SIMATIC S7-300 Series
PLC agreement MPI support agreement with Siemens S7-
300 Series PLC communications in Monitoring Software.
Need your computer to install or use MPI PC-Card
Adapter.
VI. CONCLUSION
Considering the actual situation and the use requirements
of electric locomotive, we designed the safety monitoring
network system. The technical problems of traditional
manual operation, such as low work efficiency, security risks
and so on, have all been solved. By using the PROFIBUS­
DP bus technology, we realized self-locking and linkage
control to Electric Locomotive Operation Readiness, and put
forward a new operational procedure, which is different from
manual operation. The duties of custody are transferred to
the attendant, so we can reduce the positions of staff on-site.
We discussed about the hardware selection and slave
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