The present invention will be further described below in conjunction with the drawings and specific embodiments of the specification.
Such asfigure 1 withfigure 2As shown, the intelligent manufacturing control system for the entire solar cell plant of this embodiment includes a control unit, an AGV unit, and multiple control stations. Each control station corresponds to a different process section, namely the texturing control station, the annealing control station, and the second Sub-cleaning control site, diffusion control site, Maiya control site, PECVD control site and silk screen control site; each control site is an independent control site with independent power supply, and each control site is linked to each other and is connected to the control unit to form Ring network: The AGV unit is connected to the ring network, and the control unit controls the AGV trolley in the AGV unit to take and feed materials between each process section. The ring network refers to that the entire communication system is connected to each other to form a circle. When there is a disconnection, the entire network is also unblocked, which reduces the failure rate and increases the Uptime time.
In this embodiment, the hardware composition of each control station includes remote modules, remote IO modules, inverters, on-site IO modules, touch screens, robot systems, and security systems; remote IO modules are used to interact with process equipment in various art segments ; The field IO module is used for the interaction of the cylinder and sensor signals of its own system; the touch screen is used as the man-machine interface and fault signal processing, which can independently control the automatic, manual, stop and fault handling of the control station, and feedback the running status of the control station, Output and fault information, while displaying the position, status and task number of AGV vehicles; the frequency converter is used as the transmission system to transmit the flower basket to the work position; the safety system includes emergency stop and safety door to prevent the occurrence of safety accidents.
In this embodiment, each control station is connected through a Profinet communication network cable; each control station is connected to a six-axis robot or a racking system, the communication with the robot uses Profinet, the racking system uses TCP/IP protocol, and the control unit uses tasks The way of scheduling controls the robot or the rack manipulator.
In this embodiment, the manipulator or truss manipulator is equipped with an RFID code reader, and each flower basket is equipped with a code carrier. The manipulator or truss manipulator grabs each pair of flower baskets once, and transmits the flower basket information to the control unit through the code reader. The information is sent to the MES system through the control unit for traceability.
In this embodiment, each control station is installed nearby the corresponding process section.
In this embodiment, the IO signal of the process equipment of each process section is connected to each control station in the form of a prefabricated line.
In this embodiment, the control unit and each control station have independent control instructions, and each control instruction corresponds to an execution mechanism; the AGV scheduling, robot scheduling, and process equipment docking procedures of the AGV unit are the same, and they are written into common blocks to directly transfer.
The present invention performs independent control in different process sections, based on hardware, and realized through software control; among them, the strong current on the hardware is powered by sub-regions to prevent over-current in one of the stations and cause power failure, affecting the normal operation of other stations ; Distributed installation of the hardware configuration is conducive to the nearby access to field sensor signals and reduces wiring; the ring-type networking on the network prevents the system from being disconnected and affecting the normal operation of other stations; the software is combined with the hardware design, Different regions are defined independently to realize sub-regional control of process sections.
The above control system will be described in detail below in conjunction with a complete specific embodiment:
The entire plant's intelligent manufacturing control system is huge, and the entire control system is composed of robots, AGVs, racks, inverters, cylinders, sensors, etc. Among them, there are 15 robots, 24 AGVs, 8 racks, more than 100 cylinders, and more than 2000 sensor signals.
Each process section is composed of several process equipments. The process section is designed as an independent control station. The codes in the figure ①②③④⑤⑥⑦⑧ are independent control stations. Each independent control station has independent automatic, manual, reset, and Control modes such as alarms. In order to simplify the wiring, reduce the number of wiring, and speed up the on-site construction speed, all IO signals enter the on-site module in the form of prefabricated wires, and the control cabinet is installed near the process section.
The entire system is centered around Siemens PLC. The network is based on Siemens Profinet and adopts a ring network design. All remote electrical cabinet sites are linked with each other, and remote sites are also linked with ①. The advantage of the ring network is to prevent the network cable from falling off and the network is disconnected. , Or a power failure occurs at one of the sites, other sites can also operate normally, complementing the impact. Such asfigure 1 The codes in ①②③④⑤⑥⑦⑧ are independent control sites, each site is independently powered, which is equivalent to a small control system. among themfigure 1 Each remote electrical cabinet in refers to the control site above.
The hardware composition of the control station includes Siemens remote module, remote IO module, inverter, field IO module, touch screen, robot system (rack system) and safety system. The remote IO module is mainly used for signal interaction with the process equipment; the field IO module is used for the interaction of the cylinder and sensor signals of the own system; the touch screen is used as the man-machine interface and fault signal processing. The frequency converter is used as the transmission system to transmit the flower basket to the work position. The safety system mainly includes emergency stop, safety door, etc., to prevent the occurrence of safety accidents. Each control station is connected to a six-axis robot or a racking system, and the communication with the robot adopts Profinet, and the racking system adopts TCP/IP protocol. The PLC uses task scheduling to control the robot or the racking manipulator, and each station uses the Profinet communication network cable. Make a connection. The touch screen of each station can independently control the automatic, manual, stop and fault handling of the station. The touch screen can implement feedback on the running status, output, and fault information of the station. In addition, the position, status, and task number of the AGV vehicles will be Display on the touch screen.
The system connects the AGV server ⑨ into the ring network, and the PLC uses task scheduling to send the task number to the AGV trolley server. After receiving the task number, the AGV trolley server will assign the trolley closest to the task point to fetch and feed the material. Because it is dispatched by the whole plant, the route of the trolley will be planned in advance in the system. During the operation, the trolley will avoid the trolley and pedestrians to prevent traffic jams from occurring and cause the system to break down.
The unloading flower basket of the process equipment is placed in a specific buffer station through the robot system of each control station. The AGV scheduling system controls the AGV trolley to transport the flower basket to the loading position of the next process equipment. At the same time, the robot gripper is equipped with RFID , Can trace the flow direction of the flower basket very well. This method can well solve the problems of low production efficiency and difficult troubleshooting, reduce the manufacturer's management cost, and bring obvious economic benefits to the manufacturer.
The manipulator or truss manipulator is equipped with an RFID code reader, and each flower basket is equipped with a code carrier. The manipulator or truss manipulator will transmit the flower basket information to the PLC through the code reader, and then send the information to the MES system solves the problem of traceability.
The software development is divided into upper computer system and lower computer system. The upper and lower computers are connected with each other, such asfigure 2Shown. ①②③④⑤⑥⑦⑧ The control of the area is independent, so there are eight sets of independent control instructions in the software, which do not affect each other. Among them, there is interlock protection in the software. Through the feedback signal, the parts that interfere with the machinery are not allowed to be operated, or the software is not executed after the operation.
The entire control system is compatible with the hardware design. Each process segment is composed of AGV, robots, process equipment and its own system. The program of its own system needs to be written separately according to the actuator, and the program of the actuator is different. However, AGV scheduling, robot scheduling, and process equipment docking procedures are basically the same. They are written into common blocks and called directly.
In the initial state of the equipment, the process section area can be started with one key. Of course, if a fault occurs in a certain process section area, the fault area mode will jump out of automatic and enter the fault state. At the same time, the program will redistribute the AGV route to prevent AGV route congestion. After the fault is processed, restart the process section area and enter the automatic Mode to restore the AGV route.
For the independent control system of the non-process section, a failure or shutdown of a process section will affect the operation of the entire system and even cause the system to be paralyzed. The power supply and independent program control in the process section of the present invention does not have the above problems. The current process section area has problems, which will only affect the current process section area and the normal operation of other process section areas. The system is segmented in hardware and software. control. Among them, the control of the sub-process section area during the debugging process has great advantages. The equipment is assembled in a targeted manner during assembly. After a certain process section area can be assembled by focusing on manpower and material resources, the process section area can start hardware and Software debugging can test the reliability of the hardware and the logic of the software. After the assembly and testing of each process section area is completed, the signal connection and software interlock protection of each process section area can be done to test the overall performance of the equipment, which greatly improves the test efficiency and saves time. In addition, it is easier to do standardized design in both hardware and software for sub-regional control of the process section.
Specifically, in the present invention, the area control by process section is: the whole plant is divided into several areas according to the process structure, such as: texturing, annealing, secondary cleaning, diffusion, plate PECVD, tubular PECVD, laser screen printing and other processes . These seven processes constitute a complete control system. . These seven process stations can operate independently and automatically, and the working status of each process section area does not affect each other.
The above are only the preferred embodiments of the present invention, and the protection scope of the present invention is not limited to the above-mentioned embodiments. All technical solutions under the idea of the present invention belong to the protection scope of the present invention. It should be noted that for those of ordinary skill in the art, several improvements and modifications without departing from the principle of the present invention should be regarded as the protection scope of the present invention.