Data acquisition and automatic control system of carbon filament winding machine

Abstract

The invention discloses a data acquisition and automatic control system for a carbon filament collecting machine, which adopts a modular design and comprises a main control module for connecting and controlling other modules, and a plurality of functional modules such as a display and operation interface module, a real-time monitoring module, a fault detection and early warning module, a shredding control module, a label printing module and a multi-device adaptation module. The system is realized on the basis of an MVVM (Model-View-ViewModel) architecture of a WPF (Wireless Power Function), and has good expansibility and maintainability. The system uses the SQL Server as a database, and the EFCore performs data operation, so that data access is more efficient and flexible. Meanwhile, the system supports parallel operation of a plurality of wire collecting machines, each wire collecting machine is managed through an independent thread, concurrence conflicts are avoided, PLC data can be obtained in real time, wire collecting machine equipment can be dynamically managed, and a proper label template is automatically selected for printing according to batch information.

Description

Technical Field

[0001] The invention relates to the technical field of carbon filament automatic control systems, and in particular to a data acquisition and automatic control system for a carbon filament winder. Background Art

[0002] In industrial automated production lines, wire winders are widely used to wind fiber materials or linear objects onto reels. Existing wire winder systems usually rely on mechanical operations or simple automation equipment. Operators manually monitor the number of meters by observing the counter on the wire winder or by physical measurement. When the predetermined number of meters is reached, the operator manually stops the wire winding, performs the wire cutting operation, and manually prints the label.

[0003] Specifically, the solution of the prior art is to achieve meter monitoring and simple automatic wire cutting operations through the mechanical counter and PLC system of the wire collecting machine. The specific process is that the operator first sets the wire cutting meter threshold, and when the counter reaches the set number of meters, the PLC triggers the wire cutting action. However, this solution is limited to the control of a single device, and multiple devices need to update the program multiple times, and after the wire cutting is completed, manual operation is required to complete the label printing. At the same time, it is difficult for traditional wire collecting systems to flexibly switch label templates according to batch information, and it is impossible to dynamically add new wire collecting equipment. There is also a lack of real-time recording and analysis of the wire ingot length data during the wire collecting process.

[0004] In summary, the problems existing in the prior art are:

[0005] Lack of automation: Existing technology still relies on manual operation, especially in the label printing process after shredding, which involves a lot of manual intervention and is cumbersome.

[0006] Insufficient precision: Due to certain errors in manual monitoring and operation by operators, the wire collection and cutting accuracy are insufficient.

[0007] Single device adaptation: Most existing technologies are designed for a single device, and each device needs to refresh the program repeatedly. The system lacks versatility and scalability, and it is difficult to adapt to the industrial environment of multiple devices. Summary of the invention

[0008] The purpose of the present invention is to solve the problems in the prior art and provide a data acquisition and automatic control system for a carbon filament receiving machine, which can obtain PLC data in real time, dynamically manage receiving machine equipment, and automatically select a suitable label template for printing according to batch information. In addition, the system has flexible scalability, and users can add receiving equipment by modifying the JSON file, and can record and display the ingot length curve in real time.

[0009] In order to achieve the above object, the technical solution of the present invention is:

[0010] A data acquisition and automatic control system for a carbon filament receiving machine, comprising:

[0011] Main control module, with built-in main system, used to connect and control other modules;

[0012] Display and operation interface module, equipped with display device, provides intuitive operation interface, through which users can set various parameters;

[0013] The real-time monitoring module is connected to the PLC device to obtain the working status data of the carbon filament winder in real time, including the real-time length of the spindle, winder speed, tension and other parameters, and display and update this information in real time on the display interface;

[0014] The fault detection and early warning module, through the fault detection algorithm integrated in the main control module, can detect problems in time when the spindle length changes too quickly, the winding speed is abnormal, or the PLC signal is interrupted. The system will automatically issue an early warning according to the set fault threshold to prompt the operator to check;

[0015] The wire cutting control module, the main control module controls the wire cutting device to perform the wire cutting operation according to the preset meter threshold value when the carbon wire length reaches the set value; when the wire collecting machine receives the wire cutting signal, the system will save the current wire ingot information to the database;

[0016] Label printing module, after the wire cutting control module controls the wire cutting, the system automatically generates wire ingot labels according to the production batch, and realizes automatic printing by connecting with the printer;

[0017] The multi-device adaptation module has a standardized system interface and is compatible with different numbers of wire collectors and various types of printers, ensuring the universality and scalability of the system.

[0018] Preferably, a multi-device collaborative work module is also included, which uses WPF's multi-threading technology to display the status of multiple wire collecting machines in parallel in the operation interface, and users can control each device independently.

[0019] Preferably, it also includes an account login and authority management module. The system supports account and password login, and users enter different function interfaces according to their identities.

[0020] Preferably, the fault detection and early warning module includes an intelligent alarm system and a remote monitoring system, the intelligent alarm system includes a visual alarm system and an auditory alarm system, and the remote monitoring system sends the real-time status and early warning information of the system to a remote terminal via a network.

[0021] Preferably, it also includes a data management module, which records the data acquired by the real-time monitoring module, stores the data in a database for a long time, and provides data query, analysis and export functions.

[0022] Preferably, in the label printing module, the system reads the ingot information from the queue in the database in sequence for printing, thereby avoiding printing confusion or label duplication.

[0023] Preferably, it also includes a report generation module, and the main control module automatically generates reports according to a set period and exports PDF or Excel format files for external use.

[0024] Preferably, it also includes a recipe and process parameter management module, which defines and saves specific wire collection process parameters according to different types of carbon fiber products. The system can control the management and switching of multiple recipes and can automatically apply corresponding parameter settings according to the production requirements of different products.

[0025] The beneficial effects of the present invention are:

[0026] Efficient data processing: The combination of EFCore and SQL Server enables efficient data access, supports multi-device parallel operations, and avoids data bottlenecks.

[0027] Efficient automation: Compared with the existing technology, the present invention reduces the dependence on manual operation through full-automatic control and significantly improves production efficiency.

[0028] Intelligent early warning and fault detection: Through the automated fault detection and early warning mechanism, the burden of manual monitoring is reduced and the stability of the production process is ensured.

[0029] Wide applicability: Flexible equipment expansion mode, wire collecting equipment can be added without modifying the code. By designing a universal interface, the present invention can be applied to a variety of equipment, has strong versatility and expansibility, and is adaptable to different industrial environments.

[0030] High-precision monitoring and stable operation: By using real-time data acquisition and processing technology, the present invention improves the accuracy of meter monitoring and slicing operations, ensuring product consistency and quality. The WPF framework is adopted, and multiple threads are used to collect data simultaneously. For thousands of signal points, the collection frequency can be achieved within 1s, ensuring real-time performance.

[0031] Dynamic interface adjustment: account and password login and multi-identity permission management have been added, which is no longer just a simple full-function opening. The system can display different function interfaces according to user identity, providing higher security and flexibility.

[0032] Queue mechanism: Through the database queue processing and scheduling mechanism, efficient management of multiple wire collecting machines in concurrent scenarios is achieved, conflicts in printing tasks are avoided, and the stability and reliability of the system are improved.

[0033] Real-time data dynamic display: Compared with the traditional wire collecting machine system, the present invention realizes real-time dynamic display of production parameters through WPF, which improves the operator's response speed.

[0034] Rich reporting and data management functions: The system supports big data storage and analysis, can automatically generate detailed production reports, and supports the generation and printing of custom labels. DETAILED DESCRIPTION

[0035] In order to enable those skilled in the art to better understand the present invention, the present invention is further described in detail below in conjunction with the implementation modes.

[0036] A data acquisition and automatic control system for a carbon filament receiving machine, comprising:

[0037] The main control module has a built-in main system, which is used to connect and control the remaining modules. The overall system adopts a modular design and is implemented based on the MVVM (Model-View-ViewModel) architecture of WPF, which has good scalability and maintainability. The system uses SQLServer as the database and EFCore for data operations, making data access more efficient and flexible. At the same time, the system supports parallel operation of multiple wire collectors, and each wire collector is managed by an independent thread to avoid concurrency conflicts. The system communicates data with the carbon wire collector through PLC and reads real-time data on the PLC, such as ingot length, wire cutting signal, etc. In addition, the system also adopts dependency injection and modular plug-in system to facilitate future functional expansion according to different user needs. Through modular design, users can add or remove functional modules according to their own production needs without affecting the overall performance of the system.

[0038] The display and operation interface module is equipped with a display device and provides an intuitive operation interface. Users can set various parameters through the interface and view the system's operating status, real-time meter curve, etc. in real time; the system records the ingot length data in real time, generates a length change curve, and stores it in the SQL Server database for subsequent analysis and tracing.

[0039] The real-time monitoring module, connected to the PLC device, can obtain the working status data of the carbon filament winder in real time, including the real-time length of the spindle, winder speed, tension and other parameters, and display and update this information in real time on the display interface. Through the animation and data binding technology of WPF, this information can be displayed and updated in real time on the interface to intuitively reflect the production status. In addition, the system automatically records historical production data and displays the changing trends of parameters such as spindle length and production speed in the form of charts to help operators better monitor production dynamics. The system uses interactive chart controls, and users can zoom in and out on specific time period data.

[0040] The fault detection and early warning module, through the fault detection algorithm integrated in the main control module, cooperates with the connected wire collecting machine and the sensors on the wire collecting machine, can detect problems in time when the spindle length changes too quickly, the wire collecting speed is abnormal, or the PLC signal is interrupted. The system will automatically issue an early warning according to the set fault threshold, prompting the operator to check. The fault detection and early warning module includes an intelligent alarm system and a remote monitoring system. The intelligent alarm system includes a visual alarm system and an auditory alarm system. The visual alarm system includes alarm lights of different colors, pop-up prompts on the operation interface, etc.; the auditory alarm system includes an alarm buzzer connected to the main control module, or other alarm sounds emitted by the system. The remote monitoring system sends the real-time status and early warning information of the system to the remote terminal through the network, so that the operator can monitor and handle problems without going to the site in person.

[0041] The wire cutting control module and the main control module are connected to the wire cutting device on the wire collecting machine. During the wire collecting process, the system can automatically trigger the wire cutting operation according to the preset meter threshold. By connecting with the PLC signal, it can ensure that when the carbon wire length reaches the set value, the wire cutting device immediately performs the wire cutting operation to ensure the continuity and accuracy of production. In addition, the upcoming wire cutting point is displayed in the form of animation on the interface to help the operator prepare in advance. It can also be connected and utilized by the machine vision system to monitor the wire cutting position and accuracy in real time, and automatically adjust the cutter position when deviations are detected to ensure that the accuracy of each wire cutting is kept within the set tolerance range. When the wire collecting machine receives the wire cutting signal, the system will save the current wire ingot information to the database.

[0042] After the wire cutting is completed by the label printing module and the wire cutting control module, the system can automatically generate wire ingot labels according to the production batch, length, tension and other data, and realize automatic printing by docking with the printer. The label template can be customized and supports barcode or QR code generation, which is convenient for subsequent inventory management and traceability. At the same time, according to the set level range, different levels of printing information are triggered to perform multi-condition and multi-template printing. In the label printing module, the system reads the wire ingot information from the queue in the database in sequence for printing to avoid printing confusion or label duplication.

[0043] Multi-device adaptation module, the main control module has a standardized system interface. Users can add wire collection devices by modifying the JSON file. It is compatible with different numbers of wire collection machines and various types of printers, ensuring the universality and scalability of the system.

[0044] The system also includes a multi-device collaborative work module. Through WPF's multi-threading technology, the status of multiple wire collecting machines is displayed in parallel in the operation interface. Users can control each device independently and automatically allocate tasks for multiple devices according to production needs to ensure seamless connection between different devices. The system also includes a data management module, which records the data obtained by the real-time monitoring module, stores the data in the database for a long time, and provides data query, analysis and export functions.

[0045] The system also includes a report generation module. The main control module automatically generates production reports according to the set cycle (such as daily, weekly, and monthly). The reports include total spindle production, quality parameters, and wire cutting records. Operators can customize report templates and export PDF or Excel format files for external use. The system also includes a recipe and process parameter management module. According to different types of carbon fiber products, specific wire collection process parameters are defined and saved. The system can control the management and switching of multiple recipes, and can automatically apply corresponding parameter settings according to the production requirements of different products.

[0046] The system also includes account login and permission management modules. The system supports account and password login, and users can enter different function interfaces according to their identities.

[0047] Visitor status: Visitors can only view limited information and cannot operate or modify data.

[0048] User identity: Users can view ingot information, generate labels and view history, control wire cutting, modify label templates, etc.

[0049] Administrator: The administrator has the highest authority and can configure devices, modify label templates, and manage all data.

[0050] The interface display of different identities is dynamically adjusted according to permissions. The system authenticates identities through account verification and provides exclusive operation interfaces for different users.

[0051] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A data acquisition and automation control system for a carbon filament receiving machine, characterized in that: include Main control module, with built-in main system, used to connect and control other modules; Display and operation interface module, equipped with display device, provides intuitive operation interface, through which users can set various parameters; The real-time monitoring module is connected to the PLC device to obtain the working status data of the carbon filament winder in real time, including the real-time length of the spindle, winder speed, tension and other parameters, and display and update this information in real time on the display interface; The fault detection and early warning module, through the fault detection algorithm integrated in the main control module, can detect problems in time when the spindle length changes too quickly, the winding speed is abnormal, or the PLC signal is interrupted. The system will automatically issue an early warning according to the set fault threshold to prompt the operator to check; The wire cutting control module, the main control module controls the wire cutting device to perform the wire cutting operation according to the preset meter threshold value when the carbon wire length reaches the set value; when the wire collecting machine receives the wire cutting signal, the system will save the current wire ingot information to the database; Label printing module, after the wire cutting control module controls the wire cutting, the system automatically generates wire ingot labels according to the production batch, and realizes automatic printing by connecting with the printer; The multi-device adaptation module has a standardized system interface and is compatible with different numbers of wire collectors and various types of printers, ensuring the universality and scalability of the system.

2. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1, characterized in that: It also includes a multi-device collaborative work module. Through WPF's multi-threading technology, the status of multiple wire collecting machines can be displayed in parallel in the operation interface, and users can control each device independently.

3. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1 is characterized in that: It also includes account login and permission management modules. The system supports account and password login, and users can enter different function interfaces according to their identities.

4. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1, characterized in that: The fault detection and early warning module includes an intelligent alarm system and a remote monitoring system. The intelligent alarm system includes a visual alarm system and an auditory alarm system. The remote monitoring system sends the real-time status and early warning information of the system to a remote terminal through a network.

5. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1, characterized in that: It also includes a data management module, which records the data obtained by the real-time monitoring module, stores the data in a database for a long time, and provides data query, analysis and export functions.

6. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1, characterized in that: In the label printing module, the system reads the ingot information from the queue in the database in sequence for printing, thereby avoiding printing confusion or label duplication.

7. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1, characterized in that: It also includes a report generation module. The main control module automatically generates reports according to the set period and exports them in PDF or Excel format for external use.

8. The data acquisition and automatic control system for the carbon filament receiving machine according to claim 1, characterized in that: It also includes a recipe and process parameter management module, which defines and saves specific wire-collecting process parameters according to different types of carbon fiber products. The system can control the management and switching of multiple recipes, and automatically apply corresponding parameter settings according to the production requirements of different products.