Black lamp factory production line safety control method

Abstract

The invention discloses a black light factory production line safety control method based on multi-means fusion control. A complete production line control system is built for a corresponding black light factory production line, environmental factors and operation parameters and normal thresholds of all equipment are counted, corresponding appropriate sensors are selected for collection and real-time monitoring, redundancy is increased, and stability and reliability are improved. And corresponding sensors are added for position judgment and operation state monitoring according to the characteristics and operation processes of the special equipment. The development management system collects and records data information such as equipment working conditions in real time, carries out statistics and management on the running state of the equipment, carries out mistake proofing and guidance on manual operation and production, carries out periodic reminding on use and maintenance of related measuring instruments, fire-fighting facilities and chemicals of a production line, and pushes early warning, health examination and predictive maintenance. The management system and the control system perform data fusion interaction to comprehensively control safe and reliable operation of the production line. In combination with an actual production process flow of the production line, multi-combination fusion monitoring and control are carried out on the safety of the production line from two aspects of hardware and software.

Description

Technical Field

[0001] The present invention belongs to the field of production line control, and more specifically, it is a safety control method for a production line in a lights-out factory. Background Art

[0002] Currently, the production lines in lights-out factories have low levels of intelligence and informatization, a large number of operators, high error rates, and high error rates of equipment failure rates. Many pieces of information regarding safety-critical products, equipment, workshops, etc. are not effectively collected, monitored, managed, and warned in real time, resulting in prominent safety problems.

[0003] At present, the construction of production lines in lights-out factories in various industries is accelerating, and the safety and stability of production lines are very important for the safe production of lights-out factories.

[0004] In order to achieve safe production of the production line in a lights-out factory, it is necessary to improve the control technology of the production line to ensure safety, stability, and reliability. Therefore, a safety control method for a production line in a lights-out factory that integrates multiple means of control is needed. Summary of the Invention

[0005] To solve the above technical problems, the present invention provides a safety control method for a production line in a lights-out factory. In view of the high complexity of the production line in a lights-out factory, combined with the actual production process flow of the production line, multi-combination fusion monitoring and control of the safety of the production line are carried out from both hardware and software aspects.

[0006] The technical solution adopted by the present invention to achieve the above object is as follows:

[0007] A safety control method for a production line in a lights-out factory, comprising the following steps:

[0008] 1) Collect different parameters during the operation of dedicated machines on the production line through different sensors, and determine whether there are hardware abnormalities in the dedicated machines by setting thresholds;

[0009] 2) For the production line in a lights-out factory, develop a management system, collect the operating condition data of dedicated machines during operation through the management system, and develop different functions of the management system to achieve real-time monitoring during the operation of the production line;

[0010] 3) The management system controls each dedicated machine on the production line based on the monitoring data to achieve the safe operation of the production line.

[0011] The step 1) includes the following steps:

[0012] 1.1) Statistically analyze the environmental factors for the production line in a lights-out factory, and set the normal operation thresholds based on the operating parameters of each dedicated machine;

[0013] 1.2) Select the sensors corresponding to the dedicated machines based on the environmental factors for real-time monitoring and collection;

[0014] 1.3) Based on the characteristics and operating processes of each special machine equipment, judge its position and monitor its operating status.

[0015] The specific steps of step 1.3) are as follows:

[0016] In view of the situation that each motor in the special machine needs to operate at multiple positions during the production process, signal detection is added at key positions including the standby position, the key assembly position of the working station, and the grasping position, and double verification is carried out with the position feedback of the motor encoder.

[0017] Step 2) includes the following steps:

[0018] 2.1) The development management system collects and records the equipment working condition information in real time, and pushes notifications for early warning, health check, and predictive maintenance;

[0019] 2.2) The management system statistically manages the operating status of the equipment;

[0020] 2.3) The management system gives periodic reminders for the relevant measuring instruments, fire protection facilities, and use and maintenance of chemical products on the production line.

[0021] The specific steps of step 2.2) are as follows:

[0022] 2.2.1) The management system develops a fault query function to record the alarm information that appears in all special machine equipment and working stations on the production line;

[0023] 2.2.2) The management system develops a calibration reminder function, and gives a reminder when calibration is required based on the parts, cycles, and requirements that need to be calibrated for the special machine equipment;

[0024] 2.2.3) The management system develops a maintenance reminder function, sets the parts, maintenance procedures, and cycles that the equipment needs to be maintained, and gives a reminder when it expires;

[0025] 2.2.4) The management system develops a maintenance record unit function to record the faults encountered in the workshop each time and the treatment methods for various situations to form a log, and to make comparisons and situation description records for each optimization and upgrade;

[0026] 2.2.5) The management system develops a production change reminder function, sets the tooling that needs to be replaced when assembling different products, and gives a reminder when replacement is required.

[0027] The specific steps of step 2.3) are as follows:

[0028] 2.3.1) Develop a metrological instrument appraisal reminder and recording system for the management system. Enter the appraisal cycles and dates of all instruments, meters, sensors on the equipment, as well as the metrological instruments used in production. Remind the management personnel to calibrate before the due date, and enter the new date after calibration.

[0029] 2.3.2) Develop a fire protection facility inspection reminder function for the management system. Enter the shelf life, inspection cycles and dates of fire extinguishers at each part of the production line, the inspection cycles and dates of fire hydrants at each part, and the inspection cycles and dates of the pressure of the fire sprinkler system at each part. Remind the responsible person to inspect or replace before the due date, and enter the new date after inspection or replacement.

[0030] 2.3.3) Develop a due date reminder function for the management system. Enter the production dates and shelf lives of the chemical products used in production. Remind the responsible person to handle before the due date.

[0031] The present invention has the following beneficial effects and advantages:

[0032] 1. The present invention provides an industry demonstration example for the construction of the control system of the typical black light factory production line, which can be widely promoted and applied in the production lines of various fields for the reference and learning of the construction units of each black light factory production line.

[0033] 2. The present invention provides a safety control strategy for environmental monitoring of the black light factory production line. By setting multi-redundant sensors to statistically monitor each environmental factor in real time and give timely warnings, the accuracy of monitoring and the safety and reliability of the production line are improved.

[0034] 3. The present invention provides a safety control strategy for the operation of special machines in the black light factory production line. By setting sensors to detect the proper movement of the equipment in the special machine and increasing the reliability of each position during equipment operation, the operation safety and reliability of the special machine equipment and the safety of the production line operation are greatly improved.

[0035] 4. The present invention provides a demonstration example of the integrated control and management of the all-round control system and management system for the construction of the intelligent black light factory production line. It comprehensively manages the production line equipment, production process, production personnel, production raw materials, workshop supporting equipment, etc., realizes the full-process, all-round and full-coverage management of all aspects related to product production in the workshop, prevents errors and provides full-process guidance for manual operation and production, and manages all possible errors and safety problems in a full-coverage manner, greatly improving the safety of the entire process, all aspects and all-round of the black light factory production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 is the overall block diagram of the control system of the black light factory production line of the present invention;

[0037] Figure 2It is the flowchart of the statistical, monitoring and judgment of environmental factors in the production line of the lights-out factory of the present invention;

[0038] Figure 3 It is the flowchart of the characteristic status and acquisition judgment of special machines in the production line of the lights-out factory of the present invention;

[0039] Figure 4 It is the flowchart of the production line management system of the lights-out factory of the present invention for collecting, recording and managing production line data information and guiding production line production. Specific implementation manners

[0040] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0041] This embodiment discloses a safety control system solution for a lights-out factory. It mainly consists of five parts: the construction of the production line control system, the statistical, monitoring and acquisition of environmental factors, the monitoring and acquisition of the characteristic status of special machines, the comprehensive acquisition and management of the management system, and the integrated safety control of the fusion of the control system and the management system.

[0042] It mainly includes the following steps:

[0043] Step S1: Build a complete production line control system for the corresponding production line of the lights-out factory;

[0044] Step S2: Statistically analyze in detail the environmental factors, the operating parameters and normal thresholds of each device for the corresponding production line of the lights-out factory;

[0045] Step S3: Select appropriate sensors for the corresponding environmental factors for real-time monitoring, and consider adding redundancy to improve stability and reliability;

[0046] Step S4: According to the characteristics and operating processes of each special machine device, add corresponding sensors for position judgment and operating status monitoring;

[0047] Step S5: Develop a management system for the production line of the lights-out factory to collect and record data information such as equipment working conditions in real time, and push early warnings, health checks and predictive maintenance;

[0048] Step S6: The management system statistically analyzes and manages the operating status of the equipment, including equipment operating status records, maintenance records, maintenance reminder, calibration reminder, confirmation of tooling replacement before production change, etc., to prevent errors and provide full-process guidance for manual operations and production;

[0049] Step S7: The management system periodically reminds of the use and maintenance of relevant measuring instruments, fire protection facilities and chemical products on the production line;

[0050] Step S8: The management system and the control system perform data fusion and interaction to comprehensively control the safe and reliable operation of the production line;

[0051] Such asFigure 1 , step S1 includes the following steps:

[0052] Step S1.1: According to the production line scale and process requirements, determine the types and quantities of software and hardware required for the control system. According to the production line scale and process requirements of a certain production line, this system uses a programmable logic controller with a fault self-diagnosis function as the remote central controller, including a material management system, an on-line non-destructive testing system, and isolators and intrinsically safe detection switches that meet explosion-proof requirements. The system applies advanced upper industrial control computer, PLC integration technology and safety technology, adopts mature field bus technology to realize the integration of multiple special machines and multiple systems, optimizes the information acquisition scheme, and realizes a distributed control system for multi-sensor information fusion;

[0053] Step S1.2: The control system adopts a master-slave distributed control mode, including an upper computer and a lower computer. The upper computer includes two industrial computers (one for monitoring the operation status of on-site equipment and one for information application services), and two database servers (one for storing and applying production process data and one for data backup and accessing external ports such as factory-level ERP). They are placed in the remote central control room. Through the upper computer, remote monitoring and parameter setting of the production line and each special machine can be realized, and various parameter information can be saved at the same time, including the operation status information of each special machine, workpiece information, operator information, etc., providing information resources for the ERP information management system;

[0054] Step S1.3: The lower computer consists of a programmable logic controller (PLC), supplemented by remote I / O slave stations, two-dimensional code reading controllers, robot controllers and corresponding special machine controllers. The system uses a PLC of the S7-1500 series of Siemens Company in Germany as the control core, which is placed in the central control room or the explosion-proof control box at the production site to realize the collaborative logic control of each on-site special machine. Each special machine uses a Siemens remote I / O slave station ET200 or S7-1200PLC as the remote control unit, which is installed near the remote special machine and communicates with the main control PLC through the Profinet bus to realize the real-time interaction of the operation information of each special machine slave station and the command information of the main control PLC;

[0055] Step S1.4: Through the Profinet bus, the interconnection of each special machine control system is realized. Through software programming, functions such as production line process control, network coordination, fault diagnosis, information processing and early warning are realized. Relatively independent control units such as logistics, assembly, detection and inkjet coding are effectively connected to realize the information exchange of each special machine and the collaborative work of each component of the system, providing a data basis for the ERP system and realizing an intrinsically safe control system.

[0056] Such as Figure 2 and Figure 3 , step S2 includes the following steps:

[0057] Step S2.1: Statistically analyze environmental factors of the production line, such as air pressure, temperature, humidity, noise, etc.;

[0058] Step S2.2: According to the product characteristic requirements and the requirements of the production line equipment, determine the reasonable and normal thresholds of the environmental factors, select the corresponding instruments for real-time monitoring, collect data and upload it to the system;

[0059] Step S2.3: Statistically analyze the characteristics of the special machine equipment mechanisms on the production line, determine the process variables that can be monitored during production and operation processes, such as motor torque, motor current, vibration conditions, operating sound decibels, power consumption, gas consumption, etc., and determine the reasonable and normal thresholds through experiments.

[0060] Such as Figure 2 and Figure 3 , the said Step S3 includes the following steps:

[0061] Step S3.1: According to the environmental factor conditions and reasonable thresholds statistically analyzed in Step S1, select the corresponding sensors for acquisition and monitoring. The sensors shall have the functions of real-time acquisition, high sensitivity, and can communicate with the PLC controller in real time, and send the acquired data to the PLC in real time;

[0062] Step S3.2: Select appropriate barometers, thermometers, hygrometers, sound level meters, etc., and perform redundant backups, and conduct installation and wiring tests.

[0063] Such as Figure 2 and Figure 3 , the said Step S4 includes the following steps:

[0064] Step S4.1: For the servo motors in the special machines of the production line equipment, write a program to collect the real-time torque and real-time current of the motors, set the reasonable and normal range thresholds through experiments, and perform emergency stop and alarm when exceeded;

[0065] Step S4.2: For the situation where each motor in the special machine needs to run at multiple positions during production, add signal detection at the standby position and some key positions, and perform double verification with the position feedback of the motor encoder to eliminate unexpected emergencies such as looseness and running deviation of the coupling on the mechanical part, improve the safety and stability of the equipment, and prepare the safety judgment conditions in advance for the next cycle of operation;

[0066] Such as Figure 4 , the said Step S5 includes the following steps:

[0067] Step S5.1: Add data analysis of the equipment operation status, and the current and historical production alarm information of the equipment on the MES system, and timely feedback the equipment production status to keep the equipment in good operation;

[0068] Step S5.2: The MES system promptly pushes device maintenance information and health inspection reports to keep the device in the best operating condition;

[0069] Step S5.3: Through the historical data query of MES, it can achieve the analysis of non-conforming products, product quality data, serial number management, data packets, and quality data traceability within the production line;

[0070] Such as Figure 4 , the said Step S6 includes the following steps:

[0071] Step S6.1: The management system can statistically manage the operating status of the device, including device operating status records, maintenance records, maintenance reminders, calibration reminders, pre-changeover tooling replacement confirmation, etc.;

[0072] Step S6.2: The management system develops a fault query function, which can record the alarm information of all devices and workstations on the assembly line. The alarm information includes the occurrence time, the device or workstation with the alarm, the operator, the fault code, etc., and can search for the alarm information of the day according to the time;

[0073] Step S6.3: The management system develops a calibration reminder function. The system can input the parts, cycles, and requirements for device calibration. When calibration is required, a reminder is given (regional human-machine interface). Only when calibration is completed on time and according to the requirements can the device operate normally. After the device completes calibration, the calibrator, time, generated data, etc. can be recorded;

[0074] Step S6.4: The management system develops a maintenance reminder function. The system sets the parts, maintenance procedures, and cycles for device maintenance. When the due date arrives, a reminder is given (human-machine interface). The device can operate normally only after being maintained according to the set procedures and confirmed, and a record is formed at the same time;

[0075] Step S6.5: The management system develops a maintenance record unit function, which details the handling methods for each fault and various situations encountered in the workshop, including time, device name, cause, phenomenon, solution, precautions, etc., to form a log; for each optimization, upgrade, and improvement, a comparison and detailed description are recorded; it is convenient for subsequent personnel to learn and transfer experience;

[0076] Step S6.6: The management system develops a changeover reminder function. The system can set the tooling to be replaced when assembling different products. When replacement is required, a reminder is given (human-machine interface). After the tooling is replaced during changeover and confirmed, the device can operate according to the automatic program;

[0077] Such as Figure 4 , the said Step S7 includes the following steps:

[0078] Step S7.1: The management system develops a verification reminder and record system for measuring instruments, enters all the instruments, meters, sensors on the equipment, as well as the verification cycles and dates of the measuring instruments used in production, reminds the management personnel to calibrate before the expiration date, and enters the new date after calibration;

[0079] Step S7.2: The management system develops a fire-fighting facility inspection reminder function. The system enters the shelf life, inspection cycles and dates of fire extinguishers at various parts of the production line, the inspection cycles and dates of fire hydrants at various parts, and the inspection cycles and dates of the pressure of the fire sprinkler system at various parts. Remind the responsible person to inspect or replace before the expiration date, and then enter the new date;

[0080] Step S7.3: The management system develops an expiration reminder function. The system enters the production dates and shelf lives of the main chemical products used in production, and reminds the responsible person to handle them before the expiration date;

[0081] Such as Figure 4 , the said Step S8 includes the following steps:

[0082] Step S8.1: The control system feeds back the information collected from the production line to the management system in real time.

[0083] Step S8.2: The management system comprehensively monitors, judges and predicts the production line conditions according to the information collected by the control system, provides the information required for optimizing the production activities from the plan to the completion of products for the assembly line, uses timely and accurate data to guide, start, respond to and record the production activities in the workshop, realizes management functions such as production plan management, material requirement management, bar code management, main data management in the production assembly process, personnel management, workstation monitoring, report generation, non-conforming product statistics, etc., and meets the requirements of quality traceability.

Claims

1. Safety control method for the production line of a dark factory, characterized in that, it includes the following steps: 1) Collect different parameters during the operation of special machines on the production line through different sensors, and judge whether there are hardware abnormalities in the special machines by setting thresholds; 2) Develop a management system for the production line of the dark factory, collect the working condition data of the special machines during operation through the management system, and develop different functions of the management system to achieve real-time monitoring during the operation of the production line; 3) The management system controls each special machine on the production line based on the monitoring data to achieve the safe operation of the production line.

2. The safety control method for the production line of the dark factory according to claim 1, characterized in that, the step 1) includes the following steps: 1.1) Statistically analyze the environmental factors for the production line of the dark factory, and set the normal operation thresholds based on the operation parameters of each special machine; 1.2) Select the sensors corresponding to the special machines based on the environmental factors for real-time monitoring and collection; 1.3) Based on the characteristics and operation processes of each special machine, judge its position and monitor its operation status.

3. The safety control method for the production line of the dark factory according to claim 2, characterized in that, the step 1.3) is specifically: For the situation where each motor in the special machine needs to run at multiple positions during production, add signal detection at key positions including the standby position, the key assembly position of the work station, and the grasping position, and perform double verification with the position feedback of the motor encoder.

4. The safety control method for the production line of the dark factory according to claim 1, characterized in that, the step 2) includes the following steps: 2.1) Develop a management system to collect and record the equipment working condition information in real time, and push notifications for early warnings, health checks, and predictive maintenance; 2.2) The management system statistically analyzes and manages the operation status of the equipment; 2.3) The management system gives periodic reminders for the relevant measuring instruments, fire protection facilities, and use and maintenance of chemical products on the production line.

5. The safety control method for the production line of the dark factory according to claim 4, characterized in that, the step 2.2) includes the following steps: 2.2.1) The management system develops a fault query function to record the alarm information that appears in all special machines and work stations on the production line; 2.2.2) The management system develops a calibration reminder function to give reminders when calibration is required based on the parts, cycles, and requirements for calibration of the special machines; 2.2.3) The management system develops a maintenance reminder function, sets the parts, maintenance procedures, and cycles for equipment maintenance, and gives reminders when due; 2.2.4) The management system develops a maintenance record unit function to record the faults encountered in the workshop each time and the treatment methods for various situations to form a log, and make comparisons and situation descriptions for each optimization and upgrade; 2.2.5) The management system develops a product change reminder function, sets the tooling that needs to be replaced when assembling different products, and gives reminders when replacement is required.

6. The safety control method for the production line of the dark factory according to claim 4, characterized in that, the step 2.3) includes the following steps: 2.3.1) Develop a metrological instrument appraisal reminder and record system for the management system. Enter the appraisal cycles and dates of all instruments, meters, sensors on the equipment, as well as the metrological instruments used in production. Remind the management personnel to calibrate before the due date, and enter the new date after calibration. 2.3.2) Develop a fire protection facility inspection reminder function for the management system. Enter the shelf life, inspection cycles and dates of fire extinguishers at various parts of the production line, the inspection cycles and dates of fire hydrants at various parts, and the inspection cycles and dates of the pressure of the fire sprinkler system at various parts. Remind the responsible person to conduct inspections or replacements before the due date, and enter the new date after inspections or replacements. 2.3.3) Develop a due date reminder function for the management system. Enter the production dates and shelf lives of the chemical products used in production. Remind the responsible person to handle them before the due date.

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