Production factor scheduling and remote operation and maintenance system

Abstract

The present invention relates to the field of production operation and maintenance technology, and discloses a production factor scheduling and remote operation and maintenance system, including a data acquisition module, a data display module, a data processing module, a remote operation and maintenance module, a data storage module and a message push module, wherein the data display module is used to display the layout information and basic operation information of the equipment on the production line, and display various equipment on the production line through a software interface; the data display module includes a user login system and an on-site material problem feedback system. The present invention binds the processing workpiece number with the processed tool, fixture, equipment and pallet, so as to facilitate tracing and data aggregation when processing problems occur in the later products; by obtaining the tool identification information, the start time of production and the number of processed workpieces, the remaining service life of the tool is warned and prompt information for tool replacement is sent to realize remote operation and maintenance, which greatly saves manpower.

Description

Technical Field

[0001] The present invention relates to the field of production operation and maintenance technology, and in particular to a production factor scheduling and remote operation and maintenance system. Background Art

[0002] At present, some intelligent processing workshops have installed sensors such as temperature, humidity, and pressure, but they are not yet able to perform data collection, display, alarm, storage and other operations; and some intelligent processing workshops have relatively complete plan distribution and material pulling systems, but there are still cases of wrong delivery, missing delivery, and multiple delivery of materials when they are pulled to the workshop workstations. The only way is to notify the team leader by phone through on-site personnel, and the team leader notifies the person in charge of workshop materials, and the person in charge then notifies the intensive department to handle the material abnormalities.

[0003] The CNC system in the processing machine usually has a tool management system, but in a CNC system, there are multiple tools of the same model (including tools in use and spare tools); during processing, tools of the same model are switched back and forth, and the number of processed workpieces can currently only be located by the tool model; and during the production process, the pallet and equipment information are only bound and recorded manually, and no traceability system has been formed. Summary of the invention

[0004] The purpose of the present invention is to provide a production factor scheduling and remote operation and maintenance system to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] The production factor scheduling and remote operation and maintenance system includes a data acquisition module, a data display module, a data processing module, a remote operation and maintenance module, a data storage module and a message push module. The data acquisition module is used to collect the temperature, humidity, current, voltage, load, hydraulic oil, lubricating oil and clamping force of the equipment, and set the process parameters based on the collected data information;

[0007] The data processing module is used to process the collected data;

[0008] The data display module is used to display the layout information and basic operation information of the equipment on the production line, and display various equipment on the production line through the software interface. If there is an alarm, a red prompt will be displayed; by clicking on a specific device on the software interface, specific tool information can be viewed;

[0009] The data display module includes a user login system and an on-site material problem feedback system;

[0010] The on-site material problem feedback system includes creating new exceptions and checking exceptions;

[0011] The remote operation and maintenance module includes tool life management, production process management, and abnormal alarm management;

[0012] The message push module is used to push the data of the device during operation to the background terminal, and adopts a hierarchical push method to push different messages to different people.

[0013] As a further solution of the present invention: the method for tool life management comprises the following steps:

[0014] S11, establishing a one-to-one correspondence table of tool model, tool part number, and total workpiece number of tool life;

[0015] S12, by reading the tool number, the number of workpieces to be processed, the start processing time, and the number of workpieces to be processed in the tool chip in real time from the data storage module, and accumulating the number of workpieces to be processed by the tool;

[0016] S13, comparing the number of workpieces processed by the tool accumulated in step S12 with the total number of workpieces of tool life in the relationship table obtained in step S11, and when the number of remaining workpieces to be processed reaches a certain value, a red warning prompt is displayed on the interface, and an email is automatically sent to the tool mailbox of the relevant business personnel;

[0017] S14. After processing the warning, click the Solve button on the page to cancel the red warning prompt.

[0018] As a further solution of the present invention: the method for production process management comprises the following steps:

[0019] S21, establishing a relationship table with the fixture number according to the equipment number and the pallet number, that is, a unique fixture number can be determined by the equipment number and the pallet number;

[0020] S22, read the equipment number, pallet number, workpiece number, and workpiece processing time from the data storage module in real time, and correspond them to the fixture number information;

[0021] S23, recording the production process data of the equipment number, pallet number, fixture number, tool model, tool part number, processing workpiece number, and processing workpiece time in real time, and storing them.

[0022] As a further solution of the present invention: the method for abnormal alarm management includes the following data:

[0023] S31, setting thresholds for various process parameters of the equipment;

[0024] S32, read the parameter value of the big data in the data storage module in real time, and compare it with the set threshold value. When an over-value alarm occurs, the interface will be marked in red;

[0025] S33. Statistical analysis is performed on the consumed materials according to time to determine whether the material consumption is abnormal. If an abnormality occurs, an alarm is issued and adjustments are made on site;

[0026] S34, for the fixture signal, whether it is clamped in place is prompted, if there is an abnormality, an alarm is prompted, and the alarm information is sent to the mailbox, and the staff is dispatched, and the alarm content is recorded and stored in the MES system;

[0027] As a further solution of the present invention: the setting of the process parameter thresholds in the step S31 includes: the setting of spindle temperature, spindle load, servo shaft load, voltage, current, servo motor temperature, electrical cabinet, workshop ambient temperature, and the upper and lower limits of the workshop ambient temperature.

[0028] As a further solution of the present invention: the operation mode of the on-site material problem feedback system includes the following steps:

[0029] S41. Enter the material number, and support fuzzy query and automatic filling by scanning the code;

[0030] S42. Select the abnormal problem type and fill in the data basis for the response. Click the Send button. The data will be automatically pushed to the intensive system and the time when the abnormal problem occurred will be automatically recorded. After the intensive system responds, the response data will be sent to this system, and this system will record the response time. The intensive system will pull the materials to the site. After confirming the problem on site, click the Solve button to form a closed loop.

[0031] S43. Count the number of material abnormalities and the average monthly response time of materials on a monthly basis.

[0032] As a further solution of the present invention: in the step S43, the monthly abnormal number of materials is statistically analyzed using a histogram, and the monthly average response time of materials is statistically analyzed using a line graph.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] The present invention calculates the number of workpieces processed by a specific tool by reading the unique identification information of the tool and issues an early warning prompt; by binding the workpiece number with the tool, fixture, equipment and pallet used for processing, it is convenient to trace and summarize the data when processing problems occur in the later products, so as to provide a basis for future process upgrades and modifications; by issuing an alarm prompt when an over-threshold value is exceeded; and by remote viewing; when an alarm occurs, it is automatically sent to the mailbox of the business personnel for timely dispatch, and the alarm information is recorded and stored in real time; by obtaining the tool identification information, the start time of production, and the number of workpieces processed, the remaining service life of the tool is warned and a prompt message for tool replacement is sent, thereby realizing remote operation and maintenance, which greatly saves manpower. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a flowchart of the tool life management method in the production factor scheduling and remote operation and maintenance system;

[0036] Figure 2 It is a flowchart of the production process management method in the production factor scheduling and remote operation and maintenance system;

[0037] Figure 3 It is a flowchart of the abnormal alarm management method in the production factor scheduling and remote operation and maintenance system;

[0038] Figure 4 This is a flowchart of the operation mode of the on-site material problem feedback system in the production factor scheduling and remote operation and maintenance system;

[0039] Figure 5 An interface diagram for setting the threshold of the on-site material problem feedback system in the production factor scheduling and remote operation and maintenance system;

[0040] Figure 6 This is the interface diagram for logging into the on-site material problem feedback system in the production factor scheduling and remote operation and maintenance system;

[0041] Figure 7 This is the interface diagram for the station settings of the on-site material problem feedback system in the production factor scheduling and remote operation and maintenance system;

[0042] Figure 8 This is the interface diagram for querying the on-site material problem feedback system in the production factor scheduling and remote operation and maintenance system;

[0043] Fig. 9 It is a histogram of the monthly abnormality frequency of materials in the production factor scheduling and remote operation and maintenance system;

[0044] Fig.10 This is a line chart of the monthly average response time of materials in the production factor scheduling and remote operation and maintenance system. DETAILED DESCRIPTION

[0045] See also Figures 1 to 10 In the embodiment of the present invention, the production factor scheduling and remote operation and maintenance system includes a data acquisition module, a data display module, a data processing module, a remote operation and maintenance module, a data storage module and a message push module. The data acquisition module is used to collect the temperature, humidity, current, voltage, load, hydraulic oil, lubricating oil and clamping force of the equipment, and set the process parameters for the collected data information;

[0046] The data processing module is used to process the collected data;

[0047] The data display module is used to display the layout information and basic operation information of the equipment on the production line, and display various equipment on the production line through the software interface. If there is an alarm, a red prompt will be displayed; by clicking on the specific equipment on the software interface, the specific tool information can be viewed;

[0048] The data display module includes the user login system (user name, password and workstation settings, click the workstation setting button, a pop-up window will display the current workstation, click to select the required workstation number) and the on-site material problem feedback system;

[0049] The on-site material problem feedback system includes creating new exceptions (including wrongly delivered demand material numbers and actual delivered material numbers, missed demand quantities and actual delivered quantities, and over-delivered demand quantities and actual delivered quantities) and checking exceptions (including frequently checking the wrongly delivered, missed, and over-delivered material numbers and quantities);

[0050] The remote operation and maintenance module includes tool life management, production process management and abnormal alarm management;

[0051] The message push module is used to push the data of the device during operation to the background terminal, and adopts a hierarchical push method to push different messages to different personnel, including from management to operators, to achieve precise management, and can add push personnel; including email, SMS and APP push.

[0052] Preferably, Figure 1 As shown, the method of tool life management includes the following steps:

[0053] S11, establishing a one-to-one correspondence table of tool model, tool part number, and total workpiece number of tool life;

[0054] S12, by reading in real time (through a Java timer task) the tool number, the number of workpieces to be processed, the start processing time, and the number of workpieces to be processed in the tool chip from the data storage module, and accumulating the number of workpieces to be processed by the tool;

[0055] S13, comparing the number of workpieces processed by the tool accumulated in step S12 with the total number of workpieces of tool life in the relationship table obtained in step S11, and when the number of remaining workpieces to be processed reaches a certain value (for example, 10), a red warning prompt is displayed on the interface (pushed to the front page via websocket), and an email is automatically sent to the tool mailbox of the relevant business personnel;

[0056] S14. After processing the warning, click the Solve button on the page to cancel the red warning prompt;

[0057] For example, suppose there are 4 different types of tools on a piece of equipment, and there are 2 tools of the same type. The life of each tool is to process 100 workpieces. The one-to-one correspondence table of equipment number, tool model, tool life and total number of workpieces is shown in Table 1 below:

[0058] Table 1

[0059]

[0060] Preferably, Figure 2 As shown, the method for production process management includes the following steps:

[0061] S21, establishing a relationship table with the fixture number according to the equipment number and the pallet number, that is, a unique fixture number can be determined by the equipment number and the pallet number;

[0062] S22, read the device number, pallet number, workpiece number, and workpiece processing time from the data storage module in real time (read through a Java timer task), and correspond them to the fixture number information;

[0063] S23, real-time recording of production process data including equipment number, pallet number, fixture number, tool model, tool part number, workpiece number, and workpiece processing time, and storage for query and traceability;

[0064] For example: suppose there are two devices, each device has two pallets, each pallet corresponds to a fixture, and the one-to-one correspondence table of device number, pallet number and fixture number is shown in Table 2 below;

[0065] Table 2

[0066]

[0067] For example, the records of workpiece number, equipment number, tool model, tool number, pallet number, fixture number, and workpiece processing time are shown in Table 3 below;

[0068] Table 3

[0069]

[0070] Preferably, Figure 3 As shown, the method of abnormal alarm management includes the following data:

[0071] S31, setting thresholds for various process parameters of the equipment;

[0072] S32, read the parameter value of the big data in the data storage module in real time (read from the data storage module through a Java scheduled task), and compare it with the set threshold. When an over-value alarm occurs, the interface will be marked in red (pushed to the front end through websocket);

[0073] S33. Perform statistical analysis on consumable materials (such as hydraulic oil and lubricating oil) according to time. For example, add oil every 20 minutes on site, take 20 minutes as a cycle, and display the consumption comparison of 10 cycles at the same time to judge whether the material consumption is abnormal. If abnormality occurs, alarm will be issued and make adjustments on site.

[0074] S34. Prompt whether the fixture signal (such as barometer value, pressure value) is clamped in place. If an abnormality occurs, an alarm is issued, and the alarm information is sent to the mailbox for dispatch by employees. At the same time, the alarm content is recorded and stored in the MES system;

[0075] Preferably, the setting of process parameter thresholds in step S31 includes: setting of spindle temperature, spindle load, servo shaft load, voltage, current, servo motor temperature, electrical cabinet, workshop ambient temperature, and upper and lower limits of the workshop ambient temperature.

[0076] Preferably, Figures 4 to 8 As shown, the operation of the on-site material problem feedback system includes the following steps:

[0077] S41. Enter the material number, support fuzzy query and automatic filling by scanning the code;

[0078] S42. Select the type of abnormal problem (for example, wrong delivery, multiple delivery, or missed delivery), and fill in the data basis for the response. Click the Send button, and the data will be automatically pushed to the centralized system (for example, you can use message push). If the centralized system has not yet been developed to receive and process the data, you can choose to push the data to the emails of relevant personnel. The time when the abnormal problem occurs will be automatically recorded. After the centralized system responds, the response data will be sent to this system (message), and this system will record the response time. The centralized system will pull the materials to the site, and after confirming the problem on site, click the Solve button to form a closed loop.

[0079] S43. Count the number of material abnormalities and the average monthly response time of materials on a monthly basis.

[0080] Preferably, Figures 9-10 As shown, in step S43, the monthly abnormal number of materials is statistically analyzed using a histogram, and the monthly average response time of materials is statistically analyzed using a line graph.

[0081] What is described above 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. The production factor scheduling and remote operation and maintenance system includes a data acquisition module, a data display module, a data processing module, a remote operation and maintenance module, a data storage module and a message push module, characterized in that: The data acquisition module is used to collect the temperature, humidity, current, voltage, load, hydraulic oil, lubricating oil and clamping force of the equipment, and to set the process parameters based on the collected data information; The data processing module is used to process the collected data; The data display module is used to display the layout information and basic operation information of the equipment on the production line, and display various equipment on the production line through the software interface. If there is an alarm, a red prompt will be displayed; by clicking on a specific device on the software interface, specific tool information can be viewed; The data display module includes a user login system and an on-site material problem feedback system; The on-site material problem feedback system includes creating new exceptions and checking exceptions; The remote operation and maintenance module includes tool life management, production process management and abnormal alarm management; wherein the tool life management method includes the following steps: S11, establishing a one-to-one correspondence table of tool model, tool part number, and total workpiece number of tool life; S12, by reading the tool number, the number of workpieces to be processed, the start processing time, and the number of workpieces to be processed in the tool chip in real time from the data storage module, and accumulating the number of workpieces to be processed by the tool; S13, comparing the number of workpieces processed by the tool accumulated in step S12 with the total number of workpieces of tool life in the relationship table obtained in step S11, and when the number of remaining workpieces to be processed reaches a certain value, a red warning prompt is displayed on the interface, and an email is automatically sent to the tool mailbox of the relevant business personnel; S14. After processing the warning, click the Solve button on the page to cancel the red warning prompt; The method for production process management comprises the following steps: S21, establishing a relationship table with the fixture number according to the equipment number and the pallet number, that is, a unique fixture number can be determined by the equipment number and the pallet number; S22, read the equipment number, pallet number, workpiece number, and workpiece processing time from the data storage module in real time, and correspond them to the fixture number information; S23, real-time recording of production process data including equipment number, pallet number, fixture number, tool model, tool part number, workpiece number, and workpiece processing time, and storage; The method for abnormal alarm management includes the following data: S31, setting thresholds for various process parameters of the equipment; S32, read the parameter value of the big data in the data storage module in real time, and compare it with the set threshold value. When an over-value alarm occurs, the interface will be marked in red; S33. Statistical analysis is performed on the consumed materials according to time to determine whether the material consumption is abnormal. If an abnormality occurs, an alarm is issued and adjustments are made on site; S34, for the fixture signal, whether it is clamped in place is prompted, if there is an abnormality, an alarm is prompted, and the alarm information is sent to the mailbox, and the staff is dispatched, and the alarm content is recorded and stored in the MES system; The message push module is used to push the data of the device during operation to the background terminal, and adopts a hierarchical push method to push different messages to different people.

2. The production factor scheduling and remote operation and maintenance system according to claim 1, characterized in that: The setting of process parameter thresholds in step S31 includes: setting of spindle temperature, spindle load, servo shaft load, voltage, current, servo motor temperature, electrical cabinet, workshop ambient temperature, and upper and lower limits of workshop ambient temperature.

3. The production factor scheduling and remote operation and maintenance system according to claim 1, characterized in that: The operation mode of the on-site material problem feedback system includes the following steps: S41. Enter the material number, and support fuzzy query and automatic filling by scanning the code; S42. Select the abnormal problem type and fill in the data basis for the response. Click the Send button. The data will be automatically pushed to the intensive system and the time when the abnormal problem occurred will be automatically recorded. After the intensive system responds, the response data will be sent to this system, and this system will record the response time. The intensive system will pull the materials to the site. After confirming the problem on site, click the Solve button to form a closed loop. S43. Count the number of material abnormalities and the average monthly response time of materials on a monthly basis.

4. The production factor scheduling and remote operation and maintenance system according to claim 3 is characterized in that: In the step S43, the monthly abnormal number of materials is statistically analyzed using a histogram, and the monthly average response time of materials is statistically analyzed using a line graph.

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