Method and system for controlling a production line
By generating work orders and automatically configuring process parameters through the MES server and collecting data in real time, the problem of independent processes without data interaction in transformer production has been solved. This has enabled production transparency and traceability, reduced product defect rates and equipment damage risks, and improved production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SIEMENS FACTORY AUTOMATION ENG
- Filing Date
- 2022-12-30
- Publication Date
- 2026-06-02
AI Technical Summary
In the current transformer production process, each process is independent and there is no data exchange. This can lead to lost production work orders, which may result in production defects. Manual setting errors can increase the risk of product defects and equipment damage, and there is a lack of traceability of production process data.
The MES server generates work orders and sends them to the workstation client, automatically configures process parameters, collects processing data and alarm information in real time, generates records, and achieves production transparency and traceability.
Reduce human error, lower product defect rates, improve production efficiency, achieve transparency and traceability in the production process, optimize energy use, and support intelligent management.
Smart Images
Figure CN116300711B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of automatic control technology, and in particular to a control method and system for a production line. Background Technology
[0002] In the current transformer production process, each component is independent, and there is no exchange of production or process data between the processes. The main problems are as follows: paper production work orders are manually passed between the processes, and if the production work orders are lost, it may have a negative impact on the production process and the warehousing process; production process parameters are set or adjusted by operators based on experience or by retrieving documents, which increases the risk of product defects and equipment damage caused by manual setting errors; there is no equipment production process data, and the product production process lacks traceable records. Summary of the Invention
[0003] In view of this, the present invention provides a production line control method and system for at least partially solving the above-mentioned technical problems.
[0004] In a first aspect, the present invention provides a method for controlling a production line, comprising:
[0005] Determine the process number and work order quantity for each process of the product to be manufactured;
[0006] A work order task for each process is generated based on the process number and the number of work orders. The work order task includes the work order number and the process number.
[0007] Send each work order task of each process to the workstation client of the corresponding process area;
[0008] When executing each process, the work order task is started through the workstation client of the current process area. Based on the process number, the corresponding process parameters are retrieved and configured into the workstation device of the corresponding workstation. After each work order task is completed, a work order task record with the corresponding work order number is generated.
[0009] In one possible implementation, before performing each of the steps, the following is also included:
[0010] Obtain the parts list for the product to be manufactured;
[0011] The parts list is broken down to obtain the parts list corresponding to each process.
[0012] Determine the daily production quantity N of the production line;
[0013] Collect the components of N products and distribute the components of the N products to the corresponding workstations in the process area according to the component list of each process.
[0014] In one possible implementation, the execution of each step further includes:
[0015] The processing parameters and / or testing data of the processing equipment and / or testing equipment at the corresponding workstation when executing the work order task are collected, and a processing parameter record or testing data record for the corresponding work order number is generated. The work order task record includes the processing parameter record and / or testing data record.
[0016] The identification of the mold used to execute the work order task is collected through the workstation client. After each work order task is completed, a mold identification record with a corresponding work order number is generated. The work order task record includes the mold identification record.
[0017] One possible implementation also includes:
[0018] Real-time collection of alarm data from the equipment at the corresponding workstation;
[0019] An alarm record is generated based on the alarm data, and the alarm level of the alarm data is determined so as to send a prompt message corresponding to the alarm level to the alarm equipment of the designated maintenance personnel.
[0020] In one possible implementation, the production line is a transformer production line, and the process includes one or more of the following: winding coil process, coil resistance testing process, coil balancing process, coil pressing process, coil drying process, transformer body assembly process, transformer body drying process, tank assembly process, and transformer oiling process.
[0021] In one possible implementation, determining the process number and work order quantity for each process of the product to be produced further includes:
[0022] The process number for each process is determined based on the type of transformer to be produced, and the number of work orders for each process is determined based on the quantity of the transformer to be produced.
[0023] One possible implementation also includes:
[0024] When executing each work order task of the winding machine coil winding process, a coil identification label is made for the coil wound for each work order task and fixed to the coil. Each coil is placed in a tray, and the work order number of each work order task in the current process, the coil identification of the corresponding coil, and the tray identification of the tray are associated to obtain the first association information.
[0025] When executing each work order task of the coil resistance testing process, the work order number of each work order task in the current process, the coil identifier of the corresponding coil, or the tray identifier of the tray in which the coil is placed is associated to obtain the second association information;
[0026] When executing each work order task of the coil balancing process, the work order number of each work order task in the current process and the pallet identifiers of the three successfully balancing pallets are combined and associated to obtain the third association information;
[0027] For the coil assembly pressing process, the coil assembly drying process, the body assembly process, the body drying process, and the oil tank assembly process in sequence, execute the corresponding work order tasks, obtain the work order number of each work order task in the current process, and associate it with any coil identifier in the corresponding coil identifier combination to obtain the fourth association information;
[0028] When executing each work order task of the transformer refueling process, the work order number of each work order task of the current process, any coil identifier in the corresponding coil identifier combination, and the identifier of the corresponding finished transformer are associated to obtain the fifth association information;
[0029] Based on the first association information, the second association information, the third association information, the fourth association information, and the fifth association information, all work order task records corresponding to each transformer identifier are obtained.
[0030] One possible implementation also includes:
[0031] The number of times the equipment at the corresponding workstation is used is collected. If the number of uses reaches a predetermined value, a prompt message is sent to the alarm device of the designated maintenance personnel.
[0032] Secondly, the present invention also provides a control system for a production line, comprising:
[0033] The MES server is used to determine the process number and work order quantity of each process of the product to be produced, generate work order tasks for each process based on the process number and work order quantity, the work order task includes the work order number and the process number, and send each work order task of each process to the MES client of the corresponding process area.
[0034] The MES client and workstation device are set at the workstation of each process, wherein the MES client is used to generate and send a configuration request of the workstation device at the current workstation to the SCADA system when the work order task is started, and the configuration request includes the corresponding work order number and process number;
[0035] The SCADA system is used to respond to the configuration request, determine the corresponding process parameters based on the process number and configure them into the workstation equipment of the current workstation, and generate a workstation task record with the corresponding workstation number after each work order task is completed.
[0036] In one possible implementation, the SCADA system is further used to collect processing data and / or detection data when the processing equipment and / or detection equipment at the current workstation executes the work order task, and generate a work order task record with the corresponding work order number.
[0037] In the embodiments of this application, compared with the prior art, at least the following advantages are included: 1. When a work order task is started, process parameters (production formula) are automatically configured to the workstation equipment, eliminating the need for manual input, selection, or modification. This greatly reduces the risk of product defects and equipment damage caused by manual configuration errors and lack of process standardization, thus lowering the product defect rate. 2. When a work order task is completed, a corresponding work order task record is automatically generated, enabling real-time recording of production process data, ensuring transparency in product production. Furthermore, the automatically generated work order task record is authentic and reliable, ensuring the traceability of the production process. 3. Real-time collection of alarm data and push of alarm levels to designated maintenance personnel for repair significantly shortens repair response time and improves production efficiency. 4. Real-time collection and calculation of electricity, water, gas, and oil consumption data provides a clear picture of energy usage. Energy consumption can be optimized and reduced based on usage, solving cost accounting, energy optimization, and waste prevention. 5. Through real-time collection of production process data, production progress, production efficiency, quality information, equipment operation, and product status can be remotely monitored, achieving factory transparency and facilitating intelligent factory management. Attached Figure Description
[0038] Figure 1 This is a schematic diagram of a production line control method according to an embodiment of the invention.
[0039] Figure 2 This is a schematic diagram of the structure of a production line control system according to one embodiment of the invention.
[0040] List of reference numerals in the attached diagram:
[0041] 20: MES Server
[0042] 21: SCADA System
[0043] 22~2M: Process Area
[0044] 221~22N1,231~23N2,…,2M1~23N n Workstation
[0045] 2211~22N11,2311~23N21,…,2M11~2MN n 1: MES Client
[0046] 2212~22N12,2312~23N22,…,2M12~2MN n2: Workstation equipment Detailed Implementation
[0047] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments. All other technical solutions obtained by those skilled in the art based on the embodiments of this application fall within the scope of protection of this application.
[0048] Terminology Explanation: The Supervisory Control and Data Acquisition (SCADA) system involved in this invention refers to a system that collects data from various sensors in a factory or other remote locations, then sends this data to a central computer, where the central computer manages and controls the data. The Manufacturing Execution System (MES) involved in this invention is a production information management system for the shop floor execution layer of manufacturing enterprises. It can provide enterprises with management modules including manufacturing data management, planning and scheduling management, production scheduling management, inventory management, quality management, human resource management, work center / equipment management, tooling management, procurement management, cost management, project dashboard management, production process control, lower-level data integration and analysis, and upper-level data integration and decomposition.
[0049] Figure 1 A production line control method according to an embodiment of the present invention is illustrated. For example... Figure 1 As shown, the control method for this production line includes:
[0050] Step S102: Determine the process number and work order quantity for each process of the product to be produced.
[0051] Step S104: Generate a work order task for each process based on the process number and the work order quantity. The work order task includes the work order number and the process number. Optionally, the number of work order tasks for each process is determined based on the quantity of semi-finished or finished products produced in the current process.
[0052] Step S106: Send each work order task of each process to the corresponding workstation client in the process area.
[0053] Step S108: When executing each process, start the work order task through the workstation client of the current process, retrieve the corresponding process parameters based on the process number and configure them in the workstation equipment of the corresponding workstation, and generate a work order task record with the corresponding work order number after each work order task is completed.
[0054] The aforementioned steps S102 to S108 can, on the one hand, automatically configure process parameters to the workstation equipment when a work order task is started, without the need for manual input, selection, or modification, greatly reducing the risk of product defects and equipment damage caused by manual configuration errors and lack of process standardization, and lowering the product defect rate. On the other hand, they can automatically generate corresponding work order task records when a work order task is completed, realizing real-time recording of production process data, ensuring the transparency of product production, and the automatically generated work order task records are authentic and reliable, ensuring the traceability of the production process.
[0055] Furthermore, prior to step S108, a material distribution step is included, specifically: obtaining a parts list for the products to be produced; splitting the parts list to obtain parts lists for each process; determining the daily production quantity N of the production line; collecting parts for N products and distributing these parts to the corresponding workstations in each process area according to the parts list for each process. This achieves on-demand and automatic material distribution to the corresponding workstations, standardizes the material distribution process, and reduces material distribution errors. The daily production quantity N can be confirmed based on historical data.
[0056] Optionally, the workstation equipment mentioned in step S108 may be, for example, but not limited to, processing equipment and / or testing equipment. Specifically, each workstation may be configured with processing equipment or testing equipment according to the process requirements, so as to configure both processing equipment and testing equipment.
[0057] Optionally, the production line control method of this embodiment further includes the following steps: when executing each of the aforementioned processes, collecting the processing parameters and / or detection data of the processing equipment and / or detection equipment at the corresponding workstation when executing the work order task, and generating a processing parameter record and / or detection data record for the corresponding work order number, wherein the work order task record includes the processing parameter record and / or detection data record.
[0058] Optionally, the production line control method of this embodiment further includes the following steps: when executing each of the aforementioned processes, collecting (e.g., by the workstation client) the identifier of the mold used to execute the work order task, wherein a mold identifier record corresponding to the work order number is generated after each work order task is completed, and the work order task record includes the mold identifier record.
[0059] Optionally, the production line control method of this embodiment further includes the following steps: real-time acquisition of alarm data from the processing equipment and / or testing equipment at the corresponding workstation; generation of alarm records based on the alarm data, and determination of the alarm level of the alarm data, so as to send a prompt message corresponding to the alarm level to the alarm equipment of the designated maintenance personnel. This achieves real-time alarm reminders for production line equipment and pushes them to designated maintenance personnel, solving the problem of real-time alarms for production line equipment, pushing alarms to designated maintenance personnel for quick fault handling, subsequent querying of alarm history records, and analysis of the causes of multiple alarms.
[0060] Optionally, the production line control method in this embodiment further includes the following steps: collecting the usage count of the processing equipment at the corresponding workstation; if the usage count reaches a predetermined value, sending a prompt message to the alarm device of the designated maintenance personnel. This ensures the production reliability of the processing equipment, avoids disruption of continuous production, and improves production efficiency.
[0061] The production line in this embodiment is, for example, but not limited to, a transformer production line. The transformer production line includes one or more of the following processes: winding coils, coil resistance testing, coil balancing, coil pressing, coil drying, transformer body assembly, transformer body drying, tank assembly, and transformer lubrication.
[0062] In the example of the transformer production line, the aforementioned step S102 can be further implemented as follows: determining the process number of each process according to the type of transformer to be produced, and determining the number of work orders for each process according to the quantity of transformers to be produced.
[0063] In the example of the transformer production line, the corresponding control method further includes the following steps: When executing each work order task of the winding machine coil winding process, a coil identification label is made for the coil wound for each work order task and fixed to the coil, and each coil is placed in a tray. The work order number of each work order task in the current process, the coil identification of the corresponding coil, and the tray identification of the tray in which the coil is placed are associated to obtain first association information; When executing each work order task of the coil resistance testing process, the work order number of each work order task in the current process, the coil identification of the corresponding coil, or the tray identification of the tray in which the coil is placed are associated to obtain second association information; When executing each work order task of the coil balancing process, the work order number of each work order task in the current process, the three trays of successfully balanced coils, and the coil identification of the coil are associated to obtain second association information. The pallet identifier combination is associated to obtain the third association information. For the coil assembly pressing process, coil assembly drying process, transformer body assembly process, transformer body drying process, and oil tank assembly process, the corresponding work order tasks are executed sequentially, obtaining the work order number of each work order task in the current process and associating it with any coil identifier in the corresponding coil identifier combination to obtain the fourth association information. When executing each work order task in the transformer lubrication process, the work order number of each work order task in the current process, any coil identifier in the corresponding coil identifier combination, and the identifier of the corresponding finished transformer are associated to obtain the fifth association information. Based on the first, second, third, fourth, and fifth association information, all work order task records corresponding to each transformer identifier are obtained. During the generation process, the work order number, coil identifier, pallet identifier, and finished transformer identifier of each work order task are interactively associated to obtain all work order task records corresponding to each transformer identifier, further ensuring the traceability of the production process.
[0064] Figure 2 A production line control system according to an embodiment of the present invention is shown. Figure 2 As shown, the control system of this production line includes an MES server 20, a SCADA system 21, and corresponding workstations 221-22N1, 231-23N2, ..., 2M1-23N1 located in each process area 22-2M. n MES clients at the following locations: 2211~22N11, 2311~23N21,…,2M11~2MN n 1 and workstation equipment 2212~22N12,2312~23N22,…,2M12~2MN n 2, where n is an integer greater than or equal to 1, N n M is an integer greater than or equal to 1, and M is an integer greater than or equal to 2.
[0065] Optionally, the number of process zones M-1 in a production line is determined by the number of processes included, and the number of workstations N1, N2, ..., N in each process zone is N1, N2, ..., N1.n It can be configured according to production needs, and each workstation is usually set up with one MES client and one or a group of workstation devices. One workstation device can be a single processing device or a single inspection device, and a group of workstation devices can be a combination of processing devices and inspection devices.
[0066] exist Figure 2 In the illustrated embodiment, the MES server 20 is used to determine the process number and work order quantity for each process of the product to be manufactured, and generates a work order task for each process based on the process number and work order quantity. The work order task includes the work order number and the determined process number, and sends each work order task for each process to the MES client 2211~22N11,2311~23N21,…,2M11~2MN in the corresponding process area. n 1. In addition, in some other embodiments, the SCADA system 21 may respond to the request of the MES server 20 to determine the process number and work order quantity of each process of the product to be produced, generate a work order task for each process based on the process number and work order quantity, the work order task including the work order number and process number, and send each work order task of each process to the MES client 2211~22N11,2311~23N21,…,2M11~2MN in the corresponding process area through the MES server 20. n 1
[0067] Optionally, the number of work orders for each process is determined based on the quantity of semi-finished or finished products produced in the current process.
[0068] Optionally, MES clients 2211~22N11, 2311~23N21, ..., or 2M11~2MN in the same process area n 1. All work order tasks are shared, meaning that once any MES client starts or completes a work order task, that work order task cannot be started or completed again by other MES clients in the same work area.
[0069] Optionally, the MES server 20 is also used to obtain a parts list of the products to be produced, and to break down the parts list into parts lists corresponding to each process. Further, for example, the production scheduler determines the daily production quantity N of the production line, collects parts for N products, and distributes these parts to workstations 221~22N1, 231~23N2, ..., 2M1~23N according to the parts list for each process area. n Place.
[0070] exist Figure 2 In the embodiment shown, the MES clients are 2211~22N11, 2311~23N21,…,2M11~2MN n1 is used to generate and send a configuration request for the workstation equipment at the current workstation to the SCADA system 21 when a work order task is started. The configuration request includes, for example, the corresponding work order number and process number.
[0071] In one implementation, in the MES client 2211~22N11,2311~23N21,…,2M11~2MN n 1. Generate a configuration request for the workstation equipment at the current workstation and send it to the SCADA system 21 via the MES server 20. In another implementation, this is done in response to MES clients 2211~22N11,2311~23N21,…,2M11~2MN. n When the work order task is initiated, the MES server 20 generates a configuration request for the workstation equipment at the current workstation and sends it to the SCADA system 21.
[0072] Optionally, the MES clients are 2211~22N11, 2311~23N21,…,2M11~2MN. n 1 is also used to collect the identifier of the mold used to execute the work order task and send it to the MES server 20. The MES server 20 is also used to generate a mold identifier record with the corresponding work order number after each work order task is completed. The work order task record includes the mold identifier record.
[0073] exist Figure 2 In the illustrated embodiment, the SCADA system 21 responds to a configuration request from the MES server 20, determines the corresponding process parameters based on the process number in the configuration request, and configures them into the workstation equipment at the current workstation. Upon completion of each work order, a work order record with the corresponding work order number is generated. This workstation equipment can be, for example, but not limited to, processing equipment or testing equipment. Taking a transformer production line as an example, the coil winding process typically uses a winding machine as the processing equipment, and the coil resistance testing process typically uses a resistance meter as the testing equipment.
[0074] Optionally, the SCADA system 21 is also used to collect processing data and / or detection data of the workstation equipment at the current workstation when performing work order tasks, and generate work order task records with corresponding work order numbers.
[0075] Optionally, the SCADA system 21 is also used to collect processing parameters or inspection data of the processing equipment and / or inspection equipment at the corresponding workstation when performing work order tasks and send them to the MES server 20. Furthermore, in this optional embodiment, the MES server 20 is also used to generate a processing parameter record or inspection data record for the corresponding work order number based on the received processing parameters or inspection data, and the work order task record includes the processing parameter record or inspection data record.
[0076] Optionally, the SCADA system 21 is also used to collect real-time data from the corresponding workstations 221~22N1, 231~23N2, ..., 2M1~23N. n The alarm data of the workstation equipment is collected; an alarm record is generated based on the alarm data, and the alarm level of the alarm data is determined so as to send the corresponding prompt information to the alarm equipment of the designated maintenance personnel.
[0077] Optionally, the SCADA system 21 is also used to collect data from the corresponding workstations 221~22N1, 231~23N2, ..., 2M1~23N. n The system monitors the number of times the processing equipment is used. If the number of uses reaches a predetermined value, a notification message is sent to the designated maintenance personnel via an alarm device. For example, the SCADA system 21 collects pressure plate and bolt data and configures a reminder function within the SCADA system 21. When the usage limit is reached, the system reminds maintenance personnel to repair and replace the equipment in a timely manner, which can greatly reduce the risk of product quality defects and equipment damage caused by pressure plate and bolt damage. This predetermined value can be determined based on historical data.
[0078] Optionally, the SCADA system 21 is also used to collect and calculate data for the entire production line, each process area 22 to 2M and / or each workstation 221 to 22N1, 231 to 23N2, ..., 2M1 to 23N n It provides data on electricity, water, gas, and oil consumption, enabling users to clearly view daily, monthly, and yearly energy usage and optimize energy consumption based on the situation.
[0079] Optionally, the production line control system in this embodiment also includes a large display screen. Furthermore, the SCADA system 21 is also used to record the collection time when collecting the aforementioned production-related process data (e.g., workstation equipment status data, alarm data, energy usage data, and current production product completion status data), and update the data to the large display screen in real time. The current production product completion status data can be determined, for example, based on the generated work order task records.
[0080] In one exemplary embodiment, the production line is a transformer production line.
[0081] The following example uses a transformer production line to illustrate the control process of the control system in this embodiment. This example is for better understanding of the content of this application and does not constitute a limitation on the scope of protection of this application. The processes in this transformer production line include one or more of the following: coil winding process, coil resistance testing process, coil balancing process, coil pressing process, coil drying process, transformer body assembly process, transformer body drying process, tank assembly process, and transformer oiling process.
[0082] Furthermore, the control flow of the transformer production line control system includes: (1) Initial material laying process: the shift leader dispatches work orders and confirms the start of the shift > the MES system (both the MES server and the MES client) issues material and mold requests > SCADA receives, processes and decomposes work orders. (2) Example of main production interaction process: (2.1) Winding machine coil winding process: the operator in the MES client 2211~22N11,2311~23N21,…,2M11~2MN n1. Select work order task and print product barcode label > Scan work order number and mold SN for binding > Work order task start > MES server 20 sends process start, work order number, mold SN binding, and work order information exchange data to SCADA system 21 > SCADA system 21 sends work order information to the equipment to automatically switch formulas (process parameters) > Operator loads mold and coil > Starts equipment to begin winding > Winding completes, clicks button on HMI to execute process completion > SCADA system 21 collects processing parameters (number of turns completed, winding speed, winding tension) and process completion signal and uploads them to MES server 20 > Operator scans work order number and tray number to bind tray > MES system sends tray binding relationship to SCADA system 21 to update database data > MES system sends coil appearance inspection request to SCADA system 21 > Calls coil appearance inspection AGV for inspection > Inspection completes, SCADA system 21 uploads inspection signal and inspection results (coil length, width, and height) to MES server 20. (2.2) Coil resistance testing and coil balancing process: Equipment scans tray identification > SCADA collects tray SN number for balancing process entry > Operator scans coil SN number and performs coil resistance test > SCADA collects coil resistance data (coil SN, low voltage resistance, high voltage resistance, temperature, humidity) and uploads it to MES server for balancing use > SCADA issues coil appearance inspection work order data > Coil appearance inspection equipment calls the corresponding inspection program according to the work order program number for inspection > SCADA system collects coil appearance inspection result data (coil SN, length, width, height) and uploads it to MES system. (2.3) Coil pressing process flow: SCADA system 21 detects the lower pressure plate arrival signal and requests balancing data from MES server 20 > SCADA receives the balancing data and sends it to the gantry robot for coil release > SCADA system 21 collects the coil release result data and uploads it to MES server 20 > SCADA system 21 issues a pressing process work order > The pressing process equipment automatically switches to the corresponding production formula according to the work order data > SCADA system 21 collects the upper pressure plate SN number and uploads it to MES server 20 > SCADA system 21 collects the bolt SN number and uploads it to MES server 20 > SCADA system 21 collects the press processing data and uploads it to MES server 20 > SCADA system 21 collects the screw gun processing data and uploads it to MES server 20 > SCADA system 21 collects the stacking machine data and uploads it to MES server 20.
[0083] In the aforementioned example of a transformer production line, the MES server 20 is also used to determine the process number of each process based on the type of transformer to be produced, and to determine the number of work orders for each process based on the quantity of transformers to be produced.
[0084] In the aforementioned transformer production line example, the MES client in the winding machine coil winding process area is also used to create coil identification labels for each coil wound in each work order task when executing the winding machine coil winding process; and the operator fixes the labels to the coils and places each coil into a tray; the MES client is also used to associate the work order number of each work order task in the current process, the coil identification of the corresponding coil, and the tray identification of the tray into which the coil is placed, to obtain first association information and send the first association information to the MES server 20; the MES client in the coil resistance testing process area is also used to associate the work order number of each work order task in the current process, the coil identification of the corresponding coil, or the tray identification of the tray into which the coil is placed, to obtain second association information when executing each work order task in the coil resistance testing process, and send the second association information to the MES server 20; the MES client in the coil balancing process area is also used to associate the work order number of each work order task in the current process, the tray identifications of the three trays that have been successfully balanced, to obtain third association information when executing each work order task in the coil balancing process, and send the third association information to the MES server 20; The third association information is sent to the MES server 20; the MES clients in the coil assembly pressing process area, coil assembly drying process area, transformer body assembly process area, transformer body drying process area, and oil tank assembly process area are also used to execute the corresponding work order tasks for the coil assembly pressing process, coil assembly drying process, transformer body assembly process, transformer body drying process, and oil tank assembly process in sequence, respectively, to obtain the work order number of each work order task in the current process and associate it with any coil identifier in the corresponding coil identifier combination, to obtain the fourth association information and send the fourth association information to the MES server 20; the MES client in the transformer lubrication process area is also used to associate the work order number of each work order task in the current process, any coil identifier in the corresponding coil identifier combination, and the identifier of the corresponding finished transformer when executing each work order task in the transformer lubrication process, to obtain the fifth association information and send the fifth association information to the MES server 20; the MES server 20 is also used to obtain all work order task records corresponding to each transformer identifier based on the first association information, the second association information, the third association information, the fourth association information, and the fifth association information. In another optional implementation, the MES client in each process area is also used to collect the identifier to be associated and send the work order number of each work order task in the current process and the identifier to be associated to the MES server 20, so that the MES server 20 can perform the corresponding association process.
[0085] This embodiment is an exemplary implementation of the control system corresponding to the aforementioned production line control method embodiment. The technical details of the aforementioned production line control method embodiment are all applicable to this embodiment, and correspondingly, the technical details of this embodiment are all applicable to the aforementioned production line control method embodiment. It should be noted that the composition and structure of the control system corresponding to the aforementioned production line control method embodiment are not limited to... Figure 2 Any other components or structures that can realize the aforementioned control method embodiments of the production line are within the protection scope of this invention.
[0086] It should be noted that in the claims and specification of this patent, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one" does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0087] Obviously, those skilled in the art will understand that the modules or steps of the embodiments described above can be implemented using general-purpose computing devices. They can be centralized on a single computing device or distributed across a network of multiple computing devices. Optionally, they can be implemented using computer-executable program code, thereby storing them in a storage device for execution by a computing device. In some cases, the steps shown or described can be performed in a different order than those presented herein, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. Thus, the embodiments of this specification are not limited to any particular combination of hardware and software.
[0088] Although the invention has been illustrated and described with reference to certain preferred embodiments thereof, those skilled in the art will understand that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
[0089] The present invention has been shown and described in detail above with reference to the accompanying drawings and preferred embodiments. However, the present invention is not limited to these disclosed embodiments. Based on the above embodiments, those skilled in the art will know that more embodiments of the present invention can be obtained by combining the code review methods in the different embodiments. These embodiments are also within the protection scope of the present invention.
Claims
1. A method for controlling a production line, characterized in that, The production line is a transformer production line, and the processes include winding coils, coil resistance testing, coil balancing, coil pressing, coil drying, transformer body assembly, transformer body drying, tank assembly, and transformer oiling; the method includes: Determine the process number and work order quantity for each process of the product to be manufactured; A work order task for each process is generated based on the process number and the number of work orders. The work order task includes the work order number and the process number. Send each work order task of each process to the workstation client of the corresponding process area; When executing each process, the work order task is started through the workstation client of the current process area. The corresponding process parameters are retrieved based on the process number and configured into the workstation device of the corresponding workstation. After each work order task is completed, a work order task record with the corresponding work order number is generated. Furthermore, the method also includes: When executing each work order task of the winding machine coil winding process, a coil identification label is made for the coil wound for each work order task and fixed to the coil. Each coil is placed in a tray, and the work order number of each work order task in the current process, the coil identification of the corresponding coil, and the tray identification of the tray are associated to obtain the first association information. When executing each work order task of the coil resistance testing process, the work order number of each work order task in the current process, the coil identifier of the corresponding coil, or the tray identifier of the tray in which the coil is placed is associated to obtain the second association information; When executing each work order task of the coil balancing process, the work order number of each work order task in the current process and the pallet identifiers of the three successfully balancing pallets are combined and associated to obtain the third association information; For the coil pressing process, the coil drying process, the body assembly process, the body drying process, and the oil tank assembly process in sequence, execute the corresponding work order tasks, obtain the work order number of each work order task in the current process, and associate it with any coil identifier in the corresponding coil identifier combination to obtain the fourth association information; When executing each work order task of the transformer refueling process, the work order number of each work order task of the current process, any coil identifier in the corresponding coil identifier combination, and the identifier of the corresponding finished transformer are associated to obtain the fifth association information; Based on the first association information, the second association information, the third association information, the fourth association information, and the fifth association information, all work order task records corresponding to each transformer identifier are obtained.
2. The production line control method according to claim 1, characterized in that, Before performing each of the above steps, the following is also included: Obtain the parts list for the product to be manufactured; The parts list is broken down to obtain the parts list corresponding to each process. Determine the daily production quantity N of the production line; Collect the components of N products and distribute the components of the N products to the corresponding workstations in the process area according to the component list of each process.
3. The production line control method according to claim 1, characterized in that, The execution of each of the above processes also includes: Collect the processing parameters and / or testing data of the processing equipment and / or testing equipment at the corresponding workstation when executing the work order task, and generate a processing parameter record or testing data record for the corresponding work order number. The work order task record includes the processing parameter record and / or testing data record. The identification of the mold used to execute the work order task is collected through the workstation client. After each work order task is completed, a mold identification record with a corresponding work order number is generated. The work order task record includes the mold identification record.
4. The production line control method according to claim 1, characterized in that, Also includes: Real-time collection of alarm data from the equipment at the corresponding workstation; An alarm record is generated based on the alarm data, and the alarm level of the alarm data is determined so as to send a prompt message corresponding to the alarm level to the alarm equipment of the designated maintenance personnel.
5. The production line control method according to any one of claims 1-4, characterized in that, The determination of the process number and work order quantity for each process of the product to be produced further includes: The process number for each process is determined based on the type of transformer to be produced, and the number of work orders for each process is determined based on the quantity of the transformer to be produced.
6. The production line control method according to claim 5, characterized in that, Also includes: The number of times the equipment at the corresponding workstation is used is collected. If the number of uses reaches a predetermined value, a prompt message is sent to the alarm device of the designated maintenance personnel.
7. A control system for a production line, characterized in that, The production line is a transformer production line, and the processes include winding coils, coil resistance testing, coil balancing, coil pressing, coil drying, transformer body assembly, transformer body drying, tank assembly, and transformer oiling; the system includes: The MES server (20) is used to determine the process number and work order quantity of each process of the product to be produced. It further determines the process number of each process based on the type of the product to be produced and the work order quantity of each process based on the quantity of the product to be produced. It generates a work order task for each process based on the process number and the work order quantity. The work order task includes the work order number and the process number. It sends each work order task of each process to the MES client (2211~22N11, 2311~23N21, ..., 2M11~2MN) in the corresponding process area (22~2M). n 1); The MES client (2211~22N11, 2311~23N21, ..., 2M11~2MN) is set at the workstation of each process. n 1) and workstation equipment (2212~22N12, 2312~23N22, …, 2M12~2MN) n 2), wherein the MES client (2211~22N11,2311~23N21,…,2M11~2MN) n 1) Used to generate and send the workstation equipment (2212~22N12, 2312~23N22, ..., 2M12~2MN) of the current workstation when the work order task is started. n 2) The configuration request is sent to the SCADA system (21), and the configuration request includes the corresponding work order number and process number; The SCADA system (21) is used to respond to the configuration request, determine the corresponding process parameters based on the process number and configure them into the workstation equipment of the current workstation, and generate a workstation task record with the corresponding workstation number after each workstation task is completed. The MES client in the winding coil process area of the winding machine is also used to make a coil identification label for each coil wound for each work order task when executing each work order task of the winding machine coil process; and the operator fixes it to the coil and puts each coil into a tray; the MES client is also used to associate the work order number of each work order task in the current process, the coil identification of the corresponding coil, and the tray identification of the tray into which it is placed, to obtain the first association information and send the first association information to the MES server (20); The MES client in the coil resistance testing process area is also used to associate the work order number of each work order task in the current process, the coil identifier of the corresponding coil, or the tray identifier of the tray in which the coil is placed when executing each work order task of the coil resistance testing process, to obtain the second association information and send the second association information to the MES server (20). The MES client in the coil balancing process area is also used to associate the work order number of each work order task in the current process with the pallet identifiers of the three pallets that have been successfully balanced when executing each work order task in the coil balancing process, to obtain the third association information and send the third association information to the MES server (20). The MES clients in the coil pressing process area, coil drying process area, transformer body assembly process area, transformer body drying process area, and oil tank assembly process area are also used to execute the corresponding work order tasks for the coil pressing process, coil drying process, transformer body assembly process, transformer body drying process, and oil tank assembly process in sequence, obtain the work order number of each work order task in the current process, associate it with any coil identifier in the corresponding coil identifier combination, obtain the fourth association information, and send the fourth association information to the MES server (20). The MES client in the transformer refueling process area is also used to associate the work order number of each work order task in the current process, any coil identifier in the corresponding coil identifier combination, and the identifier of the corresponding finished transformer when executing each work order task in the transformer refueling process, to obtain the fifth association information and send the fifth association information to the MES server (20). The MES server (20) is also used to obtain all work order task records corresponding to each transformer identifier based on the first association information, the second association information, the third association information, the fourth association information and the fifth association information.
8. The control system for the production line according to claim 7, characterized in that, The SCADA system (21) is also used to collect processing data and / or detection data of the processing equipment and / or detection equipment at the current workstation when executing the work order task, and generate a work order task record with the corresponding work order number.