Automatic passing-station control method, device, electronic equipment and storage medium for silk ingots

Abstract

The present disclosure provides a method, apparatus, electronic device and storage medium for automatic passing-station control of silk ingots, relating to the field of chemical fiber intelligent technology. The specific solution is as follows: The automatic passing-station control system for silk ingots includes MES, a first PLC and multiple second PLCs; the automatic passing-station control method for silk ingots includes: when the control button of the first PLC is switched from the offline mode to the online mode and the first PLC resumes communication with MES, if it is detected that there is offline data stored in the offline cache area, the offline data is synchronized to MES, wherein the offline data is passing-station records that need to be synchronized to MES and are stored when the first PLC is disconnected from MES. According to the solution of the present disclosure, it is possible to achieve automatic synchronization of offline passing-station record management for silk ingots and improve the passing-station efficiency of silk ingots.

Description

Technical Field

[0001] The present disclosure relates to the field of chemical fiber intelligent technologies, and particularly to a method, device, electronic device and storage medium for automatic passing - station control of silk ingots. Background Art

[0002] In the field of chemical fiber production, an efficiently operating production line is the key to ensuring production capacity and efficiency. On this production line, there are multiple precisely coordinated workstations densely arranged. Particularly importantly, the smooth transfer of numerous silk ingots on the production line, and their passing - station speed is directly related to the overall production rhythm and efficiency, becoming one of the bottlenecks that cannot be ignored in improving production capacity. Therefore, how to achieve the rapid passing - station of silk ingots on the production line has become an important issue that urgently needs to be overcome in the current innovation of chemical fiber production technology. Summary of the Invention

[0003] The present disclosure provides a method, device, electronic device and storage medium for automatic passing - station control of silk ingots.

[0004] According to the first aspect of the present disclosure, there is provided a method for automatic passing - station control of silk ingots, which is applied to an automatic passing - station control system for silk ingots. The automatic passing - station control system for silk ingots includes a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and multiple second PLCs. Each of the second PLCs is used to control at least one workstation; the multiple second PLCs are respectively connected to the first PLC, and the first PLC can be connected to the MES. The method for automatic passing - station control of silk ingots includes:

[0005] Monitoring whether the control button of the first PLC switches from the offline mode to the online mode, and whether the first PLC resumes communication with the MES;

[0006] When the control button of the first PLC switches from the offline mode to the online mode and the first PLC resumes communication with the MES, if it is detected that there is offline data stored in the offline cache area, synchronize the offline data to the MES, where the offline data is passing - station records that need to be synchronized to the MES and are stored when the first PLC is disconnected from the MES.

[0007] According to the second aspect of the present disclosure, there is provided an automatic passing - station control device for silk ingots, which is applied to an automatic passing - station control system for silk ingots. The automatic passing - station control system for silk ingots includes MES, a first PLC, and multiple second PLCs. Each of the second PLCs is used to control at least one workstation; the multiple second PLCs are respectively connected to the first PLC, and the first PLC can be connected to the MES. The automatic passing - station control device for silk ingots includes:

[0008] A monitoring module, configured to monitor whether the control button of the first PLC switches from the offline mode to the online mode, and whether the first PLC resumes communication with the MES;

[0009] A first control module, configured to, when the control button of the first PLC switches from the offline mode to the online mode and the first PLC resumes communication with the MES, synchronize the offline data to the MES if it is detected that there is offline data stored in the offline cache area, where the offline data is the passing record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES.

[0010] According to a third aspect of the present disclosure, there is provided an electronic device, including:

[0011] At least one processor; and

[0012] A memory communicatively connected to the at least one processor; wherein,

[0013] The memory stores instructions executable by the at least one processor, and when the instructions are executed by the at least one processor, the at least one processor is enabled to execute any method in the embodiments of the present disclosure.

[0014] According to a fourth aspect of the present disclosure, there is provided a non-transitory computer-readable storage medium storing computer instructions, wherein the computer instructions are used to cause the computer to execute any method in the embodiments of the present disclosure.

[0015] According to the technology of the present disclosure, it is possible to realize the automated synchronous offline passing record management of the silk ingots and improve the passing efficiency of the silk ingots.

[0016] It should be understood that the content described in the summary of the invention section is not intended to limit the key or important features of the embodiments of the present disclosure, nor is it used to limit the scope of the present disclosure. Other features of the present disclosure will become easily understood through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In combination with the accompanying drawings and with reference to the following detailed description, the above and other features, advantages and aspects of the embodiments of the present disclosure will become more apparent. In the drawings, the same or similar reference numerals denote the same or similar elements, where:

[0018] Figure 1 is a schematic diagram of the silk ingot automatic passing control system according to an embodiment of the present disclosure;

[0019] Figure 2 is a flowchart of the silk ingot automatic passing control method according to an embodiment of the present disclosure Figure 1 ;

[0020] Figure 3Schematic flow of the automatic ingot passing control method according to an embodiment of the present disclosure Figure 2 ;

[0021] Figure 4 Schematic diagram of the processing flow for the first PLC to upload offline passing records to MES according to an embodiment of the present disclosure;

[0022] Figure 5 Schematic diagram of the structure of the automatic ingot passing control device according to an embodiment of the present disclosure;

[0023] Figure 6 Block diagram of an electronic device for implementing the automatic ingot passing control method according to an embodiment of the present disclosure. Detailed implementation manners

[0024] The following describes exemplary embodiments of the present disclosure with reference to the accompanying drawings. Various details of the embodiments of the present disclosure are included to facilitate understanding, and they should be considered merely exemplary. Therefore, those of ordinary skill in the art should recognize that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, descriptions of well-known functions and structures are omitted in the following.

[0025] Terms such as "first", "second", and "third" in the description, claims, and above-mentioned drawings of the present disclosure are used to distinguish similar objects and do not necessarily describe a specific order or sequence. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a method, system, product, or device that includes a series of steps or units does not necessarily have to be limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or are inherent to these processes, methods, products, or devices.

[0026] Before introducing the technical solutions of the embodiments of the present disclosure, further explanations are made on the technical terms that may be used in the present disclosure:

[0027] MES: A software system used to monitor and manage the manufacturing process, capable of collecting, processing, and analyzing production data in real time to optimize production plans and resource allocation.

[0028] PLC: An industrial digital computer used to control automation equipment, such as mechanical devices and robots on a production line. It can perform logical operations and processing on input signals according to a preset program and output control signals to control the operation of the equipment.

[0029] Business data: Data related to business generated during the manufacturing process, such as equipment status, product quantity, production progress, etc. These data are the basis for decision-making and control by MES and PLC.

[0030] Passing station instruction information (also known as passing station command): Instructions and parameter information generated by the MES based on business data analysis to guide the equipment to execute passing station tasks.

[0031] Figure 1 The schematic diagram of the automatic passing station control system for silk ingots is shown, as Figure 1 shown, the automatic passing station control system for silk ingots includes an MES, a first PLC, and multiple second PLCs. The multiple second PLCs are respectively connected to the first PLC, and the first PLC is connected to the MES. Each second PLC is responsible for controlling at least one work station. Among them, the second PLC is mainly responsible for collecting and processing the real-time business data of the target work station and providing it for the first PLC to use. The first PLC is responsible for interacting with the second PLC to obtain the second business data from the second PLC; the first PLC is also responsible for interacting with the MES, sending the first business data to the MES, and receiving the passing station instruction information issued by the MES based on the first business data, and then notifying the second PLC to execute the passing station instruction information for the target work station.

[0032] In some embodiments, the MES is used to determine passing station instruction information for the target work station based on the first business data sent by the first PLC and return the passing station instruction information to the first PLC.

[0033] In some embodiments, the first PLC is used to obtain the first business data for the target work station according to the second business data for the target work station obtained from the second PLC.

[0034] In some embodiments, each second PLC is used to obtain and store the second business data of the target work station controlled by it.

[0035] Here, the first business data is a data set collected and processed by the first PLC, including information such as the real-time status of the target work station, the processing progress of the silk ingot, the silk ingot quality inspection result, and the request type. These data are of great significance for monitoring the operation status of the production line and making decisions on whether to allow passing through the station.

[0036] Here, the second business data is a data set collected and processed by the second PLC, including information such as the real-time status of the target work station, the processing progress of the silk ingot, the silk ingot quality inspection result, and the silk ingot barcode. These data are of great significance for monitoring the operation status of the production line.

[0037] The automatic silk ingot passing station control system of the embodiments of the present disclosure enables the MES to monitor the status of each work station in real time and make adjustments and optimizations as needed through real-time communication and data processing among the MES, the first PLC, and the second PLCs. Through the above-mentioned automatic control, manual intervention is reduced, the efficiency and accuracy of the silk ingot passing station are improved; material waste and downtime caused by human errors are reduced, and the production cost is lowered. Through the above-mentioned automatic control, the stability and consistency of the silk ingot during the passing station process are ensured, which helps to improve the overall production rhythm and efficiency. By using the first PLC as the middle layer between the MES and multiple second PLCs, the automatic silk ingot passing station control system has significant advantages in aspects such as centralized management, data integration, reducing the burden on the MES, enhancing system scalability, improving security and stability, and simplifying the network structure.

[0038] If the MES directly communicates with multiple second PLCs, it will need to process a large amount of real-time data and requests, which may increase the burden on the MES and affect its performance. By using the first PLC as the middle layer, the MES only needs to communicate with the first PLC, thus reducing its processing burden. In the absence of the first PLC as the middle layer, the MES needs to establish direct communication connections with each second PLC, which will make the network structure complex and difficult to manage. By using the first PLC for transit, the network structure can be greatly simplified, making the entire communication process clearer and more orderly. The first PLC can act as a security barrier to verify and filter the data from the second PLCs, preventing malicious or incorrect data from entering the MES system. At the same time, the redundancy and fault tolerance mechanisms of the first PLC can improve the stability and reliability of the system, ensuring the normal operation of the production line even when some equipment fails.

[0039] As the production line expands and upgrades, more second PLCs may need to be added. If the MES directly communicates with each second PLC, corresponding configurations and modifications to the MES are required for each expansion. By using the first PLC as the middle layer, only the support for the new second PLC needs to be added in the first PLC, without modifying the configuration of the MES. The first PLC can centrally receive the business data from multiple second PLCs and perform unified processing and analysis. This way makes the control of the entire production line more centralized and orderly, reducing the complexity and chaos of the MES directly communicating with multiple second PLCs. The first PLC can integrate the data from different second PLCs to form a more comprehensive production view, which enables the MES to make decisions based on more comprehensive data, thereby optimizing the production plan and resource allocation. At the same time, the first PLC can also preprocess and filter the data to reduce the amount of data transmitted to the MES and improve the communication efficiency.

[0040] An embodiment of the present disclosure provides a method for automatically controlling a silk ingot to pass through a station. Figure 2 FIG. Figure 2 is a schematic flowchart of a method for automatically controlling a silk ingot to pass through a station according to an embodiment of the present disclosure. The method for automatically controlling a silk ingot to pass through a station can be applied to a device for automatically controlling a silk ingot to pass through a station, which is located on an electronic device, and the electronic device is applied to a control system for automatically controlling a silk ingot to pass through a station. The electronic device includes, but is not limited to, a fixed device and / or a mobile device. For example, the fixed device includes, but is not limited to, a server, and the server can be a cloud server or a general server. For example, the mobile device includes, but is not limited to: mobile phones, tablet computers, laptop computers, etc. In some possible implementation manners, the method for automatically controlling a silk ingot to pass through a station can also be implemented by a processor calling computer-readable instructions stored in a memory. As Figure 2 shown, the method for automatically controlling a silk ingot to pass through a station includes:

[0041] S201: Monitor whether the control button of the first PLC switches from the offline mode to the online mode, and whether the first PLC resumes communication with the MES;

[0042] S202: When the control button of the first PLC switches from the offline mode to the online mode and the first PLC resumes communication with the MES, if it is detected that there is offline data stored in the offline cache area, synchronize the offline data to the MES, where the offline data is the passing record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES.

[0043] In some embodiments, monitoring the status of the control button of the first PLC includes: reading the status signal of the control button through the input module of the first PLC, and determining whether it changes from the offline mode (usually represented by a specific input value, such as =0) to the online mode (another specific input value, such as =1).

[0044] In some embodiments, monitoring the communication status between the first PLC and the MES includes: using heartbeat detection or a specific instruction in the communication protocol to periodically detect whether the communication link between the first PLC and the MES is normal. Heartbeat detection usually includes the first PLC periodically sending a short signal to the MES, and the MES replies with an acknowledgment after receiving it, thereby confirming that the communication between the two parties is normal.

[0045] In some embodiments, a plurality of offline cache areas are provided in a storage medium connected internally or externally to the first PLC for storing offline data such as passing records generated during a communication interruption. The first PLC determines whether there is offline data that needs to be synchronized by reading the status or content of this area.

[0046] In some embodiments, synchronizing offline data to MES includes: Once it is confirmed that the first PLC has switched to the online mode and communication is restored, the first PLC will start the data synchronization program. This program will read all the offline data in the offline cache area and send this data to the MES system according to the data interface standards of MES (such as Application Programming Interface (API), database interface, etc.). During the synchronization process, issues such as data format conversion, data encryption, and error checking may need to be handled.

[0047] Suppose the silk ingot packaging is automatically controlled by the first PLC and the second PLC, and the first PLC interacts with the MES system in real time to produce data. One day, due to a network failure, the communication between the first PLC and the MES is interrupted, and key data such as passing records generated during this period are stored in the offline cache area of the first PLC. When the network failure is resolved, the first PLC detects that the control button has switched from the offline mode to the online mode, and the communication with the MES is restored. At this time, the first PLC automatically starts the data synchronization program to synchronize data such as passing records in the offline cache area to the MES system, ensuring the integrity and real-time nature of the production data.

[0048] The technical solution of the embodiment of the present disclosure, when the control button of the first PLC switches from the offline mode to the online mode and the first PLC resumes communication with the MES, if it is detected that there is offline data stored in the offline cache area, the offline data is synchronized to the MES, which can ensure that the key data in the production process can be synchronized to the MES system in a timely manner, helping the management to grasp the production status in real time and make a quick response. Through the offline cache mechanism, the integrity and traceability of key data can be ensured even in the case of disconnection, avoiding the impact on production caused by data loss. Through the automatic synchronization mechanism, communication failures can be detected and resolved in a timely manner, improving the stability and reliability of the system.

[0049] In some embodiments, before synchronizing offline data to MES, as Figure 3 shown, the method further includes:

[0050] S301: The first PLC obtains the second service data of the target station from the second PLC corresponding to the target station, and obtains the first service data of the target station according to the second service data;

[0051] S302: In the case where the first PLC is disconnected from the MES, the first PLC records the first service data and sends a passing instruction message to the second PLC, so that the second PLC controls the target station to perform the silk ingot passing task based on the passing instruction message; wherein, the passing instruction message is permission to pass;

[0052] S303: The first PLC stores offline data in the offline cache area, where the offline data is the passing record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES.

[0053] Here, the first service data is transformed from the second service data obtained by the first PLC from the second PLC corresponding to the target work station. These second service data usually contain information such as the real-time production status, parameters, results, etc. of the target work station. When the first PLC is disconnected from the MES, the first PLC will record the first service data transformed from these second PLCs. The first service data is mainly used to support the production control of the target work station, such as the control of the silk ingot passing task in this example. It reflects the working status of the target work station in real-time or near real-time.

[0054] Here, different from the first service data, the offline data does not directly come from the transformation of real-time data on the production site, but refers to the data that needs to be recorded during the disconnection between the first PLC and the MES for subsequent synchronization to the MES. These data may include various production records, events, status changes, etc. When the first PLC is disconnected from the MES, in order to maintain the continuity and integrity of the data, these data need to be stored in the offline cache area. The main purpose of the offline data is to synchronize these data to the MES system after the network is restored or the connection with the MES is re-established, so as to ensure that the data in the MES system is up-to-date and can reflect the real situation of the production site. This is crucial for production management, data analysis, report generation, etc.

[0055] In some embodiments, each second PLC collects and processes relevant second service data (such as silk ingot position, status, quantity, etc.) according to the status of the work station it controls, and stores these data in the data storage area allocated for the work station it is responsible for, such as a data block (Data Blocks, DB block), by the second PLC.

[0056] In some embodiments, the first PLC obtains the second service data of each work station from each second PLC and generates the first service data for each work station. These first service data contain information about the status of all relevant work stations and the operations that need to be performed. The MES analyzes the first service data to determine the passing instruction information of the target work station (i.e., the work station that needs to perform the silk ingot passing task currently). The passing instruction information includes permission to pass or prohibition to pass. Among them, when the passing instruction information is permission to pass, it may also include parameters such as the specific time of passing, the target position, the speed, etc. The MES sends the generated passing instruction information to the first PLC through the network or other communication means such as a management interface (Management Interface, MI).

[0057] In some embodiments, after the first PLC receives the passing station instruction information from the MES, it performs parsing and processing to extract specific control instructions and parameters. After the first PLC finishes parsing, it sends the parsing result (i.e., specific control instructions and parameters) to the second PLC corresponding to the target station through a communication interface or communication protocol. After receiving the parsing result, the second PLC controls the mechanical device or robot and other passing station equipment at the target station to perform the task of passing the silk ingot through the station according to the control instructions and parameters in the parsing result.

[0058] In some embodiments, when the system starts up, the communication protocol and parameters between the first PLC and the second PLC are configured to ensure stable communication between the two. The connection between the first PLC and the MES is configured to ensure that the first PLC can send the first service data to the MES and receive the passing station instruction information returned by the MES. The first PLC actively obtains the second service data (such as the current working status, the number of silk ingots to be processed, the processing time, etc.) of the target station from the second PLC corresponding to the target station. After the first PLC obtains the second service data, according to a preset algorithm or logic, it converts these data into the first service data (such as whether the passing station condition is met, the estimated passing station time, etc.). If the connection between the first PLC and the MES is disconnected due to reasons (such as network failure, MES maintenance, etc.), the first PLC will automatically switch to the offline working mode. In this mode, the first PLC will record the first service data and send a passing station instruction information (such as a "permission to pass the station" signal) to the second PLC. After receiving the passing station instruction information, the second PLC will control the target station to perform the task of passing the silk ingot through the station, including moving the silk ingot to the next station and updating the status information, etc. Once the connection between the first PLC and the MES is restored, the system can automatically synchronize the data and adjust the subsequent operations according to the latest instructions of the MES.

[0059] For example, assume that there are multiple stations on the production line, and each station is responsible for different processing tasks. The first PLC regularly obtains the second service data of the current station from the second PLC. When the silk ingot at a certain station (such as the weighing station) is processed and needs to enter the next process. At this time, if the MES system is temporarily unavailable, the first PLC will send a passing station instruction information of "permission to pass the station" to the second PLC on behalf of the MES. Subsequently, the second PLC sends an instruction to the passing station equipment (such as a conveyor belt or a manipulator) to transfer the processed silk ingot to the next station (such as the roll diameter measurement station) for subsequent processing.

[0060] In the solutions of the embodiments of the present disclosure, the main types of yarn packages involved may include one or more of partially oriented yarns (POY), fully drawn yarns (FDY), draw textured yarns (DTY) (or low elastic yarns), etc. For example, the types of yarns may specifically include polyester partially oriented yarns, polyester fully drawn yarns, polyester drawn yarns, polyester draw textured yarns, polyester staple fiber (PSF), etc.

[0061] In the technical solution of the embodiments of the present disclosure, through the real-time communication and data processing among the MES, the first PLC, and multiple second PLCs, the MES can monitor the status of each work station in real time and adjust and optimize the passing strategy as needed. Even when the first PLC is disconnected from the MES, the system can still operate independently and complete the passing task, enhancing the stability and reliability of the system. Through the automated offline forced passing control, the manual intervention is reduced, the speed and accuracy of the yarn package passing are accelerated, and the production cost and time cost caused by manual errors or delays are reduced.

[0062] In the embodiments of the present disclosure, the second PLC controls the target work station to execute the yarn package passing task based on the passing instruction information, including: when the passing instruction information is permission to pass, the second PLC notifies the passing equipment or directly controls the passing equipment to transfer the yarn package processed at the target work station to the next work station of the target work station.

[0063] Here, the passing equipment refers to the automated equipment used on the production line to transfer materials (such as yarn packages) between different work stations, such as conveyor belts, manipulators, automatic handling carts, etc. The above is only an exemplary description and does not limit all possible equipment included in the passing equipment. Here, an exhaustive list is not made.

[0064] In some embodiments, the passing instruction information may include the evaluation result of whether the yarn package at the target work station meets the passing conditions by the first PLC, which is used to guide subsequent control operations.

[0065] In some embodiments, when the passing - station indication information is "permission to pass", the second PLC will send an instruction or signal to the passing - station equipment, notifying it to prepare to transfer the spools that have been processed at the target station. After receiving the instruction from the second PLC, the passing - station equipment will transfer the spools from the target station to the next station according to a preset program or path. During the transfer process, a series of actions such as grasping, handling, and placing the spools may be involved, and these actions need to be precisely controlled to ensure the safe and accurate transfer of the spools.

[0066] In some embodiments, the second PLC will continuously monitor the operating state of the passing - station equipment and the transfer situation of the spools. Once the transfer is completed, the passing - station equipment will send a feedback signal to the second PLC to confirm that the current spool has successfully reached the next station. The second PLC updates its internal state based on the feedback signal to prepare for subsequent control operations.

[0067] For example, assume that there are multiple stations on the production line, and each station is responsible for different processing tasks. When the spools at a certain station (such as the weighing station) are processed, the second PLC receives the parsing result of this station. Whether the parameters such as weight, specification, and batch number meet the requirements or not, as long as the forced passing - station variable = 1, it is determined as "permission to pass". Subsequently, the second PLC sends an instruction to the passing - station equipment (such as a conveyor belt or a manipulator) to transfer the processed spools to the next station (such as the coil diameter measurement station) for subsequent processing.

[0068] In this way, through the first PLC and multiple second PLCs, the passing - station process of the spools can be precisely controlled, reducing waiting time and manual intervention, improving the overall efficiency of the production line; reducing errors caused by human factors, and improving the stability and reliability of the production process. PLC programming is flexible and can quickly adjust the control logic according to production requirements to adapt to the processing of different types and specifications of spools. The first PLC supports forced passing - station, which can not only significantly shorten the residence time of the spools at the station, improve the overall smoothness of the production line, but also effectively reduce energy consumption and labor costs.

[0069] In the embodiments of the present disclosure, the spool automatic passing - station control method further includes: when the first PLC detects that the control button corresponding to the first PLC rotates to the offline mode, it determines that the first PLC is disconnected from the MES.

[0070] In some embodiments, the offline mode generally refers to the state where the system operates independently without communicating with the upper - level management system (such as MES). In this mode, the system can rely on its own logic and preset parameters to execute control tasks.

[0071] In some embodiments, the control button is a physical switch or knob for controlling the working mode of the first PLC. It is used to switch the working mode of the first PLC (such as online mode or offline mode). The offline mode is a specific position or mark on the control button. When the button is rotated to this position, it indicates that the offline mode is selected, which is used to actively interrupt the communication with the MES. The online mode is a specific position or mark on the control button. When the button is rotated to this position, it indicates that the online mode is selected, which is used when hoping to maintain communication with the MES.

[0072] In some embodiments, the first PLC continuously monitors the status of the control button directly connected to it. This button is usually installed on the control panel, allowing the operator to manually switch the working mode of the first PLC. When it is detected that the control button is rotated to the "offline mode" position, the first PLC immediately records this event and considers that the connection with the MES has been or is about to be disconnected. It should be noted that this detection method mainly relies on hardware signals (such as the switch state of the button), so it is immediate and reliable. After determining the offline mode, the first PLC will obtain the second business data of the target work station from the second PLC according to the established process and convert it into the first business data. Based on the processed first business data, the first PLC will decide whether to send a passing station instruction message to the second PLC to control the passing station task of the silk ingot. Generally speaking, the first PLC will send a "permission to pass" passing station instruction message to the second PLC. The system should be capable of handling various abnormal situations and automatically synchronize data or restore the connection with the MES when the conditions are restored.

[0073] Taking the automatic packaging line in the chemical fiber industry as an example, due to a network failure, the MES is temporarily unable to communicate with the first PLC. At this time, the operator can walk to the control panel where the first PLC is located and rotate the control button to the "offline mode". After the first PLC detects this change, it will automatically determine that the connection with the MES has been disconnected and immediately start the passing station control process in the offline mode. Subsequently, the first PLC will send a "permission to pass" passing station instruction message to the second PLC to ensure that the silk ingot can smoothly move from the current work station to the next work station.

[0074] Thus, by introducing control buttons, it allows operators to directly intervene in the production process under specific circumstances, improving the flexibility of the system and its ability to respond to emergencies. By allowing the operator to manually switch the working mode of the first PLC, the system can quickly adjust its operating state according to actual needs, enhancing the flexibility and adaptability of the system. The status detection of the control buttons provides an intuitive indication of the connection status between the first PLC and MES, helping to promptly detect and handle connection problems, thereby improving the reliability of the system. In the case where MES is unavailable, the operator can simply rotate the control button to switch the first PLC to the offline mode, enabling the system to continue performing the passing-station tasks, simplifying the operation process and reducing the downtime.

[0075] In the embodiments of the present disclosure, the automatic passing-station control method for the silk ingot further includes: when the first PLC detects a communication interruption between the first PLC and MES, it determines that the connection between the first PLC and MES is disconnected.

[0076] In some embodiments, communication interruption refers to a state in which, during the communication process, due to various reasons (such as network failures, equipment failures, signal interferences, etc.), the communication link is unable to transmit data normally.

[0077] In some embodiments, a communication status monitoring module is integrated inside the first PLC, and this module continuously monitors the communication link with MES. The monitoring content includes but is not limited to key indicators such as the success rate of data packet sending and receiving, communication delay, and the number of timeouts. When it is detected that the communication link is abnormal (such as consecutive failures in sending multiple data packets, communication delay exceeding a preset threshold, the number of timeouts reaching the upper limit, etc.), it is determined as a communication interruption. Once a communication interruption is determined, the first PLC immediately records this event and considers that the connection with MES has been disconnected. Subsequently, the first PLC will switch to the offline working mode. In the offline working mode, the first PLC continues to obtain the second service data of the target station from the second PLC and converts it into the first service data. Based on the processed first service data, the first PLC decides whether to send passing-station instruction information to the second PLC to control the passing-station tasks of the silk ingot. When the first PLC detects that the communication link with MES returns to normal, it automatically switches to the online working mode; in the online working mode, the first PLC will perform synchronization operations with MES to ensure the consistency and accuracy of the data.

[0078] Suppose on an automated production line, the first PLC is responsible for monitoring and managing the operating status of multiple spindle processing stations. One day, due to a network failure, the communication link between the first PLC and the MES is interrupted. The communication status monitoring module of the first PLC immediately detects this anomaly and determines it as a communication interruption. Subsequently, the first PLC automatically switches to the offline working mode and continues to obtain business data from the second PLC and control the spindle passing tasks. When the network failure is resolved and the communication link returns to normal, the first PLC synchronizes with the MES again to ensure data consistency and accuracy.

[0079] In this way, by automatically detecting communication interruptions and switching to the offline working mode, the system can continue to execute control tasks when the MES is unavailable without manual intervention, improving the automation level of the system. The automatic detection and handling mechanism for communication interruptions enables the system to cope with various communication failures, enhancing the stability and reliability of the system. After the communication is restored, the system can automatically synchronize data and resume the normal working state, reducing the downtime caused by communication problems.

[0080] In the embodiments of the present disclosure, the automatic spindle passing control method further includes: when the MES is disconnected from the first PLC, the MES does not perform the judgment and processing of the online passing conditions.

[0081] In some embodiments, when the communication between the MES and the underlying control system is interrupted, the MES takes a series of alternative processing measures to maintain the normal operation of the system, and these measures may not rely on real-time data.

[0082] In some embodiments, the judgment and processing of the online passing conditions include: the process in which the MES evaluates and analyzes the received business data according to preset rules and algorithms to determine whether to allow the target station to perform the passing operation. These conditions may include various factors such as production plans, equipment status, and material supply situations.

[0083] In some embodiments, when the MES receives the first business data sent by the first PLC, it first performs data reception and preliminary verification. If the data format is correct and contains valid forced passing variables, the MES will record these data completely in its internal database or log system for subsequent data traceability. The recorded content may include all or part of the key fields of the first business data, as well as information such as the timestamp of the received data. Under normal circumstances, the MES will judge and process the online passing conditions according to the preset rules and algorithms for the received business data to decide whether to allow the target station to pass.

[0084] In some embodiments, a stable communication connection is established between the MES and the first PLC, and the status of this connection is continuously monitored. When the first PLC detects a communication interruption with the MES, it will notify the MES through a preset communication protocol or heartbeat mechanism. After receiving the communication interruption notice from the first PLC, the MES immediately identifies that the current connection status with the first PLC is disconnected. The MES then stops executing any online in-station passing condition judgment processing that depends on real-time communication with the first PLC. The MES may initiate an offline processing strategy, which may include recording the communication interruption event, sending an alert to the system administrator, and performing a certain degree of predictive processing according to preset rules or historical data (if applicable). However, in any case, the MES will not perform any online in-station passing condition judgment that requires real-time data acquisition from the first PLC. When the first PLC detects the restoration of communication with the MES, it will notify the MES again. After receiving the notice of communication restoration, the MES will re-establish the communication connection with the first PLC and resume the execution of the in-station passing condition judgment processing.

[0085] Taking the automatic packaging line in the chemical fiber industry as an example, the MES is responsible for monitoring the entire production process and judging whether the silk ingots meet the in-station passing conditions based on real-time data. However, due to a network failure, the communication between the MES and the first PLC is suddenly interrupted. At this time, the MES immediately stops executing the in-station passing condition judgment processing and records this event through the system log. At the same time, the system administrator receives an alert of the communication interruption and immediately starts troubleshooting. After the fault is resolved and the communication is restored, the MES re-establishes the connection with the first PLC and continues to execute the in-station passing condition judgment processing.

[0086] In this way, during the communication interruption, the MES does not perform unnecessary online in-station passing condition judgment, thereby reducing the consumption of computing resources. By avoiding executing processing that depends on real-time data during communication interruption, potential problems caused by data inconsistency or errors in the system are reduced. The system administrator can receive an alert of the communication interruption in a timely manner and intervene as needed, thereby improving the maintainability of the system and the user experience.

[0087] In the embodiments of the present disclosure, the judgment processing of the in-station passing conditions may include: determining whether the silk ingots at the target station meet the in-station passing conditions based on the target string data corresponding to the target station, where the target string data is obtained by the MES parsing the first service data; if the in-station passing conditions are met, it is determined that the in-station passing instruction information is "permitted to pass"; if the in-station passing conditions are not met, it is determined that the in-station passing instruction information is "forbidden to pass".

[0088] In some embodiments, the in-station passing instruction information is used to indicate whether the silk ingots on the production line can continue to be transferred to the next station for processing. According to the judgment result of the in-station passing conditions, the in-station passing instruction information can be "permitted to pass" or "forbidden to pass".

[0089] In some embodiments, the MES first receives the first service data sent from the first PLC. This data usually includes the status information of the target workstation on the production line, the processing progress of the silk ingot, the quality inspection results, and how many times the passing station has been requested, etc. There is a dedicated data parsing module inside the MES for parsing the received first service data to extract the target string data corresponding to the target workstation. This target string data may be encoded and represents specific working states or attributes.

[0090] In some embodiments, based on the parsed target string data, the MES further performs a comparative analysis with the preset passing station conditions. These passing station conditions may include whether the processing quality of the silk ingot meets the standard, whether all processing tasks of the current workstation have been completed, whether there are equipment failures or production anomalies, etc. If the silk ingot at the target workstation meets all the preset passing station conditions, the MES determines that the passing station instruction information is "permission to pass", indicating that the silk ingot can be safely transferred to the next workstation for further processing. If the silk ingot at the target workstation does not meet any of the passing station conditions, the MES determines that the passing station instruction information is "prohibited from passing" and may trigger the corresponding alarm mechanism to notify the on-site personnel for inspection and handling.

[0091] In some embodiments, the MES takes the determination result (permission to pass or prohibited from passing) as the passing station instruction information and sends it to the second PLC or other relevant control devices through the communication interface. These passing station devices execute the corresponding control logic according to the received passing station instruction information, such as starting or stopping the transfer action of the silk ingot.

[0092] Taking the automatic packaging line in the chemical fiber industry as an example, when the first PLC detects that the processing of the silk ingot at a certain workstation (such as the weighing workstation) is completed, it will send the first service data containing the status information of this workstation to the MES. After receiving the data, the MES first parses out the target string data (such as the QR code and weight information of the passing station request silk ingot), and then compares it with the preset passing station conditions (such as whether the weight of the silk ingot of this specification is within the allowable range, Grade A: within the allowable range, Grade B: light weight, Grade C: heavy weight). If the quality grade of the silk ingot is Grade A, the MES determines that the passing station instruction information is "permission to pass" and notifies the second PLC to start the transfer action of the silk ingot; if the quality grade of the silk ingot is Grade B or Grade C, it is determined as "prohibited from passing" and the alarm mechanism is triggered.

[0093] Thus, through the parsing of the first business data by the MES and the accurate judgment of the passing conditions, it can be ensured that only the spindles meeting the requirements can continue to be transferred, thereby improving the accuracy and reliability of production. Timely detection and prevention of the transfer of spindles that do not meet the passing conditions can reduce abnormal situations in the production process, such as equipment failures, quality problems, etc., thereby reducing production risks. By automatically judging and indicating the passing information, manual intervention and waiting time can be reduced, and the overall operating efficiency of the production line can be improved.

[0094] In the embodiments of the present disclosure, the first PLC obtains the second business data of the target station from the second PLC corresponding to the target station, including: the first PLC regularly obtains the second business data of the target station from the second PLC.

[0095] In some embodiments, a timer is set in the first PLC to control the time interval of data acquisition. This time interval can be adjusted according to the actual requirements of the production line to ensure that the latest data can be obtained in a timely manner without increasing the burden on the system due to overly frequent data exchanges. When the timer reaches the set time point, the first PLC sends a data request signal to the second PLC. This signal contains information such as the data type to be acquired and the target station identifier, so that the second PLC can accurately return the corresponding data.

[0096] In some embodiments, after receiving the data request from the first PLC, the second PLC retrieves the second business data of the target station from its own database or real-time data cache according to the information in the request and sends it to the first PLC through the communication interface. These data may include the real-time status of the target station, the processing progress, the quality inspection results, etc.

[0097] In some embodiments, after obtaining the second business data, the first PLC parses and processes it to extract the information needed for subsequent decision-making or control operations. At the same time, these data may also be used to update the relevant data in the MES or generate reports.

[0098] Thus, by regularly obtaining the second business data of the target station from the second PLC, real-time monitoring of the production line status can be achieved, ensuring the transparency and traceability of the production process. Based on the real-time data, the MES or the first PLC can timely detect abnormal situations in the production process and take corresponding adjustment measures, such as stopping passing, adjusting process parameters, etc., to improve production efficiency and product quality. Through the analysis of historical data and real-time data, strong support can be provided for the optimization decision-making of the production line, such as predicting production trends and optimizing production plans.

[0099] In the embodiments of the present disclosure, the first PLC obtains the first service data based on the second service data of the target station obtained from the second PLC corresponding to the target station, including: the first PLC converts the second service data into the first service data in the data storage format according to the preset data storage format, where the first service data is stored in the data storage area allocated by the first PLC for the target station, and different types of variables in the first service data correspond to different fixed addresses in the data storage area.

[0100] Here, the data storage format refers to the specific format or specification adopted during data storage or transmission, including data types, data units, data encoding, etc.

[0101] Here, the data storage area refers to a specific area inside the first PLC for storing data.

[0102] Here, the fixed address refers to the unique and unchanging storage location allocated for different variables in the data storage area. Through the fixed address, rapid access and modification of variables can be achieved.

[0103] In some embodiments, in the automatic bobbin passing station control system, the first PLC is responsible for generating the first service data of the target station based on the second service data of the target station. These data may contain various types of information, such as status codes, numerical parameters, timestamps, etc. The first PLC is internally configured with a preset data storage format to ensure efficient data exchange and parsing between different PLCs or between the PLC and the MES. The first PLC converts the second service data according to this preset format. The conversion process may include data type conversion (such as integer to floating point), data unit unification (such as from millimeters to inches), data encoding decoding (such as base conversion), etc. The converted data is the first service data, which follows the preset data storage format for subsequent processing and transmission. The first PLC allocates a dedicated data storage area for each target station on the production line. The first service data is stored in the data storage area corresponding to the target station. When storing, different variables (such as status codes, numerical parameters, etc.) are allocated to different fixed addresses in the storage area. When it is necessary to read or modify the value of a certain variable, it can be directly accessed through its corresponding address, improving the efficiency of data processing.

[0104] In this way, through the preset data storage format and the format conversion process, the consistency and accuracy of data from different sources during the exchange and processing are ensured. Allocating fixed storage addresses for each variable simplifies the data access and processing process and improves the overall performance of the system. The allocation and format definition of the data storage area have a certain degree of flexibility and can be expanded and adjusted according to the actual needs of the production line.

[0105] In some embodiments, the automatic passing-station control method for the silk ingot further includes: the first PLC allocates multiple offline buffer areas and an offline control area for all target workstations. The multiple offline buffer areas are shared by all target workstations. The offline control area includes relevant data bits and control bits for synchronizing offline data to the MES.

[0106] Here, the offline buffer area is a specific area divided in the first PLC or other storage devices, and is used to store the data to be synchronized when the communication between the first PLC and the MES is interrupted.

[0107] Here, the offline control area is a dedicated area set in the second PLC, and includes relevant data bits and control bits for controlling the offline data synchronization process.

[0108] In some embodiments, the first PLC allocates multiple shared offline buffer areas for all target workstations. These areas are used to store the offline data generated by each workstation during the interruption of the communication between the PLC and the MES, such as passing-station records, production parameters, etc.

[0109] In some embodiments, a dedicated offline control area is set in the first PLC. This area includes relevant data bits and control bits for controlling the offline data synchronization process. These data bits and control bits are used to store key information such as synchronization status, target MES address, synchronization priority, etc., to ensure that the offline data can be accurately and orderly synchronized to the MES system.

[0110] In some embodiments, when the communication between the first PLC and the MES is interrupted, the offline data generated by each target workstation will be automatically stored in the shared offline buffer area. At the same time, the relevant data bits and control bits in the offline control area will be updated to reflect the current synchronization status and priority. Once the communication between the first PLC and the MES is restored, the first PLC will check the status information in the offline control area and decide which offline data needs to be synchronized to the MES system according to the priority and synchronization policy. Then, the first PLC will send the offline data from the buffer area to the MES system according to the predetermined format and protocol.

[0111] In some embodiments, after receiving the offline data, the MES system will perform verification and confirmation. Once the data is successfully received and processed, the MES system will send a synchronization confirmation signal to the first PLC. After receiving the confirmation signal, the first PLC will update the status information in the offline control area and clear the synchronized offline data to release the buffer space for subsequent use.

[0112] In this way, by allocating a shared offline cache area for all target workstations, it is ensured that critical data generated during communication interruptions is properly preserved, avoiding the impact on production caused by data loss. The setting of the offline control area enables the PLC to flexibly control the synchronization process of offline data, including synchronization priorities, target MES addresses, etc., thus meeting the requirements in different production scenarios. Once communication resumes, the PLC can quickly synchronize the offline data to the MES system, ensuring that the management can grasp the production status in real time and make rapid responses, thereby improving production efficiency. Through the synchronization confirmation and cleaning mechanism, it can be ensured that the synchronized offline data is promptly deleted from the cache area, avoiding occupying excessive storage space resources.

[0113] In some embodiments, the main steps for synchronizing offline data to the MES are as follows:

[0114] System startup and status check: After the system starts, continuously check whether the first PLC is in the online mode and the offline passing record synchronization function is enabled.

[0115] Offline data check: If the conditions are met, check whether there is a queue (data) to be processed in the offline cache area.

[0116] Control area status preparation: Ensure that the relevant data bits and control bits in the offline control area are in the initial state; otherwise, perform a reset operation.

[0117] Data transmission and passing control: Transmit the first queue data in the offline cache area to the offline control area, and set the control bit to indicate that the second PLC starts to process passing.

[0118] Request and response processing: Trigger the first PLC to send a request (AVI_REQUEST) to the MES through the control bit, and wait for the response from the MES.

[0119] Response verification and data processing: Verify the format of the data returned by the MES. If it is correct, parse the data to the business data area (IT_RES_1) of the offline control area, and check whether the response result is valid and error-free.

[0120] Error handling and status update: According to the response result, perform error handling or update the control bit to indicate that the data processing is completed.

[0121] Queue and data area reset: Perform queue shifting on the offline cache area, and reset the relevant control bits and business data area in the offline control area to prepare for the next round of synchronization, ensuring the effective synchronization and processing of offline data. In some embodiments, the offline data can be synchronized to the MES according to the following steps:

[0122] a. System startup;

[0123] b. The first PLC is in the online mode and synchronous offline passing record is enabled. If so, execute step c; if not, continuously execute step b;

[0124] c. Determine whether the number of queues in the offline cache area is not less than 1. If so, execute step d; if not, continuously execute step c;

[0125] d. Determine whether the relevant data bits and relevant control bits in the offline control area are all in the initial state. If so, execute step e; if not, clear and reset the relevant data bits and reset the relevant control bits;

[0126] e. Transmit the relevant data of the spindle corresponding to the first queue in the offline cache area to the first position in the offline control area, and the first position is used to cache the service data read from the offline cache area;

[0127] f. Set the control bit in the offline control area indicating the start of passing of the second PLC; g. Check whether the value of the control bit in the offline control area indicating the start of passing of the second PLC is 1. If so, execute step h; otherwise, continuously execute step g;

[0128] h. Set the control bit in the offline control area indicating that the first PLC writes AVI_REQUEST, and AVI_REQUEST represents the request message sent by the first PLC to the MES;

[0129] i. Check whether the control bit in the offline control area indicating that the first PLC receives the data returned by the MES is not empty. If so, execute step j; if not, continuously execute step i;

[0130] j. Check whether the format of the data returned by the MES in the offline control area is correct. If the format is incorrect, execute step k; if the format is correct, execute step l;

[0131] k. Write the error code indicating that the AVI_RESPONSE1 format is incorrect, and then execute step q;

[0132] l. Set the control bit in the offline control area indicating that the first PLC receives the data returned by the MES;

[0133] m. Parse the data returned by the MES into IT_RES_1, and IT_RES_1 represents the service data output by the first PLC;

[0134] Check whether RESPONSE_RESULT of IT_RES_1 is 1 and RESPONSE_ERROR is 0. If both conditions are met, execute step p; otherwise, execute step o. RESPONSE_RESULT = 1 indicates that there is a response result, and RESPONSE_ERROR = 0 indicates that the response result has no error.

[0135] o. Write an error code indicating that the processing result does not meet expectations, and then execute step q.

[0136] p. Set the control bit used to indicate the completion of the first PLC data processing in the offline control area.

[0137] q. Shift the queue in the offline cache area, and reset the relevant control bits and relevant service data areas corresponding to the offline control area.

[0138] It can be understood that the above steps can be set or adjusted according to actual needs. For example, steps can be added or reduced, or the content of some steps can be changed.

[0139] In this way, through detailed step control, including checking the queue number in the offline cache area, the status of the offline control area, the format of the MES return data, etc., it is ensured that only the offline data that meets the requirements will be synchronized to the MES system, thus avoiding data errors or omissions. The system can automatically start the synchronization process after the communication between the first PLC and the MES is restored, and through the loop check and waiting mechanism, ensure that each operation is carried out in the correct state. At the same time, for possible error situations (such as incorrect data format, processing result not meeting expectations, etc.), the system can give a clear error code and take corresponding reset measures, thereby improving the fault tolerance and stability of the system. Through the queue shift processing and reset mechanism, the system can timely clean up the synchronized offline data and release the cache space for subsequent use. This can not only avoid the problem of cache overflow, but also improve the response speed and performance of the system. The synchronization process adopts a modular and configurable design concept. By modifying the relevant data bits and control bits in the offline control area, parameters such as synchronization strategies and priorities can be flexibly adjusted to meet the requirements in different production scenarios. At the same time, this synchronization method is also easy to integrate and expand with other systems or modules. By synchronizing offline data to the MES system in real time, the management can grasp the operation status and key data of the production line in real time, and thus make more accurate and timely decisions. This can not only improve production efficiency, but also enhance data transparency and traceability, providing strong support for the continuous improvement and optimization of the enterprise.

[0140] Next, taking IT-PLC as the first PLC and ME-PLC as the second PLC as an example, the processing flow of the first PLC, which is the intermediate layer between MES and the second PLC, will be described.

[0141] Figure 4 The schematic diagram of the processing flow for the first PLC to upload the offline passing record to MES is shown. As Figure 4 shown, this process includes:

[0142] S401: The system starts;

[0143] S402: Is IT-PLC ON LINE(I0.0)=1 and DB6200.STATION_CFG.TRO=1? If yes, execute S403; if no, continue to execute S402;

[0144] Here, IT-PLC ON LINE(I0.0)=1 means that the control button of the IT-PLC is set to the "online mode", and STATION_CFG.TRO=1 means enabling the synchronization of offline passing records. DB6200 is the DB block used by the IT-PLC to store the relevant control bits for synchronizing offline passing records.

[0145] S403: Is DB6241.QTY_UNLOAD≥1? If yes, execute S404; if no, continue to execute S403;

[0146] Here, QTY_UNLOAD represents the number of queues in the offline cache in DB6241.

[0147] Here, DB6241 - DB6248 are eight DB blocks allocated for all workstations to cache offline records. Among them, DB6241 is the first DB block of the eight DB blocks. When DB6241 is full, data starts to be stored in DB6242; after DB6242 is full, data starts to be stored in DB6243. Among these 8 DB blocks, each DB block can store a certain number of queues. When synchronously uploading offline records, they are uploaded in the order of DB6241 - DB6248. For example, first upload the offline data of the first target spool in DB6241 (the first spool in DB6241). After the offline data of the first target spool is uploaded, clear the offline data of the first target spool, and move the offline data in the eight DB blocks of DB6241 - DB6248 forward by one position. As a result, the offline data of the second spool in DB6241 moves forward by one position, and the second spool in DB6241 will be the new target spool.

[0148] S404: Call FC64007 to perform the following judgment: Is the data in DB6200.ME_MSG.ME_AVI_MSG empty, and DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE = 0, and DB6200.IT_MSG.IT_CTRL_WRD.TR_SENT = 0, and DB6200.IT_MSG.IT_CTRL_WRD.TS_RECEIVED = 0, and DB6200.IT_MSG.IT_CTRL_WRD.MES_COMPLETE = 0? If yes, execute S405; if no, execute S418;

[0149] Among them, FC64007 is a pre-set function module used to call FC16 to judge whether the area of DB6200.ME_MSG.ME_AVI_MSG is empty when synchronizing offline data. ME_MSG.ME_AVI_MSG represents the service data read from the cache, such as the spindle two-dimensional code information and specifications. FC16 is a function module for judging whether the area of DB6200.ME_MSG.ME_AVI_MSG is empty.

[0150] Among them, IT_CTRL_WRD.TR_SENT represents the variable indicating whether it is set after the IT-PLC writes AVI_REQUEST; IT_CTRL_WRD.TR_SENT = 1 means it is set after the IT-PLC writes AVI_REQUEST; IT_CTRL_WRD.TR_SENT = 0 means the variable is currently in the initial state.

[0151] Among them, IT_CTRL_WRD.TS_RECEIVED represents the variable indicating whether it is set after the IT-PLC receives MES data; IT_CTRL_WRD.TS_RECEIVED = 1 means it is set after the IT-PLC receives MES data; IT_CTRL_WRD.TS_RECEIVED = 0 means the variable is currently in the initial state.

[0152] Among them, IT_CTRL_WRD.MES_COMPLETE represents the variable indicating whether the IT-PLC has completed the current data processing; IT_CTRL_WRD.MES_COMPLETE = 1 means the IT-PLC has completed the current data processing; IT_CTRL_WRD.MES_COMPLETE = 0 means the variable is in the initial state.

[0153] S405: Call FC64005 to transfer the data content of the target spindle in DB6241 - DB6248 to the corresponding position in DB6200.ME_MSG.ME_AVI_MSG;

[0154] Here, the target spindle is the spindle with the earliest storage position among the eight DB blocks of DB6421 - DB6428.

[0155] Among them, FC64005 is a pre - set function module for transferring the content in DB6241 - DB6248 to the corresponding positions in DB6200.ME_MSG.ME_AVI_MSG.

[0156] Here, ME_MSG.ME_AVI_MSG represents the service data read by the IT - PLC from the cache.

[0157] S406: The IT - PLC sets DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE;

[0158] Here, ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE indicates that the IT - PLC starts to upload the offline passing - station cache data.

[0159] S407: Is DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE = 1? If yes, execute S408; otherwise, continue to execute S407;

[0160] Here, ME_CTRL_WRD.ASSY_COMPLETE = 1 means that the IT - PLC has set and started synchronization.

[0161] S408: The IT - PLC sets DB6200.IT_MSG.IT_CTRL_WRD.TR_SENT, and then executes S409;

[0162] Here, setting IT_MSG.IT_CTRL_WRD.TR_SENT = 1 means that the IT - PLC sets it after writing AVI_REQUEST.

[0163] After the IT - PLC completes S408, it waits for the message returned by the MES.

[0164] S409: Is DB6200.MI_RESPONSE.AVI_RESPONSE1 ≠ empty string? If yes, execute S410; if no, continue to execute S409;

[0165] Here, MI_RESPONSE.AVI_RESPONSE1 ≠ empty string means that the MES has written the response information of this passing - station into AVI_RESPONSE1.

[0166] S410: Is the format of DB6200.MI_RESPONSE.AVI_RESPONSE1 correct? If yes, execute S412; if no, continue to execute S411;

[0167] Here, the format of AVI_RESPONSE1 can be set or adjusted according to the actual situation.

[0168] S411: Write error code 3548, and then execute S418;

[0169] Here, error code 3548 is used to indicate that the format of MI_RESPONSE.AVI_RESPONSE1 is incorrect.

[0170] S412: IT-PLC sets DB6200.IT_MSG.IT_CTRL_WRD.TS_RECEIVED;

[0171] Among them, setting IT_CTRL_WRD.TS_RECEIVED = 1 means that it is set after IT-PLC receives MES data.

[0172] S413: Call FC64004 to parse AVI_RESPONSE1 into the corresponding IT_RES_1;

[0173] Here, IT_RES_1 (IT_MSG.IT_RES_1) represents the result after IT-PLC parses the response information of MES.

[0174] Here, FC64004 is a module integrated with the function of parsing AVI_RESPONSE1 into the corresponding IT_RES_1.

[0175] S414: Is DB6200.IT_MSG.IT_RES_1.RESPONSE_RESULT = 1 and DB6200.IT_MSG.IT_RES_1.RESPONSE_ERROR = 0? If yes, execute S416; if no, execute S415;

[0176] IT_RES_1.RESPONSE_RESULT = 1 indicates that the result in the response string information sent by MES to IT-PLC is normal;

[0177] IT_RES_1.RESPONSE_ERROR = 0 indicates that there is no error code in the response string information sent by MES to IT-PLC.

[0178] S415: Write error code 3549, and then execute S418;

[0179] Here, error code 3549 is used to indicate at least one of the following:

[0180] IT_RES_1.RESPONSE_RESULT ≠ 1;

[0181] IT_RES_1.RESPONSE_ERROR ≠ 0.

[0182] S416: The IT-PLC clears and resets MI_RESPONSE.AVI_RESPONSE1;

[0183] Here, MI_RESPONSE.AVI_RESPONSE1 represents the response string sent by the MES to the IT-PLC.

[0184] S417: DB6200.IT_MSG.IT_CTRL_WRD.MES_COMPLETE = 1;

[0185] Here, IT_MSG.IT_CTRL_WRD.MES_COMPLETE = 1 indicates that the IT-PLC data processing has been completed.

[0186] S418: Call FC64021 to shift the queue in DB6241; the IT-PLC clears and resets the corresponding control bits of DB6200, resets the corresponding service data area, and then returns to S402.

[0187] Among them, the IT-PLC clearing and resetting the corresponding control bits may include:

[0188] DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE = 0;

[0189] DB6200.IT_MSG.IT_CTRL_WRD.TR_SENT = 0;

[0190] DB6200.IT_MSG.IT_CTRL_WRD.TS_RECEIVED = 0;

[0191] DB6200.IT_MSG.IT_CTRL_WRD.MES_COMPLETE = 0.

[0192] Here, ASSY_COMPLETE indicates that the IT-PLC is ready to synchronize the offline passing station cache information to the MES.

[0193] Here, TR_SENT indicates that the IT-PLC has sent an offline passing station cache information to the MES.

[0194] Here, TS_RECEIVED indicates that the IT-PLC has received the correct response information returned by the MES.

[0195] Here, MES_COMPLETE indicates that the offline passing station cache information of the IT-PLC has been successfully completed this time.

[0196] Among them, resetting the corresponding business data area may include:

[0197] Calling FC11 to reset DB6200.ME_AVI_MSG;

[0198] Calling FC14 to clear and reset the data for storing the target spindle in DB6241;

[0199] Calling FC8 to shift the offline queue to ensure that data is always read starting from the position of the first spindle in DB6241.

[0200] Here, resetting DB6101.ME_AVI_MSG is considered to continue the data processing process of the previous time when the condition is accidentally triggered.

[0201] It should be noted that the above station numbers, error code numbers, DB block numbers, variable names, storage address names, FC function module names, and FB function module names are only exemplary and not restrictive, and can all be set or adjusted according to actual needs.

[0202] It should be understood that Figure 1 、 Figure 4 The schematic diagrams shown are only exemplary and not restrictive, and they are extensible. Those skilled in the art can make various obvious changes and / or substitutions based on Figure 1 、 Figure 4 examples, and the obtained technical solutions still fall within the scope of the disclosure of the embodiments of the present disclosure.

[0203] The embodiments of the present disclosure provide a spindle automatic passing station control device, which is applied to a spindle automatic passing station control system. The spindle automatic passing station control system includes an MES, a first PLC, and a plurality of second PLCs. The plurality of second PLCs are respectively connected to the first PLC, and the first PLC is connected to the MES; among them, each second PLC is used to control at least one station; as Figure 5 shown, the spindle automatic passing station control device may include:

[0204] A monitoring module 501, configured to monitor whether the control button of the first PLC switches from the offline mode to the online mode, and whether the first PLC resumes communication with the MES;

[0205] The first control module 502 is configured to, when the control button of the first PLC is switched from the offline mode to the online mode and the first PLC resumes communication with the MES, synchronize the offline data to the MES if it is detected that the offline data is stored in the offline cache area, where the offline data is the passing record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES.

[0206] In some embodiments, the first control module 502 is configured to synchronize the offline data to the MES according to the following steps:

[0207] After the system starts up, continuously check whether the first PLC is in the online mode and enable the offline passing record synchronization function;

[0208] If the conditions are met, check whether there is a queue to be processed in the offline cache area;

[0209] Ensure that the relevant data bits and control bits in the offline control area are in the initial state, otherwise perform a reset operation;

[0210] Transmit the first queue data in the offline cache area to the offline control area, and set the control bit to indicate that the second PLC starts to process the passing;

[0211] Trigger the first PLC to send a request to the MES through the control bit and wait for the response of the MES;

[0212] Verify the format of the data returned by the MES. If it is correct, parse the data to the business data area of the offline control area, and check whether the response result is valid and error-free;

[0213] According to the response result, perform error handling or update the control bit to indicate that the data processing is completed;

[0214] Perform queue shifting on the offline cache area, and reset the relevant control bits and business data area of the offline control area to prepare for the next round of synchronization.

[0215] In some embodiments, the automatic passing control device for the silk ingot further includes: a second control module ( Figure 5 not shown in the figure) for: the first PLC obtains the second business data of the target work station from the second PLC corresponding to the target work station, and obtains the first business data of the target work station according to the second business data;

[0216] A third control module ( Figure 5 not shown in the figure) for: when the first PLC is disconnected from the MES, the first PLC records the first business data and sends a passing instruction message to the second PLC, so that the second PLC controls the target work station to perform the silk ingot passing task based on the passing instruction message; wherein, the passing instruction message is permission to pass;

[0217] A recording module ( Figure 5 not shown in the figure) is used to store offline data in an offline cache area, where the offline data is the passing record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES.

[0218] In some embodiments, the automatic passing control device for the silk ingot further includes a first judgment module ( Figure 5 not shown in the figure), where the first judgment module is used to: when the first PLC detects that the control button corresponding to the first PLC rotates to the offline mode, determine that the first PLC is disconnected from the MES.

[0219] In some embodiments, the automatic passing control device for the silk ingot further includes a second judgment module ( Figure 5 not shown in the figure), where the second judgment module is used to: when the first PLC detects that the communication between the first PLC and the MES is interrupted, determine that the first PLC is disconnected from the MES.

[0220] In some embodiments, the automatic passing control device for the silk ingot further includes a fourth control module ( Figure 5 not shown in the figure), where the fourth control module is used to: when the MES is disconnected from the first PLC, the MES does not perform the judgment process of the online passing condition.

[0221] In some embodiments, the automatic passing control device for the silk ingot further includes a fifth control module ( Figure 5 not shown in the figure), where the fifth control module is used to: based on the target string data corresponding to the target station, determine whether the silk ingot at the target station meets the passing condition; if it meets the passing condition, determine that the passing indication information is permission to pass; if it does not meet the passing condition, determine that the passing indication information is prohibited from passing; the target string data is obtained by the MES parsing the first service data.

[0222] In some embodiments, the automatic passing control device for the silk ingot further includes a sixth control module ( Figure 5 not shown in the figure), where the sixth control module is used to: the first PLC allocates multiple offline cache areas and one offline control area for all target stations, the multiple offline cache areas are shared by all target stations, and the offline control area includes relevant data bits and relevant control bits for synchronizing the offline data to the MES.

[0223] Those skilled in the art should understand that the functions of the processing modules in the automatic spindle passing station control device according to the embodiments of the present disclosure can be understood with reference to the relevant descriptions of the aforementioned automatic spindle passing station control method. Each processing module in the automatic spindle passing station control device according to the embodiments of the present disclosure can be implemented by an analog circuit that implements the functions of the embodiments of the present disclosure, or can be implemented by the operation of software that executes the functions of the embodiments of the present disclosure on an electronic device.

[0224] The automatic spindle passing station control device according to the embodiments of the present disclosure can achieve automatic and synchronous offline record management of spindles, improving the spindle passing station efficiency.

[0225] According to an embodiment of the present disclosure, the present disclosure also provides an electronic device and a readable storage medium.

[0226] Figure 6 It is a structural block diagram of an electronic device according to an embodiment of the present disclosure. As Figure 6 shown, the electronic device includes: a memory 610 and a processor 620. The memory 610 stores a computer program that can run on the processor 620. The number of the memory 610 and the processor 620 can be one or more. The memory 610 can store one or more computer programs. When the one or more computer programs are executed by the electronic device, the electronic device executes the method provided in the above method embodiments. The electronic device may further include: a communication interface 630, configured to communicate with external devices and perform data interaction and transmission.

[0227] If the memory 610, the processor 620, and the communication interface 630 are implemented independently, the memory 610, the processor 620, and the communication interface 630 can be connected to each other through a bus and complete communication with each other. The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. The bus can be divided into an address bus, a data bus, a control bus, etc. For the sake of representation, Figure 6 only a thick line is used to represent it in the figure, but it does not mean that there is only one bus or one type of bus.

[0228] Optionally, in a specific implementation, if the memory 610, the processor 620, and the communication interface 630 are integrated on a chip, the memory 610, the processor 620, and the communication interface 630 can complete communication with each other through an internal interface.

[0229] It should be understood that the above-mentioned processor can be a Central Processing Unit (CPU), or other general-purpose processors, Digital Signal Processors (DSPs), Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor, etc. It is worth noting that the processor can be a processor that supports the Advanced RISC Machines (ARM) architecture.

[0230] Further, optionally, the above-mentioned memory can include a read-only memory and a random access memory, and can also include a non-volatile random access memory. The memory can be a volatile memory or a non-volatile memory, or can include both volatile and non-volatile memories. Among them, the non-volatile memory can include a Read-Only Memory (ROM), a Programmable ROM (PROM), an Erasable PROM (EPROM), an Electrically EPROM (EEPROM), or a flash memory. The volatile memory can include a Random Access Memory (RAM), which is used as an external cache. By way of example but not limitation, many forms of RAM are available. For example, Static Random Access Memory (SRAM), Dynamic Random Access Memory (DRAM), Synchronous DRAM (SDRAM), Double Data Date SDRAM (DDR SDRAM), Enhanced SDRAM (ESDRAM), Synchlink DRAM (SLDRAM), and Direct RAMBUS RAM (DR RAM).

[0231] In the above embodiments, it can be implemented in whole or in part by software, hardware, firmware, or any combination thereof. When implemented using software, it can be implemented in whole or in part in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer instructions are loaded and executed on a computer, the processes or functions described in the embodiments of the present disclosure are generated in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions can be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wired (e.g., coaxial cable, fiber optic, Digital Subscriber Line (DSL)) or wireless (e.g., infrared, Bluetooth, microwave, etc.) means. The computer-readable storage medium can be any available medium that can be accessed by a computer, or a data storage device such as a server or data center that includes one or more available media integrated. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., Digital Versatile Disc (DVD)), or a semiconductor medium (e.g., Solid State Disk (SSD)), etc. It should be noted that the computer-readable storage medium mentioned in the present disclosure can be a non-volatile storage medium, in other words, a non-transitory storage medium.

[0232] Those of ordinary skill in the art can understand that all or part of the steps for implementing the above embodiments can be completed by hardware, or can be completed by a program instructing relevant hardware. The program can be stored in a computer-readable storage medium, and the storage medium mentioned above can be a read-only memory, a magnetic disk, an optical disc, or the like.

[0233] In the description of the embodiments of the present disclosure, the descriptions referring to terms such as "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present disclosure. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples.

[0234] In the description of the embodiments of the present disclosure, unless otherwise specified, " / " means "or". For example, A / B may mean A or B. "And / or" herein is merely a description of the association relationship between associated objects, indicating that there can be three relationships. For example, A and / or B may mean: A exists alone, A and B exist simultaneously, and B exists alone.

[0235] In the description of the embodiments of the present disclosure, the terms "first" and "second" are used only for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the embodiments of the present disclosure, unless otherwise specified, "a plurality of" means two or more.

[0236] The above are only exemplary embodiments of the present disclosure and are not intended to limit the present disclosure. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present disclosure shall be included within the protection scope of the present disclosure.

Claims

1. An automatic control method for silk ingots to pass through stations, which is applied to an automatic control system for silk ingots to pass through stations, and is characterized in that, The automatic silk ingot passing station control system includes a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and multiple second PLCs. Each second PLC is used to control at least one station. The multiple second PLCs are respectively connected to the first PLC, and the first PLC can be connected to the MES. The first PLC is equipped with an offline passing station record synchronization function switch. The automatic silk ingot passing station control method includes: Detecting whether the control button of the first PLC is switched from the offline mode to the online mode, and whether the first PLC and the MES resume communication. When the control button of the first PLC is switched from the offline mode to the online mode and the first PLC and the MES resume communication, if it is detected that the offline passing station record synchronization function is enabled and there is offline data stored in the offline cache area, synchronize the offline data to the MES. The offline data is the passing station record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES. Before synchronizing the offline data to the MES, the method further includes: The first PLC obtains the second service data of the target station from the second PLC corresponding to the target station, and obtains the first service data of the target station according to the second service data. The first service data includes: the real-time status of the target station, the processing progress of the silk ingot, the silk ingot quality inspection result, and the request type. The second service data includes: the real-time status of the target station, the processing progress of the silk ingot, the silk ingot quality inspection result, and the silk ingot barcode. When the first PLC is disconnected from the MES, the first PLC records the first service data and sends a passing station instruction message to the second PLC, so that the second PLC controls the target station to execute the silk ingot passing station task based on the passing station instruction message. The passing station instruction message is permission to pass the station. When the control button of the first PLC is switched from the offline mode to the online mode and the first PLC and the MES resume communication, if it is detected that the offline passing station record synchronization function is enabled and there is offline data stored in the offline cache area, synchronizing the offline data to the MES includes: After the system starts, continuously check whether the first PLC is in the online mode and the offline passing station record synchronization function is enabled. If the conditions are met, check whether there is a queue to be processed in the offline cache area. Ensure that the relevant data bits and control bits in the offline control area are in the initial state, otherwise perform a reset operation. Transfer the first queue data in the offline cache area to the offline control area, and set the control bit to indicate that the second PLC starts to process the passing station. Trigger the first PLC to send a request to the MES through the control bit and wait for the response of the MES. Verify the format of the data returned by the MES. If it is correct, parse the data to the service data area in the offline control area, and check whether the response result is valid and error-free. According to the response result, perform error handling or update the control bit to indicate that the data processing is completed. Perform queue shifting on the offline cache area, and reset the relevant control bits and service data area of the offline control area to prepare for the next round of synchronization.

2. The method according to claim 1, wherein The automatic spindle passing station control method further includes: When the first PLC detects that the control button corresponding to the first PLC rotates to the offline mode, it determines that the first PLC is disconnected from the MES.

3. The method according to claim 1, characterized in that The automatic spindle passing station control method further includes: When the first PLC detects a communication interruption between the first PLC and the MES, it determines that the first PLC is disconnected from the MES.

4. The method according to claim 2 or 3, characterized in that, The automatic spindle passing station control method further includes: When the MES is disconnected from the first PLC, the MES does not perform the judgment process of the online passing station condition.

5. The method according to claim 4, wherein The judgment process of the online passing station condition includes: Based on the target string data corresponding to the target station, determine whether the spindle at the target station meets the passing station condition; if the passing station condition is met, determine that the passing station indication information is permission to pass; if the passing station condition is not met, determine that the passing station indication information is prohibited from passing; the target string data is obtained by the MES parsing the first service data.

6. The method according to claim 1, wherein The automatic spindle passing station control method further includes: The first PLC allocates multiple offline cache areas and one offline control area for all target stations. The multiple offline cache areas are shared by all target stations. The offline control area includes relevant data bits and relevant control bits for synchronizing offline data to the MES.

7. An automatic control device for silk ingots to pass through stations, which is applied to an automatic control system for silk ingots to pass through stations, and is characterized in that The automatic spindle passing station control system includes a manufacturing execution system MES, a first programmable logic controller PLC, and multiple second PLCs. Each second PLC is used to control at least one station; the multiple second PLCs are respectively connected to the first PLC, and the first PLC can be connected to the MES; the automatic spindle passing station control device includes: A monitoring module, used to monitor whether the control button of the first PLC switches from the offline mode to the online mode, and whether the first PLC resumes communication with the MES; A first control module, used to, when the control button of the first PLC switches from the offline mode to the online mode, and the first PLC resumes communication with the MES, if it detects that there is offline data stored in the offline cache area, synchronize the offline data to the MES, where the offline data is the passing station record that needs to be synchronized to the MES and is stored when the first PLC is disconnected from the MES; A second control module, used for the first PLC to obtain the second service data of the target station from the second PLC corresponding to the target station, and obtain the first service data of the target station according to the second service data; the first service data includes: the real-time status of the target station, the spindle processing progress, the spindle quality inspection result, and the request type; the second service data includes: the real-time status of the target station, the spindle processing progress, the spindle quality inspection result, and the spindle barcode. The third control module is used to record the first service data by the first PLC and send the passing station indication information to the second PLC when the first PLC is disconnected from the MES, so that the second PLC controls the target work station to perform the silk ingot passing station task based on the passing station indication information; wherein, the passing station indication information is permission to pass the station. The first control module is used for: After the system starts, continuously check whether the first PLC is in the online mode and enable the offline passing station record synchronization function; if the conditions are met, check whether there is a queue to be processed in the offline cache area; ensure that the relevant data bits and control bits in the offline control area are in the initial state, otherwise perform a reset operation. Transfer the first queue data in the offline cache area to the offline control area and set the control bit to indicate that the second PLC starts to process the passing station. Trigger the first PLC to send a request to the MES through the control bit and wait for the response of the MES. Verify the format of the data returned by the MES. If it is correct, parse the data to the service data area in the offline control area and check whether the response result is valid and error-free; according to the response result, perform error handling or update the control bit to indicate that the data processing is completed. Perform queue shifting on the offline cache area and reset the relevant control bits and service data area in the offline control area to prepare for the next round of synchronization.

8. An electronic device, characterized in that, Comprising: At least one processor; And A memory communicatively connected to the at least one processor; wherein, The memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can execute the method according to any one of claims 1 to 6.

9. A non-transitory computer-readable storage medium storing computer instructions, characterized in that, The computer instructions are used to cause the computer to execute the method according to any one of claims 1 to 6.

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