Automobile coating process monitoring system

Abstract

The invention provides an automobile coating process monitoring system. The system comprises a sensor, a programmable logic controller, a server and a client. The sensors and the programmable logic controllers are distributed in a plurality of workshops of the automobile coating process and are in communication connection with the industrial control networks of the workshops where the sensors and the programmable logic controllers are located. The industrial control networks of the plurality of workshops communicate with the production information and control system area network through the firewall, and the firewall is used for executing one-way data transmission from the industrial control networks to the production information and control system area network. The server is communicably connected to the production information and control system area network. According to the invention, data security is guaranteed while a data transmission channel is opened.

Description

Technical Field

[0001] The embodiments of the present invention generally relate to the technical field of automobile painting process, and more specifically, to an automobile painting process monitoring system. Background Art

[0002] The automobile painting process can generally be divided into two parts: one is the surface treatment of the metal before painting, also called pre-treatment technology; the other is the construction process of painting. It is necessary to monitor and manage the painting process. The existing technology generally uses paper records and manual inspections, and the degree of automation is low.

[0003] Patent document CN107991982A discloses a drying room monitoring system and method for an automobile coating production line based on LABVIEW. The host computer is based on the LABVIEW platform, and the current drying room temperature and temperature curve can be viewed on the host computer. When the temperature exceeds the limit, an alarm prompt will be displayed on the host computer. The host computer also communicates with the mobile phone, and the real-time drying room temperature can be viewed on the mobile phone. When the temperature exceeds the limit, an alarm prompt can also be viewed on the mobile phone. The PLC controller obtains the current temperature by connecting the temperature sensor through the A / D module, and adjusts the collected drying room temperature by combining the fuzzy PID controller designed in the LABVIEW environment, outputs the adjustment amount, and adjusts the air valve and electric regulating valve through the D / A module. The invention can view the temperature of the drying room in real time through the host computer and the mobile phone, improves the diversification of the drying room temperature display terminal, and uses the fuzzy PID controller to reduce the influence of the unstable factors of the drying room control system on the drying room temperature, thereby improving the stability and real-time performance of the drying room control system.

[0004] However, the above patent document only discloses a solution in which PLC transmits field sensor data to the platform and the platform sends alarm information to the mobile phone, and it is limited to collecting temperature and wind speed, and does not solve the problems of data security and data integrity between the production network and the external network. Summary of the invention

[0005] In order to solve the above problems in the prior art, in the first aspect, an embodiment of the present invention provides an automobile coating process monitoring system, the system comprising a sensor, a programmable logic controller, a server and a client, wherein the sensor and the programmable logic controller are distributed in multiple workshops of the automobile coating process, and are communicatively connected to the industrial control network of the workshop where they are located, and the industrial control networks of multiple workshops communicate with the production information and control system area network through a firewall, wherein the firewall is used to perform unidirectional data transmission from the industrial control network to the production information and control system area network. The server is communicatively connected to the production information and control system area network. The sensor is used to: sense the real-time value of the parameter of the coating process field equipment, and send the real-time value of the parameter to the programmable logic controller corresponding to the sensor through the industrial control network where the sensor is located, or send the real-time value of the parameter to the server through the industrial control network where the sensor is located and the production information and control system area network; in response to receiving the supplementary collection instruction sent by the server, obtain the real-time value of the supplementary collection parameter, and send the real-time value of the supplementary collection parameter to the programmable logic controller corresponding to the sensor through the industrial control network where the sensor is located, or send it to the server through the industrial control network where the sensor is located and the production information and control system area network. The programmable logic controller is used to: receive the real-time value of the parameter sent by the corresponding sensor through the industrial control network where the programmable logic controller is located, and send the real-time value of the parameter to the server through the production information and control system area network; and control the operation of the corresponding coating process equipment in the workshop where it is located in real time according to the real-time value of the parameter; in response to receiving the supplementary collection instruction sent by the server, obtain the real-time value of the supplementary collection parameter from the corresponding sensor, and send the real-time value of the supplementary collection parameter to the server through the production information and control system area network. The server is used to: receive the real-time value of the parameter sent by the sensor and / or the programmable logic controller through the production information and control system area network; compare the real-time value of the parameter with the predefined parameter items, and when there is a missing between the real-time value of the parameter and the parameter items, send a supplementary acquisition instruction to the sensor and / or programmable logic controller corresponding to the missing parameter, and receive the real-time value of the supplementary acquisition parameter sent by the corresponding sensor and / or programmable logic controller; store the real-time value of the parameter as parameter data; in response to receiving a data acquisition request from the client, send the parameter data corresponding to the data acquisition request to the client. The client is used to: send a data acquisition request to the server; receive the parameter data corresponding to the data acquisition request from the server.

[0006] In some implementations, the industrial control networks of various workshops cannot communicate with each other.

[0007] In some implementations, the server is further configured to: when no corresponding real-time value of the supplementary collection parameter is received within a predetermined period of time after sending the supplementary collection instruction, send parameter missing prompt information to a client of a user associated with the parameter.

[0008] In some implementations, the server is further configured to: when data anomalies occur in the real-time value of the parameter or the real-time value of the supplementary acquisition parameter, send data anomaly alarm information to a client of a user associated with the parameter.

[0009] In some embodiments, the client is also used to: after receiving the data abnormality alarm information, receive the cause analysis and countermeasures information input by the user, and send the cause analysis and countermeasures information to the server; the server is also used to: receive and store the cause analysis and countermeasures information from the client.

[0010] In some embodiments, the client is also used to: receive a historical data query request input by a user, wherein the historical data query request includes historical time period and parameter type information; the server is also used to: in response to receiving the historical data query request, retrieve historical parameter data corresponding to the historical data query request from the stored parameter data, and send the historical parameter data to the client.

[0011] In some implementations, the client is communicatively connected to the server via an office network.

[0012] In some implementations, the server is further configured to classify, label, and store the received real-time parameter values ​​according to their business fields, business types, and data sources.

[0013] In some embodiments, the server is further configured to: display the received real-time values ​​of the parameters in a pre-generated automobile painting process shop map and / or automobile painting process schematic diagram in real time.

[0014] In some embodiments, the client is also used to: receive status data of the coating process equipment filled in by the user, and send the status data to the server; the server is also used to: receive the status data of the coating process equipment and store it in association with the real-time value of the parameters corresponding to the coating process equipment.

[0015] The system proposed in the embodiment of the present invention innovatively links the equipment intranet (industrial control network), the company extranet, and the production network (FIS network), and adopts one-way transmission and anti-virus protection during data transmission, thus ensuring the safe operation of field equipment. The main function of this system is to ensure safe data transmission and cross the boundary between different networks, avoiding the risk of network virus attacks and ensuring data security. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The above and other objects, features and advantages of the embodiments of the present invention will become readily understood by reading the following detailed description with reference to the accompanying drawings. In the accompanying drawings, several embodiments of the present invention are shown in an exemplary and non-limiting manner, in which:

[0017] Figure 1 A schematic diagram of an automobile painting process monitoring system according to an embodiment of the present invention is shown.

[0018] In the drawings, the same or corresponding reference numerals represent the same or corresponding parts. DETAILED DESCRIPTION

[0019] The principle and spirit of the present invention will be described below with reference to several exemplary embodiments. It should be understood that these embodiments are provided only to enable those skilled in the art to better understand and implement the present invention, and are not intended to limit the scope of the present invention in any way.

[0020] In one aspect, an embodiment of the present invention provides a system for monitoring an automobile coating process. Figure 1 , which shows a schematic diagram of an automobile coating process monitoring system according to an embodiment of the present invention. The automobile coating process monitoring system includes a sensor, a programmable logic controller (PLC), a server and a client. The client can be a mobile terminal, such as a mobile phone, a tablet computer, etc., or a personal computer, a workstation, etc.

[0021] The sensors and programmable logic controllers are distributed in multiple workshops of the automobile painting process and are communicatively connected to the industrial control networks of their respective workshops.

[0022] The industrial control networks of multiple workshops communicate with the production information and control system area (FIS-DMZ) network through a firewall, where the firewall is used to perform one-way data transmission from the industrial control network to the production information and control system area network.

[0023] The server is communicatively connected to a production information and control system area network.

[0024] Sensors are the key to factory field equipment reading process data. Sensors are used to: sense the real-time values ​​of parameters of field equipment in the coating process, and send the real-time values ​​of parameters to the corresponding programmable logic controller of the sensor through the industrial control network where the sensor is located, or send the real-time values ​​of parameters to the server through the industrial control network where the sensor is located and the production information and control system area network; in response to receiving the supplementary collection instruction sent by the server, obtain the real-time value of the supplementary collection parameter, and send the real-time value of the supplementary collection parameter to the corresponding programmable logic controller of the sensor through the industrial control network where the sensor is located, or send it to the server through the industrial control network where the sensor is located and the production information and control system area network.

[0025] For example, the real-time value of a parameter may be the temperature, pressure, flow rate, frequency, etc. at the process site.

[0026] PLC is a large-scale plant equipment that stores key processes and logic and program data after calculation. The programmable logic controller is used to: receive the real-time value of the parameter sent by the corresponding sensor through the industrial control network where the programmable logic controller is located, and send the real-time value of the parameter to the server through the production information and control system area network; and, according to the real-time value of the parameter, control the operation of the corresponding coating process equipment in the workshop where it is located in real time; in response to receiving the supplementary collection instruction sent by the server, obtain the real-time value of the supplementary collection parameter from the corresponding sensor, and send the real-time value of the supplementary collection parameter to the server through the production information and control system area network. PLC has a central processing unit, which needs to perform data processing, perform logical operations, and control the field status in real time. For example, the action of the equipment, such as rising and falling, is judged by the collected data.

[0027] The server is used to: receive real-time values ​​of parameters sent by sensors and / or programmable logic controllers through a production information and control system area network; compare the real-time values ​​of parameters with predefined parameter items, and when there is a missing between the real-time values ​​of parameters and the parameter items, send a supplementary collection instruction to the sensor and / or programmable logic controller corresponding to the missing parameter, and receive the supplementary collection parameter real-time value sent by the corresponding sensor and / or programmable logic controller; store the real-time values ​​of parameters as parameter data; and in response to receiving a data acquisition request from a client, send parameter data corresponding to the data acquisition request to the client.

[0028] The server is a key link in data storage and data processing in vehicle manufacturing. Optionally, it is also the terminal display of intelligent WEB display.

[0029] The client is used to: send a data acquisition request to the server; and receive parameter data corresponding to the data acquisition request from the server.

[0030] In general, the server receives PLC data, sensor data, and mobile terminal data, removes noise from the data, stores it in the database, processes the data, and displays the processing results. If an abnormality is detected, an alarm message is sent to the mobile terminal APP.

[0031] As an implementation mode of the present invention, the industrial control networks of each workshop cannot communicate with each other. The industrial control networks are not interconnected, which can ensure that the operation of the process equipment is not interfered by external information and ensure the correct operation of the process equipment.

[0032] As an embodiment of the present invention, the server is further configured to: when the corresponding real-time value of the supplementary collection parameter is not received within a predetermined period of time after the supplementary collection instruction is sent, send parameter missing prompt information to the client of the user associated with the parameter.

[0033] As an embodiment of the present invention, the server is further used to: when data abnormality occurs in the real-time value of the parameter or the real-time value of the supplementary collected parameter, send data abnormality alarm information to the client of the user associated with the parameter.

[0034] As an embodiment of the present invention, the client is further used to: after receiving the data abnormality alarm information, receive the cause analysis and countermeasure information input by the user, and send the cause analysis and countermeasure information to the server;

[0035] The server is also used to: receive and store cause analysis and countermeasure information from the client.

[0036] As an embodiment of the present invention, the client is further used to: receive a historical data query request input by a user, wherein the historical data query request includes historical time period and parameter type information. The server is further used to: in response to receiving the historical data query request, retrieve historical parameter data corresponding to the historical data query request from the stored parameter data, and send the historical parameter data to the client.

[0037] As an embodiment of the present invention, the client is communicably connected to the server via an office network. Alternatively, the client is communicably connected to the server via an external network.

[0038] As an embodiment of the present invention, the server is further used to classify, label and store the received real-time parameter values ​​according to the business field, business type and data source of the real-time parameter values.

[0039] As an embodiment of the present invention, the server is further used to: display the received real-time values ​​of the parameters in real time in a pre-generated automobile painting process shop map and / or automobile painting process schematic diagram.

[0040] As an embodiment of the present invention, the client is also used to: receive the status data of the coating process equipment filled in by the user, and send the status data to the server. The server is also used to: receive the status data of the coating process equipment and store it in association with the real-time value of the parameter corresponding to the coating process equipment.

[0041] Relying on the automobile coating process monitoring system described above, the whole process monitoring and management of the coating process can be realized. Optionally, it can include production management, quality management, safety management, equipment management, personnel management, administrative management, process management, environmental management, equipment management, etc. It can cover all data of the whole vehicle production process. The data "collection, storage and display (collection, back-end storage, front-end display)" method of each module is the same.

[0042] Production management: mainly includes important information such as output, target, location, etc. in the production process. The decision-maker can issue control based on the set output target for today.

[0043] Quality management: In the body quality management link, data entry and related management can be performed for the management of body defects and key quality issues.

[0044] Safety management: Company managers regularly perform safety inspections, and keep detailed records of safety hazard inspections and other work. Managers can issue instructions based on the data, thereby achieving online closed-loop management.

[0045] Equipment management: refers to the management of factory equipment, such as routine inspections, patrol inspections, faults, equipment shutdown records, and real-time notifications.

[0046] Personnel management: such as personnel work schedule, duty, working hours, etc.

[0047] Administrative management: refers to the main content window for conveying information, information notification and feedback of basic workshop work, with the advantages of data entry, instruction issuance and closed-loop management.

[0048] Process management: refers to the window of key process management in the body manufacturing process.

[0049] Environmental management: refers to the monitoring of key environmental emission outlets in workshop equipment as required by the government.

[0050] Equipment management: refers to the production process in the workshop, such as mobile carts, outsourced equipment, and windows managed by third parties.

[0051] In actual use, users can click on the required functional modules, enter the corresponding data and manage and monitor. The data entered by the mobile terminal will be sent to the server for further management. Mobile APP: It is used to remotely view the site, convenient and quick to make intelligent decisions to ensure the normal operation of the equipment.

[0052] Take the environmental management module as an example: connect multiple platforms (workshop industrial control platform, workshop office platform, DingTalk platform, WeChat public account platform, cloud platform) data sources, collect data back to the enterprise for storage through Python code development, and then develop PC front-end interface and mobile APP interface. Realize the functions of real-time monitoring of environmental protection business data, early warning and push of computer and mobile alarm information when data is abnormal, fill in the cause and measures on the mobile terminal after abnormal processing to conduct closed-loop management of problems, and query historical data. The collection, storage and display (collection, back-end storage, front-end display) solution of environmental protection data can be applied to the exploration of digital transformation of manufacturing enterprises.

[0053] The automobile coating process monitoring system proposed in the embodiment of the present invention opens up the data storage between the workshop Ethernet and the company's FIS-DMZ area (production information and control system). Through the firewall, one-way data transmission is set (Ethernet can output data to the FIS-DMZ area in real time, but the FIS-DMZ area cannot output any data to the workshop Ethernet area), so that the workshop Ethernet data can be safely output to the FIS-DMZ area for storage, so that the office network can directly access the data in this area, and indirectly realize the data connection between the office network and the workshop Ethernet. It prevents the workshop Ethernet from being attacked by unsafe attacks from the office network area.

[0054] In terms of data storage, data is classified and labeled according to business areas, business types, and data sources. The design of the database base table and the fields of the table are strictly standardized according to custom documents. During the data storage process, if data is lost due to data collection problems, the back-end collection has been designed for automatic monitoring. When data cannot be collected, an early warning will be sent to the system operation and maintenance personnel to inform the information. This is convenient for operation and maintenance personnel to handle in a timely manner. For the collected data, in order to facilitate users to view the real-time production status of the workshop under different networks, a computer-side web interface and a mobile-side APP interface have been developed, so that users can view the production status of the workshop under the office network, and realize the display of one data source on multiple platforms. On the mobile APP side and the office computer side, real-time reminders can be given to enterprise managers, avoiding space limitations, improving the timeliness of information, and facilitating enterprise managers to make quick decisions and maximize the efficiency of the enterprise.

[0055] The system provided by the embodiment of the present invention is composed of a server, a PLC, a mobile terminal and a sensor. The mobile terminal has an APP developed to realize the data collection function. The system can realize the management and monitoring of the entire coating process, not limited to temperature and wind speed. In addition, the system provides a set of secure data dedicated lines to ensure the security of data transmission.

[0056] In the past, in terms of traditional factory electrification, personnel had to be stationed on-site to understand whether the on-site process equipment was operating normally and whether the process parameters exceeded the standard. Understanding these functions relied on traditional software, which had an unfriendly interface, required a high degree of specialization, and had a slow speed in data search and acquisition. It was not suitable for the factory's senior decision-makers to quickly grasp the factory's information and make intelligent decisions.

[0057] The system proposed in the embodiment of the present invention innovatively links the equipment intranet (industrial control network), the company extranet, and the production network (FIS network), and adopts one-way transmission and anti-virus protection during data transmission, thus ensuring the safe operation of field equipment. The main function of this system is to ensure safe data transmission and cross the boundary between different networks, avoiding the risk of network virus attacks and ensuring data security.

[0058] For the purpose of illustration, the foregoing description of the embodiments of the present invention has been given, which is not exhaustive nor intended to limit the present invention to the disclosed exact form. It will be appreciated by those skilled in the art that various changes can be made without departing from the scope of the present invention, and that the elements therein can be replaced with equivalents. In addition, without departing from the basic scope of the present invention, many modifications can be made so that specific situations or materials are adapted to the teachings of the present invention. Therefore, the present invention is not intended to be limited to the specific embodiments disclosed as the best mode for realizing the present invention, and the present invention will include all embodiments falling within the scope of the appended claims.

Claims

1. An automobile painting process monitoring system, characterized in that: The system includes a sensor, a programmable logic controller, a server and a client, wherein: The sensors and the programmable logic controller are distributed in multiple workshops of the automobile painting process and are communicatively connected to the industrial control networks of the workshops where they are located. The industrial control networks of multiple workshops all communicate with the production information and control system area network through a firewall, wherein the firewall is used to perform one-way data transmission from the industrial control network to the production information and control system area network. The server is communicatively connected to the production information and control system area network, The sensor is used to: sense the real-time value of the parameter of the coating process site equipment, and send the real-time value of the parameter to the programmable logic controller corresponding to the sensor through the industrial control network where the sensor is located, or send the real-time value of the parameter to the server through the industrial control network where the sensor is located and the production information and control system area network; in response to receiving the supplementary collection instruction sent by the server, obtain the real-time value of the supplementary collection parameter, and send the real-time value of the supplementary collection parameter to the programmable logic controller corresponding to the sensor through the industrial control network where the sensor is located, or send it to the server through the industrial control network where the sensor is located and the production information and control system area network; The programmable logic controller is used to: receive the real-time value of the parameter sent by the corresponding sensor through the industrial control network where the programmable logic controller is located, and send the real-time value of the parameter to the server through the production information and control system area network; and control the operation of the corresponding coating process equipment in the workshop where it is located in real time according to the real-time value of the parameter; in response to receiving the supplementary collection instruction sent by the server, obtain the real-time value of the supplementary collection parameter from the corresponding sensor, and send the real-time value of the supplementary collection parameter to the server through the production information and control system area network; The server is used to: receive the real-time value of the parameter sent by the sensor and / or the programmable logic controller through the production information and control system area network; compare the real-time value of the parameter with the predefined parameter items, and when there is a missing between the real-time value of the parameter and the parameter items, send a supplementary acquisition instruction to the sensor and / or programmable logic controller corresponding to the missing parameter, and receive the real-time value of the supplementary acquisition parameter sent by the corresponding sensor and / or programmable logic controller; store the real-time value of the parameter as parameter data; and in response to receiving a data acquisition request from the client, send the parameter data corresponding to the data acquisition request to the client; The client is used to: send a data acquisition request to the server; and receive parameter data corresponding to the data acquisition request from the server.

2. The system according to claim 1, characterized in that The industrial control networks of various workshops cannot communicate with each other.

3. The system according to claim 1, characterized in that The server is further configured to send parameter missing prompt information to a client of a user associated with the parameter when no corresponding real-time value of the supplementary collection parameter is received within a predetermined period of time after the supplementary collection instruction is sent.

4. The system according to claim 1, characterized in that The server is also used to send data abnormality alarm information to the client of the user associated with the parameter when data abnormality occurs in the real-time value of the parameter or the real-time value of the supplementary collection parameter.

5. The system according to claim 4, characterized in that The client is also used to: after receiving the data abnormality alarm information, receive the cause analysis and countermeasure information input by the user, and send the cause analysis and countermeasure information to the server; The server is also used to: receive and store the cause analysis and countermeasure information from the client.

6. The system according to claim 1, characterized in that The client is also used to: receive a historical data query request input by a user, wherein the historical data query request includes historical time period and parameter type information; The server is further configured to: in response to receiving the historical data query request, retrieve historical parameter data corresponding to the historical data query request from the stored parameter data, and send the historical parameter data to the client.

7. The system according to claim 1, characterized in that The client is communicatively connected to the server via an office network.

8. The system according to claim 1, characterized in that The server is further used to classify, label and store the received real-time parameter values ​​according to the business field, business type and data source of the real-time parameter values.

9. The system according to claim 1, characterized in that The server is also used for: displaying the received real-time values ​​of the parameters in real time in a pre-generated automobile painting process workshop map and / or automobile painting process schematic diagram.

10. The system according to claim 9, characterized in that The client is also used to: receive status data of the coating process equipment filled in by the user, and send the status data to the server; The server is also used to receive the status data of the coating process equipment and store it in association with the real-time value of the parameter corresponding to the coating process equipment.

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