Intelligent point inspection system and point inspection method for production line

Abstract

A production line intelligent point inspection system provided by the present invention comprises a PLC module, a relay module, a touch screen module, a communication module, a switch and a power supply module, the switch is connected with the PLC module and the touch screen module, the PLC module is connected with the relay module, the relay module is connected with a safety sensor on a production line, the communication module is connected with the PLC module, and the power supply module is connected with the PLC module. The communication module is in communication connection with a production line control system; and the PLC module is also directly connected with a safety sensor on the production line. During point inspection, the relay module in the system can simulate triggering of the safety sensor, and reset of the safety sensor is controlled through the PLC module. In the process, a control system of the production line judges the change condition of a safety sensor signal and feeds back the change condition to the PLC module. And the PLC module judges whether the point inspection of the safety sensor is abnormal or not according to the change condition of the signal. Through the spot inspection system, manual spot inspection can be replaced, the spot inspection efficiency of the safety sensor is improved, and the problem of missing inspection can be solved.

Description

Technical Field

[0001] The present invention relates to the technical field of safety sensor spot inspection, and in particular to an intelligent spot inspection system and a spot inspection method for a production line. Background Art

[0002] Safety sensors are devices used for automatic detection and automatic control in industry and applications. They are usually composed of sensitive elements that directly respond to the measured value, conversion elements that produce usable signal outputs, and corresponding electronic circuits. Sensors that meet safety standards are called safety sensors. These sensors play an important role in industrial automation, and their products include safety switches, safety gratings (safety light curtains), safety door locks, emergency stop buttons, maintenance switches, etc. Usually, many safety sensors are installed on an automated production line. The main functions of installing safety sensors in the production line include protecting operators, preventing equipment damage, improving production safety, and meeting safety standards.

[0003] In order to detect potential safety hazards in a timely manner, safety sensors on the production line need to be inspected regularly to promptly detect and resolve safety hazards, avoid accidents, and ensure the personal safety of employees.

[0004] For the inspection of safety sensors on the production line, the current method used is manual inspection, that is, it is necessary to manually patrol along the production line and trigger the safety sensors one by one, which is time-consuming and labor-intensive. For an automated production line with a total length of several hundred meters or thousands of meters, it takes at least 1-2 days to manually trigger the safety sensors one by one to complete the inspection of all the safety sensors. In addition, the manual triggering of safety sensors still has the problem of missed inspections. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a new type of intelligent inspection system for production lines, which can replace manual inspection and improve the efficiency of safety sensor inspection.

[0006] The present invention is achieved in that:

[0007] In a first aspect, the present invention provides an intelligent inspection system for a production line, comprising a PLC module, a relay module for simulating the triggering of a safety sensor, a touch screen module for human-computer interaction, a communication module, a switch, and a power supply module for providing power to the inspection system, wherein the switch is connected to the PLC module and the touch screen module respectively, the PLC module is connected to the relay module, the relay module is connected to the safety sensor on the production line, the communication module is connected to the PLC module, and the communication module is connected to the production line control system for communication;

[0008] The PLC module is also directly connected to the safety sensor on the production line to reset the triggered safety sensor;

[0009] During inspection, the PLC module controls the relay module to send out an analog signal, simulates the triggering of the safety sensor, and controls the analog signal to be reset through the PLC module; during this process, the production line control system determines the changes in the analog safety sensor signal and feeds back to the PLC module; the PLC module determines whether there is any abnormality in the entire safety control loop based on the changes in the signal.

[0010] Furthermore, the safety sensors on the production line include safety light curtains respectively arranged on the partition, the top plate, the pallet loading, the lower stacking exit and the baler; the safety sensors on the production line also include a first safety door, a second safety door and a third safety door;

[0011] The PLC module includes a second PLC and a third PLC;

[0012] The relay module includes a first relay module, a second relay module and a third relay module, the second PLC is connected to the first relay module and the second relay module, the first relay module is connected to the first safety door, the second safety door, the third safety door and the safety light curtain arranged at the partition, and the second relay module is connected to the safety light curtain arranged at the partition, the top plate and the tray loading place;

[0013] The third PLC is connected to the third relay module, and the third relay module is connected to the safety light curtains arranged at the pallet loading point, the stacking outlet and the baling machine.

[0014] Further, the third PLC is also connected to the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the lower stack exit and the baler, and is used to reset the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the lower stack exit and the baler;

[0015] The PLC module also includes a first PLC, which is connected to the safety light curtains respectively arranged at the partition, the top plate and the pallet loading location, and is used to reset the safety light curtains arranged at the partition, the top plate and the pallet loading location.

[0016] Furthermore, the PLC module is also connected to an alarm light and a buzzer.

[0017] Furthermore, a control cabinet is included, in which the PLC module, relay module, communication module, switch and power supply module are arranged.

[0018] Furthermore, the model of the power module is DC 24V / 10A EDR-120-24.

[0019] In a second aspect, the present invention provides a production line intelligent inspection method, based on the production line intelligent inspection system in the first aspect, comprising the following steps:

[0020] S1, the PLC module controls the relay module to simulate triggering the safety sensors on the production line one by one;

[0021] S2. As each safety sensor is triggered in simulation, the control system of the production line determines whether the safety sensor signal and the corresponding safety partition signal have changed one by one, and feeds back the signal change of each safety sensor to the PLC module. If a safety sensor signal or the corresponding safety partition signal has not changed, the PLC module determines that the safety sensor has an abnormal inspection.

[0022] S3. After a safety sensor is simulated and triggered by the relay module, the PLC module controls the safety sensor to reset, and the control system of the production line again determines the change of the safety sensor signal and the corresponding safety partition signal, and again feeds back the output signal of each safety sensor to the PLC module;

[0023] S4. Based on the two input signals to the safety sensor and the two output signals of the safety sensor fed back to the PLC module, the PLC module determines whether the input and output of the safety sensor are synchronized. If not, the PLC module determines that the safety sensor is abnormal.

[0024] S5. In steps S2 and S4, if the PLC module determines that a safety sensor inspection is abnormal, then after the inspection of all safety sensors on the production line is completed, the PLC module controls the alarm light and buzzer to start, and feeds back the signal of the safe shutdown of all machines to the control system of the production line.

[0025] The present invention has the following advantages: during spot inspection, the relay module in the system can simulate the triggering of the safety sensor, and the reset of the safety sensor can be controlled by the PLC module. In this process, the control system of the production line determines the change of the safety sensor signal and feeds it back to the PLC module. The PLC module determines whether the spot inspection of the safety sensor is abnormal based on the change of the signal and displays it on the touch screen module. Through this spot inspection system, manual spot inspection can be replaced, the efficiency of safety sensor spot inspection can be improved, and the problem of missed inspection can be overcome. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present invention will be further described below in conjunction with embodiments with reference to the accompanying drawings.

[0027] Figure 1 It is a schematic diagram of the connection structure of the intelligent inspection system for the production line of the present invention.

[0028] Figure 2 It is a schematic diagram of the connection structure between the power module and the terminal block of the present invention.

[0029] Figure 3 This is the first PLC wiring diagram of the present invention.

[0030] Figure 4 This is the second PLC wiring diagram of the present invention.

[0031] Figure 5 This is the third PLC wiring diagram of the present invention.

[0032] Figure 6 This is the wiring diagram of the first relay module of the present invention.

[0033] Figure 7 This is the wiring diagram of the second relay module of the present invention.

[0034] Figure 8 This is the wiring diagram of the third relay module of the present invention.

[0035] Fig. 9 This is the wiring diagram of the switch of the present invention.

[0036] Fig.10 This is the wiring diagram of the touch screen module of the present invention.

[0037] Description of the numbers in the figure:

[0038] 1. PLC module; 11. First PLC; 12. Second PLC; 13. Third PLC; 2. Relay module; 21. First relay module; 22. Second relay module; 23. Third relay module; 3. Touch screen module; 4. Communication module; 5. Switch; 6. Power module; 7. Safety sensor; 8. Control cabinet; DETAILED DESCRIPTION

[0039] For example, see Figure 1-10 The present invention provides an intelligent inspection system for a production line, comprising a PLC module 1, a relay module 2, a touch screen module 3 for human-computer interaction, a communication module 4, a switch 5, and a power module 6 for providing power to the inspection system. The power module 6 is used to convert 220V mains electricity into 24V direct current. The power module 6 is connected to the PLC module 1, the relay module 2, the touch screen module 3, the communication module 4, and the switch 5 through a terminal block and supplies power to them. The switch 5 is respectively connected to the PLC module 1 and the touch screen module 3. The PLC module 1 and the touch screen module 3 are connected in communication through the switch 5. The PLC module 1 is connected to the relay module 2, and the relay module 2 is connected to the safety sensor 7 on the production line. The communication module 4 is connected to the PLC module 1, and the communication module 4 is connected in communication with the production line control system.

[0040] The PLC module 1 is also directly connected to the safety sensor 7 on the production line to reset the triggered safety sensor 7 .

[0041] During inspection, the PLC module in this system can control the relay module to send out an analog signal to simulate the triggering of the safety sensor (the safety sensor signal is shielded at this time), and the analog signal is reset through the PLC module (the safety sensor resumes normal operation after reset). In this process, the control system of the production line determines the changes in the analog safety sensor signal and feeds it back to the PLC module. The PLC module determines whether there is an abnormality in the entire safety control loop based on the changes in the signal. This inspection system can replace manual inspection, improve the efficiency of safety sensor inspection, and overcome the problem of missed inspection.

[0042] Specifically, the safety sensor 7 on the production line includes safety light curtains respectively arranged on the partition, top plate, pallet loading, lower stacking exit and baler; the safety light curtains arranged on the partition, top plate, pallet loading and lower stacking exit have two inner and outer contacts, and all the safety light curtains also have emergency stop contacts. Therefore, the contacts of the safety light curtains on the production line are divided into: outer contacts of the partition light curtain, inner contacts of the partition light curtain, emergency stop contacts of the partition light curtain, outer contacts of the top plate light curtain, inner contacts of the top plate light curtain, emergency stop contacts of the top plate light curtain, outer contacts of the pallet light curtain, inner contacts of the pallet light curtain, emergency stop contacts of the pallet light curtain, outer contacts of the lower stacking light curtain, inner contacts of the lower stacking light curtain, emergency stop contacts of the lower stacking light curtain, contacts of the baler light curtain and emergency stop contacts of the baler light curtain;

[0043] The safety sensor 7 on the production line also includes a first safety door, a second safety door and a third safety door; each safety door has a safety door protection contact and an emergency stop contact. Therefore, the safety door contacts of the production line are divided into: a first safety door protection contact, a first safety door emergency stop contact, a second safety door protection contact, a second safety door emergency stop contact, a third safety door protection contact, and a third safety door emergency stop contact.

[0044] The PLC module 1 includes a second PLC 12 and a third PLC 13; as shown in the figure, the models of the second PLC 12 and the third PLC 13 are both Siemens 6ES7222-1BH32-0XB0.

[0045] The relay module 2 includes a first relay module 21, a second relay module 22 and a third relay module 23. As shown in the figure, each relay module contains eight relays; the relay has two pairs of normally closed auxiliary contacts. Each relay controls two input signals of a safety sensor 7 (safety light curtain, safety door or emergency stop button); each relay is controlled by a separate PLC output point;

[0046] The second PLC12 is connected to the first relay module 21 and the second relay module 22, the first relay module 21 is connected to the first safety door, the second safety door, the third safety door and the safety light curtain arranged at the partition, more specifically, the eight relays in the first relay module 21 are respectively connected to the first safety door protection contact, the first safety door emergency stop contact, the second safety door protection contact, the second safety door emergency stop contact, the third safety door protection contact, the third safety door emergency stop contact, the partition light curtain outer contact and the partition light curtain emergency stop contact;

[0047] The second relay module 22 is connected to the safety light curtains arranged at the partition, top plate and pallet loading location; more specifically, the relays in the second relay module 22 are respectively connected to the inner contacts of the partition light curtain, the outer contacts of the top plate light curtain, the inner contacts of the top plate light curtain, the emergency stop contacts of the top plate light curtain, the outer contacts of the pallet light curtain and the emergency stop contacts of the pallet light curtain;

[0048] The third PLC 13 is connected to the third relay module 23, and the third relay module 23 is connected to the safety light curtains arranged at the pallet loading, the lower stacking exit and the baler. The third relay module 23 is respectively connected to the inner contact of the pallet light curtain, the outer contact of the light curtain at the lower stacking, the inner contact of the light curtain at the lower stacking, the emergency stop contact of the light curtain at the lower stacking, the light curtain contact at the baler and the emergency stop contact of the light curtain at the baler;

[0049] Specifically, the third PLC13 is also connected to the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the lower stack exit and the baler, and is used to reset the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the lower stack exit and the baler;

[0050] The PLC module 1 also includes a first PLC 11, the model of the first PLC 11 is Siemens 6ES7215-1AG40-0XB0, and the first PLC 11 is connected to the safety light curtains respectively arranged on the partition, the top plate and the pallet loading location, and is used to reset the safety light curtains arranged on the partition, the top plate and the pallet loading location.

[0051] Specifically, the PLC module 1 is also connected to an alarm light and a buzzer. As shown in the figure, the alarm light and the buzzer are connected to the first PLC 11.

[0052] Specifically, a control cabinet 8 is also included, and the PLC module 1 , the relay module 2 , the communication module 4 , the switch 5 and the power supply module 6 are arranged in the control cabinet 8 .

[0053] Specifically, the model of the power module 6 is DC 24V / 10A EDR-120-24.

[0054] In the second embodiment, the present invention provides a production line intelligent inspection method, based on the production line intelligent inspection system in the first embodiment, comprising the following steps:

[0055] S1, the PLC module 1 controls the relay module 2 to operate, so that the relay module 2 simulates triggering the safety sensors 7 located on the production line one by one;

[0056] S2. As each safety sensor 7 is triggered in simulation, the control system of the production line determines whether the signal of the safety sensor 7 and the corresponding safety partition signal have changed one by one, and feeds back the signal change of each safety sensor 7 to the PLC module 1. If the signal of a safety sensor 7 or the corresponding safety partition signal has not changed, the PLC module 1 determines that the inspection of the safety sensor 7 is abnormal;

[0057] S3, after a safety sensor 7 is triggered by the relay module 2, the PLC module 1 controls the safety sensor 7 to reset, and the control system of the production line again determines the change of the safety sensor 7 signal and the corresponding safety partition signal, and again feeds back the output signal of each safety sensor 7 to the PLC module 1;

[0058] S4, based on the two input signals to the safety sensor 7 and the two output signals of the safety sensor 7 fed back to the PLC module 1, the PLC module 1 determines whether the input and output of the safety sensor 7 are synchronized, if not, the PLC module 1 determines that the spot check of the safety sensor 7 is abnormal;

[0059] S5. In steps S2 and S4, if the PLC module 1 determines that a certain safety sensor 7 has an abnormal inspection, then after the inspection of all safety sensors 7 on the production line is completed, the PLC module 1 controls the alarm light and buzzer to start, and feeds back the signal of the safe shutdown of the entire machine to the control system of the production line.

[0060] A specific application of the present invention is:

[0061] The touch screen module 3 has a spot inspection screen, which has a "spot inspection start" button and a "spot inspection reset" button. Compared with the manual spot inspection in the prior art, the spot inspection system of the present invention has a one-key spot inspection function, and can only be used when the production line is in a normal shutdown state, all safety inputs are in a normal state, and there is no safety alarm. The "spot inspection reset" button can only work during the spot inspection process, and the function of this button is automatically eliminated after the spot inspection is completed.

[0062] Each safety sensor 7 has a separate status display: during the spot inspection, the normal indicator light is yellow, and the abnormal indicator light is red. During the non-spot inspection process, the sensor is triggered red, and the non-triggered sensor is green.

[0063] After pressing the "Inspection Start" button, each safety sensor 7 is inspected separately, and the PLC module 1 triggers the safety sensor 7 through the relay module. The inspection time of each safety sensor 7 is 3 seconds, including the relay action time of 1 second and the reset time of 1 second. After the relay is actuated, if the control system of the production line can determine that the input of the corresponding safety sensor 7 has changed from two "1" signals to "0" signals, and at the same time, the safety output of the corresponding safety partition has also changed from a "1" signal to a "0" signal (each safety output relay or contactor takes an auxiliary contact signal to connect to the PLC module 1); the control system of the production line determines whether the safety sensor 7 signal and the corresponding safety partition signal have changed one by one, and feeds back the signal change of each safety sensor 7 to the PLC module 1; if the safety sensor 7 and the safety partition signals have changed, the PLC module 1 determines that the inspection of the safety sensor 7 is normal; if a safety sensor 7 signal or the corresponding safety partition signal has not changed, the PLC module 1 determines that the inspection of the safety sensor 7 is abnormal;

[0064] After each safety sensor 7 is triggered by simulation, the PLC module 1 automatically resets the analog signal of the safety sensor to determine whether the output and input are synchronized. If any signal is wrong, the spot check is judged to be abnormal. If any spot check is abnormal, an alarm will be immediately issued after the overall spot check is completed and the entire machine will be safely shut down.

[0065] When an alarm occurs, the corresponding sound and light alarm has a red alarm message and makes a sound alarm (ie, the PLC module 1 controls the buzzer and the alarm light to work), and at the same time, there is a corresponding alarm message on the touch screen module.

[0066] After all inspections are completed, after pressing the reset button on the touch screen module, if the alarm information has not been processed, the buzzer can stop beeping first, that is, the buzzer stops sounding, but the alarm light is still on. Only after all faults have been processed can all resets (including optical alarm reset and information reset on the touch screen module) be completed. Optical alarm reset means that the alarm light goes out, and information reset on the touch screen module means that there is no corresponding alarm information on the touch screen module.

[0067] During normal production, if the input signals of all safety sensors 7 change from "1" to "0" and from "0" to "1" within a period of normal production (accumulated time can be 8 hours to 1 week depending on the frequency of normal triggering during production), (changes during spot inspection are not included), otherwise it is considered as a spot inspection abnormality and an alarm is issued. The spot inspection is completed once a week, otherwise the equipment will be shut down safely until the spot inspection is completed.

[0068] At the same time, the system also has the following data records: the time of the last data record reset, the number of inspections, the number of abnormal inspections, the number of normal entries into the device for each channel, and the number of abnormal entries into the device.

[0069] During inspection, the relay module in this system can trigger the safety sensor, and the PLC module can control the reset of the safety sensor. During this process, the control system of the production line determines the change of the safety sensor signal and feeds it back to the PLC module. The PLC module determines whether the inspection of the safety sensor is abnormal based on the change of the signal and displays it on the touch screen module. This inspection system can replace manual inspection, improve the efficiency of safety sensor inspection, and overcome the problem of missed inspection.

[0070] Although the specific implementation modes of the present invention are described above, those skilled in the art should understand that the specific implementation modes described are only illustrative and are not intended to limit the scope of the present invention. Equivalent modifications and changes made by those skilled in the art in accordance with the spirit of the present invention should be included in the scope of protection of the claims of the present invention.

Claims

1. A production line intelligent inspection system, characterized by: It includes a PLC module, a relay module for simulating triggering of a safety sensor, a touch screen module for human-computer interaction, a communication module, a switch and a power module. The switch is connected to the PLC module and the touch screen module respectively, the PLC module is connected to the relay module, the relay module is connected to the safety sensor on the production line, and the communication module is connected to the PLC module; at the same time, the communication module is connected to the production line control system; The PLC module is also directly connected to the safety sensor on the production line to reset the triggered safety sensor; During inspection, the PLC module controls the relay module to send out an analog signal, triggers the analog safety sensor, and resets the analog signal through the PLC module. During this process, the production line control system determines the changes in the analog safety sensor signal and feeds it back to the PLC module. The PLC module determines whether there is any abnormality in the entire safety control loop based on the changes in the signal.

2. The intelligent inspection system for a production line according to claim 1, characterized in that: The safety sensors on the production line include safety light curtains respectively arranged on the partition, top plate, pallet loading, lower stacking exit and baler; the safety sensors on the production line also include a first safety door, a second safety door and a third safety door; The PLC module includes a second PLC and a third PLC; The relay module includes a first relay module, a second relay module and a third relay module, the second PLC is connected to the first relay module and the second relay module, the first relay module is connected to the first safety door, the second safety door, the third safety door and the safety light curtain arranged at the partition, and the second relay module is connected to the safety light curtain arranged at the partition, the top plate and the tray loading place; The third PLC is connected to the third relay module, and the third relay module is connected to the safety light curtains arranged at the pallet loading point, the stacking outlet and the baling machine.

3. The intelligent inspection system for a production line according to claim 2 is characterized in that: The third PLC is also connected to the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the lower stack exit and the baler, and is used to reset the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the lower stack exit and the baler; The PLC module also includes a first PLC, which is connected to the safety light curtains respectively arranged at the partition, the top plate and the pallet loading location, and is used to reset the safety light curtains arranged at the partition, the top plate and the pallet loading location.

4. The intelligent inspection system for a production line according to claim 1 is characterized in that: The PLC module is also connected with an alarm light and a buzzer.

5. The intelligent inspection system for a production line according to claim 1 is characterized by: The system also includes a control cabinet, in which the PLC module, relay module, communication module, switch and power supply module are arranged.

6. The intelligent inspection system for a production line according to claim 1 is characterized by: The model of the power module is DC 24V / 10A EDR-120-24.

7. A production line intelligent inspection method, characterized in that: The production line intelligent inspection system according to any one of claims 1 to 6 comprises the following steps: S1, the PLC module controls the relay module to simulate triggering the safety sensors on the production line one by one; S2. As each safety sensor is triggered in simulation, the control system of the production line determines whether the safety sensor signal and the corresponding safety partition signal have changed one by one, and feeds back the signal change of each safety sensor to the PLC module. If a safety sensor signal or the corresponding safety partition signal has not changed, the PLC module determines that the safety sensor has an abnormal inspection. S3. After a safety sensor is simulated and triggered by the relay module, the PLC module controls the safety sensor to reset, and the control system of the production line again determines the change of the safety sensor signal and the corresponding safety partition signal, and again feeds back the output signal of each safety sensor to the PLC module; S4, based on the two input signals to the safety sensor and the two output signals of the safety sensor fed back to the PLC module, the PLC module determines whether the input and output of the safety sensor are synchronized. If not, the PLC module determines that the safety sensor is abnormal. S5. In steps S2 and S4, if the PLC module determines that a safety sensor inspection is abnormal, then after the inspection of all safety sensors on the production line is completed, the PLC module controls the alarm light and buzzer to start, and feeds back the signal of the safe shutdown of all machines to the control system of the production line.

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