Full-automatic production line data communication optimization method based on distributed network topology

Abstract

The invention relates to the technical field of vehicle part production line communication, and provides a distributed network topology-based full-automatic production line data communication optimization method, which comprises the following steps of: obtaining distributed nodes of all production line workstations, and determining corresponding distributed communication nodes; determining a distributed network topology structure according to the distributed communication nodes and a production line production sequence corresponding to the production work station; constructing a distributed production line interaction network according to the distributed network topology structure; wherein the distributed production line interaction network comprises a data sharing layer, a data sequence interaction layer and a data exception uploading layer; and when a communication request of any workstation on the production line is received, determining a communication event, and responding to the corresponding communication event through the distributed production line interactive network.

Description

Technical Field

[0001] The present invention relates to the field of production line communication optimization, and in particular to a method for optimizing data communication of a fully automatic production line based on a distributed network topology. Background Art

[0002] At present, the automation rate of stamping, welding and painting in the automotive industry has reached more than 70%, while the automation rate of vehicle assembly is relatively low, about 10%, or even lower than 10%. This shows that although some processes have been highly automated, there is still room for improvement in the automation of vehicle assembly and other links. It is difficult for automated equipment to completely replace the flexibility of human hands and eyes in terms of control and detection accuracy, especially in multi-variety, flexible and high-beat production lines. With the emergence of distributed technology, fully automatic production can be achieved.

[0003] However, in complex production lines, a large amount of data needs to be transmitted between different control units and devices. If the communication network is not efficient enough, it may cause data transmission delays, affecting the real-time control and operation of the production line. On high-speed production lines, data communication may cause data loss or damage due to various reasons (such as electromagnetic interference, hardware failure, etc.), affecting the accuracy and reliability of the production process; as the degree of automation of the production line increases, the amount of data that needs to be transmitted is also increasing. If the network bandwidth is not sufficient to support this amount of data, it may cause communication congestion and affect production efficiency. Summary of the invention

[0004] The present invention proposes a data communication optimization method for a fully automatic production line based on a distributed network topology, which is used to solve the problem that a large amount of data needs to be transmitted between different control units and devices in a complex production line. If the communication network is not efficient enough, data transmission delays may occur, affecting the real-time control and operation of the production line. On a high-speed production line, data communication may cause data loss or damage due to various reasons (such as electromagnetic interference, hardware failure, etc.), affecting the accuracy and reliability of the production process; as the degree of automation of the production line increases, the amount of data that needs to be transmitted is also increasing. If the network bandwidth is not sufficient to support these data volumes, communication congestion may occur, affecting production efficiency. Situation.

[0005] The present invention proposes a data communication optimization method for a fully automatic production line based on a distributed network topology, comprising:

[0006] Configure all production line workstations as distributed nodes and determine the corresponding distributed communication nodes;

[0007] Determine the distributed network topology structure based on the distributed communication nodes and the production line production sequence corresponding to the production workstations;

[0008] According to the distributed network topology, a distributed production line interactive network is constructed; wherein the distributed production line interactive network includes: a data sharing layer, a data sequence interaction layer, and a data abnormality upload layer;

[0009] When a communication request is received from any workstation on the production line, the communication event is determined and the corresponding communication event is responded to through the distributed production line interaction network.

[0010] Furthermore, the internal equipment of the production line workstation is configured with a real-time Ethernet protocol, wherein the internal equipment includes: a robot, a sensor device and a PLC device;

[0011] The real-time Ethernet protocol performs master-slave synchronous communication through the first cycle on the fully automatic production line and the second cycle of the internal equipment; there is a clock deviation between the second cycle and the first cycle, and the first cycle is continuously compensated by the clock deviation.

[0012] Furthermore, the master-slave synchronous communication also includes:

[0013] Obtain the first network hop count of the fully automatic production line and the second network hop count of the internal equipment;

[0014] Calculate the difference between the first network hop count and the second network hop count to obtain the target network hop count difference between the fully automatic production line and the internal equipment;

[0015] According to the mapping relationship between the target network hop count difference and the clock deviation, a synchronization adjustment threshold of the active synchronization period is determined.

[0016] Further, the determining the corresponding distributed communication node also includes:

[0017] Obtain the pre-uploaded production line production plan and determine the target production line workstation in the fully automated production line in real time;

[0018] Upload the target production line workstation to the interactive communication link;

[0019] Determine the production sequence and communication time of the target production line workstations based on the interactive communication link and production line production plan;

[0020] Determine the priority of distributed communication nodes according to the production sequence of the production line;

[0021] Based on the workstation communication time, determine the network tuning time for each distributed communication node.

[0022] Furthermore, after determining the distributed network topology, the method further includes:

[0023] Determine the node status and communication flow information of each distributed communication node according to the production sequence of the production line;

[0024] Calculate the network topology performance by using the network optimization model to calculate the node status and communication flow information, and determine the performance calculation results;

[0025] According to the performance calculation result, an tunable first distributed communication node and a second distributed communication node with communication redundancy are determined.

[0026] Furthermore, the construction of a distributed production line interactive network includes:

[0027] According to the distributed network topology, set up interactive ports, shared data upload ports and abnormal data upload ports for different production line workstations;

[0028] Extract the communication address and communication equipment information corresponding to each production line workstation;

[0029] According to the communication address and communication equipment information, the production line workstations are clustered and divided to determine the cluster type;

[0030] According to the clustering type and interaction port, set the data sequence interaction layer;

[0031] According to the cluster type and shared data upload port, a data sharing layer is set up in the communication server of the fully automatic production line;

[0032] According to the clustering type and abnormal data upload port, set up the data abnormality upload layer in the control terminal of the fully automatic production line;

[0033] The data sequence interaction layer, data sharing layer and data exception upload layer are integrated to form a distributed production line interaction network.

[0034] Furthermore, the data sharing layer is used to:

[0035] When the data sharing layer receives the shared data sent by the production line workstation, it determines the corresponding target distributed workstation; wherein the shared data is uploaded to the data sharing layer by any distributed communication node;

[0036] Set up data directories and data indexes for shared data in the data sharing layer according to the communication areas of the distributed production line interactive network;

[0037] According to the data directory, set the storage area for shared data;

[0038] Set the viewing permissions and query methods for shared data based on the data index.

[0039] Furthermore, the data sequence interaction layer is used to:

[0040] Determine the first interactive workstation adjacent to the workstations of different production lines according to the production sequence of the production lines, and determine the second workstation with which communication interaction exists according to the current production plan;

[0041] When the first production line workstation sends a data interaction request to the second production line workstation, the data interaction request is uploaded to the data sequence interaction layer;

[0042] Determine whether the first production line workstation and the second production line workstation are adjacent production workstations, and output a first determination result;

[0043] Determine whether the first production line workstation and the second production line workstation are production workstations with communication interaction, and output a second determination result;

[0044] When the first judgment result or the second communication result is met, an exclusive communication channel between the first production line workstation and the second production line workstation is set in the data sequence interaction layer.

[0045] Furthermore, the data anomaly upload layer is used to:

[0046] When an abnormal communication event is received from any production line workstation, the abnormal communication event content is obtained and matched with the preset abnormal type;

[0047] If the content of the abnormal communication event matches the preset abnormal type, it is confirmed that the corresponding production line workstation has an abnormality, and an emergency management tag is set for the corresponding production line workstation;

[0048] According to the emergency management tag, the abnormal communication event content is sent to the data anomaly upload layer for analysis;

[0049] If the data exception upload layer does not receive the abnormal communication event content, the data sequence interaction layer calls any associated workstation that interacts with the corresponding production line workstation to upload the abnormal communication event content.

[0050] Furthermore, the distributed production line interaction network is also used for:

[0051] When there is an abnormality in a distributed communication node, a transfer port corresponding to the distributed communication node is set;

[0052] According to the transfer port, the interaction data of the corresponding distributed communication node is transmitted to the preset transfer center through the transfer port; wherein the transfer center is used to connect the cloud extension server and the local extension server.

[0053] The beneficial effects of the present invention are

[0054] The distributed network topology of the present invention optimizes the data transmission path, reduces the data transmission time in the network, thereby reducing communication delays and improving the real-time control capabilities of the production line. Improve data integrity: Through the data exception upload layer, errors in data transmission can be discovered and processed in a timely manner, ensuring the integrity and accuracy of the data. Improve production efficiency: The application of the data sharing layer and the data sequence interaction layer ensures the real-time and sequential nature of production data, which helps to improve the operating efficiency of the production line.

[0055] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings.

[0056] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The accompanying drawings are used to provide further understanding of the present invention and constitute a part of the specification. They are used to explain the present invention together with the embodiments of the present invention and do not constitute a limitation of the present invention.

[0058] In the attached picture:

[0059] Figure 1 A method flow chart of a method for optimizing data communication of a fully automatic production line based on a distributed network topology in an embodiment of the present invention;

[0060] Figure 2 This is a flow chart of constructing a distributed production line interactive network in an embodiment of the present invention;

[0061] Figure 3 It is a composition diagram of a fully automatic production line in an embodiment of the present invention;

[0062] Figure 4 This is a diagram of the data system composition of the fully automatic production line in an embodiment of the present invention. DETAILED DESCRIPTION

[0063] The preferred embodiments of the present invention are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0064] like Figure 1 As shown, this embodiment provides a data communication optimization method for a fully automatic production line based on a distributed network topology, including:

[0065] Configure all production line workstations as distributed nodes and determine the corresponding distributed communication nodes;

[0066] Determine the distributed network topology structure based on the distributed communication nodes and the production line production sequence corresponding to the production workstations;

[0067] According to the distributed network topology, a distributed production line interactive network is constructed; wherein the distributed production line interactive network includes: a data sharing layer, a data sequence interaction layer, and a data abnormality upload layer;

[0068] When a communication request is received from any workstation on the production line, the communication event is determined and the corresponding communication event is responded to through the distributed production line interaction network.

[0069] The principle of the above technical solution is:

[0070] In the specific implementation process, distributed node modules are installed in all production line workstations, and each node module can communicate with other node modules and share data. The node module can be connected to other components in the production system by wireless or wired means. The communication methods supported by each node include Ethernet, PROFIBUS-DP, PROFINET, RS-232, etc. According to the communication between the node modules and the requirements of the production workstation, a corresponding distributed communication protocol is established. These protocols may include the priority of data transmission, the format and encoding of the data, the address of the node, etc. Using the above-mentioned distributed communication protocol, all node modules are connected to form a distributed network topology. If the distributed network is Ethernet, any network segment can connect 1024 devices. If it is PROFIBUS-DP, a network can connect up to 127 devices. If it is PROFINET, it can connect up to 256 devices. RS232 has only one sending device and one receiving device, but different communication methods can communicate through a distributed production line interactive network. The topology can be adjusted according to the production sequence of the production workstation to ensure data circulation and collaboration between node modules. According to the above-mentioned distributed network topology and the location of the node modules, a distributed production line interaction network is constructed. The network includes multiple levels of structure, such as data sharing layer, data sequence interaction layer and data exception upload layer. When a production workstation sends a data communication request, it is forwarded to the corresponding node module through the node's routing mechanism. The node module converts the request into the corresponding message type and then responds through the corresponding network path. If the node module cannot respond to the request directly, it will pass the request to the upper node module or send it to a specific interface for further processing. When a production workstation encounters an abnormality during the data interaction process, the node module will upload it to the upper node module or the central management system through the abnormal upload layer for analysis and recording.

[0071] In the specific implementation, the distributed node deployment needs to obtain all the production line workstations and treat them as distributed nodes, with each node corresponding to a workstation. Each distributed node is equipped with corresponding communication equipment, such as industrial Ethernet switches, wireless access points, etc. Determine the distributed network topology, and determine the connection relationship of the distributed communication nodes according to the layout of the production line and the production sequence of the workstations. Use a ring, star or bus topology to ensure the optimal communication path between each node. In the process of building a distributed production line interactive network, the data sharing layer: build a central database to store the production data of all workstations. Each distributed node can access and update the data in the database in real time. Data sequence interaction layer: set a priority for each workstation according to the production sequence to ensure that the data is transmitted in the correct order. Data abnormality upload layer: when data abnormality is detected, the abnormal information is immediately uploaded to the monitoring center for rapid response and processing. Communication event response includes: when receiving a communication request from any workstation on the production line, immediately determine the type of communication event (such as production data upload, equipment status query, etc.). According to the event type, respond to the corresponding communication event through the distributed production line interactive network. For example, for production data upload, the data is written to the central database through the data sharing layer, and the data sequence interaction layer ensures that the data sequence is correct. For equipment status query, the monitoring center obtains the real-time status information of related equipment through the data sharing layer.

[0072] In a practical embodiment, the production line includes multiple workstations such as stamping, welding, painting, and assembly. As the scale of production expands, data communication problems in the production line become increasingly prominent, and data transmission delays and packet loss occur frequently, seriously affecting production efficiency and product quality.

[0073] After adopting the technical solution of the present invention:

[0074] When getting distributed nodes:

[0075] The company regards all workstations on the production line as distributed nodes, including stamping workstations, welding workstations, painting workstations and assembly workstations, totaling 20 distributed nodes.

[0076] When determining distributed communication nodes:

[0077] According to the functions and locations of each workstation, the enterprise has equipped each distributed node with a corresponding communication node to ensure the efficiency and stability of data transmission.

[0078] Determine the distributed network topology, specifically:

[0079] The enterprise determines the following according to the production line production sequence of distributed communication nodes and production workstations: Figure 1The distributed network topology shown in Figure 1 divides the production line into four areas, each of which contains several workstations, and the areas are connected by a backbone network.

[0080] Construct a distributed production line interactive network, specifically:

[0081] Based on the distributed network topology, the company has built a distributed production line interactive network, which includes the following three layers: Data sharing layer: used to share production data between workstations, such as production plans, process parameters, etc. Data sequence interaction layer: ensure that production data is transmitted according to the production sequence of the production line to avoid data confusion. Data abnormality upload layer: when data transmission abnormality occurs, the abnormal information is uploaded in time to facilitate rapid location and resolution of the problem.

[0082] Respond to communication events, specifically:

[0083] When receiving a communication request from any workstation on the production line, the enterprise responds to the following communication events through the distributed production line interactive network: Production data query: The workstation queries the data sharing layer for the required production data. Production data update: The workstation sends a production data update request to the data sequence interaction layer to ensure real-time data synchronization. Abnormal alarm: When a data transmission abnormality occurs, the workstation reports the abnormal information through the data abnormality upload layer, and the system automatically notifies the relevant personnel to handle it.

[0084] The beneficial effect of the above technical solution is

[0085] The distributed network topology of the present invention optimizes the data transmission path, reduces the data transmission time in the network, thereby reducing communication delays and improving the real-time control capabilities of the production line. Improve data integrity: Through the data exception upload layer, errors in data transmission can be discovered and processed in a timely manner, ensuring the integrity and accuracy of the data. Improve production efficiency: The application of the data sharing layer and the data sequence interaction layer ensures the real-time and sequential nature of production data, which helps to improve the operating efficiency of the production line.

[0086] As an embodiment of the present invention, the internal equipment of the production line workstation is configured with a real-time Ethernet protocol, wherein the internal equipment includes: a robot, a sensor device and a PLC device;

[0087] The real-time Ethernet protocol performs master-slave synchronous communication through the first cycle on the fully automatic production line and the second cycle of the internal equipment; there is a clock deviation between the second cycle and the first cycle, and the first cycle is continuously compensated by the clock deviation.

[0088] The principle of the above technical solution is:

[0089] In all production line workstations, real-time Ethernet protocol is configured for robots, sensor devices and PLC devices. This protocol allows them to perform high-speed data transmission on the network, thereby improving the data communication efficiency of the entire production line. The real-time Ethernet protocol adopts a master-slave synchronous communication mode, that is, the first cycle is the master node and the second cycle is the master node. In the first cycle of the fully automatic production line, the data communication between the various workstations is carried out through master-slave synchronous communication. This means that at the beginning of each cycle, the master node (usually the first workstation on the production line) sends commands and data to all slave nodes. The slave nodes perform tasks according to the predetermined production sequence and send feedback information to the master node when encountering specific events or states. At this time, the master node coordinates the production process by detecting the feedback information. However, due to the existence of network clock deviation, master-slave synchronous communication may be affected. For example, clock deviation may occur when two adjacent workstations are located in different geographical locations or their internal devices (such as PLC devices) have inaccurate clocks. In order to ensure the quality and stability of communication, the system continuously compensates by clock deviation in the first cycle. At the beginning of each cycle, the clock deviation between each slave node and the master node is calculated. The master node then fine-tunes the data generated by each slave node based on the values ​​of these deviations. This allows the slave node to correctly understand and respond to the master node's instructions even in the presence of clock deviations. After the first cycle, the clock deviations of the master and slave nodes are self-corrected. This will further improve the stability and robustness of the system and ensure that data communication during the production process is always accurate. The above solution effectively utilizes the advantages of the real-time Ethernet protocol, realizes master-slave synchronous communication, and effectively compensates for clock deviations. This greatly improves the data communication efficiency of the production line,

[0090] As an embodiment of the present invention, the master-slave synchronous communication further includes:

[0091] Obtain the first network hop count of the fully automatic production line and the second network hop count of the internal equipment;

[0092] Calculate the difference between the first network hop count and the second network hop count to obtain the target network hop count difference between the fully automatic production line and the internal equipment;

[0093] According to the mapping relationship between the target network hop count difference and the clock deviation, a synchronization adjustment threshold of the active synchronization period is determined.

[0094] The principle of the above technical solution is:

[0095] In the specific implementation process, it is necessary to first obtain the first network hop count of the fully automatic production line, which refers to the first hop count determined from the total network hop count of the production line. Next, the system also needs to obtain the second network hop count of the internal device, which means obtaining the next network hop count after obtaining the first network hop count of the fully automatic production line. The acquisition of these two network hop counts can be carried out in any effective way, such as by reading a database or using an API interface. Calculate the difference between the first network hop count and the second network hop count. The calculation of this difference is to obtain the target network hop count difference between the fully automatic production line and the internal device. In other words, it is hoped that the target state to be achieved can be determined by calculating the difference between the two. According to the mapping relationship between the target network hop count difference and the clock deviation, determine the synchronization adjustment threshold of the active synchronization cycle. This step is the most core step because it directly determines the synchronization strategy. Specifically, it is necessary to find a function that can map the target network hop count difference to the clock deviation, and then according to this function, a synchronization adjustment threshold of an active synchronization cycle can be determined. The setting of this threshold will affect the synchronization strategy, thereby further affecting the efficiency of the entire production line. According to the synchronization adjustment threshold of this active synchronization cycle, the data communication between the fully automatic production line and the internal equipment is adjusted in real time. For example, if the current network hop count difference is less than the threshold, then synchronization is performed according to the original synchronization cycle; if the difference is greater than or equal to the threshold, then synchronization is performed according to the new synchronization cycle. In this way, it can be ensured that the synchronization strategy is always consistent with the set target.

[0096] As an embodiment of the present invention, the determining the corresponding distributed communication node further includes:

[0097] Obtain the pre-uploaded production line production plan and determine the target production line workstation in the fully automated production line in real time;

[0098] Upload the target production line workstation to the interactive communication link;

[0099] Determine the production sequence and communication time of the target production line workstations based on the interactive communication link and production line production plan;

[0100] Determine the priority of distributed communication nodes according to the production sequence of the production line;

[0101] Based on the workstation communication time, determine the network tuning time for each distributed communication node.

[0102] The principle of the above technical solution is:

[0103] During the specific implementation process, a complete and up-to-date production line production plan will be obtained from the pre-set server. This plan usually includes all production tasks, workpiece information, material information, equipment information, etc. Then, according to this production plan, the specific location and working status of each target production line workstation in the fully automatic production line are determined in real time. In this process, factors that need to be considered include but are not limited to the operating status of the equipment, the urgency of the task, the demand for materials, etc. Next, the obtained target production line workstation is uploaded to the interactive communication link. The interactive communication link is a high-speed and stable communication method that ensures that all workstations can exchange data quickly and accurately. In this way, real-time monitoring and management of the target production line workstation can be achieved. Then, based on the information of the interactive communication link and the production line production plan, the production line production sequence and workstation communication time of the target production line workstation are further determined. The determination of this information can help better control the operation of the workstation and ensure the continuity and stability of production. In this process, the priority of each distributed communication node is also determined according to the production sequence of the production line. The purpose of this is to enable important information and instructions to be transmitted to each workstation faster and improve work efficiency. Finally, the network tuning time of each distributed communication node is determined based on the communication time of each workstation. The purpose of this is to maximize network performance and allow each workstation to obtain the best network connection and usage experience.

[0104] As an embodiment of the present invention, after determining the distributed network topology structure, the method further includes:

[0105] Determine the node status and communication flow information of each distributed communication node according to the production sequence of the production line;

[0106] Calculate the network topology performance by using the network optimization model to calculate the node status and communication flow information, and determine the performance calculation results;

[0107] According to the performance calculation result, an tunable first distributed communication node and a second distributed communication node with communication redundancy are determined.

[0108] The principle of the above technical solution is:

[0109] In the specific implementation process, the node status and communication flow information of each distributed communication node will be further determined according to the current production order of the production line under the set network topology. The key to this step is that the status of each node needs to be flexibly adjusted according to the actual working conditions and production needs to ensure that they have sufficient communication bandwidth and processing power when they are most needed. Then, these node status and communication flow information are used as input to perform a performance calculation through the network optimization model. The goal of this step is to use advanced algorithms and technologies to accurately predict the performance improvement or decline brought about by various possible network topology combinations, so as to select the optimal configuration in the subsequent system. In this way, the network performance can be continuously optimized without affecting production, further improving production efficiency. Finally, according to the results of the performance calculation, some tunable first distributed communication nodes and second distributed communication nodes with communication redundancy will be determined. In actual implementation, the distributed nodes correspond to the workstations on the production line. The selection and setting of distributed nodes need to take into account production needs, as well as factors such as system load balancing and fault tolerance.

[0110] As an embodiment of the present invention, the construction of a distributed production line interactive network includes:

[0111] According to the distributed network topology, set up interactive ports, shared data upload ports and abnormal data upload ports for different production line workstations;

[0112] Extract the communication address and communication equipment information corresponding to each production line workstation;

[0113] According to the communication address and communication equipment information, the production line workstations are clustered and divided to determine the cluster type;

[0114] According to the clustering type and interaction port, set the data sequence interaction layer;

[0115] According to the cluster type and shared data upload port, a data sharing layer is set up in the communication server of the fully automatic production line;

[0116] According to the clustering type and abnormal data upload port, set up the data abnormality upload layer in the control terminal of the fully automatic production line;

[0117] The data sequence interaction layer, data sharing layer and data exception upload layer are integrated to form a distributed production line interaction network.

[0118] The principle of the above technical solution is:

[0119] In the specific implementation process, firstly, according to the distributed network topology, the interactive ports, shared data upload ports and abnormal data upload ports of different production line workstations are set. The settings of these ports can be dynamically adjusted according to production needs and actual conditions to adapt to different production environments and tasks. Then, the communication address and communication equipment information corresponding to each production line workstation are extracted, and clustering is performed based on this information to determine the cluster type. These cluster types can be based on various factors such as the complexity of the task, the performance level of the equipment, and the geographical location. Next, according to the cluster type and interactive port, the data sequence interaction layer is set. This layer is mainly responsible for the orderly transmission and reception of data, ensuring the validity and accuracy of the data. Then, according to the cluster type and shared data upload port, the data sharing layer is set in the communication server of the fully automatic production line. This layer is responsible for sharing data between different workstations, improving the utilization rate of data and facilitating the collaborative work between different sites. Finally, according to the cluster type and abnormal data upload port, the data abnormality upload layer is set in the control terminal of the fully automatic production line. This layer is mainly used to process and record abnormal data to prevent abnormal data from affecting normal production, and also provides a basis for subsequent data analysis and troubleshooting. By integrating these four levels, a complete distributed production line interactive network is formed. This network can realize efficient, stable and reliable data exchange between multiple sites at the same time, greatly improving the working efficiency of the fully automatic production line and reducing production costs.

[0120] In actual implementation, the company selected the following communication protocols based on the characteristics of the equipment on the production line and allocated communication channels accordingly: Ethernet: used for communication between the PLC controller, human-machine interface (HMI) and the upper-level monitoring computer on the production line. PROFIBUS-DP: used to connect field devices such as sensors and actuators on the production line. PROFINET: used for high-speed motion control equipment, such as robots, servo drives, etc. RS-232: used for maintenance and monitoring of some old equipment. Ethernet communication channel definition, IP address and port number: Assign a unique IP address to each Ethernet device on the production line, such as 192.168.1.10 for the PLC controller, 192.168.1.11 for the HMI, and 192.168.1.12 for the monitoring computer. The port numbers are set to the default TCP / UDP port or a custom port.

[0121] PROFIBUS-DP communication channel definition, device station number: Assign a unique station number to each PROFIBUS-DP device on the production line, such as station number 1 for the sensor and station number 2 for the actuator, to ensure that each device has a unique identification on the bus.

[0122] PROFINET communication channel definition, IP address and device name: Assign IP addresses to PROFINET devices, such as 192.168.1.20 for robots and 192.168.1.21 for servo drives. At the same time, set an easily recognizable device name for each device, such as "Robot01" for robots.

[0123] RS-232 communication channel definition, port number, baud rate, parity, stop bit, data bit: set the communication parameters for the RS-232 device, such as setting the serial port parameters of the maintenance computer to COM1, baud rate 9600, no parity, 1 stop bit, 8 data bits.

[0124] Implementation of communication system and construction of network: Based on the communication channels allocated above, the company built the data communication network of the production line, including Ethernet network, PROFIBUS-DP bus, PROFINET network and RS-232 connection.

[0125] Configure equipment: configure the communication parameters of each device to ensure that the device can exchange data according to the established protocol and channel. Test verification: conduct actual operation tests on the production line to verify whether the communication between the devices is stable and reliable.

[0126] As an embodiment of the present invention, the data sharing layer is used for:

[0127] When the data sharing layer receives the shared data sent by the production line workstation, it determines the corresponding target distributed workstation; wherein the shared data is uploaded to the data sharing layer by any distributed communication node;

[0128] Set up data directories and data indexes for shared data in the data sharing layer according to the communication areas of the distributed production line interactive network;

[0129] According to the data directory, set the storage area for shared data;

[0130] Set the viewing permissions and query methods for shared data based on the data index.

[0131] The principle of the above technical solution is:

[0132] In the specific implementation process, the main function of the data sharing layer is to manage and organize the shared data distributed on different distributed communication nodes. When the data sharing layer receives the shared data sent by the production line workstation, it needs to first determine the corresponding target distributed workstation to avoid repeated or invalid data transmission in the network. Then, the data sharing layer will classify and organize the received shared data according to certain rules for future search and use. Specifically, the data sharing layer will set up data directories and data indexes according to the communication area of ​​the distributed production line interactive network. The data directory and data index are equivalent to an index or directory, which can clearly distinguish which data is where, thereby facilitating users to find and access data. Next, the data sharing layer will set up the storage area of ​​the shared data according to the data directory. In other words, there will be one or more data storage areas under each data directory, which can be physical storage devices or servers in the cloud. Finally, the data sharing layer will set the viewing permissions and query methods of the shared data according to the data index. For example, only specific users or user groups have the authority to access the data in a certain data directory, or the user's identity can be verified through specific methods (such as passwords, fingerprints, etc.) to ensure the security and privacy of the data. Figure 4 As shown, the data system is the core of the entire production line. It has functions such as data collection and storage, fool-proofing, and one-key model change. It records the operating data of each process and has a fool-proofing function (such as: if the previous process is NG or it is not completed and flows into the next process, the equipment will automatically alarm to prompt the abnormal situation of the current part in the previous process).

[0133] As an embodiment of the present invention, the data sequence interaction layer is used for:

[0134] Determine the first interactive workstation adjacent to the workstations of different production lines according to the production sequence of the production lines, and determine the second workstation with which communication interaction exists according to the current production plan;

[0135] When the first production line workstation sends a data interaction request to the second production line workstation, the data interaction request is uploaded to the data sequence interaction layer;

[0136] Determine whether the first production line workstation and the second production line workstation are adjacent production workstations, and output a first determination result;

[0137] Determine whether the first production line workstation and the second production line workstation are production workstations with communication interaction, and output a second determination result;

[0138] When the first judgment result or the second communication result is met, an exclusive communication channel between the first production line workstation and the second production line workstation is set in the data sequence interaction layer.

[0139] The principle of the above technical solution is:

[0140] In the specific implementation process, the data sequence interaction layer will determine the first interactive workstation adjacent to the workstations of different production lines according to the production sequence of the production line, and determine the second workstation with communication interaction based on this. The purpose of this is to ensure that the data transmission between the workstations can be carried out according to the production needs and processes, thereby improving the accuracy and real-time performance of the data. Next, when the first production line workstation sends a data interaction request to the second production line workstation, these requests will be transmitted to the data sequence interaction layer. This step is mainly to realize data exchange between workstations and facilitate the sharing and transmission of various data in the production process. Then, the data sequence interaction layer will judge the workstation that issues the request (i.e., the first production line workstation) and the workstation that receives the request (i.e., the second production line workstation) based on the received data interaction request to determine whether they are adjacent workstations. If this condition is met, a judgment result will be generated. Next, the data sequence interaction layer will further judge this judgment result to determine whether the workstation is a production workstation with communication interaction. If this condition is met, a corresponding judgment result will also be generated. Finally, when any of the above conditions is met, the data sequence interaction layer will set up an exclusive communication channel between the first production line workstation and the second production line workstation internally. This exclusive communication channel can ensure efficient, safe and stable data transmission between workstations, which is a very important feature of the present invention. Determine the interactive workstation, the adjacent first interactive workstation, and determine the adjacent workstations of each workstation according to the production sequence of the production line. For example, the adjacent workstation of the injection molding workstation is the assembly workstation.

[0141] The second workstation with communication interaction determines the non-adjacent workstations that need to exchange data with the first workstation according to the current production plan. For example, although the inspection workstation is not directly adjacent to the assembly workstation in the production sequence, it needs to receive the assembled component data for quality inspection. Data interaction request processing, data interaction request upload.

[0142] When the injection molding workstation (first workstation) needs to send a data interaction request to the assembly workstation (second workstation), the request is uploaded to the data sequence interaction layer. To determine the relationship between the workstations, the data sequence interaction layer determines whether the injection molding workstation and the assembly workstation are adjacent production workstations, and outputs the first judgment result as "yes". The data sequence interaction layer further determines whether the injection molding workstation and the inspection workstation are production workstations with communication interaction, and outputs the second judgment result as "yes". Setting an exclusive communication channel When the first judgment result or the second judgment result is "yes", an exclusive communication channel is set in the data sequence interaction layer between the injection molding workstation and the assembly workstation, and between the injection molding workstation and the inspection workstation.

[0143] As an embodiment of the present invention, the data anomaly upload layer is used to:

[0144] When an abnormal communication event is received from any production line workstation, the abnormal communication event content is obtained and matched with the preset abnormal type;

[0145] If the content of the abnormal communication event matches the preset abnormal type, it is confirmed that the corresponding production line workstation has an abnormality, and an emergency management tag is set for the corresponding production line workstation;

[0146] According to the emergency management tag, the abnormal communication event content is sent to the data anomaly upload layer for analysis;

[0147] If the data exception upload layer does not receive the abnormal communication event content, the data sequence interaction layer calls any associated workstation that interacts with the corresponding production line workstation to upload the abnormal communication event content.

[0148] The principle of the above technical solution is:

[0149] In the specific implementation process, when a workstation in the production line (hereinafter referred to as the "workstation") receives an abnormal communication event, the workstation will first parse the content of the event and match it with the preset abnormal type. If the match is successful, the workstation will determine that the abnormality belongs to a pre-defined specific type and add the information of the type to the emergency management tag of the workstation. Then, the workstation will send the communication event content containing the abnormal type information to the data abnormality upload layer for analysis and processing. The data abnormality upload layer will further process the received abnormal communication event content, such as filtering, compression or encryption, so as to be more efficient and secure in the subsequent processing process. If the data abnormality upload layer does not receive any abnormal communication event content within the specified time, the workstation will try to find other associated workstations with which it has an interactive relationship through the data sequence interaction layer, and transmit the abnormal communication event content to it. The purpose of this is to ensure that all places where abnormalities may occur can be covered, so as to minimize the occurrence of abnormal events. In addition, if a new abnormal event occurs during the entire processing process, the workstation will also upload it to the data abnormality upload layer for analysis. In this way, even if the upload layer cannot handle data anomalies, it can be ensured that data communication on the production line can be processed in a timely manner.

[0150] As an embodiment of the present invention, the distributed production line interaction network is also used for:

[0151] When there is an abnormality in a distributed communication node, a transfer port corresponding to the distributed communication node is set;

[0152] According to the transfer port, the interaction data of the corresponding distributed communication node is transmitted to the preset transfer center through the transfer port; wherein the transfer center is used to connect the cloud extension server and the local extension server.

[0153] The principle of the above technical solution is:

[0154] In the specific implementation, if uploading an abnormal event fails, that is, the distributed communication node is abnormal, the cloud extension server and the local extension server can be connected through the transfer port to allow the cloud extension server and the local extension server to replace the function of the distributed communication node.

[0155] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. A method for optimizing data communication of a fully automatic production line based on a distributed network topology, characterized in that: include: Configure all production line workstations as distributed nodes and determine the corresponding distributed communication nodes; Determine the distributed network topology structure based on the distributed communication nodes and the production line production sequence corresponding to the production workstations; According to the distributed network topology, a distributed production line interactive network is constructed; wherein the distributed production line interactive network includes: a data sharing layer, a data sequence interaction layer, and a data abnormality upload layer; When a communication request is received from any workstation on the production line, the communication event is determined and the corresponding communication event is responded to through the distributed production line interaction network.

2. The data communication optimization method for a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: The internal equipment of the production line workstation is configured with a real-time Ethernet protocol, wherein the internal equipment includes: a robot, a sensor device and a PLC device; The real-time Ethernet protocol performs master-slave synchronous communication through the first cycle on the fully automatic production line and the second cycle of the internal equipment; there is a clock deviation between the second cycle and the first cycle, and the first cycle is continuously compensated by the clock deviation.

3. The data communication optimization method for a fully automatic production line based on a distributed network topology as claimed in claim 2, characterized in that: The master-slave synchronous communication also includes: Obtain the first network hop count of the fully automatic production line and the second network hop count of the internal equipment; Calculate the difference between the first network hop count and the second network hop count to obtain the target network hop count difference between the fully automatic production line and the internal equipment; According to the mapping relationship between the target network hop count difference and the clock deviation, a synchronization adjustment threshold of the active synchronization period is determined.

4. The data communication optimization method for a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: The determining of the corresponding distributed communication node further comprises: Obtain the pre-uploaded production line production plan and determine the target production line workstation in the fully automated production line in real time; Upload the target production line workstation to the interactive communication link; Determine the production sequence and communication time of the target production line workstations based on the interactive communication link and production line production plan; Determine the priority of distributed communication nodes according to the production sequence of the production line; Based on the workstation communication time, determine the network tuning time for each distributed communication node.

5. The method for optimizing data communication of a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: After the distributed network topology is determined, the method further includes: Determine the node status and communication flow information of each distributed communication node according to the production sequence of the production line; Calculate the network topology performance by using the network optimization model to calculate the node status and communication flow information, and determine the performance calculation results; According to the performance calculation result, an tunable first distributed communication node and a second distributed communication node with communication redundancy are determined.

6. The method for optimizing data communication of a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: The construction of a distributed production line interactive network includes: According to the distributed network topology, set up interactive ports, shared data upload ports and abnormal data upload ports for different production line workstations; Extract the communication address and communication equipment information corresponding to each production line workstation; According to the communication address and communication equipment information, the production line workstations are clustered and divided to determine the cluster type; According to the clustering type and interaction port, set the data sequence interaction layer; According to the cluster type and shared data upload port, a data sharing layer is set up in the communication server of the fully automatic production line; According to the clustering type and abnormal data upload port, set up the data abnormality upload layer in the control terminal of the fully automatic production line; The data sequence interaction layer, data sharing layer and data exception upload layer are integrated to form a distributed production line interaction network.

7. The method for optimizing data communication of a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: The data sharing layer is used to: When the data sharing layer receives the shared data sent by the production line workstation, it determines the corresponding target distributed workstation; wherein the shared data is uploaded to the data sharing layer by any distributed communication node; Set up data directories and data indexes for shared data in the data sharing layer according to the communication areas of the distributed production line interactive network; According to the data directory, set the storage area for shared data; Set the viewing permissions and query methods for shared data based on the data index.

8. The data communication optimization method for a fully automatic production line based on a distributed network topology as claimed in claim 1, characterized in that: The data sequence interaction layer is used to: Determine the first interactive workstation adjacent to the workstations of different production lines according to the production sequence of the production lines, and determine the second workstation with which communication interaction exists according to the current production plan; When the first production line workstation sends a data interaction request to the second production line workstation, the data interaction request is uploaded to the data sequence interaction layer; Determine whether the first production line workstation and the second production line workstation are adjacent production workstations, and output a first determination result; Determine whether the first production line workstation and the second production line workstation are production workstations with communication interaction, and output a second determination result; When the first judgment result or the second communication result is met, an exclusive communication channel between the first production line workstation and the second production line workstation is set in the data sequence interaction layer.

9. The method for optimizing data communication of a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: The data anomaly upload layer is used to: When an abnormal communication event is received from any production line workstation, the abnormal communication event content is obtained and matched with the preset abnormal type; If the content of the abnormal communication event matches the preset abnormal type, it is confirmed that the corresponding production line workstation has an abnormality, and an emergency management tag is set for the corresponding production line workstation; According to the emergency management tag, the abnormal communication event content is sent to the data anomaly upload layer for analysis; If the data exception upload layer does not receive the abnormal communication event content, the data sequence interaction layer calls any associated workstation that interacts with the corresponding production line workstation to upload the abnormal communication event content.

10. The method for optimizing data communication of a fully automatic production line based on a distributed network topology according to claim 1, characterized in that: The distributed production line interaction network is also used for: When there is an abnormality in a distributed communication node, a transfer port corresponding to the distributed communication node is set; According to the transfer port, the interaction data of the corresponding distributed communication node is transmitted to the preset transfer center through the transfer port; wherein the transfer center is used to connect the cloud extension server and the local extension server.

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