Automatic collection method for comprehensive efficiency data of automation equipment

Abstract

The invention discloses a method for automatically acquiring comprehensive efficiency data of automation equipment, which comprises the following steps of: configuring a data acquisition interface and a data uploading trigger logic, namely configuring an equipment state reporting interface and configuring the data uploading trigger logic: actively uploading equipment state data according to the frequency of once per second; configuring an equipment abnormal shutdown reporting interface and configuring a data uploading trigger logic as follows: actively uploading data when shutdown alarm is triggered and alarm is finished; a feeding port sensor, a discharging port sensor and an NG product sensor are arranged and used for counting products. And calling the interface data based on the data uploading trigger logic to calculate the time utilization rate, the performance utilization rate and the yield rate, and finally calculating the comprehensive efficiency of the equipment. According to the method, the time utilization rate, the performance utilization rate and the yield data of the equipment are accurately, comprehensively and detailedly collected and recorded, the collected data are directly available, secondary calculation, cleaning and time conformity verification are not needed, and the efficient collection and availability of the data are greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of equipment data processing, in particular to an automatic collection method for comprehensive efficiency data of automated equipment. Background Art

[0002] The current automated production line equipment OEE (overall equipment efficiency) data collection has the following problems: ① Manual recording cannot guarantee the authenticity and completeness of data, and there is serious information missing; ② Directly collect PLC data at a fixed frequency (such as 100ms), which places a huge load on data investigation, identification, and collection; ③ After collecting data through information technology, data screening and deduplication are still required before use, and data cleaning and verification consume a long time; ④ The working hours for product defects and rework (including multiple rework) overlap with the time waiting for materials, and it is impossible to accurately calculate the rework working hours to ensure the accuracy of OEE data. Summary of the invention

[0003] In order to solve the problems existing in the prior art, the present invention proposes a method for automatically collecting comprehensive efficiency data of automated equipment, which actively uploads data only when an abnormal shutdown is triggered, greatly reducing the data collection load and eliminating data processing and cleaning work. The collected data can be directly used for calculating the comprehensive efficiency of the equipment, and data such as the cause of loss and start time can be used directly. At the same time, the accuracy of time utilization rate, performance utilization rate, and yield indicators can be guaranteed, ensuring that the data is true, the collection is efficient, and it is directly available.

[0004] In order to achieve the above technical objectives, the present invention is implemented by the following technical solutions: The present invention provides a method for automatically collecting comprehensive efficiency data of automation equipment, comprising: Configure the data collection interface and data upload trigger logic; Call interface data based on data upload trigger logic to calculate time utilization rate; Based on the data upload trigger logic, call the interface data to calculate the performance utilization rate; Based on the data upload trigger logic, the interface data is called to calculate the yield; Calculate the overall equipment efficiency based on time utilization rate, performance utilization rate and yield rate.

[0005] Preferably, the configuration data collection interface and data upload trigger logic include: Configure the device status reporting interface and configure the data upload trigger logic to upload data to the AI ​​industrial control system once every second; Configure the equipment abnormal shutdown reporting interface and configure the data upload trigger logic: actively upload data to the AI ​​industrial control system when the shutdown alarm is triggered and the alarm ends; the shutdown alarm includes passive shutdown alarm, active shutdown alarm, material blockage alarm and waiting alarm; Equipped with a feed inlet sensor to count products and calculate the time when the products are fed and the interval between adjacent times, and to count the actual feeding rhythm of the products; Equipped with a discharge port sensor to count products and calculate the time when the products come off the line and the interval between adjacent times, and to count the actual production rhythm of the products; Equipped with NG product sensor to count NG products.

[0006] In this preferred solution, by configuring the equipment abnormal shutdown reporting interface, the interface is called to upload the shutdown data only when the status changes, which greatly reduces the collection load; the uploaded data does not need to be cleaned twice, such as avoiding the overlap of various shutdown data and secondary calculations such as deduplication and cleaning, and the data can be used directly.

[0007] Preferably, the device status reporting interface and the device abnormal shutdown reporting interface are configured on the AI ​​industrial control system, and the device status reporting interface and the device abnormal shutdown reporting interface perform data exchange with the automation equipment host computer through an API interface; The feed inlet sensor is arranged at the feed inlet of the automation equipment; The discharge port sensor is arranged at the discharge port of the automation equipment; The NG product sensor is arranged in front of the discharge port sensor.

[0008] In this preferred solution, by configuring the feed port sensor, the discharge port sensor and the NG product sensor, it is convenient to calculate the product feed rhythm, product output rhythm and NG product statistics, providing a data basis for subsequent performance utilization rate calculation and yield calculation.

[0009] Preferably, the data field uploaded by the device status reporting interface includes tenant ID, device code, upload time and device status signal bit, The device status signal bits include: Running status, 0 means not running, 1 means running; Standby state, 0 means non-standby, 1 means standby; Fault status, 0 means no fault, 1 means fault; Blockage status, 0 means no blockage, 1 means blockage; Waiting state, 0 means not waiting, 1 means waiting; Moreover, the five states are mutually exclusive.

[0010] In this preferred solution, five status signals are configured and are mutually exclusive, that is, only one of the five status signals is 1 at present, which is convenient for determining the abnormal shutdown type of the current device and triggering the corresponding abnormal shutdown interface based on the abnormal shutdown type.

[0011] Preferably, the data fields uploaded by the device abnormal shutdown reporting interface include tenant ID, device code, upload time, device abnormal shutdown start time, end time and abnormal shutdown reason.

[0012] Preferably, the device abnormal shutdown reporting interface includes: Passive shutdown interface, configure data upload trigger logic as follows: when passive shutdown occurs, the passive shutdown interface is triggered to actively upload the fault start time and fault cause to the AI ​​industrial control system; when the passive shutdown is eliminated, the passive shutdown interface is triggered again to actively upload the fault start time, fault cause and fault end time to the AI ​​industrial control system; Active shutdown interface, configure data upload trigger logic as follows: when active shutdown occurs, trigger the active shutdown interface to actively upload the active shutdown start time to the AI ​​industrial control system; when active shutdown is eliminated, trigger the active shutdown interface again to actively upload the active shutdown reason, active shutdown start time and active shutdown end time to the AI ​​industrial control system; The blocking interface and waiting interface are configured with the data upload trigger logic as follows: when waiting or blocking occurs, the time from the feed port sensing the product passing through to one theoretical beat is used as the starting point of waiting, and the time from the discharge port sensing the product passing through is used as the starting point of blocking. The waiting interface or blocking interface is triggered to actively upload the waiting start time and waiting reason to the AI ​​industrial control system; when waiting or blocking ends, the time from the feed port sensing the next product passing through is used as the waiting end point, and the time from the discharge port sensing the next product passing through is used as the blocking end point. The waiting interface or blocking interface is triggered again to actively upload the waiting start time, waiting reason and waiting end time to the AI ​​industrial control system.

[0013] In this preferred scheme, the abnormal shutdown reporting interface is further configured as a passive shutdown interface, an active shutdown interface, a material blocking interface and a material waiting interface according to the abnormal shutdown type. Different shutdown interfaces are triggered according to different abnormal shutdown types to upload data. The actual unplanned downtime is the sum of the four abnormal shutdown times minus the NG product loss time.

[0014] Preferably, in normal operation or in a blocked material waiting state, the equipment stops and the fault state signal becomes 1, and the operation state signal, the blocked material state signal or the waiting material state signal becomes 0, then it is determined that the passive shutdown occurs; when the fault state signal becomes 0, and the operation state signal, the blocked material state signal or the waiting material state signal becomes 1, then it is determined that the passive shutdown is eliminated; In normal operation or blocked waiting state, when the standby state signal becomes 1 and the running state signal, blocked state signal or waiting state signal becomes 0, it is judged that the active shutdown occurs; when the standby state signal becomes 0 and the running state signal, blocked state signal or waiting state signal becomes 1, it is judged that the active shutdown is eliminated; In normal operation or waiting state, when the blocking state signal becomes 1, the operation state signal or the waiting state signal becomes 0, and the fault state signal and the standby state signal are both 0, it is determined that the blocking occurs; when the blocking state signal becomes 0, the operation state signal, the standby state signal or the fault state signal becomes 1, it is determined that the blocking ends; Under normal operation, when the waiting state signal becomes 1, the running state signal becomes 0, and the fault state signal, standby state signal, and material blocking state signal are all 0, it is judged that waiting for material occurs; when the waiting state signal becomes 0, and the running state signal or the material blocking state signal or the standby state signal or the fault state signal becomes 1, it is judged that waiting for material ends.

[0015] In this preferred solution, the start time and end time of the abnormal shutdown are further determined based on the equipment status signal, and the data upload logic is triggered at the start time and end time, which greatly reduces the amount of collection load.

[0016] Preferably, if fault B occurs before the passive shutdown of fault A is eliminated, fault B does not trigger the passive shutdown data upload logic; when all passive shutdown faults are eliminated, the passive shutdown interface data upload logic is triggered again, and the start time of fault A, the cause of fault A, and the end time of the last passive shutdown fault eliminated are sent to the AI ​​industrial control system.

[0017] In this preferred solution, the data upload logic when multiple passive shutdown failures occur simultaneously is limited to avoid data overlap and secondary calculations such as deduplication and cleaning.

[0018] Preferably, if active shutdown, material blockage or waiting for material occurs before the passive shutdown ends, the active shutdown, material blockage, waiting for material data upload logic is not triggered, and the fault state signal remains at 1 until the operating state signal changes to 1 and the fault state signal changes to 0; If passive shutdown, material blockage or waiting for material occurs before the active shutdown ends, the passive shutdown, material blockage and waiting for material data upload logic will not be triggered, and the standby state signal will remain at 1 until the running state signal changes to 1 and the standby state signal changes to 0.

[0019] In this preferred solution, the priority of the data long transmission logic triggered by different abnormal shutdown types is limited to avoid data overlap and secondary calculations such as deduplication and cleaning.

[0020] Preferably, if there is material waiting before the material blocking ends, the logic of uploading the material waiting data will not be triggered; If active or passive shutdown occurs before the end of the blocking, the active or passive shutdown interface upload logic is immediately triggered, and the blocking interface upload end information is triggered, the blocking state signal changes to 0, and the fault state signal or standby state signal changes to 1; If other abnormal shutdowns occur before the end of waiting for materials, the active shutdown interface, passive shutdown interface or material blocking interface upload logic will be triggered immediately, and the waiting for materials interface upload end information will be triggered, the waiting for materials status signal will change to 0, and the fault status signal, standby status signal or material blocking status signal will change to 1.

[0021] In this preferred solution, the priority of the data long transmission logic triggered by different abnormal shutdown types is limited to avoid data overlap and secondary calculations such as deduplication and cleaning.

[0022] Preferably, the time utilization rate calculation based on the data upload trigger logic calling interface data includes: When the passive shutdown interface is triggered, the fault start time, fault cause and fault end time are obtained, and the passive shutdown time is obtained by subtracting the fault start time from the fault end time; When the active shutdown interface is triggered, the active shutdown reason, active shutdown start time and active shutdown end time are obtained, and the active shutdown time is obtained by subtracting the active shutdown start time from the active shutdown end time; When the blocking waiting interface is triggered, the waiting start time, waiting reason and waiting end time are obtained, and the blocking time and waiting time are calculated by subtracting the waiting start time from the waiting end time; Calculate the unplanned downtime as: Unplanned downtime = passive downtime + active downtime + material blocking time + waiting time - NG product loss time; Among them, NG product loss time = NG product sensor statistical number * theoretical beat; The calculation time utilization rate is: Time utilization rate = (load time - unplanned downtime) / load time, Among them, load time = calendar time - planned downtime, Calendar time, planned downtime, and theoretical cycle time are all set values.

[0023] Preferably, the method of calculating the performance utilization rate based on the data upload trigger logic calling the interface data includes: Call the discharge port sensor to count the number of products passing through and get the number of products off the line; Call the NG product sensor to count the number of defective products; The production number is calculated as: Production quantity = number of products off the line + number of defective products. The computing performance utilization rate is: Performance utilization rate = theoretical beat / actual beat, Among them, actual cycle time = (load time - unplanned downtime) / production number.

[0024] Preferably, the method of performing yield calculation based on the data upload trigger logic calling interface data includes: Yield rate = (production number - statistical number of NG sensors) / production number.

[0025] Preferably, the overall equipment efficiency is calculated based on the time utilization rate, performance utilization rate and yield rate as follows: Equipment overall efficiency = time utilization rate * performance utilization rate * yield rate.

[0026] The beneficial effects of the present invention are: The present invention provides an automatic collection method for comprehensive efficiency data of automated equipment. During the collection process of equipment time utilization rate, performance utilization rate and yield rate data, the status and abnormal shutdown data are actively uploaded, and the interface is called to upload the shutdown data only when the status changes, which greatly reduces the collection load.

[0027] The data collected by the present invention is directly usable without the need for secondary calculation, cleaning, or time conformity verification, which greatly improves data efficient collection and usability.

[0028] In the calculation of the time utilization rate, the present invention removes the NG product loss time mixed in the material blocking data to ensure the authenticity of the calculation of the equipment comprehensive efficiency.

[0029] Compared with the traditional manual abnormal shutdown data recording and abnormal data separate collection method, the present invention maximizes the data utilization level, has low investment, is easy to standardize, and is convenient for large-scale promotion. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a flowchart of the AI ​​industrial control system interface call in the method for automatically collecting comprehensive efficiency data of automation equipment provided by the present invention; Figure 2 This is a flow chart of the method for automatically collecting comprehensive efficiency data of automation equipment provided by the present invention. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments and the accompanying drawings. Here, the illustrative embodiments of the present invention and their descriptions are used to explain the present invention, but are not intended to limit the present invention.

[0032] It should also be noted that, in order to avoid obscuring the present invention due to unnecessary details, only structures and / or processing steps closely related to the solutions according to the present invention are shown in the accompanying drawings, while other details that are not closely related to the present invention are omitted.

[0033] It should be emphasized that the term “include / comprises” when used herein refers to the presence of features, elements, steps or components, but does not exclude the presence or addition of one or more other features, elements, steps or components.

[0034] It should also be noted that, unless otherwise specified, the term “connection” herein may refer not only to a direct connection but also to an indirect connection involving an intermediate.

[0035] It should be emphasized here that the step marks mentioned below are not intended to limit the order of the steps, but it should be understood that the steps can be executed in the order mentioned in the embodiment, or in a different order from the embodiment, or several steps can be executed simultaneously.

[0036] It should also be noted that the "one embodiment" or "embodiment" referred to in the present invention refers to a specific feature, structure or characteristic that can be included in at least one implementation of the present invention. The "in one embodiment" that appears in different places in this specification does not refer to the same embodiment, nor is it a separate or selective embodiment that is mutually exclusive with other embodiments.

[0037] In an automated production line, the overall efficiency of the equipment is calculated as follows: OEE (Overall Equipment Effectiveness) = (Actual Output of Good Products * Theoretical Cycle Time) / Load Time = Time Utilization Rate * Performance Utilization Rate * Yield Rate, Specifically, Time utilization rate = (load time - unplanned downtime) / load time, Among them, load time = calendar time - planned downtime; Performance utilization rate = theoretical beat / actual beat, Among them, actual cycle time = (load time - unplanned downtime) / production number, the production number includes the number of defective products; Yield = number of good products / number of production, Among them, the qualified number is the number of products off the line, and the production number is the number of products off the line + the number of defective products. Because the number of work-in-progress inside the equipment is the same when production starts and ends (full or empty), the production number = the number of products on the line.

[0038] Based on the above theory, the OEE calculation of automation equipment requires the collection of time utilization rate, performance utilization rate and yield rate data. Based on this, the present invention provides an automatic collection method for OEE data of automation equipment, see Figure 2 ,include: S1. Configure the data collection interface and data upload trigger logic as follows: S11, Equipment status category and equipment status interface: The equipment status is divided into five states: running, fault, standby, material blocking, and waiting for material, and they are mutually exclusive; the equipment status reporting interface is configured in the AI ​​industrial control system, and the equipment status reporting interface exchanges data with the equipment host computer through the API interface. The equipment host computer communicates with the PLC in the equipment, and can collect PLC data and reverse control PLC actions. The data collected by the host computer includes the equipment status data. The equipment host computer obtains the equipment status data, and the equipment status reporting interface receives and stores the equipment status data, and uploads the data to the AI ​​industrial control system at a frequency of once every 1 second.

[0039] In the present invention, data is actively uploaded at a frequency of once per second. The data field includes tenant ID, device code, upload time and device status signal bit. There are five equipment status signal bits: running status (expressed as: run, 0 non-running, 1 running), standby status (expressed as: wait, 0 non-standby, 1 standby), fault status (expressed as: fault, 0 non-fault, 1 fault), material blocking status (expressed as: waitDown, 0 non-material blocking, 1 material blocking), and waiting for material (expressed as: waitMaterial, 0 non-material waiting, 1 waiting for material). The standby status is the status corresponding to the active shutdown. During normal production, the equipment status must be one of the five states, and only one state exists at the same time.

[0040] JSON message body example: { "tenantID": 4000001, "equipCode": "XZ2-01-02-QJ-QJ-02", "operateId": "Username", "run": "1", "wait": "0", "fault": "0", "waitMaterial": "0", "waitDown": "0", "uploadTime": "2024-08-19 08:45:00" } S12, abnormal shutdown type and abnormal shutdown interface: Abnormal shutdown types include passive shutdown, active shutdown, material blocking and waiting for material. Passive shutdown is the equipment failure state, active shutdown is the waiting stop state, and material blocking and waiting for material are the equipment is available but not processing normally. The above four states are all considered abnormal shutdown states.

[0041] The abnormal shutdown interface is configured in the AI ​​industrial control system, and the abnormal shutdown interface interacts with the device host computer through the API interface.

[0042] The device abnormal shutdown reporting interface receives and stores the device abnormal shutdown alarm data, and actively uploads the data when the shutdown alarm is triggered or the alarm ends. The data fields include tenant ID, device code, upload time, device abnormal shutdown start time & end time, and abnormal shutdown reason. The shutdown alarm mainly includes passive shutdown alarm, active shutdown alarm, material blocking alarm, and waiting alarm. The calling logic is as follows: Figure 1 shown.

[0043] The calling logic of different abnormal shutdown interfaces is as follows: Passive shutdown interface: When a passive shutdown occurs, the oeeWarning interface is triggered, and the fault start time and fault cause are sent at the same time; when the passive shutdown is eliminated, the oeeWarning interface is triggered again, and the fault start time, fault cause, and fault end time are sent. The fault time is calculated by fault end time - fault start time. The alarm code is maintained by uploading an Excel file to the AI ​​industrial control system. In Excel, the equipment manufacturer needs to provide the alarm code, alarm code type (prompt type, safety type, shutdown type) and alarm code specific information.

[0044] Active shutdown interface: When active shutdown occurs, the equipment is manually operated to change from running state to shutdown state (i.e., the automatic button is manually adjusted to the manual button, and the equipment is adjusted from automatic state to manual state). The equipment shutdown is the start signal, and the developed active shutdown interface pops up. In the active shutdown interface, select the active shutdown reason, press the start button, and the equipment resumes operation as the end signal. If the reason is not selected, the equipment cannot be started. When active shutdown occurs, the oeeManualTriggerWarning interface is triggered, and the active shutdown start time is sent; when the active shutdown is eliminated and the equipment is started, the oeeManualTriggerWarning interface is triggered again, and the active shutdown reason, active shutdown start time, and active shutdown end time are sent. The active shutdown time is calculated by the active shutdown end time - active shutdown start time.

[0045] It should be noted that passive shutdown means that the equipment stops due to equipment failure. When the automatic button is adjusted to the manual button by manual operation, there is no need to pop up the active shutdown interface. Only when the equipment is in the other three states, namely normal operation state, material blocking state, and waiting for material state, and the automatic button is adjusted to the manual button by manual operation, the active shutdown interface will pop up, the active shutdown interface will be triggered, and the standby state will become 1.

[0046] Blocking interface and waiting interface: Waiting blocking refers to the lack of material in the front process of the equipment and the blocking of the back process. If the fixed beat time is exceeded and the next product is not sensed to pass the feeding point or the discharging point, the starting point of the blocking is the time just after the fixed beat is exceeded, and the end point of the blocking is the time when the product is sensed next time. That is, when the feeding port senses the passing of the product, it will wait for 1 theoretical beat and start as the waiting starting point, when the discharging port senses the passing of the product, it will wait for 1 theoretical beat and start as the blocking starting point, when the feeding port senses the passing of the next product, it will be the waiting end point, and when the discharging port senses the passing of the next product, it will be the blocking end point. When waiting / blocking occurs, the oeeWaiting / oeeWaitingDown interface is automatically triggered, and the waiting start time and waiting reason are sent at the same time; when waiting / blocking ends, the oeeWaiting / oeeWaitingDown interface is triggered again, and the waiting start time, waiting reason, and waiting end time are sent. The waiting time is calculated by the waiting end time - waiting start time.

[0047] S13, online, offline, NG product sensing interface, Specifically include: A sensor is installed at the feeding port of the equipment to count the products and calculate the feeding time and the interval between adjacent times of the sensing products, and to count the actual feeding rhythm of the products; Sensors are installed at the discharge port of the equipment to count the products and calculate the time when the products are sensed to come off the line and the interval between adjacent times, and to count the actual production rhythm of the products; NG products are counted on the NG pull belt (a small conveyor belt storage location for storing defective products, set in front of the discharge port sensor).

[0048] S2. Based on the data upload trigger logic, call the interface data to calculate the time utilization rate, as follows: S21, calculating calendar time, That is, the time period for which OEE calculation is required, such as 8:00-20:00, where the calendar time is 12 hours.

[0049] S22. Set planned downtime. Enter the planned downtime period in the AI ​​industrial control system, such as 8:00-10:00, and there is no production plan. During this period, the status interface, shutdown interface, import and export, and NG product sensor interface will not upload data.

[0050] S23. Call the device abnormal shutdown reporting interface data to calculate the downtime, including the following situations: S23A, in normal operation or blocking waiting state, when a fault triggers and causes shutdown, at this time, the fault status signal becomes 1, the operation status and blocking waiting state signals become 0 and the information is uploaded. When the blocking waiting shutdown interface is sent, data needs to be sent, triggering the oeeWarning interface (if it does not cause shutdown, the interface will not be called) to send the start time of fault A and the cause of the fault to the AI ​​industrial control system; It should be noted that if fault B occurs in other parts of the equipment before the alarm type of fault A disappears, fault B will not be triggered. When fault B is resolved (at this time, A has been resolved before B) or when fault A is resolved (at this time, B has been resolved before A), the oeeWarning interface will be triggered again to send the start time of fault A, the cause of fault A, and the end time of fault A or B (the last fault resolved) to the AI ​​industrial control system. The passive downtime is calculated by fault end time - fault start time.

[0051] Fault removal means that the fault status signal becomes 0, the fault has been repaired, the running status signal or the blocking status signal becomes 1, and the passive shutdown interface is triggered to upload the end data.

[0052] The data uploaded and recorded at this time mainly include the fault start time, end time and fault cause. This example can be used when multiple fault types occur continuously and overlap with each other.

[0053] It should be noted that if the equipment failure has not ended, the equipment is manually adjusted to manual state. At this time, the active shutdown interface is not triggered, and the equipment state is still in the fault state. Before the equipment is restarted, although the equipment failure has been repaired, the entire equipment state remains in the fault state, and the fault state signal is 1. When the equipment is adjusted to the automatic state and the equipment can operate normally, the oeeWarning interface is triggered. At this time, the fault state signal becomes 0, and the operation state signal or the material blocking state signal or the material waiting state signal becomes 1. If the next state is the material blocking state, the material blocking shutdown interface is triggered, and the material blocking shutdown start data is uploaded. At the same time, the fault start time, fault cause and fault end time are sent. The passive shutdown time is calculated by the fault end time - fault start time. At this time, the uploaded and recorded data are mainly the fault start time, end time and fault cause.

[0054] S23B. In normal operation or blocked waiting state, active shutdown trigger causes shutdown. At this time, the standby state signal becomes 1, the running state signal and the blocked material state signal become 0 and the information is uploaded. The blocked waiting shutdown interface needs to send data when sending the end, trigger the oeeManualTriggerWarning interface, send the active shutdown start time to the AI ​​industrial control system, and then the operator selects the active shutdown reason. Before the equipment is restarted, although the equipment fault has been repaired, the entire equipment state remains in the standby state. When the equipment is adjusted to the automatic state and the equipment can operate normally, the oeeManualTriggerWarning interface is triggered. At this time, the standby state signal becomes 0, the running state signal or the blocked material signal or the waiting material signal becomes 1. If the next state is the blocked waiting state, the blocked waiting shutdown interface is triggered, and the blocked waiting shutdown start data is uploaded. At the same time, the active shutdown start time, the active shutdown reason and the fault end time are sent to the AI ​​industrial control system. The active shutdown time is calculated by the active shutdown end time - the active shutdown start time.

[0055] The data uploaded and recorded at this time mainly include the start time, end time and reason of the active shutdown.

[0056] S23C, in normal operation or waiting state, material blocking triggers and causes shutdown. At this time, the material blocking state signal changes to 1, the normal operation state and waiting signal change to 0 and upload the information. The waiting shutdown interface needs to send data when it ends. If the theoretical beat time is exceeded and the next product is not sensed to pass through the feeding point or the discharging point, the just exceeded theoretical beat is taken as the material blocking start point, and the oeeWaitingDown interface is automatically triggered, and the waiting start time and waiting reason are sent to the AI ​​industrial control system at the same time; the next time the product is sensed is the material blocking end point, and the oeeWaitingDown interface is triggered again. At this time, the material blocking state signal changes to 0, and the other 4 equipment states are triggered at the same time and the state signal changes to 1. If the next state is an abnormal operation state, the active shutdown, passive shutdown, and waiting shutdown interfaces are triggered to send start data at the same time, and the waiting start time, waiting reason and waiting end time are sent to the AI ​​industrial control system. The material blocking time is calculated by the waiting end time - waiting start time.

[0057] It should be noted that, because the blocking signal is triggered first, and if there is waiting for material during this duration, the waiting signal will not be triggered (blocking priority is higher than waiting priority). If active or passive shutdown occurs during this duration, the active or passive shutdown interface upload logic will be triggered immediately, and the blocking interface upload end information will be triggered, the blocking state will change to 0, and the fault state or standby state will change to 1.

[0058] S23D. Under normal operation, the waiting trigger causes shutdown. At this time, the waiting status signal changes to 1, the running status signal changes to 0 and the information is uploaded. If the theoretical beat time is exceeded and the next product is not sensed passing through the feeding point or the discharging point, the waiting start point is just exceeded as the theoretical beat, and the oeeWaiting interface is automatically triggered, and the waiting start time and waiting reason are sent to the AI ​​industrial control system at the same time; the next time the product is sensed is the waiting end point, and the oeeWaiting interface is triggered again. At this time, the waiting status signal changes to 0, and the other 4 equipment states are triggered at the same time and the status signal changes to 1. If the next state is an abnormal operation state, the active shutdown, passive shutdown, and material blocking shutdown interfaces are triggered and the start data is sent at the same time, and the waiting start time, waiting reason and waiting end time are sent to the AI ​​industrial control system; the waiting time is calculated by the waiting end time - waiting start time.

[0059] It should be noted that if other abnormal shutdown types occur during the waiting time, the waiting will be terminated immediately, triggering the end signal and the oeeWaiting interface. At this time, the waiting status signal becomes 0, and other status signal types are triggered at the same time to upload the information. Other types of shutdown interfaces need to send data when sending the start, and send the waiting start time, waiting reason and waiting end time to the AI ​​industrial control system; the waiting time is calculated by the waiting end time - waiting start time.

[0060] It should be noted that if active shutdown, material blockage or waiting for material occurs before the passive shutdown ends, the active shutdown, material blockage or waiting for material data upload logic will not be triggered, and the fault status will remain at 1 until the normal operation signal changes to 1 and the fault status signal changes to 0.

[0061] It should be noted that if passive shutdown, material blockage, or waiting for material occurs before the active shutdown ends, the passive shutdown, material blockage, or waiting for material data upload logic will not be triggered, and the standby state will remain at 1 until the normal operation signal changes to 1 and the standby state signal changes to 0.

[0062] In summary, unplanned downtime = passive downtime + active downtime + material blocking time + waiting time - NG product loss time. The uploaded data does not need to be cleaned and can be used directly. Among them, NG product loss time = NG product sensor statistics number * theoretical beat.

[0063] Then calculate the time utilization rate: Time utilization rate = (load time - unplanned downtime) / load time, Among them, load time = calendar time - planned downtime.

[0064] S3. Based on the data upload trigger logic, the interface data is called to calculate the performance utilization rate as follows: S31. The theoretical beat is filled in the AI ​​industrial control system according to the equipment technical protocol requirements, and the data can be automatically matched and used.

[0065] S32, production number = number of products off the line + number of defective products, The number of products passing through the sensor set at the equipment outlet is counted as the number of products off the line, and the number of NG products counted by the sensor is the number of defective products. The load time and unplanned downtime are known before, and the performance utilization rate can be calculated: Performance utilization rate = theoretical beat / actual beat, The actual cycle time = (load time - unplanned downtime) / production number.

[0066] S4. Calculate the yield as follows: Yield = (production number - NG product sensor statistics) / production number, Based on the above S3 call data, the production number and the statistical number of NG product sensors can be known, and the yield rate can be directly calculated.

[0067] S5. Based on the calculation results of S2 to S4, the overall efficiency of the equipment is calculated as follows: OEE (Overall Equipment Effectiveness) = Time Utilization Rate * Performance Utilization Rate * Yield Rate.

[0068] Finally, it should be noted that because the shutdown interface data is synchronized with the equipment status, the start and end points of the shutdown data match the status duration.

[0069] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A method for automatically collecting comprehensive efficiency data of automation equipment, characterized in that: include: Configure the data collection interface and data upload trigger logic; Call interface data based on data upload trigger logic to calculate time utilization rate; Based on the data upload trigger logic, call the interface data to calculate the performance utilization rate; Based on the data upload trigger logic, the interface data is called to calculate the yield; Calculate the overall equipment efficiency based on time utilization rate, performance utilization rate and yield rate.

2. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 1, characterized in that: The configuration data collection interface and data upload trigger logic include: Configure the device status reporting interface and configure the data upload trigger logic to upload data to the AI ​​industrial control system once every second; Configure the equipment abnormal shutdown reporting interface and configure the data upload trigger logic: actively upload data to the AI ​​industrial control system when the shutdown alarm is triggered and the alarm ends; the shutdown alarm includes passive shutdown alarm, active shutdown alarm, material blockage alarm and waiting alarm; Equipped with a feed inlet sensor to count products and calculate the time when the products are fed and the interval between adjacent times, and to count the actual feeding rhythm of the products; Equipped with a discharge port sensor to count products and calculate the time when the products come off the line and the interval between adjacent times, and to count the actual production rhythm of the products; Equipped with NG product sensor to count NG products.

3. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 2, characterized in that: The device status reporting interface and the device abnormal shutdown reporting interface are configured on the AI ​​industrial control system, and the device status reporting interface and the device abnormal shutdown reporting interface perform data exchange with the automation equipment host computer through an API interface; The feed inlet sensor is arranged at the feed inlet of the automation equipment; The discharge port sensor is arranged at the discharge port of the automation equipment; The NG product sensor is arranged in front of the discharge port sensor.

4. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 3, characterized in that: The device status reporting interface upload data field includes tenant ID, device code, upload time and device status signal bit. The device status signal bits include: Running status, 0 means not running, 1 means running; Standby state, 0 means non-standby, 1 means standby; Fault status, 0 means no fault, 1 means fault; Blockage status, 0 means no blockage, 1 means blockage; Waiting state, 0 means not waiting, 1 means waiting; Moreover, the five states are mutually exclusive.

5. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 3, characterized in that: The data fields uploaded by the device abnormal shutdown reporting interface include tenant ID, device code, upload time, device abnormal shutdown start time, end time and abnormal shutdown reason.

6. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 5, characterized in that: The device abnormal shutdown reporting interface includes: Passive shutdown interface, configure data upload trigger logic as follows: when passive shutdown occurs, the passive shutdown interface is triggered to actively upload the fault start time and fault cause to the AI ​​industrial control system; when the passive shutdown is eliminated, the passive shutdown interface is triggered again to actively upload the fault start time, fault cause and fault end time to the AI ​​industrial control system; Active shutdown interface, configure data upload trigger logic as follows: when active shutdown occurs, trigger the active shutdown interface to actively upload the active shutdown start time to the AI ​​industrial control system; when active shutdown is eliminated, trigger the active shutdown interface again to actively upload the active shutdown reason, active shutdown start time and active shutdown end time to the AI ​​industrial control system; The blocking interface and waiting interface are configured with the data upload trigger logic as follows: when waiting or blocking occurs, the time from the feed port sensing the product passing through to one theoretical beat is used as the starting point of waiting, and the time from the discharge port sensing the product passing through is used as the starting point of blocking. The waiting interface or blocking interface is triggered to actively upload the waiting start time and waiting reason to the AI ​​industrial control system; when waiting or blocking ends, the time from the feed port sensing the next product passing through is used as the waiting end point, and the time from the discharge port sensing the next product passing through is used as the blocking end point. The waiting interface or blocking interface is triggered again to actively upload the waiting start time, waiting reason and waiting end time to the AI ​​industrial control system.

7. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 6, characterized in that: In normal operation or blocked material waiting state, the equipment stops and the fault status signal changes to 1, and the operation status signal, blocking material status signal or waiting material status signal changes to 0, then it is judged that the passive shutdown occurs; when the fault status signal changes to 0, and the operation status signal, blocking material status signal or waiting material status signal changes to 1, then it is judged that the passive shutdown is eliminated; In normal operation or blocked waiting state, when the standby state signal becomes 1 and the running state signal, blocked state signal or waiting state signal becomes 0, it is judged that the active shutdown occurs; when the standby state signal becomes 0 and the running state signal, blocked state signal or waiting state signal becomes 1, it is judged that the active shutdown is eliminated; In normal operation or waiting state, when the blocking state signal becomes 1, the operation state signal or the waiting state signal becomes 0, and the fault state signal and the standby state signal are both 0, it is determined that the blocking occurs; when the blocking state signal becomes 0, the operation state signal, the standby state signal or the fault state signal becomes 1, it is determined that the blocking ends; Under normal operation, when the waiting state signal becomes 1, the running state signal becomes 0, and the fault state signal, standby state signal, and material blocking state signal are all 0, it is judged that waiting for material occurs; when the waiting state signal becomes 0, and the running state signal or the material blocking state signal or the standby state signal or the fault state signal becomes 1, it is judged that waiting for material ends.

8. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 7, characterized in that: If fault B occurs before the passive shutdown of fault A is eliminated, fault B will not trigger the passive shutdown data upload logic; When all passive shutdown faults are resolved, the passive shutdown interface data upload logic is triggered to send the start time of fault A, the cause of fault A, and the end time of the last resolved passive shutdown fault to the AI ​​industrial control system.

9. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 7, characterized in that: If active shutdown, material blockage or waiting for material occurs before passive shutdown ends, the active shutdown, material blockage and waiting for material data upload logic will not be triggered, and the fault status signal will remain at 1 until the running status signal changes to 1 and the fault status signal changes to 0; If passive shutdown, material blockage or waiting for material occurs before the active shutdown ends, the passive shutdown, material blockage and waiting for material data upload logic will not be triggered, and the standby state signal will remain at 1 until the running state signal changes to 1 and the standby state signal changes to 0.

10. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 7, characterized in that: If there is material waiting before the material blocking ends, the logic of uploading the waiting material data will not be triggered; If active or passive shutdown occurs before the end of the blocking, the active or passive shutdown interface upload logic is immediately triggered, and the blocking interface upload end information is triggered, the blocking state signal changes to 0, and the fault state signal or standby state signal changes to 1; If other abnormal shutdowns occur before the end of waiting for materials, the active shutdown interface, passive shutdown interface or material blocking interface upload logic will be triggered immediately, and the waiting for materials interface upload end information will be triggered, the waiting for materials status signal will change to 0, and the fault status signal, standby status signal or material blocking status signal will change to 1.

11. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 6, characterized in that: The method of calling the interface data based on the data upload trigger logic to calculate the time utilization rate includes: When the passive shutdown interface is triggered, the fault start time, fault cause and fault end time are obtained, and the passive shutdown time is obtained by subtracting the fault start time from the fault end time; When the active shutdown interface is triggered, the active shutdown reason, active shutdown start time and active shutdown end time are obtained, and the active shutdown time is obtained by subtracting the active shutdown start time from the active shutdown end time; When the blocking waiting interface is triggered, the waiting start time, waiting reason and waiting end time are obtained, and the blocking time and waiting time are calculated by subtracting the waiting start time from the waiting end time; Calculate the unplanned downtime as: Unplanned downtime = passive downtime + active downtime + material blocking time + waiting time - NG product loss time; Among them, NG product loss time = NG product sensor statistical number * theoretical beat; The calculation time utilization rate is: Time utilization rate = (load time - unplanned downtime) / load time, Among them, load time = calendar time - planned downtime, Calendar time, planned downtime, and theoretical cycle time are all set values.

12. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 11, characterized in that: The method of calling the interface data based on the data upload trigger logic to calculate the performance utilization rate includes: Call the discharge port sensor to count the number of products passing through and get the number of products off the line; Call the NG product sensor to count the number of defective products; The production number is calculated as: Production quantity = number of products off the line + number of defective products. The computing performance utilization rate is: Performance utilization rate = theoretical beat / actual beat, Among them, actual cycle time = (load time - unplanned downtime) / production number.

13. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 12, characterized in that: The method of calling the interface data based on the data upload trigger logic to perform yield calculation includes: Yield rate = (production number - statistical number of NG sensors) / production number.

14. The method for automatically collecting comprehensive efficiency data of automation equipment according to claim 13, characterized in that: The overall efficiency of the equipment is calculated based on the time utilization rate, performance utilization rate and yield rate as follows: Equipment overall efficiency = time utilization rate * performance utilization rate * yield rate.

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