Unit automation rate operation index evaluation rule method and system

Abstract

The invention discloses a unit automation rate operation index evaluation rule method. The method comprises the following steps: S1, collecting and processing autostep signals of main line equipment and roll changing equipment; and S2, the automation rate of the main line equipment and the automation rate of the roller changing equipment are calculated. The invention further discloses a unit automation rate operation index evaluation rule system. According to the invention, the problem of unstable evaluation accuracy caused by evaluation of the industrial automation degree depending on artificial experience is solved.

Description

Technical Field

[0001] The present invention relates to industrial automation technology, and more specifically, to a method and system for evaluating a unit automation rate operation index rule. Background Art

[0002] Industrial automation is a general term for the information processing and process control of machines, equipment or production processes that achieve measurement, manipulation, etc. according to the expected goals without direct human intervention. The automation rate and automation operation index of a workshop can well reflect the degree of industrial automation in a modern workshop. The operation index evaluation of the automation rate of the acid rolling unit production line of an enterprise can be carried out from the following two aspects:

[0003] 1) Automation rate of main line equipment;

[0004] 2)Automation rate of roller changing automatic step.

[0005] However, when evaluating the degree of industrial automation in the above two aspects, most people use expert experience to evaluate the degree of industrial automation in modern workshops, and the accuracy of the evaluation is heavily dependent on manual experience. Summary of the invention

[0006] In view of the defects existing in the prior art, the purpose of the present invention is to provide a method and system for evaluating the operation index of the unit automation rate, so as to solve the problem that the evaluation accuracy is unstable due to relying on manual experience to evaluate the degree of industrial automation.

[0007] To achieve the above object, the present invention adopts the following technical solutions:

[0008] A first aspect of the present invention provides a method for evaluating a unit automation rate operation index rule, comprising the following steps:

[0009] S1. Collect and process the automatic step signals of the main line equipment and roll changing equipment;

[0010] S2. Calculate the automation rate of the main line equipment and the automation rate of the roll changing equipment.

[0011] Preferably, the step S1 collects and processes the automatic step signal of the main line equipment as follows:

[0012] The production line server sends out the N-address data of all automatic steps in sequence through UDP communication at a frequency of once per second. Each N-address data is 2 bytes. The program listens to the port where UDP sends data. After receiving the data, it traverses all automatic steps in the automatic step signal list in sequence to determine whether the Master On signal of the automatic step is triggered.

[0013] Preferably, the step S1 collects and processes the automatic step signal of the roll changing device as follows:

[0014] The roll insertion signal consists of two signals: the working roll and the working roll + intermediate roll. As long as one of them appears, it means that the frame starts to change rolls. A roll change record is inserted into the rollchange_automation_score table. When the roll change automatic step is traversed, the corresponding roll change record is queried in the rollchange_automation_score table according to the time, and the id of the record is updated to the automation_step table record of this roll change automatic step. After traversing all the automatic steps in the automatic step list, the automatic step data received in this cycle is processed, and the above process is repeated when waiting for the next cycle UDP data to be received, and this cycle is repeated.

[0015] Preferably, the step S2 of calculating the automation rate of the main line equipment specifically includes the following steps:

[0016] S211, divide the automation rate area;

[0017] S212, roll number statistics;

[0018] S213, automatic step sequence statistics;

[0019] S214, automatic step and roll number binding analysis;

[0020] S215, calculating the automation rate of the same volume number;

[0021] S216. Automation rate of computer group.

[0022] Preferably, the step S211 of dividing the automation rate areas specifically includes:

[0023] The automation rate area is divided into three areas: entrance section, pickling section, and exit section.

[0024] Preferably, the step S212 of volume number statistics specifically includes:

[0025] By reading the operation history file, the volume number and the time point when the key equipment in each area was passed are obtained.

[0026] Preferably, the automatic step sequence counting in step S213 specifically includes:

[0027] Sort out the total automatic steps in all areas, and classify them by area, find the flag bit of each automatic step operation, and record the corresponding time and automatic step name when the flag bit changes.

[0028] Preferably, the automatic step and volume number binding analysis in step S214 specifically includes:

[0029] Through time matching, it is counted whether each volume number is triggered in different areas among all automatic steps, and the number of automatic steps triggered in different areas is counted to obtain the number of automatic steps executed by the same volume number in each area.

[0030] Preferably, the step S215 of calculating the automation rate of the same volume number specifically includes:

[0031] The automation rate of different areas of the same roll number = (the number of automatic steps executed for the same roll number in the area / the total number of automatic steps in the area) * 100%;

[0032] The total automation rate of the same roll number = the automation rate of the entrance area of ​​the same roll number * weight + the automation rate of the pickling area of ​​the same roll number * weight + the automation rate of the exit area of ​​the same roll number * weight.

[0033] Preferably, the step S216 of calculating the automation rate of the computer group specifically includes:

[0034] The automation rate of each area in the current time period or a certain time period is counted by region. Each area is multiplied by a different weight and the total is added up to get the automation rate of the entire unit.

[0035] Preferably, the step S2 of calculating the automation rate of the roll changing equipment specifically comprises the following steps:

[0036] S221, dividing the automation rate area;

[0037] S222, automatic step sequence statistics;

[0038] S223, calculating the roll changing automation rate of each rack;

[0039] S224, calculating the roll changing automation rate.

[0040] Preferably, the step S221 of dividing the automation rate areas specifically includes:

[0041] Divided into racks 1 to 5, a total of 5 areas.

[0042] Preferably, the automatic step sequence counting in step S222 specifically includes:

[0043] Sort out the total automatic steps in all areas and classify them according to the racks. Find the flag position of the automatic step operation after the roller insertion flag position of each rack. When the flag position changes, record the corresponding time and automatic step name.

[0044] Preferably, the step S223 of calculating the roll changing automation rate of each rack specifically includes:

[0045] The roll changing automation rate of each rack = (the number of automatic steps executed by the rack / the total number of automatic steps of the rack)*100%.

[0046] Preferably, the step S224 of calculating the roll changing automation rate specifically includes:

[0047] The automation rate of each area in the current time period or a certain time period is counted by the rack. Each area is multiplied by a different weight, and the total is added to get the roll changing automation rate of the entire unit.

[0048] A second aspect of the present invention provides a unit automation rate operation index evaluation rule system, comprising:

[0049] Automatic step signal collection and processing module, used to collect and process the automatic step signals of main line equipment and roll changing equipment;

[0050] An automation rate calculation module, used to calculate the automation rate of the main line equipment and the automation rate of the roll changing equipment;

[0051] The unit automation rate operation index evaluation rule system implements the unit automation rate operation index evaluation rule method.

[0052] The present invention provides a method and system for evaluating rules for the operation index of the unit automation rate, which collects and processes the automatic step signal through the automatic step signal collection and processing module and calculates the main line equipment automation rate and the roll changing automation rate through the automation rate calculation module. The main line equipment automation rate and the roll changing automation rate can be automatically obtained through the unit data, so that the automation level of the production line can be analyzed based on the obtained main line equipment automation rate and roll changing automation rate, thereby improving the automation level of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 It is a flow chart of the method for evaluating the rule of the unit automation rate operation index of the present invention;

[0054] Figure 2 It is a flow chart of step S1 in the method for evaluating the rule of the unit automation rate operation index of the present invention;

[0055] Figure 3 It is a schematic flow chart of the automation rate calculation in the unit automation rate operation index evaluation rule method of the present invention;

[0056] Figure 4 It is a page schematic diagram of the display form of the unit automation rate operation index evaluation rule method of the present invention (the score is 97.9);

[0057] Figure 5It is a page schematic diagram of the display form of the unit automation rate operation index evaluation rule method of the present invention (the score is 84). DETAILED DESCRIPTION

[0058] In order to better understand the above technical solution of the present invention, the technical solution of the present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0059] Combination Figure 1 As shown, a method for evaluating a unit automation rate operation index rule provided by the present invention comprises the following steps:

[0060] S1. Collect and process the automatic step signals of the main line equipment and roll changing equipment, including:

[0061] Combination Figure 2 As shown, the automatic step signals of the main line equipment are collected and processed: the production line server sends out the N address data of all automatic steps in sequence through UDP communication at a frequency of once per second. Each N address data is 2 bytes. The program listens to the port where UDP sends data. After receiving the data, it traverses all automatic steps in the automatic step signal list in sequence to determine whether the Master On signal of the automatic step is triggered.

[0062] Take the "entrance 1# coil trolley coil receiving automatic step" as an example, as shown in Table 1 below, the Master On signal flag of this automatic step is the 6th bit of N address N11816. When this bit is 1 and the bit is 0 in the previous cycle signal, the Master On signal is triggered. The operation log table log_records is queried according to the keyword of this automatic step to obtain the steel coil number, and an automatic step data is inserted into the automation_step table. In the same way, it is judged whether the Seq End signal is triggered. When the Seq End signal is triggered, the previous unfinished automatic step is searched in the automation_step table. The duration of the automatic step is calculated by the end time and start time of the automatic step. According to the normal duration range of the automatic step in the configuration table, it is judged whether this automatic step is automatically completed, and the duration and whether it is automatically completed are updated to the automation_step record.

[0063] Table 1

[0064] Automatic Step List HMI SEQ LIST Master On SEQ END Entrance 1# roll-up trolley with automatic coil receiving #1 C / C COIL RECEIVE N11816|6 N11816|5 Entrance 1# winding trolley centering automatic step #1 C / C HEIGHT ADJ N11816|D N11816|C Entrance 1# roll-up trolley with automatic roll feeding #1 C / C COIL LOADING N11817|4 N11817|3 Entrance 1# winding trolley returns to the starting position automatically #1 C / C RETURN TO HP N11817|B N11817|A Entrance 1# unwinding preparation automatic step #1 POR PREPA N11818|2 N11818|1 Entrance 1# unwinding (1) automatic step #1 COIL OPENING(1) N11824|F N11824|E Entrance 1# unwinding (2) automatic step #1 COIL OPENING(2) N11825|D N11825|5 Entrance 1# Straightening Machine Belt Threading Automatic Step #1 LEVELLER THREAD N11826|B N11825|C Entrance 1# with head shear automatic step #1 TOP CUT N11826|4 N11826|3

[0065] Collect and process the automatic step signals of the roll changing equipment: the insert roll signal consists of two signals, the working roll and the working roll + intermediate roll. As long as one of them appears, it means that the frame starts to change rolls. Insert a roll change record into the rollchange_automation_score table. When traversing the roll change automatic step, query the corresponding roll change record in the rollchange_automation_score table according to the time, and update the id of the record to the automation_Step table record of this roll change automatic step. After traversing all the automatic steps in the automatic step list, the automatic step data received in this cycle is processed, and the above process is repeated when waiting for the next cycle UDP data to be received, and this cycle is repeated.

[0066] S2. Calculate the automation rate of the main line equipment and the automation rate of the roll changing equipment;

[0067] S21. Calculating the automation rate of the main line equipment specifically includes the following steps:

[0068] S211, dividing the automation rate area: dividing the automation rate area into three areas: entrance section, pickling section, and exit section;

[0069] S212, roll number statistics: by reading the operation history file, obtain the roll number and the time point of passing through each area key equipment;

[0070] S213, automatic step sequence statistics: sort out the total automatic steps in all areas, and classify them according to the areas, find the flag bit of each automatic step operation, and record the corresponding time and automatic step name when the flag bit changes;

[0071] S214, automatic step and volume number binding analysis: through time matching, count whether each volume number is triggered in different areas among all automatic steps, and count the number of automatic steps triggered in different areas, and obtain the number of automatic steps executed by the same volume number in each area;

[0072] S215, calculating the automation rate of the same volume number: the automation rate of different areas of the same volume number = (the number of automatic steps executed for the same volume number in the area / the total number of automatic steps in the area) * 100%;

[0073] The total automation rate of the same roll number = the automation rate of the entrance area of ​​the same roll number * weight + the automation rate of the pickling area of ​​the same roll number * weight + the automation rate of the exit area of ​​the same roll number * weight;

[0074] S216, computer group automation rate: the automation rate of each area in the current time period or a certain time period is counted by region, and each area is multiplied by different weights, and the total is the automation rate of the entire unit. That is:

[0075] The automation rate of the main line equipment of the unit (within a certain time period) = SUM (automation rate of all rolls in the entrance area in a certain time period) / number of rolls in the time period + SUM (automation rate of all rolls in the pickling area in a certain time period) / number of rolls in the time period + SUM (automation rate of all rolls in the exit area in a certain time period) / number of rolls in the time period.

[0076] S22, calculating the automation rate of the roll changing equipment specifically comprises the following steps:

[0077] S221, division of automation rate area: divided into 1-5 racks, a total of 5 areas;

[0078] S222, automatic step sequence statistics: sort out the total automatic steps in all areas, and classify them according to the racks, find the automatic step running flag after the roller insertion flag of each rack, and record the corresponding time and automatic step name when the flag changes;

[0079] S223, calculating the roll changing automation rate of each rack: roll changing automation rate of each rack = (number of automatic steps executed by the rack / total number of automatic steps of the rack)*100%;

[0080] S224, calculate the roll changing automation rate: the automation rate of each area in the current time period or a certain time period is counted by rack, each area is multiplied by different weights, and the total is added to get the roll changing automation rate of the entire unit. That is:

[0081] The unit roll changing automation rate (within a certain time period) = SUM (the automation rate of all roll numbers of 1-5# frames in a certain time period) / the number of roll numbers in the time period.

[0082] In step S21 and step S22, the statistical calculation logic of the main line equipment and roll changing automation rate is as follows: the calculation of the main line equipment automation rate and the roll changing automation rate is performed in another thread. The main line equipment automation rate is calculated first, and the program timing loop queries the records with steel coil numbers and no scores in the automatic step data table automation_step. The queried data can be classified by steel coil number to obtain each steel coil number and all automatic step data corresponding to the steel coil number, and the number of automatic steps automatically completed / the total number of automatic steps are calculated. The result is the automation rate of the steel coil number, and a record is inserted into the coil_automation_score table. The roll changing automation rate is calculated by querying the automatic step data table automation_step for the roll changing record id, and the queried data is classified by the roll changing record id, and the number of automatic steps automatically completed corresponding to each roll changing record id / the total number of automatic steps is calculated. The result is the automation rate of this roll change, which is updated to the rollchange_automation_score table.

[0083] The page of the present invention is shown as Figure 4 and Figure 5 As shown, the page includes: steel coil automation rate score, steel coil number list, automation rate evaluation percentage, entrance section automation rate score, pickling section automation rate evaluation, exit section automation rate evaluation; query date, roll changing automation rate score, rack evaluation percentage, rack No. 1, rack No. 2, rack No. 3, rack No. 4, rack No. 5.

[0084] The present invention also provides a unit automation rate operation index evaluation rule system, comprising:

[0085] Automatic step signal collection and processing module, used to collect and process the automatic step signals of main line equipment and roll changing equipment;

[0086] Automation rate calculation module, used to calculate the automation rate of main line equipment and roll changing equipment;

[0087] The unit automation rate operation index evaluation rule method of the present invention is realized through the unit automation rate operation index evaluation rule system of the present invention.

[0088] Example

[0089] In this example, the automation rate of the main line equipment is evaluated by taking the steel coil number 137017070300 as an example. The automatic step data are as follows:

[0090]

[0091]

[0092] Automation rate of entrance section = (15 / 16)*100% = 93.7%

[0093] Automation rate of pickling section = (8 / 8)*100% = 100%

[0094] Automation rate of export section = (6 / 7)*100% = 85.7%

[0095] The total automation rate of this steel coil number = (93.7% + 100% + 85.7%) / 3 = 93.1%

[0096] In this embodiment, the roll changing automation rate takes the roll changing record of a certain day as an example, and the roll changing automation step data is as follows:

[0097]

[0098]

[0099]

[0100] The automation rate of the first roll change of the 1st rack = (7 / 9) * 100% = 77.7% The automation rate of the second roll change of the 1st rack = (9 / 9) * 100% = 100% The automation rate of the roll change of the 1st rack = (77.7% + 100%) / 2 = 88.8% The automation rate of the first roll change of the 2nd rack = (8 / 9) * 100% = 88.8%

[0101] The second roll change automation rate of the 2nd stand = (9 / 9) * 100% = 100%

[0102] 2. Frame roll changing automation rate = (88.8% + 100%) / 2 = 94.4%

[0103] The automation rate of the first roll change of the 3rd stand = (8 / 9) * 100% = 88.8%

[0104] The automation rate of the second roll change of the 3rd frame = (9 / 9) * 100% = 100%

[0105] 3. Frame roll changing automation rate = (88.8% + 100%) / 2 = 94.4%

[0106] The automation rate of the first roll change of the 4-stand = (8 / 9) * 100% = 88.8%

[0107] The second roll change automation rate of 4 stands = (8 / 9) * 100% = 88.8%

[0108] 4. Frame roll changing automation rate = (88.8% + 88.8%) / 2 = 88.8%

[0109] The automation rate of the first roll change of the 5-stand = (8 / 9) * 100% = 88.8%

[0110] The second roll change automation rate of 5 stands = (9 / 9) * 100% = 100%

[0111] 5. Frame roll changing automation rate = (88.8% + 100%) / 2 = 94.4%

[0112] The roll changing automation rate of this embodiment = (88.8% + 94.4% + 94.4% + 88.8% + 94.4%) / 5 = 92.2%

[0113] Those skilled in the art should recognize that the above embodiments are only used to illustrate the present invention, and are not intended to limit the present invention. As long as they are within the spirit of the present invention, any changes or modifications to the above embodiments will fall within the scope of the claims of the present invention.

Claims

1. A method for evaluating the operation index of unit automation rate, characterized in that: The following steps are involved: S1. Collect and process the automatic step signals of the main line equipment and roll changing equipment; S2. Calculate the automation rate of the main line equipment and the automation rate of the roll changing equipment.

2. The method for evaluating the unit automation rate operation index according to claim 1, characterized in that: The step S1 collects and processes the automatic step signal of the main line equipment as follows: The production line server sends out the N-address data of all automatic steps in sequence through UDP communication at a frequency of once per second. Each N-address data is 2 bytes. The program listens to the port where UDP sends data. After receiving the data, it traverses all automatic steps in the automatic step signal list in sequence to determine whether the Master On signal of the automatic step is triggered.

3. The method for evaluating the unit automation rate operation index according to claim 1, characterized in that: The step S1 collects and processes the automatic step signal of the roll changing device as follows: The roll insertion signal consists of two signals: the working roll and the working roll + intermediate roll. As long as one of them appears, it means that the frame starts to change rolls. A roll change record is inserted into the rollchange_automation_score table. When the roll change automatic step is traversed, the corresponding roll change record is queried in the rollchange_automation_score table according to the time, and the id of the record is updated to the automation_step table record of this roll change automatic step. After traversing all the automatic steps in the automatic step list, the automatic step data received in this cycle is processed, and the above process is repeated when waiting for the next cycle UDP data to be received, and this cycle is repeated.

4. The method for evaluating the unit automation rate operation index according to claim 1, characterized in that: The step S2 of calculating the automation rate of the main line equipment specifically includes the following steps: S211, divide the automation rate area; S212, roll number statistics; S213, automatic step sequence statistics; S214, automatic step and roll number binding analysis; S215, calculating the automation rate of the same volume number; S216. Automation rate of computer group.

5. The method for evaluating the unit automation rate operation index according to claim 4 is characterized in that: The step S211 of dividing the automation rate areas specifically includes: The automation rate area is divided into three areas: entrance section, pickling section, and exit section.

6. The method for evaluating the unit automation rate operation index rule according to claim 5 is characterized in that: The step S212 of volume number statistics specifically includes: By reading the operation history file, the volume number and the time point when the key equipment in each area was passed are obtained.

7. The method for evaluating the unit automation rate operation index according to claim 6, characterized in that: The step S213 of automatic step sequence counting specifically includes: Sort out the total automatic steps in all areas, and classify them by area, find the flag bit of each automatic step operation, and record the corresponding time and automatic step name when the flag bit changes.

8. The method for evaluating the unit automation rate operation index rule according to claim 7 is characterized in that: The automatic step and volume number binding analysis in step S214 specifically includes: Through time matching, it is counted whether each volume number is triggered in different areas among all automatic steps, and the number of automatic steps triggered in different areas is counted to obtain the number of automatic steps executed by the same volume number in each area.

9. The method for evaluating the unit automation rate operation index rule according to claim 8, characterized in that: The step S215 of calculating the automation rate of the same volume number specifically includes: The automation rate of different areas of the same roll number = (the number of automatic steps executed for the same roll number in the area / the total number of automatic steps in the area) * 100%; The total automation rate of the same roll number = the automation rate of the entrance area of ​​the same roll number * weight + the automation rate of the pickling area of ​​the same roll number * weight + the automation rate of the exit area of ​​the same roll number * weight.

10. The method for evaluating the unit automation rate operation index rule according to claim 9, characterized in that: The step S216 of calculating the automation rate of the computer group specifically includes: The automation rate of each area in the current time period or a certain time period is counted by region. Each area is multiplied by a different weight and the total is added up to get the automation rate of the entire unit.

11. The method for evaluating the unit automation rate operation index according to claim 1, characterized in that: The step S2 of calculating the automation rate of the roll changing equipment specifically comprises the following steps: S221, dividing the automation rate area; S222, automatic step sequence statistics; S223, calculating the roll changing automation rate of each rack; S224, calculating the roll changing automation rate.

12. The method for evaluating the unit automation rate operation index rule according to claim 11, characterized in that: The step S221 of dividing the automation rate area specifically includes: Divided into racks 1 to 5, a total of 5 areas.

13. The method for evaluating the unit automation rate operation index rule according to claim 12, characterized in that: The automatic step sequence statistics of step S222 specifically include: Sort out the total automatic steps in all areas and classify them according to the racks. Find the flag position of the automatic step operation after the roller insertion flag position of each rack. When the flag position changes, record the corresponding time and automatic step name.

14. The method for evaluating the unit automation rate operation index rule according to claim 13, characterized in that: The step S223 of calculating the roll changing automation rate of each rack specifically includes: The roll changing automation rate of each rack = (the number of automatic steps executed by the rack / the total number of automatic steps of the rack)*100%.

15. The method for evaluating the unit automation rate operation index rule according to claim 14, characterized in that: The step S224 of calculating the roll changing automation rate specifically includes: The automation rate of each area in the current time period or a certain time period is counted by the rack. Each area is multiplied by a different weight, and the total is added to get the roll changing automation rate of the entire unit.

16. A unit automation rate operation index evaluation rule system, characterized in that: include: Automatic step signal collection and processing module, used to collect and process the automatic step signals of main line equipment and roll changing equipment; An automation rate calculation module, used to calculate the automation rate of the main line equipment and the automation rate of the roll changing equipment; The unit automation rate operation index evaluation rule system implements the unit automation rate operation index evaluation rule method as described in any one of claims 1-15.

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