Production line control system based on real-time data acquisition

Abstract

The invention discloses a production line control system based on real-time data acquisition, which relates to the technical field of production line control and comprises a data acquisition module, an equipment work analysis module, a production line analysis module, an early warning analysis module, a personnel equipment analysis module, a matching adjustment module and a database. Working parameters of production line equipment, production line maintenance and operation parameters, production line production parameters, operator operation parameters and production line equipment production parameters are received, counted and analyzed to obtain a production line comprehensive different-deviation bottleneck value and a manual evaluation value, and the production line comprehensive different-deviation bottleneck value and the manual evaluation value are analyzed and judged. The device temperature, the device operation speed, the device pressure adjustment value, the production line abnormal condition adjustment set and the adjustment method when the production line meets the bottleneck can be obtained, early warning can be given out and corresponding adjustment can be made when the production line is abnormal, and the production efficiency of enterprises is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of production line control, and in particular to a production line control system based on real-time data collection. Background Art

[0002] With the continuous development of industrial production, enterprises have higher and higher requirements for production efficiency, production cost and cost control. The traditional production line control method is too dependent on manual regular inspection and experience judgment. This traditional method has the disadvantages of being unable to adjust in time and too single adjustment method. It is difficult to meet the current industrial enterprises. The production line control system based on real-time data collection came into being.

[0003] The current production line control system is unable to take into account the working parameters of each equipment in the production line, the maintenance status of the production line, and the shutdown status of the production line. It is unable to identify which production line has a bottleneck and has no corresponding abnormal adjustment method. As a result, fault investigation increases the time for production line fault repair, which greatly reduces the efficiency of the company's industrial production and increases the company's cost of industrial production.

[0004] The current production line control system is unable to automatically adjust in time when equipment has temperature, operating speed and pressure problems, causing mechanical equipment failures to occur frequently.

[0005] In order to solve the above defects, a technical solution is now provided. Summary of the invention

[0006] In order to solve the technical problems raised by the above background technology, the present invention is proposed. An embodiment of the present invention provides a.

[0007] The purpose of the present invention can be achieved through the following technical solutions: a production line control system based on real-time data acquisition, including a data acquisition module, an equipment work analysis module, a production line analysis module, an early warning analysis module, a personnel and equipment analysis module, a matching adjustment module and a database.

[0008] The equipment operation analysis module is used to receive the operating parameters of the production line equipment, determine and analyze them, obtain the abnormal attenuation value of the production line equipment, and send it to the production line analysis module;

[0009] The production line analysis module is used to receive the production line equipment abnormal decay value, production line maintenance parameters and production line production parameters, determine and analyze them, obtain the production line maintenance difference value, production line deviation value and production line comprehensive abnormal deviation bottleneck value, and send them to the early warning analysis module;

[0010] The early warning analysis module is used to receive the comprehensive deviation bottleneck value of the production line, analyze and determine it, and generate corresponding signals for early warning and alarm;

[0011] The personnel and equipment analysis module is used to receive the operating parameters of the operating personnel and the production parameters of the production line equipment, and make judgments and analyses on them to obtain the personnel evaluation value, and send it to the matching adjustment module;

[0012] The matching adjustment module is used to receive human setting evaluation values, equipment temperature abnormal values, equipment operating speed abnormal values ​​and equipment pressure abnormal values, make judgments and analyses thereof, obtain an adjustment set of production line abnormal conditions, equipment temperature adjustment values, equipment operating speed adjustment values ​​and equipment pressure adjustment values, and adjust production work according to the adjustment set of production line abnormal conditions, equipment temperature adjustment values, equipment operating speed adjustment values ​​and equipment pressure adjustment values.

[0013] Furthermore, the specific operation steps of the abnormal attenuation value of the production line equipment are as follows:

[0014] Obtain the equipment temperature, operating speed and pressure values ​​of the production line, analyze and calculate the temperature abnormality value WZi, operating speed abnormality value VZi, pressure abnormality value YZi and working abnormality value Zi;

[0015] The working state abnormal value of the equipment is obtained and matched to each monitoring time point to obtain the working state abnormal value of the equipment with time change graph; the working state abnormal value of the equipment is compared and analyzed with the set working state abnormal value. When the working state abnormal value of the equipment is greater than the maximum value of the set interval, the state abnormal value is marked as a first-level abnormal value, and the corresponding time is generated as a first-level abnormal value moment; when the working state abnormal value of the equipment is within the set interval, the state abnormal value is marked as a second-level abnormal value, and the corresponding time is generated as a second-level abnormal value moment; the generated first-level abnormal value moment and second-level abnormal value moment are marked on the time axis, and the interval lengths of adjacent first-level abnormal value moments and second-level abnormal value moments are obtained according to the generated abnormal value change graph, and they are summed to obtain the total length of the first-level abnormal value interval and the total length of the second-level abnormal value interval, which are recorded as JDi and JEi respectively; the average values ​​of each working state abnormal value in the first-level abnormal value and each working state abnormal value in the second-level abnormal value are obtained, and marked as DPi and EPi; the total length of the first-level abnormal value interval JDi, the total length of the second-level abnormal value interval JEi, the first-level abnormal value average value DPi and the second-level abnormal value average value EPi are normalized according to the set formula The equipment decay coefficient SXi is obtained, where α1, α2, α3, and α4 are respectively the set proportional coefficients;

[0016] The numerical values ​​corresponding to the equipment's working abnormality value Zi and the equipment's decay coefficient SXi are converted into lengths according to a certain ratio; a cone is constructed with the length of the working abnormality value Zi as the base diameter of the cone and the length of the equipment's decay coefficient SXi as the height of the cone, and the volume of the cone is extracted as the equipment's deviation index value SZi.

[0017] Collect the equipment deviation index values ​​SZi of each production line, divide the equipment deviation index values ​​into multiple groups, mark the values ​​within the threshold range as YZ2, those above the threshold range as YZ1, and those below the threshold range as YZ3, calculate the proportion of YZ1 and YZ2 in the entire data, that is, YZG1 and YZG2, respectively, normalize the obtained proportion values ​​YZG1 and YZG2 and substitute them into the formula The production line equipment abnormal attenuation value SYB is calculated, where δ1 and δ2 are preset weight factors, and σ is a preset correction factor.

[0018] Furthermore, the specific operation steps of the production line maintenance and operation difference value, production line production deviation value and production line comprehensive deviation bottleneck value are as follows:

[0019] Obtain the number of times the production line is maintained and the total maintenance time within a period of time, and obtain the maintenance frequency and average maintenance time of the production line by calculation; obtain the cost of each maintenance of the production line, and perform average calculation to obtain the average cost of each maintenance; obtain a period of time for the production line and decompose it into several sub-periods, and sort the maintenance time of the sub-periods in chronological order, calculate the difference between two adjacent sub-periods, subtract the sub-difference from the sub-period to obtain the sub-difference, sum all the sub-differences to obtain the total sub-difference, take the maximum and minimum maintenance time of each sub-period as the difference, and obtain the sub-extreme value; normalize the maintenance frequency, average maintenance time, average maintenance cost, total sub-difference and sub-extreme value of the production line, perform weighted calculation, and multiply by the corresponding proportional factor to obtain the production line maintenance status value SW;

[0020] Through time research, production records and sensor data, the waiting time GDm and service time GFm of each process in the production line are collected, where m = 1, 2, 3, ..., M, where M is the maximum value of the process number. The average waiting time GDP and the average service time GFP of the production line process are calculated by summing and averaging. According to the formula

[0021]

[0022] Get the production line process trend value GYB, b1, b2, b3, b4 are the set proportional coefficients, GDmax and GFmax are the maximum waiting time of the production line process and the maximum service time of the production line process respectively;

[0023] Get the production line running time SY and downtime ST within a period of time according to the set formula Get the production line operation rate SL; normalize the production line maintenance status value SW, the production line process change value GYB and the production line operation rate SL and substitute them into the set formula The production line maintenance difference variable WYB is obtained, where U1, U2 and U3 are all preset weight factors;

[0024] By acquiring the output of the production line, a two-dimensional coordinate system is established with time as the horizontal axis and the output of the production line as the vertical axis. The output of the production line is displayed through the curve of the coordinate system, and a curve of the standard output of the production line over time is established in the coordinate system. The closed area formed by the production line output change curve and the standard output curve is statistically analyzed, and the sum is obtained to obtain the production deviation reference value SCC of the production line; the maximum and minimum values ​​of the output in the production line change curve are obtained, and the difference calculation is performed to obtain the extreme value SCJ of the production line output;

[0025] Obtain the total output SZ produced by the production line within a certain period of time, measure the reflectivity of the production line products to light of different wavelengths by a spectrophotometer, and obtain the light reflectivity of the production line products; measure the length, width, height, and diameter of the production line products, and make a weighted calculation by subtracting the length, width, height, and diameter values ​​of the production line products from the set reference length, reference width, reference height, and reference diameter values, and multiply by the corresponding proportional factor to obtain the size deviation value of the production line products; drop a certain amount of sand from a certain height to impact the surface of the production line products, measure the wear depth MS on the product surface, apply gradually increasing pressure to the production line products until the products are destroyed, and record the relationship between pressure and deformation, so as to determine the compressive strength YQ and compression modulus YM of the products, normalize the wear depth, compression strength, and compression modulus, and substitute them into the following formula: To obtain the production line product performance deviation value PZZ, where c1, c2 and c3 are all preset weight factors; after normalizing the production line product light reflectivity, production line product size deviation and production line product performance deviation, the production line product size deviation is used as the bottom circle radius, and the production line product performance deviation is used as the height to establish a cone, and a hollow sphere is constructed inside the cone with the production line product light reflectivity as the radius, and then the solid volume of the cone is calculated and its value is marked as the product quality deviation value CZP, and this deviation value is used as the standard for measuring product quality of the production line.

[0026] The calculated production line output reference deviation value SCC, production line output range value SCJ and product quality deviation value CZP are normalized and substituted into the set formula The production line output deviation value CYB is obtained, where ε is the preset weight coefficient of the sum of the production line output reference deviation value, the production line output extreme value and the product quality deviation value.

[0027] The numerical values ​​corresponding to the production line equipment abnormal degradation value SYB and the production line maintenance and operation difference value WYB are converted into lengths according to a certain ratio; an ellipse is constructed with the lengths of the production line equipment abnormal degradation value SYB and the production line maintenance and operation difference value WYB as the major axis and minor axis respectively; the production line deviation value CYB is converted into length according to a certain ratio, the center of the ellipse is selected as the starting point, and the length of the production line deviation value CYB is selected as the height to construct a cone entity; then the volume of the cone entity is identified and marked as the comprehensive deviation bottleneck value of the production line.

[0028] Furthermore, the specific operation steps for the corresponding signals to carry out early warning and alarm are as follows:

[0029] Set the reference threshold WW1 of the comprehensive deviation bottleneck value of the production line, and compare and analyze the comprehensive deviation bottleneck value of the production line with the set reference threshold WW1 of the comprehensive deviation bottleneck value;

[0030] When the comprehensive deviation bottleneck value of the production line is greater than the set reference threshold WW1, the corresponding production line production will be evaluated as an abnormal production state, and corresponding early warnings and alarms will be executed, and a signal of "this production line is abnormal, it is a key focus production line, and the equipment and operators in the production line need to be adjusted" will be issued; when the comprehensive deviation bottleneck value of the production line is equal to the set reference threshold WW1, the corresponding production line production will be evaluated as an abnormal production state, and corresponding early warnings and alarms will be executed, and a signal of "this production line is abnormal, it is a secondary focus production line, and the equipment and operators in the production line need to be adjusted" will be issued.

[0031] Furthermore, the specific operation steps of the personality evaluation value are as follows:

[0032] The operator's work efficiency value ZXZ is obtained through the operator's unit time output, the operator's product qualification rate, the operator's attendance rate Zq and the operator's total working hours.

[0033] The production line equipment production evaluation value PZ is obtained through the time interval, the number of failures per unit time and the output per unit time;

[0034] Normalize the calculated operator's effectiveness value ZXZ and production line equipment's production evaluation value PZ and substitute them into the set formula Get the personality evaluation value RYZ, where It is the preset weight coefficient of the sum of the operator's work efficiency value ZXZ and the production line equipment's production evaluation value.

[0035] Furthermore, the specific operation steps of adjusting the abnormal situation of the production line, the equipment temperature adjustment value, the equipment operating speed adjustment value and the equipment pressure adjustment value are as follows:

[0036] Compare the human setting evaluation value with the set human setting evaluation value reference value. If the human setting evaluation value is greater than the set human setting evaluation value reference value, identify the operator and equipment as the adjustment set of the production line abnormality, and sort the adjustment set of the production line abnormality from high to low according to the human setting evaluation value;

[0037] Match the production lines whose comprehensive deviation bottleneck values ​​are greater than or equal to the set reference threshold with the adjustment set of production line abnormalities, and select the corresponding operators and equipment from the adjustment set of production line abnormalities in descending order to adjust production work;

[0038] If the temperature abnormality value, operating speed abnormality value, and pressure abnormality value corresponding to the equipment of the production line are greater than the upper limit value of the set temperature abnormality value, operating speed abnormality value, and pressure abnormality value threshold value corresponding to the equipment, the temperature, operating speed, and pressure of the equipment of the production line will be marked as abnormal, and the difference between the two will be calculated to obtain the custom value. The custom value will be multiplied by the temperature, operating speed, and pressure conversion coefficient to obtain the equipment temperature adjustment value, operating speed adjustment value, and pressure adjustment value. The production line system will automatically adjust the equipment temperature, operating speed, and pressure according to the equipment temperature adjustment value, operating speed adjustment value, and pressure adjustment value.

[0039] Compared with the prior art, the present invention has the following beneficial effects:

[0040] 1. The present invention obtains the comprehensive deviation bottleneck value of the production line by analyzing the equipment temperature value, operating speed value, pressure value, production line maintenance data, waiting time of the production line process, process service time, process production line operation time, production line downtime and production parameter determination of the production line, and analyzes and determines it, and generates corresponding signals for early warning and alarm. It can comprehensively consider various situations, analyze the abnormal moment when the production line production bottleneck period occurs, and can timely remind the staff to warn and alarm.

[0041] 2. The present invention obtains a human evaluation value by statistics and analysis of the operating parameters of the operating personnel and the production parameters of the production line equipment, and analyzes it to obtain an adjustment set of abnormal conditions of the production line. It can make production adjustments in time when the abnormal situation of the bottleneck period is identified, which greatly improves the production efficiency of the enterprise and saves the production cost of the enterprise.

[0042] 3. The present invention obtains equipment temperature adjustment value, operating speed adjustment value and pressure adjustment value through statistics and analysis of equipment temperature abnormal values, operating speed abnormal values ​​and pressure abnormal values. The equipment adjusts the equipment temperature, operating speed and pressure respectively according to the above adjustment values, which can better ensure the safety of production and greatly reduce the failure rate of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. The following drawings are not intentionally scaled to the actual size, and the focus is on illustrating the main purpose of the present invention.

[0044] Figure 1 is a system block diagram of the present invention; Figure 2 It is a schematic diagram of the two-dimensional coordinate system of the present invention. DETAILED DESCRIPTION

[0045] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work also fall within the scope of protection of the present invention.

[0046] like Figure 1 As shown, a production line control system based on real-time data acquisition includes a data acquisition module, an equipment work analysis module, a production line analysis module, an early warning analysis module, a personnel and equipment analysis module, a matching and adjustment module and a database.

[0047] The data acquisition module is used to receive the working parameters of the production line equipment, the maintenance parameters of the production line, the production parameters of the production line, the operating parameters of the operators and the production parameters of the production line equipment, and send them to the equipment work analysis module, the production line analysis module and the personnel equipment analysis module. The working parameters of the production line equipment include the equipment temperature value, the running speed value and the pressure value of the production line; the maintenance parameters of the production line include the production line maintenance data, the waiting time of the production line process, the process service time, the process production line operation time and the production line downtime; the production parameters of the production line include the production data of the production line and the product data of the production line; the operating parameters of the operators include the unit time output of the operators, the product qualification rate of the operators, the attendance rate of the operators and the total working hours of the operators; the production parameters of the production line equipment include fault data and equipment production output.

[0048] The equipment operation analysis module is used to receive the working parameters of the production line equipment, make judgments and analyses on them, obtain the abnormal attenuation value of the production line equipment, and send it to the production line analysis module. The specific analysis is as follows:

[0049] Obtain the working parameters of the production line equipment. The working parameters specifically include the equipment temperature value, operating speed value and pressure value of the production line, and are recorded as Wir, Vir, Yir respectively, i represents the number of the equipment in the production line, r represents the number of the monitoring time, r = 1, 2, 3, ..., R, R is the maximum value of the detection time number, such as Figure 2As shown, with time as the horizontal axis and the temperature, operating speed and pressure of the equipment in the production line as the vertical axis, a two-dimensional coordinate system is established, the temperature value, operating speed value and pressure value of the equipment in the production line corresponding to each monitoring time point are taken and points are drawn in the coordinate system, and the coordinate points of the maximum and minimum values ​​of the equipment temperature, operating speed and pressure are respectively identified, and the temperature, operating speed and pressure coordinate points of each monitoring time are respectively connected with the maximum value coordinate points of the equipment temperature, operating speed and pressure. When the connecting line forms an obtuse angle with the horizontal line, it is marked as the first slope, and the absolute values ​​of all the first slopes are summed to obtain the total slope values ​​WDir, VDir and YDir respectively. When the connecting line forms an obtuse angle with the horizontal line, it is marked as the first slope, and the absolute values ​​of all the first slopes are summed to obtain the total slope values ​​WDir, VDir and YDir respectively. When the connecting line forms an acute angle with the horizontal line, it is marked as the second slope, and all the second slopes are summed to obtain the total slope values ​​WEir, VEir and YEir respectively; the temperature, operating speed and pressure coordinate points of each monitoring time are connected with the equipment temperature, operating speed and pressure minimum value coordinate points respectively. When the connecting line forms an obtuse angle with the horizontal line, it is marked as the third slope, and all the third slopes are summed to obtain the total slope values ​​WSir, VSir and YSir respectively. When the connecting line forms an acute angle with the horizontal line, it is marked as the fourth slope, and all the fourth slopes are summed to obtain the total slope values ​​WFir, VFir and YFir respectively; according to the set formula

[0050]

[0051] The temperature anomaly value WZi, the running speed anomaly value VZi, the pressure anomaly value YZi and the working anomaly value Zi are calculated; among them, a1, a2, a3, a4, a5, a6, a7, a8, a9, a10, a11, a12, a13, a14, a15, a16, a17, a18, a19, a20 and a21 are the set proportional coefficients respectively, and their sizes are custom settings, and the values ​​are 1.1, 2.1, 3.2, 1.1, 3.1, 3.1, 1.1, 3.2, 2.1, 4.2, 2.1, 3.2, 2.1, 1.2, 4.1, 3.2, 2.1, 5.2, 2.1, 4.2 and 3.2 respectively; WFiMAX, VFimax and YFimax are the maximum values ​​of temperature, running speed and pressure of the equipment in the production line corresponding to the monitoring time; Zj is the vibration value corresponding to the jth acquisition moment; is the average power corresponding to different acquisition moments, W′, V′, Y′ are the reference temperature change variance, reference running speed change variance, and reference pressure change variance of the device, WD′, VD′, YD′ are the reference temperature, reference running speed, and reference pressure slope total value 1 of the device, WE′, VE′, YD′ are the reference temperature, reference running speed, and reference pressure slope total value 2 of the device, WS′, VS′, YS′ are the reference temperature, reference running speed, and reference pressure slope total value 3 of the device, WF′, VF′, YF′ are the reference temperature, reference running speed, and reference pressure slope total value 4 of the device is the average value of temperature, running speed and pressure corresponding to different monitoring moments, W1, V1 and Y1 are the maximum reference temperature, the maximum reference running speed and the maximum reference pressure;

[0052] The working state abnormal value of the equipment is obtained and matched to each monitoring time point to obtain the working state abnormal value of the equipment with time change graph; the working state abnormal value of the equipment is compared and analyzed with the set working state abnormal value. When the working state abnormal value of the equipment is greater than the maximum value of the set interval, the state abnormal value is marked as a first-level abnormal value, and the corresponding time is generated as a first-level abnormal value moment; when the working state abnormal value of the equipment is within the set interval, the state abnormal value is marked as a second-level abnormal value, and the corresponding time is generated as a second-level abnormal value moment; the generated first-level abnormal value moment and second-level abnormal value moment are marked on the time axis, and the interval lengths of adjacent first-level abnormal value moments and second-level abnormal value moments are obtained according to the generated abnormal value change graph, and they are summed to obtain the total length of the first-level abnormal value interval and the total length of the second-level abnormal value interval, which are recorded as JDi and JEi respectively; the average values ​​of each working state abnormal value in the first-level abnormal value and each working state abnormal value in the second-level abnormal value are obtained, and marked as DPi and EPi; the total length of the first-level abnormal value interval JDi, the total length of the second-level abnormal value interval JEi, the first-level abnormal value average value DPi and the second-level abnormal value average value EPi are normalized according to the set formula The equipment decay coefficient SXi is obtained, where α1, α2, α3, and α4 are set proportional coefficients, and their sizes are custom settings, with values ​​of 1.12, 2.21, 3.12, and 3.11 respectively;

[0053] The numerical values ​​corresponding to the equipment's working abnormality value Zi and the equipment's decay coefficient SXi are converted into lengths according to a certain ratio; a cone is constructed with the length of the working abnormality value Zi as the base diameter of the cone and the length of the equipment's decay coefficient SXi as the height of the cone, and the volume of the cone is extracted as the equipment's deviation index value SZi.

[0054] Collect the equipment deviation index values ​​SZi of each production line, divide the equipment deviation index values ​​into multiple groups, mark the values ​​within the threshold range as YZ2, those above the threshold range as YZ1, and those below the threshold range as YZ3, calculate the proportion of YZ1 and YZ2 in the entire data, that is, YZG1 and YZG2, respectively, normalize the obtained proportion values ​​YZG1 and YZG2 and substitute them into the formula The production line equipment abnormal attenuation value SYB is calculated, where δ1 and δ2 are preset weight factors, σ is a preset correction factor, and its size is a custom setting with values ​​of 1.02, 3.21, and 1.12 respectively.

[0055] The production line analysis module is used to receive the abnormal attenuation value of the production line equipment, the production line maintenance parameters and the production parameters of the production line, make judgments and analyses on them, obtain the comprehensive abnormal deviation bottleneck value of the production line, and send it to the early warning analysis module. The specific analysis is as follows:

[0056] Obtain the number of times the production line is maintained and the total maintenance time within a period of time, and obtain the maintenance frequency and average maintenance time of the production line by calculation; obtain the cost of each maintenance of the production line, and perform average calculation to obtain the average cost of each maintenance; obtain a period of time for the production line and decompose it into several sub-periods, and sort the maintenance time of the sub-periods in chronological order, calculate the difference between two adjacent sub-periods, subtract the sub-difference from the sub-period to obtain the sub-difference, sum all the sub-differences to obtain the total sub-difference, take the maximum and minimum maintenance time of each sub-period as the difference, and obtain the sub-extreme value; normalize the maintenance frequency, average maintenance time, average maintenance cost, total sub-difference and sub-extreme value of the production line, perform weighted calculation, and multiply by the corresponding proportional factor to obtain the production line maintenance status value SW;

[0057] Through time research, production records and sensor data, the waiting time GDm and service time GFm of each process in the production line are collected, where m = 1, 2, 3, ..., M, where M is the maximum value of the process number. The average waiting time GDP and the average service time GFP of the production line process are calculated by summing and averaging. According to the formula

[0058]

[0059] The production line process trend value GYB is obtained. b1, b2, b3, and b4 are the set proportional coefficients, and their sizes are custom settings. The values ​​are 2.12, 3.21, 3.42, and 1.11 respectively. GDmax and GFmax are the maximum waiting time of the production line process and the maximum service time of the production line process respectively.

[0060] Get the production line running time SY and downtime ST within a period of time according to the set formula Get the production line operation rate SL; normalize the production line maintenance status value SW, the production line process change value GYB and the production line operation rate SL and substitute them into the set formula The production line maintenance difference variable value WYB is obtained, where U1, U2 and U3 are preset weight factors, and their sizes are custom settings, with values ​​of 2.1, 3.1 and 3.2 respectively.

[0061] By acquiring the output of the production line, a two-dimensional coordinate system is established with time as the horizontal axis and the output of the production line as the vertical axis. The output of the production line is displayed through the curve of the coordinate system, and a curve chart of the standard output of the production line over time is established in the coordinate system. The closed area formed by the production line output change curve and the standard output curve is statistically analyzed, and the sum is used to obtain the production reference deviation value SCC of the production line. The higher the reference deviation value, the worse the production performance of the production line; the maximum and minimum values ​​of the output in the production line change curve are obtained, and the difference calculation is performed to obtain the extreme value SCJ of the production line output;

[0062] Obtain the total output SZ produced by the production line within a certain period of time, measure the reflectivity of the production line products to light of different wavelengths by a spectrophotometer, and obtain the light reflectivity of the production line products. It should be noted that the light reflectivity of the products is used to reflect the uniformity of the product appearance; measure the length, width, height, and diameter of the production line products, and make a difference between the length value, width value, height value, and diameter value of the production line products and the set reference length value, reference width value, reference height value, and reference diameter value, perform weighted calculation, and multiply by the corresponding proportional factor to obtain the size deviation value of the production line products; drop a certain amount of sand from a certain height to impact the surface of the production line products, measure the wear depth MS on the product surface, apply gradually increasing pressure to the production line products until the products are destroyed, and record the relationship between pressure and deformation, so as to determine the compressive strength YQ and compression modulus YM of the products, normalize the wear depth, compression strength, and compression modulus, and substitute them into the following formula: To obtain the production line product performance deviation value PZZ, where c1, c2 and c3 are preset weight factors, and their sizes are custom settings, with values ​​of 1.1, 1.21 and 1.1 respectively; after normalizing the production line product light reflectivity, production line product size deviation and production line product performance deviation, the production line product size deviation is used as the bottom circle radius, and the production line product performance deviation is used as the height to establish a cone, and a hollow sphere is constructed inside the cone with the production line product light reflectivity as the radius, and then the solid volume of the cone is calculated and its value is marked as the product quality deviation value CZP, and this deviation value is used as the standard for measuring product quality of the production line.

[0063] The calculated production line output reference deviation value SCC, production line output range value SCJ and product quality deviation value CZP are normalized and substituted into the set formula The production line output deviation value CYB is obtained, where ε is the preset weight coefficient of the sum of the production line output reference deviation value, the production line output range value and the product quality deviation value. Its size is a custom setting and the value is 1.1.

[0064] The values ​​corresponding to the abnormal decay value SYB of the production line equipment and the maintenance and operation difference value WYB of the production line are converted into lengths according to a certain ratio; an ellipse is constructed with the lengths of the abnormal decay value SYB of the production line equipment and the maintenance and operation difference value WYB of the production line equipment as the major axis and the minor axis respectively; the production deviation value CYB of the production line is converted into lengths according to a certain ratio, the center of the ellipse is selected as the starting point, and the length of the production deviation value CYB of the production line is selected as the height to construct a cone entity; then the volume of the cone entity is identified and marked as the comprehensive abnormal deviation bottleneck value of the production line;

[0065] The early warning analysis module is used to receive the comprehensive deviation bottleneck value of the production line, analyze and determine it, and generate corresponding signals for early warning and alarm. The specific analysis is as follows:

[0066] Set the reference threshold WW1 of the comprehensive deviation bottleneck value of the production line, and compare and analyze the comprehensive deviation bottleneck value of the production line with the set reference threshold WW1 of the comprehensive deviation bottleneck value;

[0067] When the comprehensive deviation bottleneck value of the production line is greater than the set reference threshold WW1, the corresponding production line will be evaluated as an abnormal production state, and corresponding warnings and alarms will be executed, and a signal of "this production line is abnormal, it is a key focus production line, and the equipment and operators in the production line need to be adjusted" will be issued; when the comprehensive deviation bottleneck value of the production line is equal to the set reference threshold WW1, the corresponding production line will be evaluated as an abnormal production state, and corresponding warnings and alarms will be executed, and a signal of "this production line is abnormal, it is a secondary focus production line, and the equipment and operators in the production line need to be adjusted" will be issued; when the comprehensive deviation bottleneck value of the production line is less than the set reference threshold WW1, the corresponding production line will be evaluated as a normal production line, and no corresponding operation will be performed;

[0068] The personnel and equipment analysis module is used to receive the operating parameters of the operating personnel and the production parameters of the production line equipment, and make judgments and analyses on them to obtain the personnel evaluation value, which is then sent to the matching adjustment module. The specific analysis is as follows:

[0069] Get the number of products completed by the operator within a period of time, divide the number of products by the time period, and get the operator's unit time output, recorded as Zc; get the number of qualified products and the total output of the operator within a period of time, divide the two, and get the operator's product qualification rate Zh; get the number of attendance days and the number of days that the operator should be present within a period of time, divide the two, and get the operator's attendance rate Zq; get the time difference between the operator's entry time and the current time to get the operator's total working time Gz; substitute the operator's unit time output Zc, the operator's product qualification rate Zh, the operator's attendance rate Zq, and the operator's total working time Gz into the set formula The operator's effectiveness value ZXZ is obtained, where d1, d2, d3, and d4 are set weight factor coefficients, and their sizes are custom settings, with values ​​of 3.11, 2.12, 1.12, and 211, respectively. Zc′, Zh′, Zq′, and Gz′ represent the reference unit time output, reference product qualification rate, reference attendance rate, and reference total working time of the set operator, respectively. ΔZc, ΔZh, ΔZq, and ΔGz represent the reference unit time output difference, reference product qualification rate difference, reference attendance rate difference, and reference total working time difference of the set operator, respectively.

[0070] Obtain the number of failures that occur in the production line equipment within a period of time, as well as the time interval between two adjacent failures Gg, and divide the number of failures by the obtained time to obtain the number of failures per unit time Gc; obtain the number of products completed by the production line equipment within a period of time, and divide the number of products by the obtained time period to obtain the unit time output of the production line equipment, recorded as Sc; normalize the time interval Gg, the number of failures per unit time Gc, and the unit time output Sc, and substitute their values ​​into the formula To obtain the production line equipment production evaluation value PZ, where η, They are the preset weight coefficient of the sum of the unit time output S and the time interval and the preset weight coefficient of the number of failures per unit time, and their sizes are custom settings, with values ​​of 3.1 and 2.1 respectively;

[0071] Normalize the calculated operator's effectiveness value ZXZ and production line equipment's production evaluation value PZ and substitute them into the set formula Get the personality evaluation value RYZ, where It is the preset weight coefficient of the sum of the operator's work efficiency value ZXZ and the production line equipment's production evaluation value. Its size is a custom setting and its value is 1.12.

[0072] The matching adjustment module is used to receive the human evaluation value, the equipment temperature abnormal value, the equipment running speed abnormal value and the equipment pressure abnormal value, and make judgments and analyses on them to obtain the adjustment set of the production line abnormality, the equipment temperature adjustment value, the equipment running speed adjustment value and the equipment pressure adjustment value. The specific analysis is as follows:

[0073] The personnel evaluation value is compared with the set personnel evaluation value reference value. If the personnel evaluation value is greater than the set personnel evaluation value reference value, the operator and equipment are identified as the adjustment set of the production line abnormality, and the adjustment set of the production line abnormality is sorted from high to low according to the personnel evaluation value.

[0074] The production lines whose comprehensive deviation bottleneck values ​​are greater than or equal to the set reference threshold are matched with the adjustment set of production line abnormalities, and the corresponding operators and equipment are selected from the adjustment set of production line abnormalities in descending order to adjust production work.

[0075] If the temperature abnormality value, operating speed abnormality value, and pressure abnormality value corresponding to the equipment of the production line are greater than the upper limit value of the set temperature abnormality value, operating speed abnormality value, and pressure abnormality value threshold value corresponding to the equipment, the temperature, operating speed, and pressure of the equipment of the production line will be marked as abnormal, and the difference between the two will be calculated to obtain the custom value. The custom value will be multiplied by the temperature, operating speed, and pressure conversion coefficient to obtain the equipment temperature adjustment value, operating speed adjustment value, and pressure adjustment value. The production line system will automatically adjust the equipment temperature, operating speed, and pressure according to the equipment temperature adjustment value, operating speed adjustment value, and pressure adjustment value.

[0076] The database is used to store the reference temperature, reference operating speed, reference pressure slope total value, reference temperature maximum value, reference operating speed maximum value and reference pressure maximum value of the device.

[0077] The above is an explanation of the present invention and should not be considered as a limitation thereof. Although several exemplary embodiments of the present invention have been described, it will be readily appreciated by those skilled in the art that many modifications may be made to the exemplary embodiments without departing from the novel teachings and advantages of the present invention. Therefore, all such modifications are intended to be included within the scope of the present invention as defined in the claims. It should be understood that the above is an explanation of the present invention and should not be considered as being limited to the specific embodiments disclosed, and modifications to the disclosed embodiments and other embodiments are intended to be included within the scope of the appended claims. The present invention is defined by the claims and their equivalents.

Claims

1. A production line control system based on real-time data acquisition, comprising a data acquisition module and a database, characterized in that: Also includes: The equipment working analysis module is used to receive the working parameters of the production line equipment, determine and analyze the working parameters to obtain the abnormal attenuation value of the production line equipment, and send it to the production line analysis module; The production line analysis module is used to receive the abnormal attenuation value of the production line equipment, the maintenance parameters of the production line, and the production parameters of the production line, and to determine and analyze them to obtain the maintenance difference value of the production line, the production deviation value of the production line, and the comprehensive abnormal deviation bottleneck value of the production line, and send them to the early warning analysis module; The early warning analysis module receives the comprehensive deviation bottleneck value of the production line, analyzes and determines it, generates corresponding signals, and issues early warnings and alarms; The personnel and equipment analysis module is used to receive the operating parameters of the operating personnel and the production parameters of the production line equipment, and to determine and analyze them to obtain the personnel evaluation value, and send the personnel evaluation value to the matching adjustment module; The matching adjustment module is used to receive the human setting evaluation value, the equipment temperature abnormal value, the equipment running speed abnormal value and the equipment pressure abnormal value, make judgments and analyses on them, obtain the adjustment set of the production line abnormality, the equipment temperature adjustment value, the equipment running speed adjustment value and the equipment pressure adjustment value, and adjust the production work according to the adjustment set of the production line abnormality, the equipment temperature adjustment value, the equipment running speed adjustment value and the equipment pressure adjustment value.

2. A production line control system based on real-time data acquisition according to claim 1, characterized in that: The specific analysis method of the abnormal attenuation value of the production line equipment is as follows: Obtain the equipment temperature, running speed and pressure values ​​of the production line, analyze and calculate to obtain the temperature abnormality value WZi, running speed abnormality value VZi, pressure abnormality value YZi and working abnormality value Zi, where i represents the number of the equipment in the production line; The working state abnormal value of the equipment is matched to each monitoring time point to obtain the working state abnormal value of the equipment over time graph; the working state abnormal value of the equipment is compared and analyzed with the set working state abnormal value. When the working state abnormal value of the equipment is greater than the maximum value of the set interval, the state abnormal value is marked as a first-level abnormal value, and the corresponding time is generated as a first-level abnormal value moment. When the working state abnormal value of the equipment is within the set interval, the state abnormal value is marked as a second-level abnormal value, and the corresponding time is generated as a second-level abnormal value moment; the generated first-level abnormal value moment and second-level abnormal value moment are marked on the time axis, and the interval lengths of adjacent first-level abnormal value moments and second-level abnormal value moments are obtained according to the generated abnormal value change graph, and the sum of them is obtained to obtain the total length of the first-level abnormal value interval and the total length of the second-level abnormal value interval, which are recorded as JDi and JEi respectively; the average values ​​of each working state abnormal value in the first-level abnormal value and each working state abnormal value in the second-level abnormal value are obtained, and marked as DPi and EPi; the total length of the first-level abnormal value interval, the total length of the second-level abnormal value interval, the average value of the first-level abnormal value and the average value of the second-level abnormal value are normalized and the values ​​of the four are taken according to the set formula Get the equipment decay coefficient SXi, where are the set proportional coefficients respectively; The values ​​corresponding to the equipment's working abnormality value and the equipment's recession coefficient are converted into lengths according to a certain ratio; a cone is constructed with the length of the working abnormality value as the base diameter of the cone and the length of the equipment's recession coefficient as the height of the cone, and the volume of the cone is extracted as the deviation index value of the equipment; Collect the equipment deviation index values ​​SZi of each production line, divide the equipment deviation index values ​​into multiple groups, mark the values ​​within the threshold range as YZ2, those above the threshold range as YZ1, and those below the threshold range as YZ3, calculate the proportion of YZ1 and YZ2 in the entire data, that is, YZG1 and YZG2, respectively, normalize the obtained proportion values ​​YZG1 and YZG2 and substitute them into the formula , calculate and obtain the abnormal attenuation value SYB of the production line equipment, where and are all preset weight factors. is the preset correction factor.

3. A production line control system based on real-time data acquisition according to claim 1, characterized in that: The specific analysis method of the production line maintenance and operation difference value, production line production deviation value and production line comprehensive deviation bottleneck value is as follows: The maintenance status value SW of the production line is obtained through the maintenance frequency, average maintenance time, average maintenance cost, total sub-difference and sub-extreme value of the production line; the waiting time and service time of each process in the production line are collected through time study, production records and sensor data to obtain the production line process change trend value GYB; Get the production line running time SY and downtime ST within a period of time according to the set formula Get the production line operation rate SL; normalize the production line maintenance status value SW, production line process change value GYB and production line operation rate SL, and substitute their values ​​into the set formula The production line maintenance difference variable WYB is obtained, where U1, U2 and U3 are all preset weight factors; By acquiring the output of the production line, a two-dimensional coordinate system is established with time as the horizontal axis and the output of the production line as the vertical axis. The output of the production line is displayed through the curve of the coordinate system, and a curve of the standard output of the production line over time is established in the coordinate system. The closed area formed by the production line output change curve and the standard output curve is statistically analyzed, and the sum is obtained to obtain the production deviation reference value SCC of the production line; the maximum and minimum values ​​of the output in the production line change curve are obtained, and the difference calculation is performed to obtain the extreme value SCJ of the production line output; Obtain the total output SZ produced by the production line within a certain period of time, measure the reflectivity of the production line products to light of different wavelengths by a spectrophotometer, and obtain the light reflectivity of the production line products; measure the length, width, height, and diameter of the production line products, and make a weighted calculation by subtracting the length, width, height, and diameter values ​​of the production line products from the set reference length, reference width, reference height, and reference diameter values, and multiply by the corresponding proportional factor to obtain the size deviation value of the production line products; drop a certain amount of sand from a certain height to impact the surface of the production line products, measure the wear depth MS on the product surface, apply gradually increasing pressure to the production line products until the products are destroyed, and record the relationship between pressure and deformation, so as to determine the compressive strength YQ and compression modulus YM of the products, normalize the wear depth, compression strength, and compression modulus, and substitute them into the following formula: To obtain the production line product performance deviation value PZZ, where c1, c2 and c3 are all preset weight factors; after normalizing the production line product light reflectivity, production line product size deviation value and production line product performance deviation value, the production line product size deviation value is used as the bottom circle radius, and the production line product performance deviation value is used to build a cone, and a hollow sphere is built inside the cone with the production line product light reflectivity as the radius, and then the solid volume of the cone is calculated and its value is marked as the product quality deviation value CZP, and this deviation value is used as the standard for measuring product quality of the production line; The calculated production line output reference deviation value SCC, production line output range value SCJ and product quality deviation value CZP are normalized and substituted into the set formula Get the production line deviation value CYB, where The preset weight coefficient is the sum of the production line output deviation value, the production line output range value and the product quality deviation value; Convert the values ​​corresponding to the production line equipment abnormal decay value SYB and the production line maintenance and operation differential value WYB into lengths according to a certain ratio; An ellipse is constructed with the lengths of the production line equipment abnormal degradation value SYB and the production line maintenance and operation differential value WYB as the major and minor axes respectively; the production line deviation value CYB is converted into length according to a certain ratio, and the center of the ellipse is selected as the starting point, and the length of the production line deviation value CYB is used as the height to construct a cone entity; then the volume of the cone entity is identified and marked as the comprehensive deviation bottleneck value of the production line.

4. A production line control system based on real-time data acquisition according to claim 1, characterized in that: The specific analysis method for the corresponding signal to perform early warning and alarm is: Set the reference threshold WW1 of the comprehensive deviation bottleneck value of the production line, and compare and analyze the comprehensive deviation bottleneck value of the production line with the set reference threshold WW1 of the comprehensive deviation bottleneck value; When the comprehensive deviation bottleneck value of the production line is greater than the set reference threshold WW1, the corresponding production line production will be evaluated as an abnormal production state, and corresponding early warnings and alarms will be executed, and a signal of "this production line is abnormal, it is a key focus production line, and the equipment and operators in the production line need to be adjusted" will be issued; when the comprehensive deviation bottleneck value of the production line is equal to the set reference threshold WW1, the corresponding production line production will be evaluated as an abnormal production state, and corresponding early warnings and alarms will be executed, and a signal of "this production line is abnormal, it is a secondary focus production line, and the equipment and operators in the production line need to be adjusted" will be issued.

5. A production line control system based on real-time data acquisition according to claim 1, characterized in that: The specific analysis method of the personality evaluation value is as follows: The operator's work efficiency value ZXZ is obtained through the operator's output per unit time, the operator's product qualification rate, the operator's attendance rate and the operator's total working hours; After processing the time interval, the number of failures per unit time and the output per unit time, the production line equipment production evaluation value PZ is obtained; Normalize the calculated operator's effectiveness value ZXZ and production line equipment's production evaluation value PZ and substitute them into the set formula Get the personality evaluation value RYZ, where It is the preset weight coefficient of the sum of the operator’s work efficiency value and the production line equipment’s production evaluation value.

6. A production line control system based on real-time data acquisition according to claim 1, characterized in that: The adjustment set of the abnormal situation of the production line, the equipment temperature adjustment value, the equipment operating speed adjustment value and the equipment pressure adjustment value, and the specific analysis method is as follows: Compare the human setting evaluation value with the set human setting evaluation value reference value. If the human setting evaluation value is greater than the set human setting evaluation value reference value, identify the operator and equipment as the adjustment set of the production line abnormality, and sort the adjustment set of the production line abnormality from high to low according to the human setting evaluation value; Match the production lines whose comprehensive deviation bottleneck values ​​are greater than or equal to the set reference threshold with the adjustment set of production line abnormalities, and select the corresponding operators and equipment from the adjustment set of production line abnormalities in descending order to adjust production work; If the temperature abnormality value, operating speed abnormality value, and pressure abnormality value corresponding to the equipment of the production line are greater than the upper limit value of the set temperature abnormality value, operating speed abnormality value, and pressure abnormality value threshold value corresponding to the equipment, the temperature, operating speed, and pressure of the equipment of the production line will be marked as abnormal, and the difference between the two will be calculated to obtain the custom value. The custom value will be multiplied by the temperature, operating speed, and pressure conversion coefficient to obtain the equipment temperature adjustment value, operating speed adjustment value, and pressure adjustment value. The production line system will automatically adjust the equipment temperature, operating speed, and pressure according to the equipment temperature adjustment value, operating speed adjustment value, and pressure adjustment value.

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