Method for determining coincidence rate of discrete manufacturing key process parameters

Abstract

The invention relates to a method for determining the coincidence rate of discrete manufacturing key process parameters, which belongs to the technical field of hot working digitization and comprises the following steps of: acquiring casting-forging-heating whole process production data by utilizing an OPC protocol and a Modbus protocol, reading a configuration software ACCESS database, recording a PDA (Personal Digital Assistant) and the like, and determining the coincidence rate of the discrete manufacturing key process parameters on the basis of the production data acquired in real time in each process of hot working casting-forging-heating; by automatically comparing process standard data, calculating the key process parameter coincidence rate of the casting-forging-heating whole process, early warning abnormal deviation process parameters and automatically pushing process adjustment information, the product quality is stably controlled, and the quality problems caused by execution deviation in the production process are reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of digital thermal processing, and in particular relates to a method for determining the compliance rate of key process parameters of discrete manufacturing. Background Art

[0002] As the main link in the current production of large castings and forgings, hot working, scientific management and refined operation are the key to ensuring product quality. However, in the actual hot working production process, there are the following problems: 1. The amount of data in the hot working production process is large, and there is a lack of refined process manufacturing monitoring. Problems are difficult to trace, and the cause analysis is unclear, which can easily lead to process misjudgment and is not conducive to product quality optimization; 2. The process execution cannot be monitored in real time, and the production data records are not refined and transparent; 3. The abnormal state of the equipment cannot be effectively monitored and warned, and equipment abnormalities occur during the production process, causing deviations in process execution and seriously affecting product quality. Summary of the invention

[0003] In order to solve the problems of opaque production process and difficult traceability of quality problems in the thermal processing industry, the present invention provides a method for determining the compliance rate of key process parameters of discrete manufacturing.

[0004] In order to achieve the above object, the technical solution adopted by the present invention is:

[0005] A method for determining the compliance rate of key process parameters of discrete manufacturing includes the following steps: (1) Real-time collection of production data: Based on the principle of "collect as much as possible", real-time collection of on-site production data is carried out according to the actual working conditions of hot processing, smelting, forging and heat treatment workshops; (2) Obtaining production process information: Connecting with the MES production management system to obtain real-time production tasks, process requirements, and material data for each workshop in the hot processing plant; (3) Data processing: Using the product part number as the unique identification code, real-time production data is associated with process standard data; (4) Calculation and presentation of key process parameter compliance rate: Real-time comparison of current production information of the entire plant's casting, forging, and heat treatment workshops, calculation and output of real-time key process parameter compliance rate; (5) Process deviation warning: Provide real-time warning and automatically push process adjustment suggestions for production process deviation information to stabilize process product quality.

[0006] Furthermore, step (1) mainly collects on-site production data in the following manner: a) Collect configuration software and PLC data using OPC method; b) Automation transformation, using Modbus protocol to collect field instrument and sensor data; c) System docking, reading configuration software ACCESS database data; d) Input data into PDA.

[0007] Furthermore, in step (4), the key process parameter compliance calculation formula is defined as: Among them, key process parameters are defined as all process parameters that affect the final quality of the product.

[0008] Furthermore, in step (4), while outputting the real-time key process parameter compliance rate, it also outputs real-time process deviation information, recent process deviation summary, the operating status of the entire plant equipment, the information of the equipment in operation, and the key process parameters of each process.

[0009] Furthermore, in step (5), process deviation warning is performed specifically in the following ways: a process deviation warning model is established to implement system message warnings, SMS warnings, vibration, sound and light warnings on tablets or mobile devices, and automatic push of process adjustment optimization suggestions to assist and guide front-line operators in adjusting their operations.

[0010] Beneficial effects:

[0011] The present invention carries out digital transformation on each hot processing workshop such as smelting, forging and heat treatment, proposes a method for determining the compliance rate of key process parameters, realizes real-time collection and display of production data, and makes the whole hot processing process transparent; the data is compared with the process standard at the moment of collection, and the compliance rate of key process parameters of the whole plant at the current moment is displayed. Real-time warning is given for process deviation, and process personnel and operators are reminded in time to adjust production deviation items, so as to solve product quality problems at the source and greatly reduce product failure rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 Flowchart of an embodiment of the present invention. DETAILED DESCRIPTION

[0013] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0014] The method for determining the compliance rate of key process parameters of discrete hot working manufacturing of the present invention takes the process standard requirements as the benchmark, collects and compares the current production data in real time, monitors whether the production situation deviates; provides real-time feedback on the compliance rate of key process parameters of each workshop of the whole plant, such as smelting, forging and heat treatment; performs real-time early warning and automatically pushes process adjustment suggestions for the deviation information of the production process, so as to stabilize the quality of the process products; and mainly comprises the following steps:

[0015] (1) Collection of production data of the entire hot processing plant. Based on the principle of "collecting as much as possible", the following means are used to collect on-site production data in real time according to the actual working conditions of hot processing smelting, forging, and heat treatment workshops:

[0016] 1) Collect configuration software and PLC data using OPC method;

[0017] 2) Automation transformation, using Modbus protocol to collect field instrument and sensor data;

[0018] 3) System docking, reading configuration software ACCESS database data;

[0019] 4) Input data into PDA.

[0020] (2) Obtain production process information. Connect with the MES production management system to obtain real-time production tasks, process requirements, and material data for each workshop in the factory.

[0021] (3) Data processing: Using the product part number as the unique identification code, real-time production data is associated with process standard data.

[0022] (4) Presentation of key process parameter compliance rate. The key process parameter compliance rate calculation formula is defined as:

[0023] Among them, the key process parameters are defined as all process parameters that affect the final quality of the product. The sum of the key process parameters is the sum of the number of key process parameters. The current production information of the smelting, forging and heat treatment workshops of the entire plant is compared in real time to output real-time key process parameter compliance rate, real-time process deviation information, recent process deviation summary, equipment operation status of the entire plant, information on equipment in operation, key process parameters of each process, etc.

[0024] (5) Process deviation warning. Build a process deviation warning model to implement system message warning, SMS warning, vibration, sound and light warning of tablets or mobile devices, automatically push process adjustment optimization suggestions, assist and guide front-line operators to adjust operations, achieve stable control of product quality, and reduce quality problems caused by execution deviation during the production process.

[0025] The present invention applies advanced digital, information and intelligent technologies, proposes a method for determining the compliance rate of key process parameters in the entire process of hot processing casting-forging-heat treatment, obtains production data information of the entire process of smelting, forging and heat treatment, monitors and warns of deviations of key process parameters of the entire plant in real time, and takes timely measures to make adjustments, thereby improving product quality.

[0026] Example 1

[0027] like Figure 1As shown, a method for determining the compliance rate of key process parameters of discrete hot working manufacturing is implemented as follows:

[0028] (1) Real-time collection of production data in the smelting and casting workshop.

[0029] The vacuum time, vacuum degree, air breaking time, molten steel composition and other data are collected through OPC and Modbus protocol; the drainage time, pouring time, pouring temperature, demoulding time, demoulding temperature and other data are collected through PDA input; and the MES system is connected to obtain data such as steel type, furnace number, product type, process standard, etc.

[0030] (2) Real-time collection of production data in the forging workshop.

[0031] The furnace temperature operation curve, heating rate, instrument temperature in each zone, natural gas reserve, power consumption, press hammer position, press real-time pressure, jaw rotation angle, forging temperature and other data are collected through OPC; the live part loading position and time, ingot utilization rate, forging time and other data are collected through PDA input; and the MES system is connected to obtain data such as work number, drawing number, name, ingot type, material, weight, and process standard.

[0032] (3) Real-time collection of production data in the heat treatment workshop.

[0033] The furnace temperature operation curve, heating rate, instrument temperature in each zone, and medium temperature after cooling are collected through OPC and Modbus protocol; the cooling method, workpiece temperature after cooling, and cooling time are collected through PDA input; and the system is connected with the MES system to obtain data such as work number, drawing number, name, material, weight, and process standard.

[0034] (4) The relationship between production tasks and process data.

[0035] The real-time collected smelting, forging and heat treatment production data are associated with the process standard data to make the huge and messy data sets readable and usable.

[0036] (5) Presentation of compliance rate of key process parameters.

[0037] Based on the process standard data, determine whether the current production execution of the casting, forging and heat treatment workshops has deviated, and define it according to the compliance rate of key process parameters:

[0038]

[0039] Output the real-time key process parameter compliance rate of the whole plant, and present real-time process deviation information, recent process deviation summary, equipment operation status of the whole plant, information of running equipment, key process parameters of each process, etc.

[0040] (5) Early warning of deviations in key process parameters.

[0041] When the system detects that a certain process is currently in progress, such as a deviation in the heating task in the forging workshop, and the furnace temperature is about 20°C lower than the process standard temperature, it will directly remind the forging technician and the heating furnace operator through system messages and PDA vibration, sound and light information to handle it in a timely manner, and give process correction suggestions.

[0042] The present invention collects production data of the entire casting-forging-heating process by utilizing the OPC protocol, Modbus protocol, reading the configuration software ACCESS database, PDA input and the like, and relies on the production data collected in real time from each hot processing casting-forging-heating process. By automatically comparing process standard data, the compliance rate of key process parameters of the entire casting-forging-heating process is calculated, and abnormal deviation process parameters are warned, and process adjustment information is automatically pushed, so as to achieve the effect of stably controlling product quality and reducing quality problems caused by execution deviation in the production process.

[0043] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with this profession can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A method for determining the compliance rate of key process parameters in discrete manufacturing, characterized by: The following steps are involved: (1) Real-time collection of production data: Based on the principle of "collect as much as possible", real-time collection of on-site production data is carried out according to the actual working conditions of hot processing, smelting, forging and heat treatment workshops; (2) Obtaining production process information: Connecting with the MES production management system to obtain real-time production tasks, process requirements and material data of each workshop in the hot processing plant; (3) Data processing: Using the product part number as the unique identification code, real-time production data is associated with process standard data; (4) Calculation and presentation of key process parameter compliance rate: Real-time comparison of current production information of the smelting, forging, and heat treatment workshops of the entire plant, calculation and output of real-time key process parameter compliance rate; (5) Process deviation warning: Provide real-time warning and automatically push process adjustment suggestions for production process deviation information to stabilize process product quality.

2. The method for determining the compliance rate of key process parameters of discrete manufacturing according to claim 1, characterized in that: Step (1) mainly uses the following methods to collect on-site production data: a) Collect configuration software and PLC data using OPC; b) Automation transformation, using Modbus protocol to collect field instrument and sensor data; c) System docking, reading configuration software ACCESS database data; d) Input data into PDA.

3. The method for determining the compliance rate of key process parameters of discrete manufacturing according to claim 1, characterized in that: In step (4), the formula for calculating the compliance rate of key process parameters is defined as: ； Among them, key process parameters are defined as all process parameters that affect the final quality of the product.

4. The method for determining the compliance rate of key process parameters of discrete manufacturing according to claim 1, characterized in that: In step (4), in addition to outputting the real-time key process parameter compliance rate, it also outputs the real-time process deviation information, the recent process deviation summary, the operating status of the entire plant equipment, the information of the equipment in operation, and the key process parameters of each process.

5. The method for determining the compliance rate of key process parameters of discrete manufacturing according to claim 1, characterized in that: In step (5), process deviation warning is specifically carried out in the following ways: building a process deviation warning model, realizing system message warning, SMS warning, vibration, sound and light warning of tablet or mobile device, automatically pushing process adjustment optimization suggestions, and assisting and guiding front-line operators to adjust their operations.

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