General equipment digital management system and method
By designing a digital management system for general equipment, the equipment management problems in the field of home appliance manufacturing are solved, real-time monitoring and management of equipment and spare parts are realized, and production efficiency and information collection accuracy are improved.
Patent Information
- Application Number
- CN202411826545.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-12
- Publication Date
- 2025-03-28
AI Technical Summary
In the field of home appliance manufacturing, there are problems such as difficulty in digital management of equipment, difficulty in real-time information collection, and difficulty in data interconnection and sharing, and there is a lack of digital management strategies for equipment in this field.
A general equipment digital management system is designed, including the equipment layer, the transmission layer and the monitoring layer. Through equipment information encoding and spare parts information encoding, information transmission and analysis are used for data protocol framework to realize real-time monitoring and management of equipment and spare parts.
It realizes intelligent management of equipment in the field of home appliance manufacturing, improves the real-time and accuracy of information collection, promotes data interconnection and sharing, improves production efficiency and timely discovers potential risks.
Smart Images
Figure CN119728734A_ABST
Abstract
Description
Technical Field
[0001] The present invention mainly relates to the technical field of digital management systems, and in particular to a digital management system and method for general equipment. Background Art
[0002] The equipment information that needs to be collected in intelligent production lines typically includes the equipment's name, model, manufacturer, location, department, production output, energy consumption, and inspection and maintenance records. This information is closely related to equipment status monitoring, as well as the production line's daily production capacity and product quality. It must be transmitted to the production control center in real time and accurately.
[0003] Currently, the digital transformation of production lines faces challenges in digital equipment management, real-time information collection, and data interconnection and sharing. While targeted equipment management technologies exist in the shipbuilding, steel, and medical sectors, there are no specific digital equipment management strategies tailored to the needs of home appliance manufacturing. Summary of the Invention
[0004] Technical problems to be solved by the present invention
[0005] Provided are a general equipment digital management system and method, aiming to improve the intelligence level of equipment digital management in the field of home appliance manufacturing.
[0006] The technical solution adopted by the present invention to solve the above technical problems
[0007] A universal equipment digital management system includes an equipment layer, a transmission layer and a monitoring layer. The equipment layer includes equipment and spare parts, the monitoring layer includes a controller, and the transmission layer stores a data protocol framework. The transmission layer extracts the equipment information code or spare part information code of the equipment layer according to the data requirements of the monitoring layer, fills in the transmission protocol framework, generates a data protocol, and transmits the generated data protocol to the monitoring layer through a communication transmission network. The monitoring layer parses the received data protocol based on the data protocol framework definition rules and the coding rules of the equipment coding information or spare part coding information to obtain equipment or spare part information.
[0008] Furthermore, the equipment information coding includes static codes and dynamic codes. The static code includes four code segments, namely, a location code indicating the location of the equipment, a classification code indicating the type of equipment, an asset code indicating the fixed asset number of the equipment, and an ownership code of the unit to which the equipment belongs; the dynamic code includes six code segments, namely, a production / usage code indicating the output / usage of the equipment, an energy consumption code representing the cumulative energy consumption of the equipment, a status code representing the current status of the equipment, an inspection code representing the number of times the equipment has been inspected or weekly inspected, a maintenance code representing the number of times the equipment has been repaired, and a maintenance level and number code representing the maintenance level and number of times the equipment has been maintained.
[0009] Furthermore, the spare part information code includes code segments of the spare part name and number code, specification model number, storage location code, existing quantity code, validity period code and supplier code.
[0010] Furthermore, the data protocol framework is specifically: packet header + total length of valid data + valid data segment + valid data segment CRC check code + packet tail, the packet header and packet tail are fixed bytes, the valid data segment includes the identity code of the device or spare part, the instruction code, the data information string and time, the identity code of the device and spare part is composed of one or more code segments selected from the device information code or the spare part information code, the instruction code is used to indicate the information type of the device or spare part to be obtained, and the data string is a specific code segment selected from the device or spare part information code according to the instruction code.
[0011] Furthermore, the device layer and the monitoring layer communicate via the Ethernet interface using Modbus / TCP or RS485; alternatively, the device layer uses the wireless transmission interface provided by Bluetooth or WiFi, and the IP network uses the TCP or UDP transport layer protocol and the HTTP application layer protocol to communicate with the monitoring layer.
[0012] Furthermore, the monitoring layer includes a host computer, a PLC controller, a smart phone, a tablet computer or a server.
[0013] The present invention also provides a general equipment digital management method applied to the above-mentioned general equipment digital management system, comprising:
[0014] The monitoring layer, as the data demand side, sends data demands to the transport layer;
[0015] Based on the received data requirements, the monitoring layer extracts the information codes of equipment and spare parts from the device layer, fills in the data protocol framework, generates the data protocol, and sends the data protocol to the data demand side;
[0016] The data demand side parses the received data protocol based on the data protocol framework definition rules and the equipment and spare parts information coding to obtain the equipment or spare parts information.
[0017] Furthermore, the method also includes establishing a ledger based on the monitoring layer of the universal digital equipment management system, compiling an equipment or spare parts inspection and maintenance plan, and managing the equipment or spare parts.
[0018] Furthermore, the universal digital equipment management system is connected with MES, QMS, SRDM systems, etc. to realize the interconnection and sharing of data between systems.
[0019] Furthermore, the method also includes: setting an information transmission cycle, the device layer actively transmitting the device information code to the transport layer based on the information transmission cycle, the transport layer generating a data protocol based on a defined transmission protocol framework, and sending it to the monitoring layer.
[0020] Beneficial effects of the present invention
[0021] Based on actual experience, the present invention summarizes a digital management system and method for various key equipment and spare parts in various links of production of home appliances, etc., which combines different equipment and spare parts into a device layer, defines a data protocol framework at the transmission layer, and encodes the equipment and spare parts information of the device layer. According to the data requirements of the monitoring layer, the information encoding of the equipment or spare parts is directly brought up to fill in the data protocol framework to generate a data protocol. The monitoring layer parses the received data protocol according to the definition rules of the data protocol framework and the encoding rules of the equipment and spare parts, and can collect information on the equipment and spare parts in a timely and convenient manner. The monitoring layer monitors the information of the equipment and spare parts, and makes production and fault elimination arrangements in a timely manner, which can effectively improve production efficiency, discover potential risks in a timely manner, and trace the status of the equipment and spare parts in each link at that time when product quality problems occur. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 This is a schematic diagram of a general equipment digital management system;
[0023] Figure 2 This is the static code structure model diagram of the device code;
[0024] Figure 3 This is the device code dynamic code structure model diagram;
[0025] Figure 4 The diagram is a structural model diagram of the spare part code information encoding;
[0026] Figure 5 This is a diagram of the data protocol framework structure. DETAILED DESCRIPTION
[0027] like Figure 1 As shown, a general equipment digital management system includes a device layer, a transmission layer and a monitoring layer. The device layer includes multiple devices and spare parts. The monitoring layer includes a host computer, a PLC controller, a smart phone, a tablet computer or a server. The transmission layer is used to store a data protocol framework. The transmission layer extracts the device information code or the spare part information code of the device layer according to the data requirements of the monitoring layer, fills in the transmission protocol framework, generates a data protocol, and transmits the generated data protocol to the monitoring layer through a communication transmission network. The monitoring layer parses the received data protocol based on the data protocol framework definition rules and the coding rules of the device coding information or spare part coding information to obtain the device or spare part information.
[0028] The device code at the device level consists of a static code and a dynamic code. The static code consists of four code segments: a location code indicating the device's location, a classification code indicating the device's category, an asset code identifying the device's fixed asset number, and an ownership code indicating the device's ownership unit. The dynamic code consists of six code segments: a production / usage code indicating the device's output / usage, an energy consumption code representing the device's cumulative energy consumption, a status code representing the device's current status, an inspection code representing the completion data of the device's spot or weekly inspections, a maintenance code representing the number of repairs, and a maintenance level and number representing the device's maintenance level and number of repairs.
[0029] The location code of the equipment in the static code includes the first location code, the second location code, the third location code and the fourth location code. The first location code consists of two letters, representing the city + park where the equipment is located, and is represented by the first letter of the pinyin of its name; the second location code consists of one letter + two decimal digits, representing the factory number where the equipment is located; the third location code consists of three decimal digits, and is numbered one by one starting from 001, specifically representing a line, an area, a floor, a room, or a workstation in the factory; the fourth location code consists of a three-digit number, representing a further precise location positioning (accurate to the meter level).
[0030] The classification code of the equipment consists of the first classification code, the second classification code and the third classification code. The first classification code consists of one letter, representing the major category to which the equipment belongs; the second classification code consists of two letters, representing the sub-category contained in a major category, and is represented by the first pinyin letter of its name; the third classification code consists of two letters, representing the sub-category contained in a major category, and is represented by the first pinyin letter of its name.
[0031] The asset code, which identifies the fixed asset number of the equipment, consists of a 10- or 11-digit decimal number. The ownership code, which indicates the unit to which the equipment belongs, consists of four letters, representing the four levels: "company + first-level department + second-level department + third-level department." The letters are represented by the initials of their pinyin names. If there are fewer than four levels, the fourth digit is replaced by a space.
[0032] The dynamic code consists of six code segments. The production / usage code is represented by an 8-digit hexadecimal number followed by a letter. The first 8 digits represent the production / usage (counting up one by one from 00000000 to FFFFFFFF); the last letter is the first letter of the unit of measurement in Pinyin. The energy consumption code is represented by an 8-digit hexadecimal number followed by a letter. The first 8 digits represent the energy consumption (counting up one by one from 00000000 to FFFFFFFF); the last letter is the first letter of the unit of measurement in Pinyin. The status code is represented by a decimal number. The inspection code, representing the completion data of equipment inspections or weekly inspections, is represented by a 4-digit hexadecimal number, counting up one by one from 0000 to FFFFFF. The maintenance code is represented by a 3-digit decimal number, starting from 001 and incrementing one by one. The maintenance level and sub-code are represented by a 1-digit Roman numeral followed by a 3-digit decimal number. The Roman numeral represents the maintenance level, and the 3-digit decimal number represents the number of repairs.
[0033] The spare part code includes the name and number code of the spare part, which consists of 2 letters + 2 digits; the 2 letters are the pinyin initials of the first two characters of the spare part name; the 2 digits are the number within the group to which it belongs. The specification model code consists of 5 letters or digits, recording the model and specifications of the spare part. The storage location code has the same structure as the second, third and fourth position codes in the equipment location code. The existing quantity code consists of 3 hexadecimal digits. The validity period code is in the form of "2 digits + 2 digits + 2 digits", representing "** year ** month ** day" respectively. The supplier code consists of 2 letters, representing the pinyin initials of the first two characters of the manufacturer's name.
[0034] like Figure 5 As shown, the control information generated by the transport layer is specifically: packet header + total length of valid data + valid data segment + CRC check code of valid data segment + packet tail, the packet header and packet tail are fixed bytes, the valid data segment includes the identity code, instruction code, data information string and time of the device, spare part or controller, the identity code of the device and spare part is composed of one or more code segments selected from the device code or spare part code, the identity code of the controller is uniquely determined, the instruction code is used to identify the information type of the device or spare part to be obtained, and the data information string is a code segment selected from the device code according to the instruction code.
[0035] The device layer and the monitoring layer communicate via the Ethernet interface using Modbus / TCP or RS485; alternatively, the device layer uses the wireless transmission interface provided by Bluetooth or WiFi, and the IP network uses the TCP or UDP transport layer protocol and the HTTP application layer protocol to communicate with the monitoring layer.
[0036] Preferably, an information transmission cycle can be set, and the device layer actively transmits device information coding to the transport layer based on the information transmission cycle. The transport layer generates a data protocol based on the defined transmission protocol framework and sends it to the monitoring layer.
[0037] The production line uses a general equipment digital management system to establish an equipment ledger, compile equipment inspection and maintenance plans, handle daily equipment management affairs, and realize data association, sharing and collaboration with MES, QMS, SRDM and other systems.
[0038] Example
[0039] Taking a certain brand of intelligent air-conditioning production workshop as an example, the key equipment in each production link is digitally managed through the general equipment digital management system.
[0040] The equipment of the air-conditioning production line is classified into the following categories: the first classification code of key equipment is Class A, the first classification code of general or universal equipment is Class B, and the first classification code of auxiliary equipment is Class C.
[0041] Taking Class A equipment as an example, Class A key equipment is divided into second classification codes: the second classification code of two-device production equipment is LQ, the second classification code of pipeline processing equipment is GL, the second classification code of electronic control production equipment is DK, the second classification code of sheet metal processing equipment is BJ, the second classification code of test and measurement equipment is CS, the second classification code of assembly and packaging equipment is ZP, the second classification code of information network equipment is IT, the second classification code of transportation and transmission equipment is YS, the second classification code of mechanical processing equipment is JX, and the second classification code of control equipment is KZ; the second classification code of security and environmental protection equipment is AF, the second classification code of power equipment is DL, and the second classification code of other types of equipment is QT.
[0042] The third classification code of the two-device production equipment LQ is divided into: the third classification code of the large U pipe bending machine is UW, the third classification code of the pipe expanding machine is ZG..., and the third classification code of other equipment is QT; the third classification code of the pipe processing equipment GL is divided into: the third classification code of the pipe cutting machine is QG, the third classification code of the pipe bending machine is WG, the third classification code of the pipe expanding machine is KK..., and the third classification code of other equipment is QT; the third classification code of the electronic control production equipment DK is divided into: the third classification code of BF is the wave crest machine..., and the third classification code of other equipment is QT; the third classification code of the sheet metal processing equipment BJ is divided into: the third classification code of the high-pressure punching machine is CC, the third classification code of the shearing machine is JB..., and the third classification code of other equipment is QT ; The third classification code of test and measurement equipment CS is divided into: helium detection equipment third classification code is HJ, vibration detection equipment third classification code is ZD, noise detection equipment third classification code is ZY, pressure detection equipment third classification code is YL, impact detection equipment third classification code is CJ, aging detection equipment third classification code is LH, temperature detection equipment third classification code is WD, electrostatic detection equipment third classification code is JD, electromagnetic detection equipment third classification code is DC, electrical equipment third classification code is DG, optical equipment third classification code is GX, chemical detection equipment third classification code is HX, spectrum equipment third classification code is PP, mass spectrometry equipment third classification code is ZP, color The third classification code of spectrum equipment is SP, the third classification code of speed detection equipment is ZS, the third classification code of high and low temperature alternating test chamber equipment is GD..., and the third classification code of other equipment is QT; the third classification code of assembly and packaging equipment ZP is divided into: the third classification code of robot arm is JB, the third classification code of robot hand is JS, the third classification code of assembly robot is JR, the third classification code of automatic packaging machine is BZ..., and the third classification code of other equipment is QT; the third classification code of information network equipment IT is divided into: the third classification code of computer is DN, the third classification code of router is LY, the third classification code of gateway is WG, the third classification code of switch is JH, the third classification code of server is FW, and the third classification code of smart wearable device is CD ..., other equipment's third classification code is QT; the third classification code of transport and transmission equipment YS is divided into: conveyor belt third classification code is CS, transfer vehicle third classification code is ZY, AGV vehicle third classification code is AG, electric forklift third classification code is CC, lift third classification code is SJ..., other equipment's third classification code is QT; the third classification code of machining equipment JX is divided into: boring machine third classification code is TC, drilling machine third classification code is ZC, lathe third classification code is CC, grinder third classification code is MC, welding third classification code is HJ, casting third classification code is ZZ, press third classification code is YL, cutting third classification code is QX, special third classification code is TZ..., other equipment's third classification code is QT;The third classification code of control equipment KZ is divided into: the third classification code of PLC equipment is LC, the third classification code of PLA equipment is LA, the third classification code of sensor is CG, ..., and the third classification code of other equipment is QT; the third classification code of security and environmental protection equipment AF is divided into: the third classification code of infrared monitoring equipment is HW, the third classification code of sewage treatment equipment is WS, the third classification code of dust removal equipment is CC, the third classification code of air purification equipment is KQ, the third classification code of solid waste treatment equipment is GF, the third classification code of noise control equipment is ZS..., and the third classification code of other equipment is QT; the third classification code of power equipment DL is divided into: the third classification code of steam equipment is ZQ, the third classification code of hydraulic equipment is YY, The third classification code for internal combustion engines is NR, the third classification code for photovoltaic equipment is GF, the third classification code for wind power equipment is FL..., and the third classification code for other equipment is QT. The third classification code for other QT equipment is divided into: vacuum degreasing equipment is TZ, surface cleaning equipment is QX, vacuum storage tanks is CG, ultra-high voltage equipment is TG (AC1000kV and above and DC±800kV and above), ultra-high voltage equipment is CG (330kV and above to below 1000kV), high voltage equipment is GY (35kV and above to 330kV), and medium voltage equipment is ZY (1kV and above to 35kV and below).
[0043] The affiliation code in the static code includes four levels, which are represented by the first letter of the pinyin of its name. If there are less than four levels, the fourth digit will be replaced by a space, such as "KZSH", "K" is air conditioning, "Z" is quality department, "S" is test center, and "H" is enthalpy difference laboratory.
[0044] According to the above static code encoding method, we can get a Figure 2 The static code result is MJJ02W01015ALQDHEKTVL8002001006008KZSH.
[0045] The output unit of the dynamic code in the equipment code, such as the number of punching times of the high-speed punch press "C", the number of welding plates of the wave soldering machine "K", etc.; the energy consumption unit, such as the power consumption "degree" is represented by "D", the water consumption "liter" is "S", the gas consumption "cubic meter" is "M", etc.
[0046] The status code in the dynamic code represents the current status of the equipment and is represented by a 1-digit decimal number: 1: normal operation; 0: fault to be repaired; 2: operating with a fault; 3: under inspection; 4: under maintenance; 5: under repair; 6: under installation / debugging; 7: upgrade and renovation; 8: idle and disabled; 9: scrapped.
[0047] The maintenance level and maintenance number in the dynamic code use I, II, and III to represent the first, second, and third level maintenance respectively.
[0048] According to the encoding rules of dynamic code, we can get a Figure 3 The dynamic code shown is 0FFFFFFKFFFFFFFFD1FFFF 017I.
[0049] Figure 4 The specific spare part information code generated according to the spare part information shown is: DG18XT86BJ02003012FFA291130LS.
[0050] The control information generated by the transport layer specifically consists of: packet header + total length of valid data + valid data segment + CRC checksum for the valid data segment + packet trailer. The packet header and trailer are fixed bytes. The valid data segment includes the device, spare part, or controller identity code, instruction code, valid data information string, and time. The device and spare part identity code consists of one or more code segments selected from the device code or spare part code. The controller's identity code is uniquely determined. The instruction code is used to identify the type of device or spare part information to be obtained; for example, "A0" represents "request to establish a connection"; "01" represents "send device static code information in full"; "02" represents "send dynamic code in full"; "03" represents "send spare part code in full"; and so on. The data information string is a code segment selected from the device code based on the instruction code. The CRC16 checksum is used to verify the data information string, which provides a relatively high error detection probability without significantly increasing the data packet overhead and computational complexity. The "current time" in the control information must include "year, month, day, hour, minute, and second" to achieve time calibration of the information string and traceability of product quality issues.
Claims
1. A general equipment digital management system, characterized in that: It includes a device layer, a transmission layer and a monitoring layer. The device layer includes devices and spare parts, the monitoring layer includes a controller, and the transmission layer stores a data protocol framework. The transmission layer extracts the device information code or spare part information code of the device layer according to the data requirements of the monitoring layer to fill in the data protocol framework, generate a data protocol, and transmit the generated data transmission protocol to the monitoring layer through the communication transmission network. The monitoring layer parses the received data protocol based on the data protocol framework definition rules and the coding rules of the device coding information or spare part coding information to obtain the equipment or spare part information.
2. A general equipment digital management system according to claim 1, characterized in that: The equipment information coding includes static code and dynamic code. The static code includes four code segments, namely, the location code indicating the location of the equipment, the classification code indicating the type of equipment, the asset code indicating the fixed asset number of the equipment, and the ownership code of the equipment; the dynamic code includes six code segments, namely, the output / usage code indicating the output / usage of the equipment, the energy consumption code representing the accumulated energy consumption of the equipment, the status code representing the current status of the equipment, the inspection code representing the number of times the equipment has been inspected or weekly inspected, the maintenance code representing the number of times the equipment has been repaired, and the maintenance level and number representing the equipment maintenance level and the number of times the equipment has been maintained.
3. A general equipment digital management system according to claim 2, characterized in that: The code segments included in the spare parts information coding are the spare parts name number code, specification model number, storage location code, existing quantity code, validity period code and supplier code.
4. A general equipment digital management system according to claim 2 or 3, characterized in that: The data protocol framework is specifically: packet header + total length of valid data + valid data segment + valid data segment CRC check code + packet tail, the packet header and packet tail are fixed bytes, the valid data segment includes the identity code of the device or spare part, the instruction code, the data information string and time, the identity code of the device and spare part is composed of one or more code segments selected from the device information code or the spare part information code, the instruction code is used to indicate the information type of the device or spare part to be obtained, and the data string is a specific code segment selected from the device or spare part information code according to the instruction code.
5. A general equipment digital management system according to claim 1, characterized in that: The device layer and the monitoring layer communicate via the Ethernet interface using Modbus / TCP and RS485; alternatively, the device layer uses the wireless transmission interface provided by Bluetooth or WiFi, and the IP network uses the TCP or UDP transport layer protocol and the HTTP application layer protocol to communicate with the monitoring layer.
6. A general equipment digital management system according to claim 1, characterized in that: The monitoring layer includes a host computer, a PLC controller, a smart phone, a tablet computer or a server.
7. A general equipment digital management method, applied to a general equipment digital management system as claimed in any one of claims 1 to 6, characterized in that: include: The monitoring layer, as the data demand side, sends data demands to the transport layer; The monitoring layer extracts the information codes of equipment and spare parts from the device layer according to the received data requirements, fills in the data protocol framework, generates the data transmission protocol, and sends the data transmission protocol to the data demand end; The data demand side parses the received data protocol based on the data protocol framework definition rules and the equipment and spare parts information encoding to obtain the equipment or spare parts information.
8. A general equipment digital management method according to claim 7, characterized in that: The method also includes establishing a ledger based on the monitoring layer of the general equipment digital management system, compiling an equipment or spare parts inspection and maintenance plan, and managing the equipment or spare parts.
9. A general equipment digital management method according to claim 7, characterized in that: The general equipment digital management system is connected with the MES, QMS and SRDM systems to realize the interconnection and sharing of data among the systems.
10. A general equipment digital management method according to claim 7, characterized in that: The method also includes: setting an information transmission cycle, the device layer actively transmitting the device information code to the transmission layer based on the information transmission cycle, the transmission layer generating a data transmission protocol based on a defined transmission protocol framework, and sending it to the monitoring layer.