Large equipment production line scheduling method and central control system

Abstract

The invention discloses a large-scale equipment production line scheduling method and a central control system, and the method achieves the full life cycle process of raw material feeding, code spraying, cutting, sorting and transportation through the unmanned process automatic control of a workshop, breaks through the information isolated island of the control of each production line, guarantees the real-time performance and effectiveness of data transmission, and improves the production efficiency. And through reasonable scheduling of production resources, high-efficiency operation of a production line is ensured, and meanwhile, data required by a workshop is automatically summarized and subjected to quantitative management, so that data support is provided for an upper-layer MES (Manufacturing Execution System).

Description

Technical Field

[0001] The present invention relates to the field of automation control technology, and in particular to a large-scale equipment production line scheduling method and a central control system. Background Art

[0002] At home and abroad, intelligent manufacturing and intelligent production line construction have been widely used and promoted in various industries and fields. However, the construction of intelligent digital production lines in heavy industries such as steel structures and ships is still in its infancy. Since the production processes of steel structures, ships, bridges, etc. have typical discrete manufacturing characteristics such as multiple varieties, small batches, customization, and diverse production processes, the current production line production process is difficult to centrally manage and control, and information is seriously dispersed. Therefore, it is urgent to develop intelligent construction production lines that are suitable for large products such as steel structures and bridges to improve production line production efficiency.

[0003] The current model of a production line is that there are multiple types of equipment in the workshop, and these equipment still need manual control and processing. It is difficult to control different types of equipment for unified scheduling, and most of the production equipment and testing equipment are not connected to the Internet, and production data cannot be collected and analyzed. In addition, the loading, coding and material transfer and transportation in the production workshop are all manually operated or partially integrated, which is not suitable for automated production. At the same time, the MES system is only a business-level management, and cannot be decentralized to the workshop. Summary of the invention

[0004] The present application provides a large-scale equipment production line scheduling method and central control system. Through the unmanned process automation control of the workshop, the whole life cycle process from raw material loading, coding, cutting, sorting and transportation is realized, the information islands of each production line control are connected, the real-time and effectiveness of data transmission are ensured, and the efficient operation of the production line is ensured through the reasonable scheduling of production resources. At the same time, the data required by the workshop is automatically summarized and counted and quantitatively managed to provide data support for the upper-level MES system.

[0005] The technical solution to solve the technical problem in this application is as follows:

[0006] According to one aspect of the present application, a large equipment production line scheduling method is provided, which includes:

[0007] Obtain material information by reading the material code of the material to be processed captured by the camera device at the material incoming position of the production line, and enter the material information into the database;

[0008] Receiving task production information generated by processing process parameters corresponding to the material input by the user through the human-computer interaction device, or receiving task production information corresponding to the material imported by the user through the human-computer interaction device, or receiving task production information issued by an upstream system, and making the task production information correspond to the material code of the material;

[0009] Randomly select a loading device or designate a loading device based on the task production information of the material to load the material to the conveying device;

[0010] The material information and the task production information corresponding to the material are obtained by reading the material code of the material after loading captured by the camera device on the conveying device, and the processing procedure of the material is determined according to the processing procedure parameters of the task production information. Combined with the actual operating status of each production equipment in the production line and the progress of other tasks undertaken, the target station of each processing procedure corresponding to the material is determined;

[0011] The material is transported to each of the target workstations in sequence through a conveying device, the material information and corresponding processing information are obtained by reading the material code of the material captured by a camera device at the target workstation, and the production equipment at the target workstation is controlled to process the material according to the processing information.

[0012] Further, the processing steps include one or more of a coding step, a cutting step, and a sorting and / or polishing step;

[0013] The coding process includes parsing the coding information corresponding to the material in advance, and after the material is transported to the coding target station, obtaining and controlling the coding equipment to code the material according to the parsed coding information;

[0014] The cutting process includes obtaining and controlling a cutting device to cut the material according to cutting processing information corresponding to the material;

[0015] The sorting and / or grinding process includes obtaining and controlling a sorting device and / or a grinding device to sort and / or grind the material according to sorting and / or grinding processing information corresponding to the material.

[0016] Furthermore, it also includes: real-time collection of PLC points and various sensor information in the production line, obtaining the operating parameters and material processing status of each device, as well as various control data and parameter configurations during the material processing process.

[0017] Furthermore, it also includes: real-time recording of fault information and alarm information of each device in the production line.

[0018] Furthermore, it also includes: real-time statistics of the progress of each task in the production line, and displaying the number of materials, semi-finished products and finished products processed in the current production line, as well as displaying the progress of each task in the production line, the status of each workstation, the status of each equipment and the progress of the operation.

[0019] According to another aspect of the present application, a large-scale equipment production line scheduling central control system is provided, which includes a database module, a QR code recognition module, a human-computer interaction module, a task management module, a production scheduling module and a conveying control module;

[0020] The database module is used to record material information and task production information corresponding to the material;

[0021] The two-dimensional code recognition module is used to read the material code of the material to be processed captured by the camera device at the incoming material position of the production line to obtain material information, and enter the material information into the database, and read the material code of the material captured by the camera device at other positions of the production line and obtain the corresponding material information;

[0022] The human-computer interaction module is used to receive the processing process parameters of the corresponding material input by the user through the human-computer interaction device, or receive the task production information of the corresponding material imported by the user through the human-computer interaction device, or receive the task production information issued by the upstream system, and upload it to the task management module, and send a material loading instruction to the production scheduling module;

[0023] The task management module is used to generate corresponding task production information according to the processing procedure parameters of the corresponding material uploaded from the human-computer interaction module, or receive the task production information uploaded from the human-computer interaction module, or receive the task production information sent from the upstream system, the task production information includes each processing procedure and parameters, and send the task production information to the production scheduling module;

[0024] The production scheduling module controls the loading equipment to load materials according to the loading instructions of the human-computer interaction module, and determines the target station of the material corresponding to each processing procedure according to the actual operation status of each production equipment in the production line and the progress of other tasks it undertakes, according to each processing procedure and parameters in the task production information corresponding to each material issued by the task management module, and issues a conveying instruction to the conveying control module. After the material is conveyed to the target station, the production equipment at the target station is controlled to process the material;

[0025] The conveying control module is used to convey materials to the target workstation according to the instructions of the production scheduling module.

[0026] Furthermore, it also includes a coding unit control module, a cutting machine control module and a robot control module;

[0027] The coding unit control module is used to control the coding equipment to perform coding processing on the material according to the coding information of the corresponding material;

[0028] The cutting machine control module is used to control the cutting equipment to cut the material according to the cutting processing information of the corresponding material;

[0029] The robot control module is used to control the sorting equipment and / or grinding equipment to sort and / or grind the materials according to the sorting and / or grinding processing information of the corresponding materials.

[0030] Furthermore, it also includes a data acquisition module, which is used to collect the operating data of each device in the production line in real time, as well as various control data and parameters of other modules. The data acquisition module is used to collect the operating parameters and material processing status of various devices through PLC points and various sensor information in the production line, as well as the control data and parameter configuration of various modules in the material processing process.

[0031] Furthermore, it also includes a fault alarm module, which is used to record the fault information and alarm information of each device in the production line in real time.

[0032] Furthermore, it also includes an analysis and statistics module, which is used to count the progress of each task in the production line in real time, and display the number of materials, semi-finished products and finished products processed in the current production line, as well as the progress of each task in the production line, the status of each workstation, the status of each equipment and the progress of the operation.

[0033] Compared with the prior art, the large-scale equipment production line scheduling method and central control system provided by this application have the following beneficial effects:

[0034] (1) Compared with the single control device method, this application provides unmanned process automation control in the workshop through the large-scale equipment production line scheduling central control system, manages the entire life cycle process from raw material loading, coding, cutting, grinding, sorting and transportation, and manages the scheduling and control of multiple equipment. It is more efficient and convenient for the workshop, improves work efficiency and reduces work costs for users, and more intuitively and vividly displays the overall operation process of the production line to users.

[0035] (2) This application can connect the information islands of each production line control, ensure the real-time and effectiveness of data transmission, rationally dispatch production resources, ensure efficient operation of the production line, realize unmanned production of the production line, automatically summarize and count the data required by the workshop, quantify management, and provide data support for the upper-level MES system.

[0036] (3) This application uniformly controls and schedules production of different production equipment in large-scale heavy industry workshops, uses task management to select process parameters for multi-process products, and uses a data acquisition module to record and save each device and task. Users can issue control instructions through production scheduling or control the operation of tasks through a visualization module to achieve control of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1This is a schematic diagram of the central control system of this application;

[0038] Figure 2 This is a schematic diagram of the application workflow;

[0039] Figure 3 This is a schematic diagram of the system architecture of this application. DETAILED DESCRIPTION

[0040] The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of this application. Unless otherwise defined, the technical terms or scientific terms used herein should be understood by people with general skills in the field to which the present disclosure belongs. What is not described in detail in this application is the known technology of technicians in this technical field.

[0041] Embodiment 1:

[0042] According to one aspect of the present application, a scheduling method for a large-scale equipment production line is provided. The large-scale equipment production line includes various types of processing equipment, conveying equipment, handling equipment, robotic equipment, detection sensor equipment, etc. The scheduling method includes:

[0043] The material information is obtained by reading the material code of the material to be processed captured by the camera device at the material incoming position of the production line, and the material information is entered into the database; before the raw materials are sent to the workshop, the material code for identifying the raw material information is generally sprayed or posted on the raw materials in advance, and the material code is preferably a QR code; the camera device is usually an industrial camera;

[0044] Receive the task production information generated by the processing procedure parameters corresponding to the material input by the user through the human-computer interaction device, or receive the task production information corresponding to the material imported by the user through the human-computer interaction device, or receive the task production information issued by the upstream system, and correspond the task production information to the material code of the material; the human-computer interaction device is a device for information exchange and operation between the user and the computer or other digital device, and is an input and output device used to realize and optimize interaction in the material processing process;

[0045] Randomly select a loading device or designate a loading device based on the task production information of the material to load the material to the conveying device;

[0046] The material information and the task production information corresponding to the material are obtained by reading the material code of the material after loading captured by the camera device on the conveying device, and the processing procedure of the material is determined according to the processing procedure parameters of the task production information. Combined with the actual operating status of each production equipment in the production line and the progress of other tasks undertaken, the target station of each processing procedure corresponding to the material is determined;

[0047] The materials are transported to each of the target stations in sequence through conveying equipment, the material information and corresponding processing information are obtained by reading the material code of the material captured by the camera equipment at the target station, and the production equipment at the target station is controlled to process the materials according to the processing information; during the material conveying process, the conveying equipment will feedback the transportation information in real time, and during the material processing process, the processing equipment will feedback the processing information in real time.

[0048] As a preferred embodiment, the processing steps include one or more of a coding step, a cutting step, and a sorting and / or polishing step;

[0049] The coding process includes parsing the coding information corresponding to the material in advance, and after the material is transported to the coding target station, obtaining and controlling the coding equipment to code the material according to the parsed coding information;

[0050] The cutting process includes obtaining and controlling a cutting device to cut the material according to cutting processing information corresponding to the material;

[0051] The sorting and / or grinding process includes obtaining and controlling a sorting device and / or a grinding device to sort and / or grind the material according to sorting and / or grinding processing information corresponding to the material.

[0052] As a preferred implementation, it also includes: real-time collection of PLC points and various sensor information in the production line, obtaining the operating parameters and material processing status of each device, as well as various control data and parameter configurations during the material processing process.

[0053] As a preferred implementation, it also includes: real-time recording of fault information and alarm information of each device in the production line.

[0054] As a preferred implementation, it also includes: real-time statistics of the progress of each task in the production line, and displaying the number of materials, semi-finished products and finished products processed in the current production line, as well as displaying the progress of each task in the production line, the status of each workstation, the status of each equipment and the progress of the operation. As a more preferred implementation, the above status display is carried out in a 3D visualization manner, so that users can understand the status of the production line more intuitively, which is convenient for optimizing business processes and improving decision-making efficiency.

[0055] In this embodiment, the material to be processed is generally a large raw material, which refers to a thicker and larger steel plate; the processing process refers to the process of converting raw materials or semi-finished products into finished products through a series of processing steps in the manufacturing industry. Each process includes specific operations, which can be mechanical processing, manual processing, heat treatment, surface treatment, etc. In large equipment workshops, it generally includes pretreatment, coding, cutting, grinding, sorting, welding, etc.

[0056] Embodiment 2:

[0057] According to another aspect of the present application, a large-scale equipment production line scheduling central control system is provided to implement the scheduling method described in Example 1, which includes a database module, a QR code recognition module, a human-computer interaction module, a task management module, a production scheduling module and a conveying control module;

[0058] The database module is used to record material information and task production information corresponding to the material; further, the database system is also used to record various types of transportation, processing and other information corresponding to various types of material processing processes;

[0059] The two-dimensional code recognition module is used to read the material code of the material to be processed captured by the camera device at the incoming material position of the production line to obtain material information, and enter the material information into the database, and read the material code of the material captured by the camera device at other positions of the production line and obtain the corresponding material information, and provide feedback to the corresponding module;

[0060] The human-computer interaction module is used to receive the processing process parameters of the corresponding material input by the user through the human-computer interaction device, or receive the task production information of the corresponding material imported by the user through the human-computer interaction device, or receive the task production information issued by the upstream system, and upload it to the task management module, and send a material loading instruction to the production scheduling module;

[0061] The task management module is used to generate corresponding task production information according to the processing procedure parameters of the corresponding materials uploaded from the human-computer interaction module, or receive the task production information uploaded from the human-computer interaction module, or receive the task production information issued by the upstream system (such as the upstream EMS system, etc.), the task production information includes each processing procedure and parameters, and issue the task production information to the production scheduling module;

[0062] The production scheduling module is responsible for planning, organizing, coordinating and controlling various resources in the material production process to ensure that production can be carried out efficiently and orderly, arranging material production based on material processing rules, modifying the operating status of various equipment during the processing, issuing various control equipment instructions, and planning different processing procedures according to the task processing attributes, deciding the task target station, and organizing the material resources of each equipment to complete the processing; specifically, controlling the loading equipment to load materials according to the loading instructions of the human-computer interaction module, and according to the processing procedures and parameters in the task production information corresponding to each material issued by the task management module, combined with the actual operating status of each production equipment in the production line and the progress of its other tasks, determining the target station of each processing procedure corresponding to the material, and issuing a conveying instruction to the conveying control module. After the material is conveyed to the target station, the production equipment at the target station is controlled to process the material;

[0063] The conveying control module is used to control the conveying equipment through PLC to convey the materials to the target workstation according to the instructions of the production scheduling module.

[0064] As a preferred embodiment, it also includes a coding unit control module, a cutting machine control module and a robot control module;

[0065] The coding unit control module is used to control the coding equipment to process the material according to the coding information of the corresponding material; the coding equipment generally includes a motion mechanism and a coding system, and the movement of the motion mechanism and the operation of the coding system are controlled by the Restful webservice interface method;

[0066] The cutting machine control module is used to control the cutting equipment to cut the material according to the cutting processing information of the corresponding material;

[0067] The robot control module is used to control the sorting equipment and / or grinding equipment to sort and / or grind the materials according to the sorting and / or grinding processing information of the corresponding materials. The sorting equipment and / or grinding equipment includes a robot and a sorting device or a grinding device arranged on the robot. The robot control module receives, processes and executes various instructions of the conveying control module, the production scheduling module, etc. and the machine vision through the motion control card to control the robot movement and operation.

[0068] As a preferred embodiment, it also includes a data acquisition module, which is used to collect the operating data of each device in the production line in real time, as well as various control data and parameters of other modules. The data acquisition module is used to collect the operating parameters and material processing status of various devices through PLC points and various sensor information in the production line, as well as the control data and parameter configuration of various modules in the material processing process.

[0069] As a preferred implementation, it also includes a fault alarm module, which is used to record the fault information and alarm information of each device in the production line in real time and synchronously display the fault processing status.

[0070] As a preferred embodiment, it also includes an analysis and statistics module, which is used to count the progress of each task in the production line in real time, and display the number of materials, semi-finished products and finished products processed in the current production line, as well as the progress of each task in the production line, the status of each workstation, the status of each equipment and the progress of the operation.

[0071] Embodiment 3:

[0072] Take the raw material processing process as an example. When large raw materials enter the workshop, the material code is read through the QR code recognition module, and the material is entered into the system database module. The user enters the task management module, sets and inputs the processing process parameters, and uploads them to the task management system to generate task production information; or imports the task production information through the human-computer interaction module and uploads it to the task management system. After the production line starts to operate automatically, the user randomly or specifies the raw materials to be loaded through the human-computer interaction module, and the system coordinates the production scheduling module to control the automatic loading equipment to load and transport the materials. After the loading is completed, the conveying control module reads the raw material information through the QR code recognition module. The system matches the task and identifies the processing process according to the task management module, and allocates the target station through the production scheduling module. When the process parameters of the task include the coding process, the system will send the required coding information to the coding unit control module in advance for analysis. After the analysis is successful, the production scheduling module coordinates the conveying control module to control the conveying equipment to start moving, transport the materials to the coding station, and the conveying control system feedbacks the transportation information in real time. When the material is transported to the coding station, the material code is read by the QR code recognition module, and the task management module matches the task information and passes the corresponding coding information to the coding unit control module. The coding unit control module reads the coding information and controls the movement of the motion mechanism and the coding system to spray. After the coding is completed, the production scheduling module determines the target cutting station of this task through the process parameters of the task and sends it to the conveying control module, directing the conveying equipment to transport the material to the cutting station (this cutting station can be any cutting such as plane cutting, bevel cutting, flame cutting, etc.), and the first step of the process is completed. After being transported to the designated cutting station, the material information at this time is read again by the QR code recognition module, and the corresponding processing information is matched, and the cutting machine control module issues instructions to control the cutting CNC system to perform processing. When the system's cutting control module receives the feedback information that the equipment has completed processing, it begins to use the production scheduling module to coordinate the conveying equipment of the conveying control module to transfer the cut materials / semi-finished products, and transport the materials to the sorting / polishing station, and the second step of the process is completed. After being transported to the designated sorting or polishing station, the material code is read by the QR code recognition module and fed back to the robot control module. After the robot receives the signal that the material is in place, it starts to perform polishing or sorting. After the execution is completed, it will be fed back to the system, and the system will record the completion of this task, and the entire material processing is completed. Among them, the data acquisition module collects data in real time, summarizes the production line production and equipment data to form an analysis and statistics module. The process parameters are manually set in the human-computer interaction module. The fault management module records system faults and equipment alarms in real time throughout the production line. In the above process, the entire workshop production line can work on multiple materials at the same time, and the production scheduling module will make overall arrangements to improve the work efficiency of the production line.

Claims

1. A large equipment production line scheduling method, characterized in that: include: Obtain material information by reading the material code of the material to be processed captured by the camera device at the material incoming position of the production line, and enter the material information into the database; Receiving task production information generated by processing process parameters corresponding to the material input by the user through the human-computer interaction device, or receiving task production information corresponding to the material imported by the user through the human-computer interaction device, or receiving task production information issued by an upstream system, and making the task production information correspond to the material code of the material; Randomly select a loading device or designate a loading device based on the task production information of the material to load the material to the conveying device; The material information and the task production information corresponding to the material are obtained by reading the material code of the material after loading captured by the camera device on the conveying device, and the processing procedure of the material is determined according to the processing procedure parameters of the task production information. Combined with the actual operating status of each production equipment in the production line and the progress of other tasks undertaken, the target station of each processing procedure corresponding to the material is determined; The material is transported to each of the target workstations in sequence through a conveying device, the material information and corresponding processing information are obtained by reading the material code of the material captured by a camera device at the target workstation, and the production equipment at the target workstation is controlled to process the material according to the processing information.

2. A large equipment production line scheduling method according to claim 1, characterized in that: The processing steps include one or more of a coding step, a cutting step, and a sorting and / or polishing step; The coding process includes parsing the coding information corresponding to the material in advance, and after the material is transported to the coding target station, obtaining and controlling the coding equipment to code the material according to the parsed coding information; The cutting process includes obtaining and controlling a cutting device to cut the material according to cutting processing information corresponding to the material; The sorting and / or grinding process includes obtaining and controlling a sorting device and / or a grinding device to sort and / or grind the material according to sorting and / or grinding processing information corresponding to the material.

3. A large equipment production line scheduling method according to claim 1, characterized in that: Also includes: Collect PLC points and various sensor information in the production line in real time, obtain the operating parameters and material processing status of each equipment, as well as various control data and parameter configurations during the material processing process.

4. A large equipment production line scheduling method according to claim 1, characterized in that: Also includes: Record the fault information and alarm information of each device in the production line in real time.

5. A large equipment production line scheduling method according to claim 1, characterized in that: Also includes: Real-time statistics of the progress of each task in the production line, and display of the number of materials, semi-finished products and finished products processed in the current production line, as well as the progress of each task in the production line, the status of each workstation, the status of each equipment and the progress of the operation.

6. A large equipment production line scheduling control system, characterized in that: It includes database module, QR code recognition module, human-computer interaction module, task management module, production scheduling module and conveying control module; The database module is used to record material information and task production information corresponding to the material; The two-dimensional code recognition module is used to read the material code of the material to be processed captured by the camera device at the incoming material position of the production line to obtain material information, and enter the material information into the database, and read the material code of the material captured by the camera device at other positions of the production line and obtain the corresponding material information; The human-computer interaction module is used to receive the processing process parameters of the corresponding material input by the user through the human-computer interaction device, or receive the task production information of the corresponding material imported by the user through the human-computer interaction device, or receive the task production information issued by the upstream system, and upload it to the task management module, and send a material loading instruction to the production scheduling module; The task management module is used to generate corresponding task production information according to the processing procedure parameters of the corresponding material uploaded from the human-computer interaction module, or receive the task production information uploaded from the human-computer interaction module, or receive the task production information sent from the upstream system, the task production information includes each processing procedure and parameters, and send the task production information to the production scheduling module; The production scheduling module controls the loading equipment to load materials according to the loading instructions of the human-computer interaction module, and determines the target station of the material corresponding to each processing procedure according to the actual operation status of each production equipment in the production line and the progress of other tasks it undertakes, according to each processing procedure and parameters in the task production information corresponding to each material issued by the task management module, and issues a conveying instruction to the conveying control module. After the material is conveyed to the target station, the production equipment at the target station is controlled to process the material; The conveying control module is used to convey materials to the target workstation according to the instructions of the production scheduling module.

7. A large equipment production line scheduling central control system according to claim 6, characterized in that: It also includes a coding unit control module, a cutting machine control module and a robot control module; The coding unit control module is used to control the coding equipment to perform coding processing on the material according to the coding information of the corresponding material; The cutting machine control module is used to control the cutting equipment to cut the material according to the cutting processing information of the corresponding material; The robot control module is used to control the sorting equipment and / or grinding equipment to sort and / or grind the materials according to the sorting and / or grinding processing information of the corresponding materials.

8. A large equipment production line scheduling central control system according to claim 6, characterized in that: It also includes a data acquisition module, which is used to collect the operating data of each device in the production line in real time, as well as various control data and parameters of other modules. The data acquisition module is used to collect the operating parameters and material processing status of various devices through PLC points and various sensor information in the production line, as well as the control data and parameter configuration of various modules in the material processing process.

9. A large equipment production line scheduling central control system according to claim 6, characterized in that: It also includes a fault alarm module, which is used to record the fault information and alarm information of each device in the production line in real time.

10. A large equipment production line scheduling central control system according to claim 6, characterized in that: It also includes an analysis and statistics module, which is used to count the progress of each task in the production line in real time, and display the number of materials, semi-finished products and finished products processed in the current production line, as well as the progress of each task in the production line, the status of each workstation, the status of each equipment and the progress of the operation.

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